Hydril - GK Bop

Manual 6609E
OPERATOR'S MANUAL
GK 11"-5000 PSI Annular Blowout Preventer
Pressure Control Equipment
Operator's Manual OPERATOR'S MANUAL

6609E
PAGE iii
Hydril Company LP/ P.O. Box 60458 / Houston, Texas 77205 Phone: (281) 449-2000 / FAX: (281) 985-2828 / WEB: www.hydril.com
2007 Hydril Company LP
Printed in U.S.A., Rev E, October 2007 All Rights Reserved
Operator's Manual
PAGE iv
Preface
This manual contains the information necessary to operate and maintain the Hydril GK 11"-5000 PSI Annular Blowout Preventer (ABOP). Hydril recommends that the information in this manual be studied thoroughly before any attempt is made to operate or perform maintenance or repair operations on this equipment and that all safety precautions be followed. Generic in construction, this manual is applicable for the operation and maintenance of all GK 11"-5000 ABOPs manufactured by Hydril. The illustrations of assemblies and operation and maintenance procedures in this manual are typical and represent most configurations. Variations in configuration are noted in the procedures where applicable. In addition, illustrated parts lists are provided for component replacement.
Operator's Manual
PAGE v
CONTENTS
PAGE Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv vii
OPERATOR QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1.0 INSTALLATION AND OPERATION

1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3 Annular BOP Removal and Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Annular BOP Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Annular BOP Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Opening the Annular BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Closing the Annular BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3 Operational Characteristics Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.4 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.5 Surface Operation and Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.6 Surface Stripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-1 1-1 1-1 1-1 1-1 1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-6 1-7
SECTION 2.0 PHYSICAL DATA

2.1 2.2 2.3 2.4 2.5 2.6 2.7 Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt and Wrench Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions - Screwed Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions - Latch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API Ring Joint Flange Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamp Hub Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-2 2-3 2-4 2-5
SECTION 3.0 PACKING UNITS AND SEALS

3.1 Packing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 Packing Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Packing Unit Replacement-Screwed Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Packing Unit Replacement-Latch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2 3-3 3-4 3-5 3-6
SECTION 4.0 MAINTENANCE AND TESTING

4.1 4.2 4.3 4.4 4.5 4.6 4.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Testing - GK Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Testing - GK With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packing Unit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOP Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-3 4-4 4-5 4-6 4-7
SECTION 5.0 DISASSEMBLY AND ASSEMBLY

5.1 5.2 5.3 5.4 Disassembly - Screwed Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly - Screwed Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly - Screwed Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly - Screwed Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-3 5-6 5-8
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PAGE vi
CONTENTS (CONTINUED)
SECTION 5.0 DISSASSEMBLY AND ASSEMBLY (CONTINUED)
5.5 5.6 5.7 5.8 Disassembly - Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly - Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly - Latched Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly - Latched Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5-13 5-16 5-18
SECTION 6.0 PARTS AND STORAGE

6.1 6.2A 6.2B 6.3 6.4 6.5A 6.5B 6.6 6.7 6.8 Parts List - Screwed Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Screwed Head With Wear Band Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Screwed Head Wear Band Modification Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Screwed Head With Wear Bands At Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Latched Head With Wear Band Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Latched Head Wear Band Modification Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List - Latched Head With Wear Bands At Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Goods Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10
Operator's Manual
GK 11"-5000 PSI Annular Blowout Preventer OPERATOR QUICK REFERENCE
1-vii
PAGE vii
Figure 1
Standard Hookup
Closing Pressure Opening Pressure
Control Pressures
Surface Control Pressure psi Initial* Closure 900 800 825 450 350 WELL PRESSUREpsi 500 825 725 450 375 275 1500 650 550 275 225 125 2500 475 375 100 100 50 3500 300 200 50 50 50 5000 50 50 50 50 50
Pipe Size 2 3/8 2 7/8" 3 1/2" 4 1/2"-5 " 5 1/2"-8 5/8"
Close cautiously to prevent collapse of casing. CSO 1150 1150 1150 1150 1150 1150
*Use closing pressure shown at initial closure to establish seal off and reduce closing pressure proportionally as well pressure is increased. Well pressure will maintain closure after exceeding the required level. See Section 1 for control pressure graph. Closing pressures are average and will vary slightly with each packing unit. Optimum stripping is obtained by adjusting the control pressure to achieve a slight drilling fluid leakage as the tool joint passes through the packing unit.
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Operator's Manual
1-viii
ANNULAR BOP TESTING AND OPERATION

Proper Procedure for pressure testing any annular blowout preventer (BOP) ensures subsequent seal off and maximum packing unit life. Reliable seal off tests are made by initially closing the packing unit with prescribed closing chamber pressure on the recommended size test pipe, proportionally reducing closing pressure as well pressure is increased, and by determining the remaining piston travel after seal off is achieved. Optimum packing unit life is obtained by testing at low rubber stress levels. Minimum packing unit stress is achieved by use of the minimum closing chamber pressure that will initiate and maintain seal off on the recommended size test pipe. The GK blowout preventer is designed to be well pressure assisted in maintaining packing unit seal off once initial seal off has been effected. Initial seal off is effected by applying pressure to the closing chamber. As well pressure or test pressure is increased, the closing force on the packing unit also increases. As well pressure exceeds the required level the packing unit is maintained closed on the recommended size test pipe by well pressure alone. Once initial seal off is achieved, it is recommended that closing pressure be proportionally reduced as well pressure is increased in order to maintain the optimum closing OPERATIONAL DATA
3
force on the packing unit. Optimum closing forces for high well pressures may require careful application of pressure to the opening chamber. Closing pressure required to effect initial seal off may vary slightly between individual packing units. Begin the test with the recommended initial closing pressure. Piston Stroke can be measured on GK blowout preventers through a vertical passage in the top of the BOP head.* The maximum and minimum distances from the top of the head to the top of the piston are stamped on the BOP head and are also listed in the table below. Piston stroke remaining at seal off is a direct indicator of remaining packing unit life. Record the piston stroke and the closing pressure at seal off for each test. Compare with previous results and with maximum piston stroke for the BOP to ensure subsequent seal offs. A valid test on any annular BOP is only achieved when the remaining piston stroke is measured at test seal off.
*Older model BOPs may not have vertical passage in head. See Section 4, Maintenance and Testing for information on modification.
Bore Closing Chamber Volume Opening Chamber Volume Recommended Test Pipe Size Full Piston Stroke
11 in. 9.81 gal. (U.S.) 8.08 gal. (U.S.) 3 1/2 in. 7 1/8 in.
279.4 mm 37.1 liters 30.6 liters 88.9 mm 181 mm TAPE MEASURE

2
5/16" ROD
Distance From Top of Head To Top of Piston Maximum Piston Full Down Minimum Piston at Full Stroke 11 1/8 in. 4 in. 283 mm 102 mm
Figure 2
Piston Stroke Measurement
Operator's Manual
PAGE 1-1
1.0 INSTALLATION AND OPERATION 1.1 Installation

1.1.1 Safety Precautions
WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. WARNING: DO NOT USE THE FOUR LIFT EYES MOUNTED ON THE ANNULAR BOP BODY TO LIFT THE BOP STACK ASSEMBLY. THESE LIFT EYES ARE FOR LIFTING THE GK 11"-5000 PSI ANNULAR BOP ASSEMBLY ONLY. B. Annular BOP Installation Procedure 1. Gather the following tools and materials: a. Lifting apparatus for lifting the annular BOP assembly. CAUTION: Ensure that the lifting apparatus is adequate to safely support the weight of the annular BOP assembly. NOTE: Refer to Section 2, "Physical Data" for estimated weight. b. Lightweight oil (Gulf "Harmony No. 46" or Exxon "Coray 100") c. One new API ring gasket for bottom connection d. Emery cloth, 240-grit or finer 2. Inspect the ring groove in the mating flange. Remove minor damage by polishing the groove with 240-grit or finer emery cloth. Apply light machine oil to the ring groove and wipe it clean, leaving only a film of oil on the surface. 3. Apply lightweight oil to a new API ring gasket and wipe it clean, leaving only a film of oil on the surface. Install the new ring gasket into the ring groove of the mating flange. 4. Attach lifting apparatus to the four padeyes/anchor shackles on the annular BOP (refer to Figure 1-1 for sling arrangement). 5. Lift and position the annular BOP over the mating connection. 6. Inspect the ring groove in the connection of the annular BOP. Remove minor damage by polishing the groove with 240-grit or finer emery cloth. Apply lightweight oil to the ring groove and wipe it clean, leaving only a film of oil on the surface. 7. Lower the annular BOP onto the mating connection, aligning the hydraulic connection ports with the hydraulic lines and taking care not to damage the ring gasket. 8. Make up the bottom connection. 9. Remove the lifting apparatus. 10. Connect the Open and Close hydraulic lines to the annular BOP.
1.1.2 Weight and Dimensions

For dimensions and weight, refer to Section 2,"Physical Data."
1.1.3 Annular BOP Removal and Installation Procedures

NOTE: For initial installation, refer to Surface Operation and Hookup and Surface Stripping Operations in this section for information on connection of hydraulic operating lines to the blowout preventer. The GK 11"-5000 PSI Annular BOP is usually installed at the top of a BOP stack. Normally, the annular BOP does not require removal from the BOP stack and subsequent installation for field repair. The procedures below are intended for those circumstances where the annular BOP would require removal from the BOP stack for inspection of the bottom connection or for other reasons and subsequently would require installation again. A. Annular BOP Removal Procedure 1. Gather a lifting apparatus for lifting the annular BOP assembly. CAUTION: Ensure that the lifting apparatus is adequate to safely support the weight of the annular BOP assembly. NOTE: Refer to Section 2, "Physical Data" for estimated weight. 2. Disassemble the BOP stack to the point where the annular BOP can be removed. 3. Attach the lifting apparatus to the four padeyes/anchor shackles on the body of the annular BOP (Refer to Figure 1-1 for sling arrangement). 4. Disconnect all hydraulic lines. 5. Disconnect bottom connection and lift the annular BOP free.
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PAGE 1-2
Figure 1-1
Sling Arrangement for Lifting BOP
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PAGE 1-3
1.2 Operation
1.2.1 Operating Procedures
2. A. Opening the Annular BOP 1. To open the annular BOP, vent operating pressure from the Close chamber. 2. Apply opening pressure to the Open chamber. Refer to Surface Operation and Hookup in this section. B. Closing the Annular BOP 1. To close the annular BOP, vent operating pressure from the Open chamber. Apply closing pressure to the Close chamber. Refer to Surface Operation and Hookup in this section.
1.2.2 Operating Data Refer to Section 2, "Physical Data." 1.2.3 Operational Characteristics Summary The GK sucessfully passed the fatigue and stripping life tests. For sealing characteristics test data, contact Hydril.
Head Wear Plate Packing Unit Clamping Screw Radial Latch
Opening Chamber Piston Closing Chamber Inner Sleeve Body
Figure 1-2
Cutaway view of GK with packing unit fully open.
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PAGE 1-4
1.2.4 Principle of Operation

The Hydril GK 11"-5000 PSI annular BOP (Figure 1-2) is an annular blowout preventer as defined by API Specification 16A. It will close and seal off on drill pipe, tool joints, tubing, casing, or wireline in the wellbore or completely seal off the open hole to full rated working pressure. Seal off is effected by raising the piston which causes the packing unit to be squeezed inward to a sealing engagement with anything in the bore or with itself on open hole (refer to Figures 1-3 through 1-7). The piston is raised by applying hydraulic pressure to the closing chamber. The optimum closing pressure is the minimum pressure that will maintain a complete seal under existing operational conditions. During well control operations, drill pipe can be rotated and tool joints stripped through a closed packing unit while maintaining a full seal on the pipe. Any normal closing unit having a separate regulator valve for the annular blowout preventer and sufficient accumulator volume can be used to operate the GK 11"-5000 PSI annular blowout preventer. Any clean, light petroleum hydraulic oil will serve as a hydraulic operating fluid. Fresh water may be used in a 50/50 water and ethylene glycol mixture with a corrosion inhibitor added. (CAUTION: Do not use synthetic fluids or fuel oils. Use of these types of operating fluids will cause serious damage to seals.) For additional discussion and specific hydraulic fluid recommendations, refer also to Hydril Engineering Bulletin EB 99009 on the Hydril Website www.hydril.com. This blowout preventer has been developed primarily for use on surface installations. In addition, the GK meets the requirements of API Recommended Practices R.P. 53* (available from the American Petroleum Institute, Production Department, 1220 L Street, Northwest, Washington, DC 20005) as well as NACE 10-75-43. NOTE: Some GK assemblies manufactured before 1980 are not be certified to NACE. Certification of these units must be performed at a Hydril Authorized Repair Facility (ARF). If certification is desired, contact Hydril or visit Hydril Website www.hydril.com for the nearest ARF.
Figure 1-3
Upward force exerted by the piston squeezes packing unit rubber inward into a sealing engagement.
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PAGE 1-5
Figure 1-4
Cutaway view of GK BOP with packing unit fully open. The Hydril GK opens to full bore to allow passage of large-diameter tools through open bore as well as maximum annulus flow of drilling fluids. Packing unit always returns to the open position due to normal resiliency of rubber packing unit. Retention of opening chamber pressure will provide positive control of piston and reduce wear caused by vibration.
Figure 1-5
Cutaway view of GK BOP with packing unit closed on drill pipe. The packing unit seals off on tool joints, drill pipe, casing, tubing, or wireline to rated pressure.
Figure 1-6
Cutaway view of GK BOP with packing unit closed on square kelly. The packing unit seals off on square or hexagonal kellys to rated pressure.
Figure 1-7
Cutaway view of GK BOP with packing unit closed on open hole. Complete closure of packing unit safely holds well pressure, without leakage, equal to the rated working pressure of the preventer.
Operator's Manual
PAGE 1-6
1.2.5 Surface Operation and Hookup

The surface hookup of the GK shown in Figure 1-8 connects the hydraulic control lines to the opening and closing chambers of the BOP Pressure applied to the closing chamber raises the piston and effects the initial seal between the packing unit and drill pipe. Well pressure or test pressure also acts on the piston below the sealed-off packing unit and further increases the closing force acting on the packing unit. As the well pressure or test pressure exceeds the required level, the preventer is maintained closed by well pressure alone. As well pressure further increases, the closing force on the packing unit also increases. Closing pressure should be proportionally reduced as well pressure is increased in order to maintain optimum closing force on the packing unit and prolong packing unit life. The Control Pressure Graph, Figure 1-9, shows the relationship of closing pressure and well pressure required to effect optimum seal off for the GK 11-5000 PSI BOP. During normal drilling operations, it is recommended that the pressure regulator valve for the GK be set at the initial closing pressure shown for the size pipe being used. This 1500
Closing Pressure Opening Pressure
Figure 1-8
Standard Hookup pressure will ensure that initial seal off is achieved should a kick be encountered. During BOP testing operations, once initial seal off is achieved, closing pressure should be proportionally reduced as well pressure is increased.
CLOSING PRESSURE-PSI
CSO
1000
*Closing pressures are average and will vary slightly with each packing unit. Use closing pressure shown at initial closure to establish seal off and reduce closing pressure proportionally as well pressure is increased. Well pressure will maintain closure after exceeding the required level. **Close cautiously to prevent collapse of casing. Operating pressure may vary at temperatures other than 70oF.
500
2 7/ 8" P IPE
23 /8" PIP E
4 1/ 2" th ru 5 "
5/8" PIPE
**5 1
/2" th
ru 8
PIP E
3 1/ 2" P IPE
0 0 1000 2000 3000 4000 5000
Figure 1-9
Average Control Pressure - GK 11"-5000 PSI
WELL PRESSURE-PSI
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PAGE 1-7
1.2.6 Surface Stripping Operations

Drill pipe can be rotated and and tool joints stripped through a closed GK packing unit (Figure1-10) while maintaining a full seal off on the pipe. Longest life for the packing unit is obtained by adjusting the closing forces low enough to maintain a seal on the drill pipe with a slight amount of drilling fluid leakage as the tool joint passes through the packing unit. This drilling fluid leakage indicates optimum seal off for minimum packing unit wear and provides lubrication for the drill pipe motion through the packing unit. When rotating in a closed packing unit, it is recommended that the pipe be reciprocated (moved up and down) to minimize heat build up between the drill pipe and the packing unit. Slow tool joint stripping speeds reduce surge pressures, and thus prolong packing unit life. The pressure regulator valve should be set to provide and maintain the proper control pressure. If the pressure regulator valve does not respond fast enough for effective BOP control, a surge absorber (accumulator) shown in Figure 1-11 should be installed in the closing chamber control line adjacent to the blowout preventer. Precharge the accumulator to one-half of the closing pressure required to effect a seal off at the existing well pressure for the pipe size in use.
Surface Hookup
Closing Pressure
Closing Pressure
Opening Pressure
Opening Pressure
Figure 1-10
Example Precharge Calculation: 500 psi well pressure, 3 1/2" drill pipe Precharge = 0.50 (Closing Pressure). From Figure 1-8: Closing Pressure = 450 psi Precharge = 0.50 x 450 psi Precharge = 225 psi
Figure 1-11
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PAGE 2-1
2.0 PHYSICAL DATA 2.1 Engineering Data

English Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 inches Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5000 PSI Shell Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 PSI Closing Chamber Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . 5000 PSI Opening Chamber Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . 5000 PSI VolumeClosing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.81 gallons VolumeOpening Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.08 gallons Piston Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1/8 inches Port Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NPT* Weight-Single (Approximatevaries with connectors) . . . . . . . . . . . . . . . . . . . . . . . 8,200 lb * 1 1/4" or 1 1/2" NPT available on request Metric 279.4 mm 351.55 kg/cm2 703.1 kg/cm2 351.5 5 kg/cm2 351.55 kg/cm2 37.1 liters 30.6 liters 181 mm 3,720 kg
2.2 Bolt and Wrench Data

Ref. No. 17 18 19 30 ... ... ... Description Thread Wrench Size 3/8" Hex Key 3/4" Hex 1 1/4" Hex 1/2" -12pt. Socket .... .... 3/4" Hex Recommended Torque Lb/Ft Nm 50 55-75 100 70 Snug Snug Snug 69 75-102 136 95 Snug Snug Snug
Pipe PlugPiston Indicator Inner Sleeve Screw Head Lock Screw Wear Plate Cap Screw Eyebolt, Piston x 10" Lg. Eyebolt, Head x 1 3/4" Lg. Protector Plate Screw
1/2" NPT 1/2"-13UNC 1"-8UNC 1/2-13UNC 5/8"-11UNC 1 1/4"-7NC 1/2"-13UNC
LATCHED HEAD ONLY 22 23 Jaw Clamping Screw Spacer Sleeve Screw 2 1/4"-8UN 5/8"-18 UNF 2 1/2" Hex 3/4" Hex Key 350-475 150 475-644 203
2.3 Lubricant List

Type Lightweight Oil Thread Lubricant Source Gulf "Harmony No. 46" or Exxon "Coray 100" or Equivalent Neverseez (0.069 Coefficient of Friction) or Equivalent Moly Paste 503 (0.065 Coefficient of Friction) or Equivalent Nonpetroleum Base Oil Corrosion Inhibitor Grease Vapor Phase Corrosion Inhibitor Castor Oil Cortec VCI 369 Cortec VCI 609
Operator's Manual
PAGE 2-2
2.4 Dimensions - Screwed Head
H AS CAST J K
E F *OPENING PORT
D AS CAST
B CLAMP HUB C STUDDED A AS CAST
*CLOSING PORT M AS CAST
N AS CAST O AS CAST
Figure 2-1
Outside DimensionsScrewed Head
* 1" NPT, 1 set of ports, 45o from lifting lug unless otherwise specified. NOTE: Lifting lugs split lower connection stud holes and are equally spaced 90o apart. Lifting lugs are 1-1/4" thick with 1-1/2" diameter holes.
Nominal Dimensions Inches

A 5M 47.75 G 11.81 10M 48.50 H 44.25 5M 44.88 J 37.50 B 10M ... K 35.75 5M 39.63 L ... C 10M 40.25 M 2.00 19.06 N 32.00 5.69 O 36.75 13 3/16 D E F
Lower Connector Pressure Rating
Operator's Manual
PAGE 2-3
2.5 Dimensions - Latched Head
H AS CAST J K E F *OPENING PORT
D AS CAST
C STUDDED
*CLOSING PORT
L AS CAST
M AS CAST N AS CAST
*1 NPT, 1 set of ports, 18 from lifting lug. NOTE: Lifting lugs are equally spaced 90o apart. Lugs are 2.12 thick with 1.75 diameter holes.
Figure 2-2
Outside Dimensions Latched Head
Nominal Dimensions Inches

A 5M 48.25 G 11.25 10M 49.00 H 44.25 5M 45.31 J 42.25 B 10M ... K 36.38 5M 40.06 L 2.00 C 10M 40.69 M 32.00 19.88 N 36.75 4.00 14.19 D E F
Lower Connector Pressure Rating On BOPs built after serial number 69730: D= 27.50
A FLANGED
B CLAMP HUB
Operator's Manual
PAGE 2-4
2.6 API Ring Joint Flange Connections
B A
Bolted Flange, Using Stud Bolts.
Figure 2-3
Bolted and Studded Flange Specifications
Studded Flange, Using Studs.
FLANGE Nominal Size (Inches) 11 11 Bore Dia. (Inches) 11 11 Max. API Service Pressure Rating (PSI) 5000 10,000 O.D. (Inches) Thickness (Inches)
SEAL RING
Dia. C (Inches)
API Ring
23 25 3/4 BOLTS & STUDSa
4 11/16 5 9/16
12 3/4 14.064
RX-54 BX-158
No. Req.
Size
Lengthb (Inches) Stud Bolts A Studs B 10 1/4 10 1/4
Bolt Circle Dia. (Inches) 19 22 1/4
12 16
1 7/8 1 3/4
14 1/2 15 3/4
POINT HEIGHT OF STUD BOLTS Bolt Diameter, Inches Max. Point Height Inches 1/8 3/16 1/4 5/16 3/8
a
1/2 to 7/8 . . . . . . . . . . . . . . . . . . . . . . Over 7/8 to 1 1/8 . . . . . . . . . . . . . . . . Over 1 1/8 to 1 5/8 . . . . . . . . . . . . . . Over 1 5/8 to 1 7/8 . . . . . . . . . . . . . . Over 1 7/8 to 2 1/2 . . . . . . . . . . . . . .
Bolt material shall be of a quality and strength not less than specified by ASTM A-193, Grade B7. Nuts shall be of a quality not less than ASTM A-194, Grade 2H. Stud bolts are threaded full length. Lengths shown herein are overall lengths, including point at both ends, as shown in table. Dimensions shown are outside diameters of 6BX flange grooves, or pitch dim. in case of 6B grooves.
Operator's Manual
PAGE 2-5
2.7 Clamp Hub Connections
A G
A G
B E F
B E F
Figure 2-4
Hub Connection Specifications
HUB Hub Size (Inches) 11 11 Bore Size A (Inches) 11 11 Rated Working Pressure (PSI) 5000 10,000 Seal Ring No. Hub Dimensions (Inches) RX Only Standoff D C 3 3/4 ... 15/32 ...
RX 53 ...
BX ... 158
B 16 1/4 16 1/4
J ... 3 5/8
NOTE: API 16A 1st Edition Nov 1, 1986 Does Not Include Clamps.
Clamp Dimensions (Inches)
E 20 13/16 20 13/16
F 28 1/2 28 1/2
G 6 3/4 6 3/4
H ... ...
Clamp dimensions may vary from those shown.
Operator's Manual
PAGE 2-6
Operator's Manual
PAGE 3-1
3.0 PACKING UNITS AND SEALS 3.1 Packing Units

The heart of the GK blowout preventer is the packing unit. The unit is manufactured by Hydril from high quality rubber, reinforced with flanged steel segments. Each unit has a large volume of tough, feedable rubber to meet any requirement. The molded-in steel segments have flanges at the top and bottom These segments anchor the packing unit within the blowout preventer and control rubber extrusion and flow when sealing off well pressures. Since the rubber is confined and kept under compression, it is resistant to tears and abrasion. All annular blowout preventer packing units are subjected to wear during closure and stripping. The design of the Hydril GK blowout preventer causes closure wear to occur on the outside of the packing unit while stripping wear occurs on the inside. Because the packing unit uses the principle of feeding rubber from the back of the packing unit to the bore, stripping life may be affected by a packing unit that is worn on the backside.
Figure 3-1
Cutaway drawing showing how rubber is molded around steel segments.
Operator's Manual
PAGE 3-2
3.1.1 Packing Unit Selection

Because of the importance of the packing unit to the operation of the blowout preventer and to the safety of the crew and rig, only genuine Hydril packing units should be used as replacements for original equipment. All Hydril packing units are tested to full rated pressure inside a test blowout preventer as part of standard performance tests before being furnished to the consumer. Packing units for Hydril blowout preventers are manufactured from compounded natural rubber or nitrile rubber. Natural Rubber is compounded for drilling with waterbase drilling fluids. Natural rubber can be used at operating o o temperatures down to 30 F (35 C). When properly operated, the compounded natural rubber packing unit will usually provide the longest service life. This all-black packing unit is identified by a serial number with the suffix "R" or "NR." Nitrile Rubber (a synthetic compound) is for use with oilbase or oil-additive drilling fluids. It provides reliable service with oil-base muds, when operated at temperao o tures below 20 F (7 C). The nitrile rubber packing unit is identified by a red colored band and a serial number with the suffix "S" or "NBR." Seals for Hydril blowout preventers are manufactured from a special nitrile rubber material which provides dependable service in sealing against oil gas, or water. Expected H2S Service does not affect selection of packing unit material. H2S service will reduce the service life of rubber products, but the longest service life is obtained by matching the packing unit material with the requirements of the specific drilling fluid. Performance of elastomeric materials can vary significantly, depending on the nature and extent of exposure to hydrogen sulfide. The operator should monitor pressure sealing integrity by frequently performing a packing unit seal test on the pipe diameter currently in use to assure no performance degradation has occurred. Storage Conditions such as light, heat or adverse conditions are significant factors in the storage life of packing units, as covered in Section 6.3 and should be avoided.
No Band
Figure 3-2
Natural Rubber Packing Unit No Band
Red Band
Figure 3-3
Synthetic Rubber Packing Unit Red Band
Operator's Manual
PAGE 3-3
3.1.2 Packing Unit Replacement Screwed Head

To replace the packing unit, use the following procedure: NOTE: The procedure that follows is the short version of more detailed procedure in Section 6. 1. Remove head lock screw. 2. Install eyebolts and unscrew blowout preventer head counter-clockwise (Figure 3-4). 3. Lift off blowout preventer head (Figure 3-5). 4. Lift out packing unit (Figure 3-6). 5. Lubricate piston bowl with castor oil. 6. Install new packing unit, lubricated with castor oil. 7. Clean and lubricate head and body threads with Neverseez lubricant. 8. Replace head and tighten to align hole for lock screw. 9. Install head lock screw and torque to 100 lb-ft. NOTE: If the head was improperly installed at last reassembly, it may be necessary to apply considerably more torque on the head by the use of a catline or winch while alternately applying and releasing pressure to the opening chamber (1500 psi maximum). CAUTION: Do not attempt to loosen the head by applying heat. Refer to Section 5, Disassembly and Assembly for further information. OPENING TORQUE
Figure 3-4
Figure 3-5
Figure 3-6
Operator's Manual
PAGE 3-4
3.1.3 Packing Unit Replacement Latched Head

The latched head design of the GK blowout preventer allows for easy replacement of the packing unit and eliminates loose parts that can be lost downhole or overboard. To replace the packing unit, use the following procedure: NOTE: The procedure that follows is the short version of more detailed procedurew in Section 6. 1. Retract jaw clamping screws four turns to release the jaws from the head (see Figures 3-8 and 3-9). 2. Remove head clamps and screws from top of head. 3. Lift off preventer head (see Figures 3-5 and 3-10). 4. Lift out the packing unit (see Figure 3-6) and lubricate the piston bowl with castor oil. 5. Install the new packing unit (see Figure 3-6), lubricated with castor oil. 6. Install the head (see Figure 3-11). HEAD 7. Tighten jaw clamping screws four turns and torque to 350 - 475 lb-ft (475-644 Nm). See Figure 3-7.
Figure 3-9
Head in place but jaw and jaw clamping screws have been retracted (four turns).
Head Clamp Screw Head Clamp
Clamping Screw
Pipe Plug SleeveScrew Spacer Sleeve Jaw Head
Figure 3-10
Head removed, but all latching mechanisms remain in body.
Standoff
Figure 3-7
Head latched in place and jaw clamping screws tightened.
Figure 3-11 Figure 3-8

Retract jaw clamping screws (4-turns counterclockwise). On assembly, if standoff between head and body occurs, use head clamps to pull head fully into place and eliminate standoff.
Operator's Manual
PAGE 3-5
3.2 Seals
The seals for Hydril blowout preventers are manufactured from a special synthetic rubber material for long troublefree sealing service. The hydraulic operating fluid may be clean, light petroleum hydraulic oil, or water with soluble oil added. In cold climates, antifreeze should be added to prevent freezing (CAUTION: To prevent seal damage, Do Not use synthetic fluids in the hydraulic operating system). For additional discussion and specific hydraulic DYNAMIC SEALS DOUBLE U-SEAL cross-section with nonextrusion rings fluid recommendations, refer also to Hydril Engineering Bulletin EB 99009 on the Hydril Website www.hydril.com. The dynamic seals are all molded, lip-type, pressureenergized rings. The static seals are of O-ring and square ring configuration. For seal replacement procedure, see Section 5, Diassembly and Assembly. For seal maintenance and testing, refer to Section 4. STATIC SEALS
U-SEAL cross-section
O-RING cross-section
SQUARE RING cross-section
Figure 3-12
Operator's Manual
PAGE 3-6
3.3 Wear Bands

Manufactured from tough durable thermoplastic and installed on new and modified models, wear bands improve the performance of the GK BOP by protecting sealing surfaces on the piston and body from metal to metal contact. As a result, seal life is increased and wear to the sealing surfaces on the piston and body is reduced significantly. Installed on models with wear bands, the rubber wiper ring prevents drilling mud and debris from entering the space between the upper piston and the head and possibly damaging the wear bands. Models not equipped with wear bands can be modified at a Hydril Authorized Repair Facility (ARF). Contact Hydril or refer to Hydril Website www. hydril.com for the nearest ARF. Refer also to Section 4.7 for additional modifications available.
Wiper Ring
Head Wear Band
Head to Piston Seal Piston Sealing Surface Body Sealing Surfaces
Wear Band Lower Piston Seal
Figure 3-13
Operator's Manual
PAGE 4-1
4.0 MAINTENANCE AND TESTING

WARNING: HYDRIL IS NOT RESPONSIBLE FOR ANY ALTERATIONS, MODIFICATIONS OR REPAIRS TO THE BLOWOUT PREVENTER (BOP), ITS INTERCONNECTS AND COMPONENTS, UNLESS PERFORMED WITH HYDRIL SUPPLIED PARTS AND THE WORK PERFORMED BY A HYDRIL AUTHORIZED REPRESENTATIVE. ALTERATIONS, MODIFICATIONS, OR REPAIRS PERFORMED OTHERWISE MAY RESULT IN DAMAGE TO THE BOP OR FAILURE OF THE BOP TO OPERATE AS DESIGNED AND MAY RESULT IN SERIOUS PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. UNAUTHORIZED ALTERATIONS, MODIFICATIONS, REPAIRS OR USE OF PARTS OTHER THAN THOSE SUPPLIED BY HYDRIL WILL VOID THE STANDARD WARRANTY OF THE BOP AS OUTLINED IN THE TERMS AND CONDITIONS AGREEMENT. WARNING: BEFORE THE INITIAL START UP, OR PRIOR TO POST REPAIR START UPS, VERIFY CONTAMINANTS, DEBRIS, AND OTHER FOREIGN MATERIALS HAVE BEEN FLUSHED FROM THE FLUID SUPPLY LINES. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE BOP OR FAILURE OF THE BOP TO OPERATE AS DESIGNED AND MAY RESULT IN SERIOUS PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
4.1 Troubleshooting
Troubleshooting the annular BOP is provided in the form of a fault analysis tree. If the packing unit fails to close and seal, refer to Figure 4-1.
4.2 Maintenance Schedule

Periodic maintenance is a very important part of keeping the Hydril GK 11"-5000 PSI Annular BOP in good operating condition. Not only will regular maintenance extend the service life of the equipment, but it will also help to eliminate unnecessary down time. This section contains a maintenance schedule (Table 4-1) that is designed to help maintain the annular BOP by displaying in tabular form the recommended service interval for each required maintenance operation.
TABLE 4-1 MAINTENANCE SCHEDULE Maintenance Operations I = Inspect; R = Replace; T = Pressure Test: P = Inspect Precharge Item Equipment/Component Service Interval & Maintenance Operations As Required 1 2 3 4
a b
c
Refa
Yearly
Between Wellsc I 4.3 4.0;3.0 4.0;5.0 5.0
GK Annular BOP Packing Unit Seals Wear Bands T T Rb Rb Rb
I I I
Paragraph where maintenance procedure is located. Not to exceed 24 calendar months. Hydril only provides recommendations for inspections and maintenance. Depending on the drilling program, it may not be possible to inspect the BOP between wells.
Operator's Manual
PAGE 4-2
PACKING UNIT FAILS TO CLOSE & SEAL
PACKING UNIT FAILS TO SEAL
PACKING UNIT FAILS TO CLOSE
PACKING UNIT LEAKAGE
WORN WEAR PLATE
CONTROL SYSTEM PROBLEMS
SEAL LEAKAGE
MECHANICAL PART FAILURE
Increase closing pressure or replace as necessary.
Inspect wear plate and replace as necessary.
Refer to operations and maintenance manual.
Test seals and replace as necessary.
Latched Head
PISTON STROKE
LATCH FAILURE
CLAMPING SCREW FAILURE
Check piston stroke.
Inspect latch and make repairs.
Inspect latch and make repairs.
Latched Head & Screwed Head

GALLED WEAR PLATE BENT PACKING UNIT INSERTS Inspect packing unit and replace if necessary.
GALLED PISTON
Inspect piston and make repairs.
Inspect wear plate and make repairs.
Figure 4-1
GK 11"-5000 Annular BOP Fault Analysis Tree - Packing Unit Fails to Close and Seal
Operator's Manual
PAGE 4-3
4.3 Inspection
NOTE: The Hydril GK blowout preventer is a primary pressure vessel. The blowout preventer surfaces exposed to wellbore fluids will meet NACE Standard MR-01-75. Proper handling and repair are required to maintain any original integrity. Field welding is not recommended as it, 1) induces undesirable stresses which must be relieved by proper heat treating procedure or controlled by special welding procedures and 2) negates certification to NACE . If your assembly was manufactured before 1980, it may not be certified to NACE. Welding, machining, stress relieving or NACE certification must be performed at a Hydril Authorized Repair Facility (ARF). Contact Hydril or go to Hydril Website www.hydril.com for the nearest ARF. Prior to placing the GK blowout preventer into service, the following visual inspections should be performed (step numbers match Figure 4-2): 1. Inspect upper and lower connections for pitting, wear, and damage, especially in ring grooves and stud bolt holes. Worn or damaged ring grooves must be welded, machined, and stress relieved (see NOTE above). Worn or damaged stud bolt holes can be drilled and tapped to the next larger size and fitted with step-studs. 2. Check the body for wear and damage, especially in the internal cylinder walls for pits and vertical scores. Minor pits and scores can be removed in the field with emery cloth. Repaired surface should be coated with castor oil. Severe pits, scores, and cracks may require machining and/or welding (see NOTE above). 3. Inspect the vertical bore for excessive wear and damage from drill string and drill tools, especially in the area of the ring grooves. If wear is excessive, see NOTE above. 4. Check the inner body sleeve for wear, damage, and looseness. Check slots in sleeve for cuttings which may restrict piston movement. Some model BOPs have a welded body sleeve and may be modified by conversion to a bolted sleeve. Contact the nearest Hydril ARF (see NOTE above) for modification. 5. Check for piston damage and wear, especially the inner and outer walls for pits and vertical scores and the tapered bowl for pits and gouges. Minor pits and scores on the walls can be removed in the field with emery cloth. Repaired surface should be coated with castor oil. Severe pits and scores may require machining and/or welding. Contact the nearest Hydril ARF (see NOTE above) for repair. Pits and gouges in the tapered bowl should be filled with a permanent type adhesive, such as epoxy. Sharp or rolled edges should be removed with emery cloth or a grinder. Repair is satisfactory when the surface is relatively smooth. 6. Check the wear plate on the inner bottom face of the head for wear. In addition to the aging process of time and use, wear of this metal surface is produced by the combination of vertical (upward thrust) and lateral forces. These forces are generated each time the packing unit is closed. Severe wear is exhibited in the form of grooves or channels shaped by the steel segments of the packing unit. The inner bottom face of the head serves as a wall to prevent upward movement of the packing unit. Friction between these metal surfaces is controlled at a level which does not impair lateral movement of the packing unit. Repair of this surface is accomplished by replacing the wear plate. Some models of this BOP do not have the wear plate, but may be modified. Contact the nearest Hydril ARF (see NOTE above) for modification. 7. Inspect the packing unit for wear, cracking, hardness, and correct elastomer composition. See Section 3 for packing unit information and this section for packing unit testing. 8. Check seals and wear bands (if equipped) for nicks, cuts, fraying of lips, and abrasion. Worn or damaged seals and wear bands should be replaced. Hydril recommends that all seals and wear bands be replaced after one year service or whenever the BOP is disassembled. See Section 4 for pressure testing of seals. 1 3 6 8 7 8 5
Figure 4-2
Operator's Manual
PAGE 4-4
4.4 Seal Testing - GK Without Wear Bands

When it is known or suspected that a seal within the GK blowout preventer is leaking, it is recommended that all seals be replaced. However, if only the seal in question is to be replaced, it must first be determined which seal is leaking. The following procedure is provided: Refer to Figure 4-3 while following this procedure.
1. Gather the following tools and materials: a. 5000 PSI (345 Bar) pressure source b. 3 1/2-inch test pipe c. Blind flange, 11-5000 PSI d. RX-54 ring gasket 2. Install the annular BOP onto test stump with hydraulic pressure source connected to the Open and Close ports. 3. Install test pipe into test stump.
4. Test seals 9 (lower) and 10 (upper). a. Pressurize closing chamber. The test pressure to be used in the closing chamber should be the initial closing pressure required using the recommended test mandrel if a packing unit is installed (1500 PSI/ 104 Bar if no packing unit is installed). b. Open opening chamber to atmosphere. IF: Closing fluid is seen at opening chamberseal 9 (lower) is leaking. IF: Closing chamber pressure gauge is dropping and no fluid is seen at opening chamberseal 10 (upper) is leaking. Test seals 8 (lower), 9 (upper), and 6. a. Pressurize opening chamber (1500 PSI). b. Open closing chamber to atmosphere. IF: Fluid is seen coming from area between body and headseal 6 is leaking. IF: Fluid is seen coming into the wellboreseal 8 (lower) is leaking. IF: Fluid is seen at closing chamberseal 9 (upper) is leaking. Test seals 8 (upper) and 10 (lower). a. Open closing chamber to atmosphere. b. Open opening chamber to atmosphere. c. Install blind flange on top and pressurize wellbore (5000 PSI/345 Bar maximum). WARNING: THE RATED WORKING PRESSURE OF THE GK ANNULAR BOP IS 5000 PSI (345 BAR). USE EXTREME CAUTION WHEN WORKING WITH HIGH PRESSURE. TAKE EVERY PRECAUTION TO PROTECT PERSONNEL FROM COMING IN CONTACT WITH PRESSURE DURING TESTING OPERATIONS. IF: Fluid is seen coming from the opening chamber seal 8 (upper) is leaking.
8 UPPER
8 LOWER
9 UPPER 9 LOWER 10 UPPER 10 LOWER
5.
6.
Figure 4-3
IF: Fluid is seen coming from the closing chamber seal 10 (lower) is leaking.
7. 8. 9. 10.
Reduce wellbore pressure to zero. Drain wellbore fluid. Remove blind flange. Test packing unit or return the BOP to service.
For packing unit testing, see procedure in this section.
Operator's Manual
PAGE 4-5
4.5 Seal Testing - GK With Wear Bands

When it is known or suspected that a seal within the GK Annular BOP is leaking, it is recommended that all seals be replaced. However, if only the seal in question is to be replaced, it must first be determined which seal is leaking. Use the following procedure for testing the seals in the GK Annular BOP. Refer to Figure 4-4 while following this procedure.
1. Gather the following tools and materials: a. 5000 PSI (345 Bar) pressure source b. 3 1/2-inch test pipe c. Blind flange, 11-5000 PSI d. RX-54 ring gasket 2. Install the annular BOP onto test stump with hydraulic pressure source connected to the Open and Close ports. 3. Install test pipe into test stump.
4. Test middle piston seal (B) and lower piston seal using closing operating pressure: a. Open opening chamber to atmosphere. b. Apply 1500 psi (104 Bar) operating pressure to the closing chamber to close the packing unit around the test pipe. IF: Closing fluid seen coming from the Open port indicates that middle piston seal (B) is leaking. IF: Closing fluid seen in the wellbore indicates that lower piston seal is leaking. Test head to piston seal, head gasket, and middle piston seal (A) using opening operating pressure: a. Reduce closing pressure to zero and open the closing chamber to atmosphere. b. Apply 1500 PSI (104 Bar) operating pressure to the opening chamber to open the packing unit. IF: Opening fluid coming from the Close port indicates that middle piston seal (A) is leaking. IF: Opening fluid seen in wellbore or coming from relief valve indicates that the head to piston seal is leaking, or the head gasket seal is leaking, or both the head to piston seal and head gasket are leaking. NOTE: The relief valve is a spring check valve which allows venting of pressure which could be trapped in the latching mechanism. This valve is reusable provided the spring is not frozen or damaged. Test head to piston seal and lower piston seal , using rated working pressure: a. Reduce opening pressure to zero and open the opening and closing chambers to atmosphere. b. Remove test pipe and attach a blind flange to top of annular BOP. c. Fill wellbore with tap water. d. Install blind flange on top and pressurize wellbore (5000 PSI/345 Bar) maximum. WARNING: THE RATED WORKING PRESSURE OF THE GK ANNULAR BOP IS 5000 PSI (345 BAR). USE EXTREME CAUTION WHEN WORK-
Head O-Ring Seal Clamping Screw O-Ring Seal Wiper Seal Head Gasket Wear Band Head to Piston Seal Middle A Piston Seals B Wear Band Lower Piston Seal
5.
Figure 4-4
6.
ING WITH HIGH PRESSURE. TAKE EVERY PRECAUTION TO PROTECT PERSONNEL FROM COMING IN CONTACT WITH PRESSURE DURING TESTING OPERATIONS. IF: Wellbore fluid coming from the Open port indicates that head to piston seal is leaking. IF: Wellbore fluid coming from the Close port indicates that lower piston seal is leaking. Testing of the head O-ring, clamping screw O-ring, and wiper seal is not required.
7.
9. 10. 11. 12.
Reduce wellbore pressure to zero. Drain wellbore fluid. Remove blind flange. Test packing unit or return the BOP to service. For
packing unit testing, see procedure in this section.
Operator's Manual
PAGE 4-6
4.6 Packing Unit Testing

Proper procedure for pressure testing any annular blowout preventer ensures subsequent seal off and maximum packing unit life. Reliable pressure seal off tests are made by closing the packing unit with prescribed closing chamber pressure on recommended size test pipe and by determining the remaining piston travel after seal off is achieved. Optimum packing unit life is obtained by testing at low rubber stress levels. Minimum packing unit stress is achieved by use of the minimum closing chamber pressure that will initiate and maintain a seal off on the recommended size test pipe.
4.6.1 Packing Unit TestingSurface

The GK blowout preventer is designed to be well pressure assisted in maintaining packing unit seal off once initial seal off has been effected. Initial seal off is effected by applying pressure to the closing chamber. As well pressure or test pressure increases, the closing force on the packing unit also increases. As well pressure exceeds the required level, the packing unit is maintained closed on pipe by well pressure alone. During routine BOP testing, once initial seal off is achieved, closing pressure should be proportionally reduced as well pressure is increased (see the Control Pressure Graph, Figure 1-9). Closing pressure required to effect initial seal off may vary between packing units. Begin the test with the recommended initial closing pressure shown in Figure 1-8, depending on the style packing unit installed. Piston Stroke can be measured on GK blowout preventers through a vertical passage* in the top of the BOP head. The maximum and minimum distances from the top of the head to the top of the piston are stamped on the BOP head and are also listed in the table below. Piston stroke remaining at seal off is a direct indicator of remaining packing unit life. Record the piston stroke and the closing pressure at initial seal off for each test. Compare with previous results and with maximum piston stroke for the BOP to ensure subsequent seal offs. A valid test on any annular BOP is only achieved when the remaining piston stroke is measured at test seal off.
3
TAPE MEASURE
2
5/16" ROD
Distance From Top of Head to Top of Piston Maximum (piston in full down position) Minimum (piston at full stroke) 11-1/8" 4"
* Older model BOPs may not have the piston indicator hole as shown in Figure 4-5. See BOP Modifications in this section for piston indicator hole modification as well as other modifications available. Themodification to add the piston indicator hole must be performed at a Hydril Authorized Repair Facility (ARF). Contact Hydril or go to Hydril Website www.hydril.com for the nearest ARF.
Figure 4-5
Piston Stroke Measurement
Operator's Manual
PAGE 4-7
4.7 BOP Modifications

Older model BOPs without piston indicator holes, wear plates, bolted inner sleeves, or wear bands can be modified at a Hydril Authorized Repair Facility (ARF). Contact Hydril or visit Hydril Website www.hydril.com for the nearest ARF.
Operator's Manual
PAGE 4-8
Operator's Manual
PAGE 5-1
5.0 DISASSEMBLY AND ASSEMBLY 5.1 Disassembly - Screwed Head Without Wear Bands
Refer to Figure 5-1 while following this procedure. Numbers in figure correspond to items numbers in procedure. WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, disassembly of the GK annular BOP can be performed with standard tools. 1. Three eyebolts (5/8-11UNC x 10 Lg.), Hydril Part No. 30952 (for lifting piston) 2. Three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 32006 (for lifting head) 3. Chain sling, Hydril Part No. 33565-M (CAUTION: The chain sling is for disassembly and assembly purposes only. Do not use the chain sling to lift the annular BOP assembly.) 4. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No. 1900076-08 (for lifting packing unit). B. Vent Pressure. 1. Vent the closing and opening chambers to atmosphere, ensuring that no trapped pressure exists which will cause injury to personnel and/or damage the equipment. 2. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. C. Remove Head. 1. Remove head lock screw (Item 19). 2. Install three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.) into the head (Item 1) 3. Unscrew the head counterclockwise from the BOP body. NOTE: Use a piece of strong pipe or rod (3" to 4" in diameter x 10' to 12' long) as a lever against the eyebolts to apply counterclockwise (left hand) torque on the head (refer to Figure 5-2). A vertical lift, using the chain sling, may be applied to the eyebolts to take the weight of the head off of the threads while applying torque to the head. This lift will reduce the required turning torque. If the head 17 19
1 6 8 29 30 2
1 3
9 10
18
Figure 5-1:
Screwed Head GK 11"-5000 PSI Without Wear BandsDisassembly
Operator's Manual
PAGE 5-2
4. 5. 6.
7.
was improperly installed at the last assembly, it may be necessary to apply considerable more torque on the head by the use of a winch or catline while alternately applying and releasing pressure to the opening chamber (1500 PSI/104 Bar maximum). CAUTION: Do not loosen the head by applying heat to the thread area. Attach the Hydril chain sling and lift the head straight up and off the body. Remove the head gasket (Item 6) and upper Useals (Items 8). Remove the capscrews (Item 30) and the wear plate (Item 29). NOTE: Some models do not have a wear plate. Remove chain sling from eyebolts.
Head Installation
Head Removal
D. Remove Packing Unit. 1. Install two eyebolts (5/8"-11UNC x 1 3/4 Lg.) into packing unit (Item 2). 2. Using the Hydril chain sling, lift the packing unit out of the piston. 3. Remove sling and eyebolts. E. Remove Piston. 1. Install three eyebolts (5/8-11UNC x 10 Lg. ) into the piston (Item 3). 2. Using Hydril chain sling, gently lift piston out of the preventer body. If a vertical lift is not possible or the piston does not lift out freely, slowly apply low (50 PSI) hydraulic pressure to the closing chamber. WARNING: DO NOT USE AIR OR GAS. 3. 4. Remove middle U-seals (Items 9) and lower Useals (Items 10). Remove the sling and eyebolts from the piston.
Figure 5-2:
Head Removal/Installation
F. Remove Inner Sleeve. NOTE: This step is not applicable to model BOPs that have a welded body sleeve which is not removable. 1. Remove the capscrews (Item 18) from around the inner sleeve (4). 2. Insert the hooks of the Hydril chain sling (equally spaced) in the slots of the inner sleeve and lift the sleeve out of the annular BOP. 3. Remove the chain sling.
Operator's Manual
PAGE 5-3
5.2 Assembly - Screwed Head Without Wear Bands

Refer to Figure 5-3 and 5-4 while following this procedure. Numbers in figures correspond to item numbers in procedure. WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, assembly of the GK annular BOP can be performed with standard tools. 1. Three eyebolts (5/8-11UNC x 10 Lg.), Hydril Part No. 30952 (for lifting piston) 2. Three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 32006 (for lifting head) 3. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No. 1900076-08 (for lifting packing unit) 4. Chain sling, Hydril Part No. 33565-M (CAUTION: The chain sling is for disassembly and assembly purposes only. Do not use the chain sling to lift the annular BOP assembly.) 5. Castor oil 6. Moly Paste 503 thread lubricant (Coefficient of Friction is .065) or equivalent 7. Neverseez lubricant 8. Spare parts including seal kit. Refer to Section 6, "Parts and Storage." B. Clean, Inspect BOP, and Lubricate. 1. Clean all components thoroughly. 2. Perform the inspection procedures that are applicable in Section 4, "Maintenance and Testing". 3. Ensure that working surfaces are free of burrs, rough edges, or other defects. 4. Inspect all seals installed in the head and piston, and replace any damaged seals in use over one year. (NOTE: Hydril recommends that all seals be replaced whenever a BOP is disassembled and assembled.) Seals must be installed as shown in Figure 5-3 and 5-4. Coat packing unit, seals, and non-extrusion rings with castor oil before installation. CAUTION: Use of petroleum base oil or grease will reduce seal life. 5. Lubricate the threads of nuts, bolts, and capscrews with Moly Paste 503 thread lubricant. 6. Coat interior surfaces with castor oil except wear band grooves in the head and piston . 7. Lubricate body threads on the head and body with Neverseez lubricant.
NOTE: Seal Rings MUST BE installed in position shown by cross-section. 17 19
1 6 8 29
30 2
1 3
9 10
18
Figure 5-3:
Screwed Head GK 11-5000 PSI- Without Wear BandsAssembly
Operator's Manual
PAGE 5-4
C. Install Inner Sleeve. NOTE: This step is not applicable for models that have a welded body sleeve . 1. Insert hooks of Hydril chain sling (equally spaced) into slots in inner sleeve (Item 4) and install the sleeve into the bore of the body. 2. Install the capscrews (Item 18) and torque to 150 lbft (203 Nm). 3. Remove chain sling. D. Install Piston. 1. Install the lower U-seals (Item 10), on the lower segment of the piston (Item 3). 2. Install the middle U-seals (Items 9) on the upper segment of the piston. 3. Install three eyebolts (5/8-11UNC x 10 Lg.) into the piston. Attach the Hydril chain sling to the eyebolts and install the piston over the inner sleeve (Item 4) and into the body. Ensure that the piston is aligned vertically with the body prior to lowering. Vent Close port. With proper vertical alignment, the piston will slide its normal full stroke to the bottom of the preventer body. CAUTION: Be careful not to damage the seals during assembly. 4. Remove the chain sling and eyebolts from the piston. E. Install Packing Unit. 1. Lubricate the bowl of the piston (Item 3) and packing unit (Item 2) with castor oil. Install two eyebolts (5/8"-11 UNC x 1 3/4 Lg.) into packing unit. Using Hydril chain sling, lift the packing unit and set it into the bowl of the piston. 2. Remove the chain sling and eyebolts from the packing unit. F. Install Head. 1. Install the wear plate (Item 29) and capscrews (Item 30) on the inner face of the annular head (Item 1). Torque the capscrews to 50 lb-ft (68 Nm). NOTE: This step is not applicable to models that do not have a wear plate. 2. Install the head gasket (Item 6) in the seal groove on the outside diameter of the head, just below the major diameter. 3. Install the upper U-seals (Item 8) on the inside bottom diameter of the head. 4. Install three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.) into the head. 5. Lubricate the body threads on the outside diameter of the head and the inside diameter of the body (Item 5) with Neverseez lubricant. 6. Install the head into the body so that the body threads on the head engage the threads of the body. Remove the chain sling.
7.
8. 9.
Tighten the head clockwise (right hand) as shown in Figure 5-2, using the pipe or rod from Step C of the disassembly procedure, until the shoulder on the head engages the body. A vertical lift, using the chain sling attached to the eyebolts, will reduce the weight on the threads and reduce the required turning torque. Align the head lock bracket with the hole in the body. Lubricate the lock screw threads (Item 19) with Moly Paste 503 and install. Tighten the lock screw using 60 lb-ft (80 Nm) torque. Remove the chain sling and eyebolts from the head. Perform seal and packing unit test procedures in Section 4, "Maintenance and Testing."
Operator's Manual
PAGE 5-5
Pipe Plug (17)
Head Lock Screw (19) BOP Head Screwed (1) Head Gasket (6) Wear Plate Capscrew (30) Wear Plate (29) U-Seal, Upper (8) Packing Unit (2) Piston (3) U-Seal, Middle (9) Body (5)
Inner Sleeve (4)
U-Seal, Lower (10)
Inner Sleeve Capscrew (18)
Figure 5-4
Cutaway of Screwed Head GK 11-5000 PSI BOP Without Wear Bands Showing Position of Parts.
Operator's Manual
PAGE 5-6
5.3 Disassembly - Screwed Head With Wear Bands

Refer to Figure 5-5 while following this procedure. Numbers in figure correspond to item numbers in procedure. WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, disassembly of the GK annular BOP can be performed with standard tools. 1. Three piston lift assemblies, Hydril Part No. 3105638-6 2. Three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 3112077 (for lifting head) 3. Chain sling, Hydril Part No. 1900179-0354 (CAUTION: The chain sling is for disassembly and assembly purposes only. Do not use the chain sling to lift the annular BOP assembly.) 4. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No. 1900076-08 (for lifting packing unit). B. Vent Pressure. 1. Vent the closing and opening chambers to atmosphere, ensuring that no trapped pressure exists which will cause injury to personnel and/or damage the equipment. 2. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. C. Remove Head. 1. Remove head lock screw (Item 19). 2. Install three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.) into the head (Item 1) 3. Unscrew the head counterclockwise from the BOP body. NOTE: Use a piece of strong pipe or rod (3" to 4" in diameter x 10' to 12' long) as a lever against the eyebolts to apply counterclockwise (left hand) torque on the head (refer to Figure 5-2). A vertical lift, using the chain sling, may be applied to the eyebolts to take the weight of the head off of the threads while applying torque to the head. This lift will reduce the required turning torque. If the head was improperly installed at the last assembly, it 17 19
1 6 15 13 12 30 2 11 29
14 34 33 4 18
Figure 5-5:
Screwed Head GK 11"-5000 PSI With Wear BandsDisassembly
Operator's Manual
PAGE 5-7
4. 5.
6. 7.
may be necessary to apply considerable more torque on the head by the use of a winch or catline while alternately applying and releasing pressure to the opening chamber (1500 PSI/104 Bar maximum). CAUTION: Do not loosen the head by applying heat to the thread area. Attach the Hydril chain sling and lift the head straight up and off the body. Remove the head gasket (Item 6), head to piston double U-seal (Items 11 and 12), wiper ring (Item 15) and wear band (Item 13) . Remove the capscrews (Item 30) and wear plate (Item 29). Remove chain sling and eyebolts.
Eyebolt
Lift Device
D. Remove Packing Unit. 1. Install two eyebolts (5/8"-11UNC x 1 3/4 Lg.) into packing unit (Item 2). 2. Using the Hydril chain sling, lift the packing unit out of the piston. 3. Remove sling and eyebolts. E. Remove Piston. 1. Install three piston lift assemblies onto the piston (Item 3) as follows and as shown in Figure 5-6: a. Screw each eyebolt into the piston. b. Tighten the eyebolts until the retaining ring and spacer block are snug against the piston. c. Check the tightness of the eyebolts prior to lifting. 2. Using Hydril chain sling, gently lift piston out of the preventer body. If a vertical lift is not possible or the piston does not lift out freely, slowly apply low (50 PSI) hydraulic pressure to the closing chamber. WARNING: DO NOT USE AIR OR GAS. 3. Remove middle U-seals (Items 9), lower piston double-U-seal (Items 33 and 34), and wear band (Item 14). Remove the sling and the lifting assemblies from the piston.
Piston Shoulder
Piston
Figure 5-6.
Piston Lift Device
4.
F. Remove Inner Sleeve. 1. Remove the capscrews (Item 18) from around the inner sleeve (4). 2. Insert the hooks of the Hydril chain sling (equally spaced) in the slots of the inner sleeve and lift the sleeve out of the annular BOP. 3. Remove the chain sling.
Operator's Manual
PAGE 5-8
5.4 Assembly - Screwed Head With Wear Bands

Refer to Figure 5-7 and 5-8 while following this procedure. Numbers in figures correspond to item numbers in procedure. WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, assembly of the GK annular BOP can be performed with standard tools. 1. Three piston lift assemblies , Hydril Part No. 31056386 2. Three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 3112077 (for lifting head) 3. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No. 1900077-08 (for lifting packing unit) 4. Chain sling, Hydril Part No. 1900179-0354 (CAUTION: The chain sling is for disassembly and assembly purposes only. Do not use the chain sling to lift the annular BOP assembly.) 5. Castor oil 6. Moly Paste 503 thread lubricant (Coefficient of Friction is .065) or equivalent 7. Neverseez lubricant 8. Spare parts including seal kit. Refer to Section 6, "Parts and Storage." B. Clean, Inspect BOP, and Lubricate. 1. Clean all components thoroughly. 2. Perform the inspection procedures that are applicable in Section 4, "Maintenance and Testing". 2. Ensure that working surfaces are free of burrs, rough edges, or other defects. 3. Inspect all seals and wear bands installed in the head and piston, and replace any damaged seals and wear bands in use over one year. (NOTE: Hydril recommends that all seals and wear bands be replaced whenever a BOP is disassembled and assembled.) Seals must be installed as shown in Figures 5-7 and 5-8. Coat packing unit, seals, nonextrusion rings, and wear bands with castor oil before installation. CAUTION: Use of petroleum base oil or grease will reduce seal life. 4. Lubricate the threads of nuts, bolts, and capscrews with Moly Paste 503 thread lubricant. 5. Coat interior surfaces with castor oil. 6. Lubricate body threads on the head and body with Neverseez lubricant. C. Install Inner Sleeve. 1. Insert hooks of Hydril chain sling (equally spaced)
NOTE: Seal Rings MUST BE installed in position shown by cross-section. 17 19
1 6 15 13 12 30 2 11 29
9 14 34 33 4
18
Figure 5-7:
Screwed Head GK 11"-5000 PSI With Wear BandsAssembly
Operator's Manual
PAGE 5-9
2. 3.
into slots in inner sleeve (Item 4) and install the sleeve into the bore of the body. Install the capscrews (Item 18) and torque to 150 lbft (203 Nm). Remove chain sling.
D. Install Piston. 1. Install the lower piston double U-seal (Items 33 and 34), and the wear band (Item 14) on the lower segment of the piston (Item 3). 2. Install the middle U-seals (Item 9) on the upper segment of the piston. 3. Install the piston lift assemblies onto the piston as shown in Figure 5-6. Attach the Hydril chain sling to the eyebolts and install the piston over the inner sleeve (Item 4) and into the body. Ensure that the piston is aligned vertically with the body prior to lowering. Vent Close port. With proper vertical alignment, the piston will slide its normal full stroke to the bottom of the preventer body. CAUTION: Be careful not to damage the seals during assembly. 4. Remove the chain sling and piston lift assemblies from the piston. E. Install Packing Unit. 1. Lubricate the bowl of the piston (Item 3) and packing unit (Item 2) with castor oil. Install two eyebolts (5/8"-11 UNC x 1 3/4 Lg.) into packing unit. Using Hydril chain sling, lift the packing unit and set it into the bowl of the piston. 2. Remove the chain sling and eyebolts from the packing unit. F. Install Head. 1. Install the wear plate (Item 29) and capscrews (Item 30) on the inner face of the annular head (Item 1). Torque the capscrews to 50 lb-ft (68 Nm). 2. Install the head gasket (Item 6) in the seal groove on the outside diameter of the head, just below the major diameter and above the body threads. 3. Install the head to piston seal, consisting of a double U-seal (Item 11) and two non-extrusion rings (Item 12), the wear band (Item 13), and the wiper ring (Item 15) into the grooves on the inside bottom diameter. 4. Install three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.) into the head. 5. Lubricate the body threads on the outside diameter of the head and the inside diameter of the body (Item 5) with Neverseez lubricant. 6. Install the head into the body so that the screw threads on the head engage the threads of the body. Remove the chain sling. 7. Tighten the head clockwise (right hand) as shown in Figure 5-2, using the pipe or rod from Step C of
8. 9.
the disassembly procedure, until the shoulder on the head engages the body. A vertical lift, using the chain sling attached to the eyebolts, will reduce the weight on the threads and reduce the required turning torque. Align the head lock bracket with the hole in the body. Lubricate the lock screw threads (Item 19) with Moly Paste 503 and install. Tighten the lock screw using 60 lb-ft (80 Nm) torque. Remove the chain sling and eyebolts from the head. Perform seal and packing unit test procedures in Section 4, "Maintenance and Testing."
Operator's Manual
PAGE 5-10
Pipe Plug (17) Head Lock Screw (19) BOP Head Screwed (1) Head Gasket (6) Wear Plate Capscrew (30) Wear Plate (29) Wiper Ring (15) Wear Band (13) Head to Piston Double U-Seal (11 and 12) Packing Unit (2) Piston (3) Middle Piston Seals (9) Body (5) Inner Sleeve (4) Wear Band (14) Lower Piston Double U-Seal (33 and 34) Inner Sleeve Capscrew (18)
Figure 5-8
Cutaway of Screwed Head GK 11 5000 PSI BOP with Wear Bands, Showing Position of Parts.
Operator's Manual
PAGE 5-11
5.5 Disassembly - Latched Head Without Wear Bands

Refer to Figure 5-9 while following this procedure. Numbers in figure correspond to item numbers in procedure. WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, disassembly of the GK annular BOP can be performed with standard tools. 1. Three piston lift assemblies, Hydril Part No. 31056386 2. Three eyebolts (1-1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 3112077 (for lifting head) 3. Chain sling, Hydril Part No. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Do not use to lift the annular BOP assembly.) 4. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No.1900077-08 (for lifting packing unit). B. Vent Pressure from Annular BOP Assembly. 1. Vent the closing and opening chambers, ensuring that no trapped pressure exists in the BOP which will cause injury to personnel and/or damage the equipment. 2. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. C. Remove Head. 1. Release the annular head (Item 1) by backing off the jaws (Item 21). Unscrew the clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws shoulder against the body (Item 5). CAUTION: Take care not to continue turning the screws after the jaws have shouldered. Excessive torque at shouldering may cause thread damage. NOTE: If a jaw does not retract as described due to the lack of engagement with spacer sleeve screw (Item 23), tighten the shoulder screw to approximately 50 lb-ft (68 Nm). 2. Remove the four head clamp screws and head clamps (Items 31 and 32) from the annular head. NOTE: Alternately loosen the screws on opposite sides to unload the head evenly. 3. Install three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.) into head. 23 22 17 32 31
1 7 6 8 29 30 2
3 9 10 18 4
25 24 26 21 5
27
Figure 5-9:
Latched Head GK 11"-5000 PSI Without Wear BandsDisassembly
Operator's Manual
PAGE 5-12
4. 5. 6.
Using Hydril chain sling , lift the head out of the body. Remove sling and eyebolts. Remove the six cap screws (Item 30) and the wear plate (Item 29). Remove the head dirt seal (Item 7), Head gasket (Item 6), and upper U-seals (Items 8).
D. Remove Packing Unit. 1. Install two eyebolts (5/8"-11UNC x 1 3/4 Lg.) into packing unit (Item 2). 2. Using Hydril chain sling, lift the packing unit out of the piston (Item 3). 3. Remove sling and eyebolts. E. Remove Piston. 1. Install three piston lifting devices onto the piston (Item 3) as follows and as shown in Figure 5-6: a. Position each lift device over the top edge of the piston above the eyebolt holes in the piston shoulder, taking care not to damage the sealing surface on the outside diameter. b. Tighten the eyebolts until the lift devices are snug against the piston shoulder. c. Check the tightness of the eyebolts prior to lifting. 2. Using Hydril chain sling 1900179-0354, gently lift piston out of the preventer body. If a vertical lift is not possible or the piston does not lift out freely, slowly apply low (50 PSI) hydraulic pressure to the closing chamber. WARNING: DO NOT USE AIR OR GAS. 3. Remove the lift devices from the piston, taking care not to damage the sealing surface on the outside diameter. Remove the middle U-seals (Items 9) and the lower U-seals (Items 10).
G. Remove Jaws. Perform the following procedure for each jaw (Item 19). 1. Remove pipe plug (Item 25). 2. Hold clamping screw (Item 22) and remove spacer sleeve screw (Item 23) from the clamping screw. 3. Remove the clamping screw and spacer sleeve (Item 24) from the body (Item 5). Remove spacer sleeve from the clamping screw. Remove the jaw (21) from the inside of the body. NOTE: Keep the jaws in sequence so that they can be returned to their original position.
4.
F. Remove Inner Sleeve. 1. Remove the capscrews (Item 18) from around the inner sleeve (Item 4). 2. Using Hydril chain sling 1900178-0354, attach the hooks (equally spaced) into the slots in the sleeve and lift the inner sleeve out of the annular BOP. 3. Remove sling.
Operator's Manual
PAGE 5-13
5.6 Assembly - Latched Head Without Wear Bands

Refer to Figure 5-10 and 5-11 while following this procedure. Numbers in figures correspond to item numbers procedure. 17 32 31
WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, assembly of the GK annular BOP can be performed with standard tools. 1. Three piston lift assemblies, Hydril Part No. 3105638-6 2. Three eyebolts (1-1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 3112077 (for lifting head) 3. Chain sling, Hydril Part No. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Do not use to lift the annular BOP assembly.) 4. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No. 1900077-08 (for lifting packing unit) 5. Castor oil 6. Moly Paste 503 thread lubricant (Coefficient of Friction is .065) or equivalent 7. Neverseez lubricant 8. Spare parts including seal kit. Refer to Section 6, "Parts and Storage." B. Clean, Inspect BOP, and Lubricate. 1. Clean all components thoroughly. 2. Perform the inspection procedures that are applicable in Section 4, "Maintenance and Testing". 3. Ensure that working surfaces are free of burrs, rough edges, or other defects. 4. Inspect all seals installed in the head and piston. Replace any damaged seals in use over one year. (NOTE: Hydril recommends that all seals be replaced whenever a BOP is disassembled and assembled.) Seals and must be installed as shown in Figures 5-10 and 5-11. Coat packing unit, seals, and non-extrusion rings with castor oil before installation. CAUTION: Use of petroleum base oil or grease will reduce seal life. 5. Lubricate all threads of fasteners with Moly Paste 503 thread lubricant except where noted in this procedure.
1 7 6 8 29 30
3 9 10 18 4 22
23
25 24 26 21 5
27
Figure 5-10:
Latched Head GK 11"-5000 PSI Without Wear BandsAssembly
Operator's Manual
PAGE 5-14
6. Coat interior surfaces with castor oil. C. 1.
2. 3.
4.
5. 6.
D. 1.
2. 3. E. 1. 2.
3.
careful not to damage the sealing surfaces on the inside diameter of the body and the seals on the outside diameter of the piston during assembly. Install Jaws. 4. Remove the sling and lift devices from the piston, Install the jaws (Item 21) into the annular body taking care not to damage the sealing surface on with the short side of the teeth down and in the the outside diameter. same sequence as disassembled. NOTE: If a new jaw is installed within a set of well worn jaws, polish the new jaw to match existing jaws to F. Install Packing Unit. 1. Lubricate the bowl of the piston (Item 3) and packensure equal load sharing. ing unit (Item 2) with castor oil. Install two eyebolts Install the O-ring (Item 26) in the external groove (5/8"-11UNC x 1 3/4 Lg.) into packing unit. Using of each clamping screw (Item 22). Hydril chain sling 1900179-0354, lift the packing Install the clamping screws and screw them allunit and set it into the bowl of the piston. the-way in hand tight. CAUTION: Be careful not 2. Remove the sling and eyebolts from the packing to overtighten the clamping screws, or the jaw will unit. extend beyond the sides of the body. Insert the spacer sleeve (Item 24) and spacer sleeve screw (Item 23) through each clamping G. Install Head. screw. Turn the screws into the jaws (Item 21) 1. Unscrew the clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws until tight (approximately 50 lb-ft/68 Nm). IMshoulder against the body (Item 5). CAUTION: PORTANT: Do not lubricate the threads of the Take care not to continue turning the screws after spacer sleeve screws. the jaws have shouldered. Excessive torque at Install pipe plugs (Item 25) into clamping screws. shouldering may cause thread damage. NOTE: If Ensure that all of the jaws are retracted fully by a jaw does not retract as described due to the lack turning the clamping screws counterclockwise of engagement with spacer sleeve screw (Item 23), until the jaws are shouldered against the body. tighten the spacer sleeve screw counterclockwise (left hand thread) to approximately 150 lb-ft (203 Install Inner Sleeve. Nm). Using Hydril chain sling 1900179-0354, attach the three hooks (evenly spaced) into the slots in 2. Install the wear plate (Item 29) on the inner face of the sleeve and install the inner sleeve (Item 4) the annular head (1) and install the capscrews into the body. (Item 30). Torque the capscrews to 50 lb-ft (68 Install the capscrews (Item 18) and torque to 150 Nm). lb-ft (203 Nm). 3. Install the head dirt seal (Item 7), head gasket (6), Remove chain sling. and upper U-seals (Items 8) onto the head. 4. Install three eyebolts (1-1/4"-7UNC x 1 3/4 Lg.) Install Piston. into head. Install thelower U-seals (Item 10) on the lower 5. Using Hydril chain sling 1900179-0354, lift and segment of the piston (Item 3). install the head into the annular body (Item 5). Install the middle U-seals (Item 9) onto the upper Remove the sling and eyebolts. segment of the piston. Orient the seal lips as 8. Install four head clamps (item 31) and screws (Item shown in Figure 5-9 and/or 5-10. 32) to secure the head fully into place. Tighten the Install the piston into the body using the piston lift head clamp screws until tight. devices. Install each device onto the piston as 9. Turn the clamping screws (Item 22) clockwise to shown in Figure 5-6, taking care not to damage engage the jaws (Item 21) fully into the locking rings the sealing surface on the outside diameter. of the preventer head and apply 350 lb-ft (475 Nm) Lubricate all mating surfaces with castor oil beof torque. CAUTION: To prevent unequal clearfore lowering the piston over the inner sleeve. ance between the head and the body, tighten the Ensure that the piston is aligned vertically with jaws/latches alternately on opposite sides or in a the inner sleeve prior to lowering. Vent the Close crisscross pattern. ports to atmosphere. With proper vertical alignment, the piston will slide its normal full stroke to the bottom of the preventer body. CAUTION: Be
Operator's Manual
PAGE 5-15
Pipe Plug (17) Head Clamp Screw (31) Head Clamp (30) Head Dirt Seal (7) Wear Plate Capscrew (30) BOP Head Latched (1) Jaw Mechanism (21,22,23,24,25,26)
Wear Plate (29) Head Gasket (6) U-Seal, Upper (8) Packing Unit (2) Piston (3)
U-Seal, Middle (9)
Body (5)
Inner Sleeve (4)
U-Seal, Lower (10)
Inner Sleeve Capscrew (18)
Figure 5-11
Cutaway of GK 11-5000 PSI Latched Head BOP Without Wear Bands, Showing Position of Parts.
Operator's Manual
PAGE 5-16
5.7 Disassembly - Latched Head With Wear Bands

Refer to Figure 5-12 while following this procedure. Numbers in figure correspond to item numbers in procedure. WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, disassembly of the GK annular BOP can be performed with standard tools. 1. Three piston lift assemblies, Hydril Part No. 31056386 2. Three eyebolts (1-1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 3112077 (for lifting head) 3. Chain sling, Hydril Part No. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Do not use to lift the annular BOP assembly.) 4. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg.), Hydril Part No. 1900077-08 (for lifting packing unit). B. Vent Pressure from Annular BOP Assembly. 1. Vent the closing and opening chambers, ensuring that no trapped pressure exists in the BOP which will cause injury to personnel and/or damage the equipment. 2. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. C. Remove Head. 1. Release the annular head (Item 1) by backing off the jaws (Item 21). Unscrew the clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws shoulder against the body (Item 5). CAUTION: Take care not to continue turning the screws after the jaws have shouldered. Excessive torque at shouldering may cause thread damage. NOTE: If a jaw does not retract as described due to the lack of engagement with spacer sleeve screw (Item 23), tighten the shoulder screw to approximately 50 lb-ft (68 Nm). 2. Remove the four head clamp nuts and head clamps (Items 31 and 32) from the annular head. NOTE: Alternately loosen the nuts on opposite sides to unload the head evenly. 3. Install three eyebolts (1 1/4"-7UNC x 1 3/4 Lg.) into head.
17
32 31
1 7 15 6 13 12 30 2 11 29
3 9 14 34 33 18 4 22
23
25 24 26 21 5
27
Figure 5-12:
Latched Head GK 11"-5000 PSI With Wear BandsDisassembly
Operator's Manual
PAGE 5-17
4. 5.
6.
Using Hydril chain sling , lift the head out of the body. Remove sling and eyebolts. Remove the head dirt seal (Item 7), wiper ring (Item 15), head gasket (Item 6), head to piston double Useal (Items 11 and 12), and the wear band (Item 13) from the head. Remove the six cap screws (Item 30) and the wear plate (Item 29).
3. 4.
sleeve screw (Item 23) from the clamping screw. Remove the O-ring (Item 26) from the clamping screw. Remove the clamping screw and spacer sleeve (Item 24) from the body (Item 5). Remove spacer sleeve from the clamping screw. Remove the jaws (Item 21) from the inside of the body. NOTE: Keep the jaws in sequence so that they can be returned to their original position.
D. Remove Packing Unit. 1. Install two eyebolts (5/8"-11UNC x 1 3/4 Lg.) into packing unit (Item 2). 2. Using Hydril chain sling, lift the packing unit out of the piston (Item 3). 3. Remove sling and eyebolts. E. Remove Piston. 1. Install three piston lifting devices onto the piston (Item 3) as follows and as shown in Figure 5-6: a. Position each lift device over the top edge of the piston above the eyebolt holes in the piston shoulder, taking care not to damage the sealing surface on the outside diameter. b. Tighten the eyebolts until the lift devices are snug against the piston shoulder. c. Check the tightness of the eyebolts prior to lifting. 2. Using Hydril chain sling 1900179-0354, gently lift piston out of the preventer body. If a vertical lift is not possible or the piston does not lift out freely, slowly apply low (50 PSI) hydraulic pressure to the closing chamber. WARNING: DO NOT USE AIR OR GAS. 3. Remove the middle U-seals (Item 9), lower piston double U-seal (Items 33 and 34), and the wear band (Item 14) from the piston. Remove the lift devices from the piston, taking care not to damage the sealing surface on the outside diameter.
4.
F. Remove Inner Sleeve. 1. Remove the capscrews (Item 18) from around the inner sleeve (Item 4). 2. Using Hydril chain sling 1900178-0354, attach the hooks (equally spaced) into the slots in the sleeve and lift the inner sleeve out of the annular BOP. 3. Remove sling. G. Remove Radial Latches. Perform the following procedure for each radial latch (Item 19). 1. Remove pipe plug (Item 25). 2. Hold clamping screw (Item 22) and remove spacer
Operator's Manual
PAGE 5-18
5.8 Assembly - Latched Head With Wear Bands

Refer to Figure 5-13 and 5-14 while following this procedure. Numbers in figures correspond to item numbers in procedure.
17
32 31
WARNING: THIS IS VERY HEAVY EQUIPMENT, AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Gather Tools and Materials. NOTE: Except for the tools listed below, assembly of the GK annular BOP can be performed with standard tools. 1. Three piston lift assemblies, Hydril Part No. 3105638-6 2. Three eyebolts (1-1/4"-7UNC x 1 3/4 Lg.), Hydril Part No. 3112077 (for lifting head) 3. Chain sling, Hydril Part No. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Do not use to lift the annular BOP assembly.) 4. Two eyebolts (5/8"-11 UNC x 1 3/4 Lg. ), Hydril Part No. 1900077-08 (for lifting packing unit) 5. Castor oil 6. Moly Paste 503 thread lubricant (Coefficient of Friction is .065) or equivalent 7. Neverseez lubricant 8. Spare parts including seal kit. Refer to Section 6, "Parts and Storage." B. Clean, Inspect BOP, and Lubricate. 1. Clean all components thoroughly. 2. Perform the inspection procedures that are applicable in Section 4, "Maintenance and Testing". 3. Ensure that working surfaces are free of burrs, rough edges, or other defects. 4. Inspect all seals and wear bands installed on the head and piston. Replace any damaged seals and wear bands in use over one year. (NOTE: Hydril recommends that all seals and wear bands be replaced whenever a BOP is disassembled and assembled.) Seals and must be installed as shown in Figures 5-13 and 5-14. Coat packing unit, seals, and non-extrusion rings with castor oil before installation. CAUTION: Use of petroleum base oil or grease will reduce seal life.
1 7 15 6 13 12 29 2 11 28
3 9 14 34 33 18 4 22
23
25 24 26 21 5
27
Figure 5-13:
Latched Head GK 11"-5000 PSI With Wear BandsAssembly
Operator's Manual
PAGE 5-19
5. Lubricate all threads of fasteners with Moly Paste 503 thread lubricant except where noted in this procedure. 6. Coat interior surfaces with castor oil. C. 1.
2. 3.
4.
5. 6.
D. 1.
2. 3. E. 1.
2.
3.
ports to atmosphere. With proper vertical alignment, the piston will slide its normal full stroke to the bottom of the preventer body. CAUTION: Be careful not to damage the sealing surfaces on the inside diameter of the body and the seals on the outside diameter of the piston during assembly. Install Jaws. 4. Remove the sling and lift devices from the piston, Install the jaws (Item 21) into the annular body taking care not to damage the sealing surface on with the short side of the teeth down and in the the outside diameter. same sequence as disassembled. NOTE: If a new jaw is installed within a set of well worn latches, polish the new jaw to match existing F. Install Packing Unit. 1. Lubricate the bowl of the piston (Item 3) and packjaws to ensure equal load sharing. ing unit (Item 2) with castor oil. Install two eyebolts Install the O-ring (Item 26) in the external groove (5/8"-11UNC x 1 3/4 Lg.) into packing unit. Using of each clamping screw (Item 22). Hydril chain sling 1900179-0354, lift the packing Install the clamping screws and screw them allunit and set it into the bowl of the piston. the-way in hand tight. CAUTION: Be careful not 2. Remove sling and eyebolts from packing unit. to overtighten the clamping screws, or the jaw will extend beyond the sides of the body. Insert the spacer sleeve (Item 24) and spacer G. Install Head. sleeve screw (Item 23) through each clamping 1. Unscrew clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws screw. Turn the screws into the jaws (Item 21) shoulder against body (Item 5). CAUTION: Take until tight (approximately 50 lb-ft/68 Nm). IMcare not to continue turning screws after the jaws PORTANT: Do not lubricate the threads of the have shouldered. Excessive torque at shouldering spacer sleeve screws. may cause thread damage. NOTE: If a jaw does Install pipe plugs (Item 25) into clamping screws. not retract as described due to the lack of engageEnsure that all of the jaws are retracted fully by ment with spacer sleeve screw (Item 23), tighten turning the clamping screws counterclockwise the spacer sleeve screw counterclockwise (left until the jaws are shouldered against the body. hand thread) to approximately 150 lb-ft (203 Nm). Install Inner Sleeve. 2. Install the wear plate (Item 28) on the inner face of Using Hydril chain sling 1900179-0354, attach the annular head (1) and install the capscrews the three hooks (evenly spaced) into the slots in (Item 29). Torque capscrews to 50 lb-ft (68 Nm). the sleeve and install the inner sleeve (Item 4) 3. Install the head gasket (6) and head dirt seal (Item into the body. 7) on the lower outside diameter of the head. Install Install the capscrews (Item 18) and torque to 150 the head to piston double U-seal (Items 11 and 12), lb-ft (203 Nm). wiper ring (Item 15), and wear band (Item 13) onto Remove chain sling. the lower inside diameter of the head. Refer to Figures 5-13 and 5-14 for seal orientation. Install Piston. 4. Install three eyebolts (1-1/4"-7UNC x 1 3/4 Lg.) Install the lower piston double U-seal (Items 33 into head. and 34) and wear band (Item 14) on lower 5. Using Hydril chain sling 1900179-0354, lift and segment of the piston (Item 3). install the head into the annular body (Item 5). Install the middle U-seals (Item 9) onto the middle Remove the sling and eyebolts. segment of the piston. Orient the seal lips as 6. Install four head clamps (item 31) and screws (Item shown in Figures 5-13 and 5-14. 32) to secure the head fully into place. Tighten the Install the piston into the body using the piston lift screws until tight. devices. Install each device onto the piston as 7 Turn clamping screws (Item 22) clockwise to enshown in Figure 5-6, taking care not to damage gage jaws (Item 21) fully into locking rings of the sealing surface on the outside diameter. preventer head and apply 350 lb-ft (475 Nm) of Lubricate all mating surfaces with castor oil betorque. CAUTION: To prevent unequal clearance fore lowering the piston over the inner sleeve. between head and the body, tighten the jaws alterEnsure that the piston is aligned vertically with nately on opposite sides or in a crisscross pattern. the inner sleeve prior to lowering. Vent the Close
Operator's Manual
PAGE 5-20
Pipe Plug (17) Head Clamp Screw (31) Head Clamp (30) Head Seal (7) Wear Plate Capscrew (30) BOP Head Latched (1) Wear Plate (29) Jaw Mechanism (21,22,23,24,25,26) Wiper Ring (15) Head Gasket (6)
Wear Band (14) Head to Piston Double U-Seal (11, 12) Packing Unit (2) Piston (3) U-Seal, Middle (9) Body (5)
Inner Sleeve (4) Wear Band (13) Lower Piston Double U-Seal (33, 34) Inner Sleeve Capscrew (18)
Figure 5-14
Cutaway of Latched Head GK 11-5000 PSI BOP with Wear Bands, Showing Position of Parts.
Operator's Manual
PAGE 6-1
6.0 PARTS AND STORAGE 6.1 Parts List Screwed Head Without Wear Bands
Item No. Part Name BOP Assembly 1 BOP Head Screwed No. Req. 1 1 1 1 1 1 1 1 2 2 2 1 12 19 Head Lock Screw 29* Wear Plate 30* Wear Plate Capscrew 1 1 6 1 1 Approx. Net Wt. (Lb) 8,200 1,880 305 311 1,380 ... 4,645 2 2.13 2 1.75 ... ... 1.19 24.15 0.13 ... 14.41 Part Number 1002140 1 1002143 1003260-01 1003260-02 1002145-1 1004201 1002141 31402 31403 30736 32599 190006505 192002612012 1002149 1004203 192002608007 1006100 1002150 18 ACCESSORIES Chain Sling Assy Eyebolt, Piston Eyebolt, Head, 1 1/4-7NC Protector Plate Protector Plate Screw 1 3 2 1 4 45 1.94 4.25 66 0.13 33565-M 30952 32006 31406 1900043 08010 Recommended spares for one year service. 5 10 1 3 6 8 29 17 19
2 Packing UnitNatural (NR) 3 Nitrile (NBR) Piston
4** Inner Sleeve 5 Body 6 8 9 10 17 Head Gasket U-Seal, Upper U-Seal, Middle U-Seal, Lower Pipe Plug, Piston Indicator
30 2
18** Inner Sleeve Screw
Field Replacement Sleeve Kit Seal Kit- Complete
For converting welded sleeve on some model BOPs to bolted sleeve only. Sleeve does not interchange with Item 4. * Requires head conversion to accept wear plate; some models of this BOP do not have the wear plate. ** Some BOPs are equipped with Sleeve P/N 1004075 and Capscrew 1920026-12016. Check P/N stamped on bottom of sleeve for replacement.
Figure 6-1:
Screwed Head GK 11"-5000 PSI without Wear Bands
Operator's Manual
PAGE 6-2
6.2A Parts List Screwed Head With Wear Band Modificationa

Item No. Part Name BOP Assembly Head - Screwed Approx. No. Net Wt. Req. (Lb) 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 6 1 2 1 1 8,200 1,880 305 311 1,380 ... 4,645 2 ... 2.13 ... ... ... ... ... Part Number 1002140-WB 3136824 1003260-01 1003260-02 3136680 1004201 1002141 31402 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 1004201 14 34 33 4 3
a
17
19
2 Packing UnitNatural (NR) 3 Nitrile (NBR) Piston
1 6 15 13 12 30 2 11 29
4** Inner Sleeve 5 Body 6 9 11 12 13 14 15 17 Head Gasket U-Seal, Middle Piston Double U-Seal, Head Non Extrusion Ring Wear Band, Head Wear Band, Piston Wiper Ring Pipe Plug, Piston
Indicator 18** Inner Sleeve Screw 19 Head Lock Screw 29* Wear Plate 30* Wear Plate Capscrew 33 34 Double U-Seal, Piston Non Extrusion Ring Field Replacement Sleeve Kit Seal Kit- Complete
1.19 1002149 24.15 1004203 0.13 ... ... ... 14.41 192002608007 3136746 3136745 1006100 3137431
18
ACCESSORIES Chain Sling Assy Eyebolt, Piston 5/8-11UNC Eyebolt, Head, 1 1/4-7UNC Protector Plate Protector Plate Screw 1 2 2 1 4 45 1.94 4.25 66 0.13 33565-M 30952 32006 31406 1900043 08010 5
Recommended spares for one year service.
For converting welded sleeve on some model BOPs to bolted sleeve only. Sleeve does not interchange with Item 4. * Requires head conversion to accept wear plate; some models of this BOP do not have the wear plate. ** Some BOPs are equipped with Sleeve P/N 1004075 and Capscrew 1920026-12016. Check P/N stamped on bottom of sleeve for replacement. a Wear band modification at Hydril Authorized Repair Facility (ARF). The abbreviation WB will be stamped on the name plate after the BOP assembly number (XXXXXXX-WB) to indicate wear band
Figure 6-2:
Screwed Head GK 11"-5000 PSI with Wear Band Modification
modification. See Parts List 6.2B (PNI04-007-02 Rev A1) for modification kit parts.
Operator's Manual
PAGE 6-3
6.2B Parts List Screwed Head Wear Band Modification Kit PNI04-007-02 Rev A1
Item No.a 1 3 13 14 ...
a
Part Name Head - Screwed Piston Wear Band, Head Wear Band, Piston Seal Kit- Complete
No. Req. 1 1 1 1 1
Approx. Net Wt. (Lb) 1,880 1,380 ... ... 14.41
Part Number 3136824 3136680 1931099-05 1931099-04 3137431
Item number refers to Parts List 6-2A and Figure 6-2.
Operator's Manual
PAGE 6-4
6.3 Parts List Screwed Head With Wear Bands At Manufacturea

Item No. Part Name BOP Assembly Head - Screwed Approx. Part No. Net Wt. Number* Req. (Lb) 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 6 1 1 6 1 2 1 8,200 1,880 305 311 1,380 ... 4,645 2.0 ... 2.13 ... ... ... ... ... 0.13 1.19 24.15 0.13 ... ... 14.41 * * 1003260-01 1003260-02 * 1004201 * 31402 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 192002612012 1002149 3123805 192002608007 3136746 3136745 3137431 19001790354 3112077 3113411-37 3105638-6 5 4 14 34 33 9 3 6 15 13 12 30 2 11 29 17 19
2 Packing UnitNatural (NR) 3 4 5 6 9 11 12 13 14 15 17 18 19 29 30 33 34 Nitrile (NBR) Piston Inner Sleeve Body Head Gasket U-Seal, Middle Piston Double U-Seal, Head Non Extrusion Ring Wear Band, Head Wear Band, Piston Wiper Ring Pipe Plug, Piston Indicator Inner Sleeve Screw Head Lock Screw Wear Plate Wear Plate Capscrew Double U-Seal, Piston Non Extrusion Ring Seal Kit- Complete
18
ACCESSORIES Chain Sling Assembly 1 Eyebolt, Head, 1 1/4-7UNC Protector Plate Piston Lift Device 3 2 3 ... 4.25 66 ...

a
Wear bands are installed at manufacture. This parts list is generic in construction and part numbers are listed for all components that are standard except for non-standard components or those that require regulatory certification, which may change from one assembly to another. These parts are specific to the assembly part number stamped on the BOP name plate. If you want a complete parts list specific to your equipment, contact Hydril. Include the assembly part number and/or serial number from the name plate. If name plate is missing or damaged, the serial number is stamped on the body.
Figure 6-3:
Screwed Head GK 11"-5000 PSI with Wear Bands
Operator's Manual
PAGE 6-5
6.4 Parts List Latched Head Without Wear Bands

Item No. Part Name Approx. No. Net Wt. Req. (Lb) 1 1 1 1 1 1 1 1 1 2 2 2 1 12 16 16 16 16 16 16 1 1 6 4 4 ... 8,200 1900 305 311 1380 ... 4645 2.44 ... 2.13 2 1.75 ... ... ... 3.75 ... ... ... 0.02 0.03 ... 0.09 0.85 0.67 18 Part Number 1004060 1002223 1003260-01 1003260-02 1002145 1004201 1004061-02 31402 51189 31403 30736 32599 1900065-05 192002612012 1004065 1004067 190018410024 1004068 1900065-08 1900001329 1900086-03 1004203 192002608007 1002351 190004914024 1004074 1 7 6 8 29 30 17 32 31
BOP Assembly 1 BOP Head-Latched 2 Packing Unit Natural Rubber (NR) Nitrile (NBR) 3 Piston 4 Inner Sleeve 5 Body 6 Head Gasket 7 Head Dirt Seal 8 U-Seal ,Upper 9 U-Seal, Middle 10 U-Seal, Lower 17 Pipe Plug, Piston Indicator 18 Inner Sleeve Screw 21 22 23 24 25 26 27 29 30 31 32 Jaw Jaw Clamping Screw Spacer Sleeve Screw Spacer Sleeve Pipe Plug Jaw Clamping Screw O-Ring Relief Fitting Wear Plate Wear Plate Capscrew Head Clamp Head Clamp Screw
3 9 10 18 4 22
23
Seal Kit- Complete
ACCESSORIES Chain Sling Assembly 1 Piston Lift Device Eyebolt, Head, 1 1/4-7UNC Protector Plate Protector Plate Screw 3 2 1 4
... ... 4.25 66 0.13
19001790354 3105638-6 3112077 31406 190004308010
25 24 26 21 5
27
Figure 6-4:
Latched Head GK 11"-5000 PSI Without Wear Bands
Operator's Manual
PAGE 6-6
6.5A Parts List Latched Head With Wear Band Modification*

Item No. Part Name Approx. No. Net Wt. Req. (Lb) 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 12 16 16 16 16 16 16 1 1 6 4 4 1 2 ... 8,200 1900 305 311 1380 ... 4645 2.44 ... ... ... ... ... ... ... ... ... 3.75 ... ... ... 0.02 0.03 ... 0.09 0.85 0.67 ... ... 18 Part Number 1004060-WB* 3136678 1003260-01 1003260-02 3136680 1004201 1004061-02 31402 51189 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 192002612012 1004065 1004067 190018410024 1004068 1900065-08 1900001329 1900086-03 1004203 192002608007 1002351 190004914024 3136746 3136745 3137417 17 32 31
BOP Assembly 1 BOP Head-Latched 2 Packing Unit Natural Rubber (NR) Nitrile (NBR) 3 Piston 4 Inner Sleeve 5 Body 6 Head Gasket 7 Head Dirt Seal 9 U-Seal, Middle Piston 11 Double U-Seal, Head 12 Non Extrusion Ring 13 Wear Band, Head 14 Wear Band, Piston 15 Wiper Ring 17 Pipe Plug, Piston Indicator 18 Inner Sleeve Screw 21 22 23 24 25 26 27 29 30 31 32 Jaw Jaw Clamping Screw Spacer Sleeve Screw Spacer Sleeve Pipe Plug Jaw Clamping Screw O-Ring Relief Fitting Wear Plate Wear Plate Capscrew Head Clamp Head Clamp Screw
1 7 15 6 13 12 30 2 11 29
3 9 14 34 33 18 4 22
23
33 Double U-Seal, Piston 34 Non Extrusion Ring Seal Kit- Complete
25 24 26 21 5
ACCESSORIES Chain Sling Assembly 1 Piston Lift Device Eyebolt, Head, 1 1/4-7UNC Protector Plate Protector Plate Screw 3 2 1 4
... ... 4.25 66 0.13
19001790354 3105638-6 3112077 31406 190004308010
27
Recommended spares for one year service. * Wear band modification at Hydril Authorized Repair Facility (ARF). The abbreviation WB will be stamped on the name plate after the BOP assembly number (XXXXXXX-WB) to indicate modification. See parts list 6.5B (PNI04-007-03 Rev A1) for modification kit parts.
Figure 6-5:
Latched Head GK 11"-5000 PSI With Wear Band Modification
Operator's Manual
PAGE 6-7
6.5B Parts List Latched Head Wear Band Modification Kit PNI04-007-03 Rev A1
Item No.a 1 3 13 14 ...
a
Part Name Head - Screwed Piston Wear Band, Head Wear Band, Piston Seal Kit- Complete
No. Req. 1 1 1 1 1
Approx. Net Wt. (Lb) 1,880 1,380 ... ... 14.41
Part Number 3136678 3136680 1931099-05 1931099-04 3137417
Item number refers to Parts List 6-5A and Figure 6-5.
Operator's Manual
PAGE 6-8
6.6 Parts List Latched Head With Wear Bands At Manufacturea

Item No. Part Name Approx. No. Net Wt. Req. (Lb) 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 12 16 16 16 16 16 16 1 1 6 4 8,200 1900 305 311 1380 ... 4645 2.44 ... ... ... ... ... ... ... ... ... 3.75 ... ... ... 0.02 0.03 ... 0.09 0.85 * * 1003260-01 1003260-02 * 1004201 * 31402 51189 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 192002612012 3136678 1004067 190018410024 1004068 1900065-08 1900001329 1900086-03 1004203 192002608007 1002351 190004914024 3136746 3136745 3137417 19001790354 3105638-6 3112077 31406 190004308010 Part Number 17 32 31
BOP Assembly 1 BOP Head-Latched 2 Packing Unit Natural Rubber (NR) Nitrile (NBR) 3 Piston 4 Inner Body Sleeve 5 Body 6 Head Gasket 7 Head Dirt Seal 9 U-Seal, Middle Piston 11 Double U-Seal ,Head 12 Non Extrusion Ring 13 Wear Band, Head 14 Wear Band, Piston 15 Wiper Ring 17 Pipe Plug, Piston Indicator 18 Inner Sleeve Screw 21 22 23 24 25 26 27 29 30 31 32 Jaw Jaw Clamping Screw Spacer Sleeve Screw Spacer Sleeve Pipe Plug Jaw Clamping Screw O-Ring Relief Fitting Wear Plate Wear Plate Capscrew Head Clamp Head Clamp Screw
1 7 15 6 13 12 30 2 11 29
3 9 14 34 33 18 4 22
23
4 0.67 ... 33 Double U-Seal, Piston 1 34 Non Extrusion Ring 2 ... Seal Kit- Complete ... 18 ACCESSORIES Chain Sling Assembly 1 ... Piston Lift Device Eyebolt, Head Protector Plate Protector Plate Screw 3 2 1 4 ... 4.25 66 0.13
25 24 26 21 5
27

a
Wear bands are installed at manufacture. This parts list is generic in construction and part numbers are listed for all components that are standard except for non-standard components or those that require regulatory certification, which may change from one assembly to another. These parts are specific to the assembly part number stamped on the BOP name plate. If you want a complete parts list specific to your equipment, contact Hydril.
Figure 6-6:
Latched Head GK 11"-5000 PSI With Wear Bands
Include the assembly part number and/or serial number from the name plate. If name plate is missing or damaged, the serial number is stamped on the body.
Operator's Manual
PAGE 6-9
6.7 Preventer Storage

The following preservation procedure protects the Hydril 11 5/8"-5000 PSI annular BOP for up to two years of storage. The protection period is dependent primarily upon the sealing integrity of the end connections and sealing of other pressure boundary penetrations. 3. 6.7.1 Preservation Procedure 4. A. Materials Required 1. Cortec VCI 369 grease (for unpainted machined face surfaces) 2. Cortec VCI 609 vapor phase corrosion inhibitor, 10 ounce (for bore and exposed interior surfaces) 3. Two protective covers for the end connections. 4. Water displacement oil such as Hougton Rust Veto 4221 or Stack Guard 180; Witco Macco 1961; or any AW Hydraulic Oil 46 (required for removal of water after hydrostatic testing) 5. One tube of silicone caulk (additional sealing for protective covers) B. Procedure 1. Disassemble, clean, inspect, lubricate, and assemble the annular BOP. Refer to the maintenance procedure in Section 4, "Maintenance and Testing" and Section 5, "Disassembly and Assembly." Replacement of worn packing units, seals, and other parts can be made conveniently at this time. Hydril recommends the replacement of all seals when the annular BOP is disassembled. 2. Test the packing unit and seals, using a 50/50 mix of fresh water (DO NOT USE SEA WATER OR BRINE) and glycol mixed with corrosion inhibitor or BOP hydraulic fluid as an operating fluid. Refer to Section 4, "Maintenance and Testing" for testing procedures. NOTE: For additional discussion on operating fluid and specific fluid recommendations, refer to Hydril Engineering Bulletin EB9909A on Hydril Website www.hydril.com. Drain the bore and rinse thoroughly behind the packing unit and inner sleeve with water displacement oil. Drain the operating fluid and flush out the operating fluid paths and chambers (Open and Close) with water displacing oil. Allow the bore, operating fluid paths and chambers (Open and Close) to dry. Install pipe plugs into Open and Close ports. Apply Cortec VCI 369 grease to bottom connection mating surface . Install a protective cover on the bottom connection. Ensure that a tight seal exists between the BOP and the cover. Use silicone cauk if necessary. Drop 10 ounces of Cortec VCI 609 vapor phase corrosion inhibitor into the bore of the BOP. Apply Cortec VCI 369 grease to the top connection mating surface. Install a protective cover on the top connection. Ensure that a tight seal exists between the BOP and the cover. Use silicone cauk if necessary. Touch up paint where necessary. Contact Hydril for paint specifications. Coat unpainted exterior surfaces with Cortec VCI 369 grease.
5. 6. 7. 8.
9. 10. 11.
12. 13.
6.7.2 Depreservation Procedure and Return to Service Remove the end connection covers and blow or rinse out the vapor phase corrosion inhibitor.
Operator's Manual
PAGE 6-10
6.8 Rubber Goods Storage

The term rubber goods includes synthetic compounds such as Nitrile Copolymers and Neoprene, as well as natural rubber parts. The ideal storage situation for rubber goods would be in air tight containers maintained 4. in a cool, dry, dark storage area. The following recommendations will allow vendors 5. and users of oil field equipment to maximize normally available storage facilities for rubber goods: 1. Keep the rubber storage area as dark as possible preferably indoors, not outdoors, and away from 6. direct sunlight, skylights, windows, and direct artificial lighting. 2. Select a cool location (approximately 65oF) that is 7. away from heaters, stoves, and direct blasts of space heaters. 3. Keep rubber goods away from electrical machinery (motors, switch gear, or any high voltage equipment producing corona and ozone). Avoid locations susceptible to drafts that will carry the atmosphere from electrical machinery to the rubber goods storage area. The practice of first-in, first-out is essential with rubber goods. Store rubber goods in a relaxed position in their normal shape. For example, do not hang O-rings on nails. Do not keep assemblies in stretched attitudes, e.g., O-rings on glands, BOP testers, and operator parts. Rubber goods storage areas should be kept as dry as possible. Remove oil, grease or other foreign materials from the storage area to preclude spillage on rubber goods. If storage for extended periods is anticipated, sealed containers are recommended. Impervious surface coverings such as waxing will increase shelf life.
OPERATOR'S MANUAL
Pressure Control Equipment

Hydril - GK Bop

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Manual 6609E

GK 11"-5000 PSI Annular Blowout Preventer

Pressure Control Equipment

Operator's Manual OPERATOR'S MANUAL

GK 11"-5000 PSI Annular Blowout Preventer

GK 11"-5000 PSI Annular Blowout Preventer

OPERATOR QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1.0 INSTALLATION AND OPERATION

SECTION 2.0 PHYSICAL DATA

SECTION 3.0 PACKING UNITS AND SEALS

SECTION 4.0 MAINTENANCE AND TESTING

SECTION 5.0 DISASSEMBLY AND ASSEMBLY

GK 11"-5000 PSI Annular Blowout Preventer

SECTION 6.0 PARTS AND STORAGE

Closing Pressure Opening Pressure

Pipe Size 2 3/8 2 7/8" 3 1/2" 4 1/2"-5 " 5 1/2"-8 5/8"

ANNULAR BOP TESTING AND OPERATION

279.4 mm 37.1 liters 30.6 liters 88.9 mm 181 mm TAPE MEASURE

1.0 INSTALLATION AND OPERATION 1.1 Installation

1.1.2 Weight and Dimensions

1.1.3 Annular BOP Removal and Installation Procedures

GK 11"-5000 PSI Annular Blowout Preventer

Head Wear Plate Packing Unit Clamping Screw Radial Latch

Opening Chamber Piston Closing Chamber Inner Sleeve Body

GK 11"-5000 PSI Annular Blowout Preventer

1.2.4 Principle of Operation

GK 11"-5000 PSI Annular Blowout Preventer

1.2.5 Surface Operation and Hookup

Closing Pressure Opening Pressure

0 0 1000 2000 3000 4000 5000

1.2.6 Surface Stripping Operations

GK 11"-5000 PSI Annular Blowout Preventer

2.0 PHYSICAL DATA 2.1 Engineering Data

2.2 Bolt and Wrench Data

1/2" NPT 1/2"-13UNC 1"-8UNC 1/2-13UNC 5/8"-11UNC 1 1/4"-7NC 1/2"-13UNC

2.3 Lubricant List

GK 11"-5000 PSI Annular Blowout Preventer

2.4 Dimensions - Screwed Head

*CLOSING PORT M AS CAST

Nominal Dimensions Inches

Lower Connector Pressure Rating

2.5 Dimensions - Latched Head

H AS CAST J K E F *OPENING PORT

Nominal Dimensions Inches

GK 11"-5000 PSI Annular Blowout Preventer

2.6 API Ring Joint Flange Connections

Bolted Flange, Using Stud Bolts.

Studded Flange, Using Studs.

23 25 3/4 BOLTS & STUDSa

Lengthb (Inches) Stud Bolts A Studs B 10 1/4 10 1/4

Bolt Circle Dia. (Inches) 19 22 1/4

2.7 Clamp Hub Connections

Clamp Dimensions (Inches)

Clamp dimensions may vary from those shown.

GK 11"-5000 PSI Annular Blowout Preventer

3.0 PACKING UNITS AND SEALS 3.1 Packing Units

GK 11"-5000 PSI Annular Blowout Preventer

3.1.1 Packing Unit Selection

3.1.2 Packing Unit Replacement Screwed Head

GK 11"-5000 PSI Annular Blowout Preventer