21 1/4″-2,000 Ram Blowout

Preventer
Operation Manual
（Hydraulic Wedge lock）
2FZ54-14 FZ54-14
 Table of Content

1 APPLICATION ........................................................................................................................1

2 TECHNICAL PARAMETER ....................................................................................................1

2.1 EXPLANATION OF THE MODEL OF RS RAM BLOWOUT PREVENTER .........................................1
2.2 TECHNICAL PARAMETERS OF THE RAM BLOWOUT PREVENTER ..............................................2
3 OPERATING PRINCIPLES.....................................................................................................5
3.1 PRINCIPLES OF THE OPEN AND CLOSURE OF THE RAM .........................................................5
3.2 PRINCIPLES OF WELL PRESSURE SEALING ..........................................................................5
4 STRUCTURES AND FEATURES OF THE MAIN COMPONENTS ........................................6
4.1 THE FEATURES OF RAM BLOWOUT PREVENTER ...................................................................6
4.2 PIPE RAM ...........................................................................................................................7
4.3 SHEAR RAM ASSEMBLY .......................................................................................................8
4.4 RAM SHAFT SEAL DEVICE ....................................................................................................9
4.5 SECONDARY SEAL DEVICE ...................................................................................................9
4.6 LOCKING SHAFT SEAL DEVICE ............................................................................................10
4.7 HYDRAULIC WEDGE LOCK DEVICE ......................................................................................10
5 PART LIST ............................................................................................................................ 11
5.1 PRODUCT STRUCTURE ...................................................................................................... 11
6 OPERATION AND CAUTIONS .............................................................................................12
6.1 PREPARE WORK BEFORE INSTALLATION..............................................................................12
6.2 OPERATION ......................................................................................................................12
6.3 CAUTION..........................................................................................................................16
7 MAINTENANCE ....................................................................................................................17
7.1 REPLACEMENT OF RAM AND RAM RUBBER ..........................................................................17
7.2 REPAIR AND REPLACEMENT OF HYDRAULIC CYLINDER ASSEMBLY .........................................18
7.3 REPLACEMENT OF BONNET SEALING RING..........................................................................19
7.4 MAINTENANCE OF HYDRAULIC WEDGE LOCK DEVICE ...........................................................20
8 STORAGE OF RUBBER ELEMENT ....................................................................................21

9 TROUBLE SHOUTING .........................................................................................................22

10 APPENDIX ............................................................................................................................24
1 Application

The ram blowout preventer is one of the key elements of the well control system. It is mainly
used to control the well head pressure during such operations as drilling, servicing and oil testing
to prevent any blow out hazard effectively and ensure safe operations. Specifically, it can be used
for the following operations:
When there is a pipe string a well, the circular space between the casing and the drill pipe
could be sealed with matched pipe rams.
When there isn’t a pipe string in a well, the wellhead could be shut off completely with blind
rams.
After the well has been sealed, such special operations as mud circulation, choking, killing
and well washing can be performed through choke and kill manifold connected to spool and side
outlet of BOP.
When used together with the pipe manifold for choking and killing, it can control the well
pressure effectively and achieve near-balance well killing operations.

2 Technical Parameter

2.1 Explanation of the Model of RS Ram Blowout Preventer

Model of RS Ram Blowout Preventer

××× ××——××

Nominal Working Pressure (MPa)）

Bore (Metric, cm)
Type
Type: FZ-Single Ram Blowout Preventer
2FZ-Double Ram Blowout Preventer
3FZ-Triple Ram Blowout Preventer
Please see the following table for the bore codes:

Table 1 Bore codes

Metric British Metric British

1 3
18 7 16 〞 48 18 4 〞
3
23 9〞 53 20 4 〞
1
28 11〞 54 21 4 〞

1
 5 3
35 13 8 〞 68 26 4 〞
3
43 16 4 〞 76 30〞
Nominal Working Pressure: There are six kinds of working pressures as listed in the
following table.

Table 2 Nominal Working Pressure Rating

14MPa（2,000psi） 21MPa(3,000psi) 35MPa(5,000psi)

70MPa(10,000psi) 105MPa(15,000psi) 140 MPa(20,000psi)

2.1.1 Temperature Grades of Metal Materials:

Table 3. Temperature Grades of Metal Materials

Temperature Grade
API Code Working Temperature Range
Code
T75 75 -59～121℃(-75～50 ºF)
T20 20 -29～121℃(-20～250 ºF)
T0 00 -18～121℃(0～250 ºF)
2.1.2 Temperature Grades of Non-metal Sealing Elements in contact with Well Liquids.
Combinations of two letters are used to indicate the upper limits and the lower limits as
described below.
Lower Limit (First Letter) Upper Limit (Second Letter)
A -15ºF(-26℃) A 180ºF(82℃)
B 0ºF(-17.8℃) B 200ºF(93℃)
C 10ºF(-12.2℃) C 220ºF(104℃)
D 20ºF(-6.7℃) D 250ºF(121℃)
For example, AB represents a temperature grade ranging from -26℃ to 93℃. The specific
temperature grade is marked with a code on a sealing member.

2.2 Technical Parameters of the Ram Blowout Preventer

Please see the following table for the technical parameters:

Table 4 Technical Parameters of the Ram Blowout Preventer

Double Ram Blowout
Item Single Ram Blowout Preventer
Preventer
Top Connection Studded Flanged Studded Flanged
Bottom Connection Flanged Flanged Flanged Flanged
Height H mm 750 945 1250 1445
7665 ㎏ 7906 ㎏ 14,635 ㎏ 14,876 ㎏
Weight
(16,940 lb) (17,472 lb) (32,343 lb) (32,876 lb)
Bore Size 539.7.1 mm (13 5/8″)
Strength test pressure 21MPa (3,000psi)
Rated working pressure 14 MPa (2,000psi)
Hydraulic Control System 31.5 MPa（4,500psi）

2
Strength Test pressure
Hydraulic Control System
21 MPa（3,000psi）
Working Pressure
Recommended Hydraulic
8.4～10 .5MPa(1,200～1,500psi)
Control Operating Pressure
Opening chamber volume
72 L
for one set of Ram
Closing chamber volume
61 L
for one set of Ram
Thread of Hydraulic Port NPT 1
Specification of the Side
3 1/16″-10,000psi or according to the specific contract
Outlet
Temperature Grade T20(-29～121℃) or according to the specific contract
Closure Ratioλ 1：11.4
Other Descriptions:
The designing and the manufacturing of the blowout preventer are in accordance with
the API Spec 16A norms.
The resistance to the corrosive stress of hydrogen disulfide of the internal parts of the
blowout preventer in contact with the well liquids conforms to the requirements
specified in NACE MR-01-75.
Table 5 Specifications of Available Rams
Blind Ram; Pipe Rams (Maximum 18 5/8”); Shear ram.
Note：The same specification of Cameron Rams can be installed in the BOP. (Except shear/blind ram)

Figure 1 FZ54-14 Single Ram Blowout Preventer

3
Figure 2 2FZ54-14 Double Ram Blowout Preventer

Figure 3 Blowout Preventer with the Bonnet Opened

4
3 Operating Principles

3.1 Principles of the Open and Closure of the Ram

Figure 4 Hydraulic Oil Circuit Diagram for Ram Open and Closure and Bonnet Open and
Closure
The ram open and close action of hydraulic close system is as following: When high pressure
oil of hydraulic pressure system is pumped into the closing cavity of left and right cylinder, it
pushes the piston with the ram shaft and ram assembly to move to the center along the orbit
limited by the body ram chamber, realizing well sealing. At one time, high pressure oil run into the
cavity of left and right lock cylinder and push the wedge piston to make the wedge face of the
wedge piston close tightly with the wedge face of lock shaft end. It can realize self-lock ram and
now release high-pressure oil from hydraulic control system. When open the ram, high pressure
oil first enter into left and right unlock cavity of lock cylinder and push the wedge piston to let the
wedge face of the wedge piston from the wedge face of ram shaft end. When it is gonging to the
total unlock position, the wedge piston begins to compress the check valve rod at the unlock
position until total compress and total open the check valve (viz. the wedge piston is at total
unlock position). High-pressure oil will enter into the ram open cavity of cylinder and push the
piston with the ram shaft and left and right ram assembly to move away from the center, opening
the wellhead. The ram switch is controlled by hydraulic system reversal valve. The lock and
unlock action of ram automatically runs with close and open of ram at the same time.

3.2 Principles of Well Pressure Sealing

A ram blowout preventer can only effectively close a well when all the four seals have taken
effect. These four seals include the seal between the ram top seal and the body, the seal

5
between the ram front seal and the pipe, and the front seal, the seal between the body and the
bonnet, and the seal between the ram shaft and the bonnet.
The ram sealing process is divided into two steps. In the first step the hydraulic oil forces the
ram shaft to impel the Front Packer rubber element to make it deformed and seal the front part
and it also lets the Top Seal rubber element be interfered and compressed to fill the gap between
the Top Seal element and the body and seal the top, thus finish the primary sealing. In the second
step, with the help of the pressure inside the well the ram is impelled from behind to allow the
further deformation of the Front Packer element and the ram is also impelled from the bottom to
let the body adhere tightly to the Top Seal element and thus achieve the reliable sealing of the
well. This is called the well pressure assisted sealing effect.

4 Structures and Features of the Main Components

4.1 The Features of Ram Blowout Preventer

 Main pressure-bearing assemblies such as the body and the bonnet are forged by alloy
steel of high strength and high toughness. The harmful chemical components and nonmetal
impurity in material are controlled strictly, and its structure is compact and non-defective with
excellent general mechanical performance and low temperature impact toughness after
appropriate heat treatment. Adopting oblong structure in ram chamber, body’s stress is greatly
reduced, and its pressure-bearing performance increased.
 Opening and shutting of ram and bonnet are all hydraulic operation, adopting the same
hydraulic oil interface. The open of bonnet assembly and close of ram assembly are the same oil
interface and the same operation. The close of bonnet assembly and open of ram assembly are
the same oil interface and the same operation.
 Ram assembly: Ram block is integral oblong type; Ram rubber is made up of top seal
and front packer, which can be replaced separately according to defective condition. It is
convenient to disassembly and assembly.
 Adopt embedding structure in the inner parts of body and locking parts of hydraulic oil
interface to avoid damaging oil interfaces during installation, transportation and usage. There are
two oil pipe saddle beside the body to avoid the NPT 1” pipe screw thread be damaged.

6
4.2 Pipe ram

3
Figure 5 Pipe Ram

Table 6：Part List of the HF Ram Assembly

No. 1 2 3
Name Ram Assembly Ram Block Top Seal Front packer
Qty.
Specification
1 1 1
RS11944.07.01.0 RS11944.07.01.0 RS11944.07.01.0 RS11944.07.01.0
Blind
0 3 1 2
RS11944.07.04.0 RS11944.07.04.0 RS11944.07.04.0
2 3/8″
0 3 2
RS11944.07.05.0 RS11944.07.05.0 RS11944.07.05.0
2 7/8″
0 3 2
RS11944.07.06.0 RS11944.07.06.0 RS11944.07.06.0
3 1/2″
0 3 2
RS11944.07.08.0 RS11944.07.08.0 RS11944.07.08.0
4″
0 3 2
RS11944.07.09.0 RS11944.07.09.0 RS11944.07.09.0
4 1/2″
0 3 2
RS11944.07.02.0 RS11944.07.02.0 RS11944.07.01.0
5″
0 3 2
RS11944.07.10.0 RS11944.07.10.0 RS11944.07.10.0
5 1/2″
0 3 2
RS11944.07.11.0 RS11944.07.11.0 RS11944.07.11.0
6 5/8″
0 3 2
RS11944.07.12.0 RS11944.07.12.0 RS11944.07.12.0
7″
0 3 2
RS11944.07.13.0 RS11944.07.13.0 RS11944.07.13.0
7 5/8″
0 3 2
RS11944.07.14.0 RS11944.07.14.0 RS11944.07.14.0
9 5/8″
0 3 2
RS11944.07.17.0 RS11944.07.17.0 RS11944.07.17.0
9 7/8″
0 3 2
RS11944.07.18.0 RS11944.07.18.0 RS11944.07.18.0
10 3/4″
0 3 2
RS11944.07.19.0 RS11944.07.19.0 RS11944.07.19.0
11 3/4″
0 3 2

7
 RS11944.07.20.0 RS11944.07.20.0 RS11944.07.20.0
12 3/4″
0 3 2
RS11944.07.21.0 RS11944.07.21.0 RS11944.07.21.0
13 3/8″
0 3 2
RS11944.07.22.0 RS11944.07.22.0 RS11944.07.22.0
13 5/8″
0 3 2
RS11944.07.23.0 RS11944.07.23.0 RS11944.07.23.0
14″
0 3 2
RS11944.07.24.0 RS11944.07.24.0 RS11944.07.24.0
16″
0 3 2
RS11944.07.15.0 RS11944.07.15.0 RS11944.07.15.0
3 1/2″～7″
0 3 2
RS11944.07.16.0 RS11944.07.16.0 RS11944.07.16.0 RS11944.07.16.0
2 7/8″～5″
0 3 1 2
4.3 Shear ram assembly

Figure 6 Shear ram assembly

The shear ram assembly is consist of top ram block, bottom ram block, top seal, side seal I,
side seal II and blade seal. The blade seal is installed into dovetail with side seal at two sides.
The installation into BOP of shear ram assembly is the same as normal ram without any modify of
BOP.
4.3.1 Instruction for assembling & disassembling shear ram of F54-14 ram blowout preventer
4.3.1.1 Assembly
 Firstly, install blade seal from side of top ram block; Use stick tapping the rubber until
both ends of blade seal is flush with ram block. Note: avoid excessive force；
 Then install side seal (Note: side seal is directional); pin of side seal shall be installed in
ram block smoothly;
 Install top seal. Tapping top seal into top seal slot.
4.3.1.2 Disassembly：
 Pry out top seal;

8
  Pry forward side seal;
 Remove blade seal from the side of ram block.
4.3.2 Shear ram specification
 The hydraulic close pressure should be set to Max. 21Mpa (3000psi) with usage of
accumulator pressure;
 The shear ram can be used as blind ram. The hydraulic close pressure is 8.4～
10.5MPa(1,200～1,500psi);
 Shear ram can be used to seal working pressure to Max. 10000psi.

Table 8：Shear capacity

Shear close pressure of
Thickness
No. D.P./Casing hydraulic system Remark
（mm）
（MPa）
1 5”，G-105 9.19 ≥14 Drill Pipe

2 5 1/2”，G-105 10.54 ≥17 Drill Pipe

3 5 “，S-135 9.19 ≥20 Drill Pipe

4.3.3 !Caution：
▲ ！The shear ram cannot resist H2S. If work in H2S environment, must be careful.
▲ ！After shearing drill pipe, the shear ram must be inspected: inspect any damage on
seals; PT for blade; inspect any damage on ram block. After that, process seal test
again. The shear ram can be used if the seal test is qualified.
▲！Avoid shearing tool joint.

4.4 Ram shaft seal device

Double directions seal between bonnet and ram shaft, Y-ring is for seal well pressure, O-ring
is for seal hydraulic control pressure.

4.5 Secondary seal device

The seal system between ram shaft and bonnet is divided to two parts. One part is used to
seal off well pressure, and another seal off control pressure. The secondary seal system is
between the two parts. But they occasionally would be damaged for some reason. In this case,
when shut well, there will be leaking. So we need the secondary seal system to treat it
emergently.
During a well is shut off, if there is liquid flowing out from the seeing hole (at the bottom
part of the middle flange), indicating that the seal rings has been damaged and we can know that
the seal on well side or the seal on control side is damaged from the liquid. At this time,
immediately remove the plug of the grease injection pore, install club-shaped in the pore, and

9
then turn the screw clock wisely with an inner hex wrench to inject the tightened plug, and inject
the secondary seal grease across the radial hole of the check valve into the circular seam so as
to achieve the seal remedy.
Caution to use secondary seal system:
 To prevent the grease from being solidified after long time, we do not put grease in BOP
in factory. And while the BOP is not used, it is also without this grease. Only before the BOP is
used in site, put in the grease. And after a well is completed and the BOP is inspected and
repaired, take out and clean the grease;
 Get special tool ready;
 During working should often notice the following notice hole plug (on it there is a little
hole) if there is liquid flowing out;
 Don’t inject too much grease when seal ring is damaged. Proper inject quantity is that
there is no liquid flowing out. Because the secondary seal grease is more frictional and with
granule substance, it impairs the ram shaft when it returns.

4.6 Locking shaft seal device

Locking shaft seal is used for sealing hydraulic pressure oil of ram closing chamber.

4.7 Hydraulic wedge lock device

The wedge lock seal device is composed of lock cylinder, wedge piston, lock piston, lock
cylinder head, unlock cylinder head, Non-return valve and Check device. The action of locking
ram & unlocking ram is driven by hydraulic pressure, the ram can be locked by the bevel face of
wedge piston when the hydraulic pressure is released.

4.7.1 Non-return valve

The function of Non-return valve is to achieve sequence of actions when unlocking ram and
opening ram. When the ram is fully unlocked in place, valve rod is forced into locking cylinder
head and the valve rod push the valve core so that the core is forced to leave valve seat. At this
time, the hydraulic pressure oil can pass into ram opening chamber through Non-return valve
smoothly. When the ram is fully locked, the valve core is forced into valve seat by spring, the
hydraulic pressure oil cannot pass into ram opening chamber. Therefore, valve seat, O-ring
25.8X3.55 and O-ring 10X2.65 is very important for seal function. Once seal failure, it would
cause such problems as the ram could not be opened or the opening pressure is too high.

4.7.2 Check device

Check device is used for indicating whether the ram is fully opened.

10
5 Part List

5.1 Product structure

See figure 5～figure13

11
6 Operation and cautions

6.1 Prepare work before installation

6.1.1 Before install on wellhead

Check the integrity of the circle slot for the seal gaskets of the flanges of the wellhead and
the blowout preventer and check that there are no bulging points on the surfaces of the flanges;
Check that it passed the pressure test.
6.1.2 After Ram BOP installed on wellhead
Check BOP is installed rightly or not: lifting ring of body should be installed on the upside;
everywhere the connecting bolt diagonal should be in turn tightened equably. See the Appendix
for recommended torque of bolts;
Inspect oil pipes to see if they are in compliance with BOP switch direction, provide
286~429psi control pressure to test each ram twice (open and close), draining air from the pipes.
If ram switch movement is not the same direction as the mark on the hand rod of control platform,
reverse the connection pipes;
Check whether the specifications of the ram of the blowout preventer are compatible with the
dimensions of the drilling tools in the well;
Check if blow off pipe, kill manifold and choke manifold separately well connect;
Wellhead equipments shall be pressure tested fully. Standards of test shall be according to
related well control specifications. After tests, every connection bolt is fixed once again avoiding
unbalanced distribution;
When do BOP test on floor, fill water into BOP & open and close ram once to drain air from
back of ram of ram cavity;
Carry out abovementioned inspection and test run, if no problems found, the equipment may
be used.

6.2 Operation

 BOP operation must be charged by specialist and professional person. Operators shall
be familiar with BOP working principle, specifications and process, and can also operate, repair,
maintain and clear troubles;
 When testing without string in hole, the max close pressure does not exceed 429psi to
prevent rubber from damage. When there is string in the well pressure prohibit closing the blind
ram;
 Closing well for a long time, lock ram with hydraulic close lock and then release
hydraulic pressure, and the wedge face on the wedge piston can self-lock ram. It shall be marked
on control platform to prevent wrong operation;
 After reaching objective interval, the rams should be opened and closed one time every

12
day to see if they are flexible lock in normal condition and if hydraulic wedge lock is useful. After
the drill string is pulled out of the well, blind ram open and close test is needed. When there is
string in hole, do not close blind ram.
6.2.1 Ram Seal Test
The testing media shall be clean water or drilling fluid. During the pressure test the timing
shall be started after the pressure has been stabilized.
6.2.1.1 Testing of the Blind Ram and the Pipe Ram
Testing Procedures：
Install the blowout preventer on the seat of the testing stump and connect the open and
closure pipe lines to the preventer. Connect the pipe lines from the high pressure test pump to the
seat of the testing stump or the side outlet of the blowout preventer;
When testing the pipe ram, install the testing mandrel in the blowout preventer and ensure
that the mandrel is reliably connected to prevent it from breaking off during the test. No mandrels
are needed when testing the blind ram;
Close the ram hydraulically under a pressure of 8.4 to 10.5MPa (1,200psi to 1,500psi) with
the hydraulic control handle at the closure position of the ram;
Improve the pressure inside the well to 1.4MPa to 2.1MPa (200psi to 300psi) and keep for 10
minutes. Check if there are any leakages and the sealing is judged as passed if there are no
leakages;
Improve the well pressure to the maximum nominal working pressure of the blowout
preventer, 14MPa (2,000psi) and keep for 10 minutes. Check if there are any leakages again and
the sealing is judged as passed if there are no leakages;
Reduce the well pressure to zero.
For a variable diameter ram, its maximum sealing drill pipe and its minimum drill pipe shall be
tested separately following the same testing procedures described above.
6.2.2.1 Testing of the Locking Device
Close the ram hydraulically under a pressure of 8.4 to 10.5MPa (1,200psi to 1,500psi)；
Reduce the hydraulic control pressure to zero and leave the hydraulic control handle at the
ram closure position；
Improve the pressure inside the well to 1.4MPa to 2.1MPa (200psi to 300psi) and keep for 10
minutes. Check if there are any leakages and the sealing is judged as passed if there are no
leakages；
Improve the well pressure to the maximum nominal working pressure of the blowout
preventer, 14MPa (2,000psi) and keep for 10 minutes. Check if there are any leakages again and
the sealing is judged as passed if there are no leakages；
Reduce the well pressure to zero；
Open the ram hydraulically。
6.2.3 Operation, test procedure and inspection for shear ram

13
 6.2.3.1 Prepare works for operation
Ensure maintaining hydraulic control pressure at 2715psi~3000psi;
Ensure that the drill pipe tool joint and drill collar thicken part is not at the shear position, then
lock brakes;
Close Annular BOP and Pipe ram BOP which is above shear ram BOP;
Open main blowout pipeline and relief pressure;
Install the corresponding fixed clamps (the well installed with the shear ram blowout
preventer shall be equipped with one corresponding fixed clamp for the drill pipe) on the
appropriate positions on the drill pipe (above the rotary disc) and connect and fix it to the driller
with steel cable。
6.2.3.2 Operation procedure
Switch the handle of the by-pass valve of the hydraulic control system to “Open” and allow
the high pressure oil of the accumulator group directly into the manifold.；
Switch the handle of the three potential four-way valve of the shear ram in the hydraulic
control system to “Close” and perform the cutting of the drill pipe；
Observe the variations in the pressure indicated on the pressure gauge of the hydraulic
control manifold. The pressure shall drop when the closure of the ram begin, it shall increase and
be stabilized after the cutting has began. The pressure shall drop suddenly at the moment when it
is cut and then increase and be stabilized. This can be used to judge the cutting operation is
successful or not；
Close the by-pass valve of the hydraulic control system and adjust the pressure of the
manifold of the remote control console to the set value。
6.2.3.3 Inspection and Maintenance
The shear ram assembly shall be taken out after each cutting operation and thoroughly
inspected. The inspection items include：
Appearance
There shall not be any cracks on any part of the cutter body and there shall not be any such
defects as notches or ridges on the blade。
There shall not be any obvious defects on the rubber sealing element。
There shall not be any defects on the binding face between the upper and the lower cutter
bodies or on the mounting groove of the cutter body seal that can affect the sealing performance。
Surface Crack Examination
After the cutting operation the P.T. shall be performed all the processing elements of the
shear ram to check if there are any defects on the surface. The inspection results shall be
recorded. The parts need to be tested (as shown by the bold line in the drawing) and the testing
requirements are described below：
 There shall not be any faulty indications on the blade of the cutter body and the binding

14
surface between the upper and the lower cutter bodies;
 There shall not be any faulty indications on the mounting groove of the rubber-sealing
element.

Figure 15 Inspection Parts of the Shear Ram

1） Maintenance
 There shall not be any welded parts on the cutter body of the shear ram;
 Mild ridges or deformations on the blade can be finely grinded with an oil stone or a
polisher and the original shape of the blade shall be kept (because the shape of the blade will
affect the cutting performance directly);
 The rubber sealing element of the cutter body shall be changed even if there is only a
minor defect on it.
2） Management
 A dedicated file shall be kept for the use of each pair of shear rams to record their use
and inspection histories in detail;
 According to the specification of API Spec 16A, the service life of a shear ram is
normally three cutting operations. It will be tested once before being released from the factory
and then it can be used only twice afterwards (cutting tests are not allowed in rehearsal blowout
preventing exercises or daily blowout prevention operations). After being used in the well it shall
be disposed of and it shall be replaced by a new ram. If the results of the test after three cutting
operations conform to the requirement of no surface defects, it is allowed to be used again.
However, the additional cutting operations shall not be more than twice.
6.2.3.4 Ground Testing Procedures of the Shear Ram：
Install the blowout preventer on the seat of the testing pile and connect the open and closure
pipe lines to the preventer. Connect the pipe lines from the high pressure test pump to the seat of
the testing pile or the side outlet of the blowout preventer;
The open pipe line, the closure pipe line and the well pressure pipe line shall be equipped
with at least one pressure transmitter each. All the pressure transmitters shall be connected with
the data collecting system to allow the permanent record;
Hang a testing drill pipe about 1.2m (4ft) in length vertically above the blowout preventer and
then put it down into the well. It is allowed to loosely straighten the pipe below the ram to avoid
over bending during the cutting operation. When cutting the drill pipe, the connection of the drill
pipe should be avoided;

15
 Set the pressure of the manifold of the hydraulic control system to 21MPa (3,000psi) and
close the ram and cut the drill pipe with one operation. The pressure at the moment the drill pipe
is cut can be obtained from the rapid variation of the pressure during the cutting operation;
Improve the pressure inside the well to 1.4MPa to 2.1MPa (200psi to 300psi) and keep the
pressure to stabilized for 10 minutes. Check if there are any leakages and the sealing is judged
as passed if there are no leakages;
Improve the well pressure to the maximum nominal working pressure of the blowout
preventer and keep the pressure to stabilized for 10 minutes. Check if there are any leakages
again and the sealing is judged as passed if there are no leakages;
Reduce the well pressure to zero and open the ram. Check the worn condition of the shear
ram of the blowout preventer and the condition of the sealing element and record the results.

Table 19 API 16A Requirements on Drill Pipe Cutting Test

Dimensions of BOP (Diameter) Drill Pipe to be Cut (Minimum)

179mm(7 1/16in) 3 1/2in 13.3 lb/ft E-75

279mm(11in) 5 in 19.5 lb/ft E-75

346mm and larger (13 5/8in) 5 in 19.5 lb/ft G-105

6.2.4 Tests for hydraulic control system
Rating operation pressure of hydraulic control system is 21MPa(3,000psi) and do open &
close tests. Test media is hydraulic oil.
Not install ram or put bonnet on open position. Caution: Not to extend ram shaft contacting
body and fix BOP on the ground to avoid leaning as result of center of gravity excursion due to
two side outlets open at same time；
Test close chamber，test pressure is 21MPa (3,000psi) and keeps pressure for 10min check
weather there is no leak or not, record results；
Reduce hydraulic control pressure to zero；
Test open chamber，test pressure is 21MPa (3,000psi) and keeps pressure for 10min check
weather there is no leak or not, record results；
Reduce hydraulic control pressure to zero.

6.3 Caution

▲！Prohibit releasing pressure by opening ram to prevent rubber from damage. Before
opening ram, check if the manual-lock system kept in unlocking position each time. And after that,
check if the ram remaining fully opened to prevent ram from drilling tool bumping;
▲！Prohibit rotate drill tools when the ram is closed;
▲！Keep hydraulic oil clean;

16
 ▲！Discharge water from BOP after pressure test and before storage. Put ram in full open
position and do rust-resisting treatment.

7 Maintenance

BOP shall be cleared completely after every testing at site. Replace damaged parts in time,
anoint so as to prevent rust after cleaned ram chamber and ram of body, (suggest to oil them by
synthetic complex aluminum grease), and oil connecting thread part by thread grease.

7.1 Replacement of ram and ram rubber

Ram rubber is the key part in a BOP. If damaged, BOP is useless in sealing well. So it is very
important to keep it well, and replace it in time if there is damage in sealing surface。Procedures
of ram and ram rubber replacement：
Open the ram completely with hydraulic pressure oil in order that the ram is at open position;
Loose bonnet bolts (Attention: If BOP is installed on the well with pressure, forbid
disassembling bonnet bolts)；
Open the bonnet assembly with hydraulic oil less than 10.5MPa. At the same time, close the
ram. Open the bonnet assembly to the limited position and now the ram is at closed position；
If the ram is not at the open position at this time, control the ram opening operation through
the hydraulic control device to open the ram and stop it after the ram is opened to the maximum
to prevent the bonnet from closing;
When replacing rams in upper chamber, lift the ram assembly from the end of ram shaft.
Attention: protect piston rod (ram change), bonnet surface and body surface in order to
prevent bump and scratches；When replacing rams in lower chamber, put U-steel on the top of
ram assembly and fixed them by M30 screw, then hang the sling at both end of U-steel and lift the
ram assembly until bottom side of ram assembly is about 30mm upwards from piston rod. Put 2
pieces of wood plate (Thickness: 30mm, Length: 1m) between piston rod and bottom side of ram
assembly, drag outward the ram assembly carefully until the ram assembly is out of body.
Attention: protect piston rod (ram change), bonnet surface and body surface in order to
prevent bump and scratches; See drawing under below for details:

17
 U-steel

U-steel

U-steel

(Tools for change rams in lower chamber)

Pull ram assembly out of the ram shaft tail. While taking out ram assembly, attention to
protect open and close piston rod & inner circle groove in the body cavity from being knocked and
scratched;
While replacing ram rubber, first upward fry out top seal, then forward dismount face seal,
last replace new rubber. Assembling order is contrary to disassembling.
▲！Caution: When close bonnet assembly and open ram, the oil pressure for opening ram should
be controlled at 3MPa. If the bonnet assembly and ram can slowly move to the bore of BOP, it
can forbid the ram assembly heavily crack to the enter of body inner cavity and damage open and
close piston rod when quickly close ram assembly.
7.2 Repair and replacement of hydraulic cylinder assembly

If there are any damages or leakages of oil at the ram shaft sealing, the piston sealing, the
locking shaft sealing or the sealing of the piston rod for opening and closing bonnet, they shall be
disassembled and repaired.
7.2.1 Procedures of disassemble hydraulic cylinder assembly
Open the bonnet and take out ram assembly as item 7.1 (1)~(5)；
relief all pressure in hydraulic cylinder, place a clean oil basin below the hydraulic cylinder to
prevent the hydraulic oil from leakage onto the ground during disassembling operation；
Take down all of bolts and nuts first, and then take down hydraulic wedge lock device.；
Take down the hydraulic cylinder (ram change) and hydraulic cylinder (open bonnet)；
Open the locking screw that on locking nut , take down locking nut and piston；
Take out ram shaft；
Push the bonnet beside body, in order to convenience to use wrench；
Hang the bonnet with a hoist and screw down the piston rod for opening and closing bonnet；
Piston rod of open & close bonnet is threaded with body and it has wrench flat side at the

18
position near body. Rotate the piston rod counter clockwise and take out it. Attention: if rotating
piston rod is not smoothly, prohibit forcing rotating. At this time, adjust hanging bonnet, then
disassembly;
Take out ram shaft sealing device, and then take out locking shaft sealing device.
7.2.2 Inspection position after disassembly
Inner surface of the Hydraulic Cylinder and the Hydraulic Cylinder sleeve: If there are any
deep longitudinal scratches in the inner surfaces of the hydraulic cylinder or the Hydraulic
Cylinder sleeve and leakages cannot be prevented even after replacing the seal ring, it shall be
replaced with a new hydraulic cylinder or cylinder body. And at the same time such related
components as the piston shall be inspected to find out the causes of the scratches and solve
them. If the scratches are shallow linear or spot scratches, they can be repaired with by a piece of
very fine sand paper or an oil stone;
Sealing Surfaces of the Ram Shaft, the Locking Shaft and the Piston Rod for Opening and
Closing the Bonnet: The judging standards and the treatment methods for scratches on the
surfaces are the same as those for the hydraulic cylinder. If the coating material is scaled off it
would cause serious leakages and it must be replaced by a new one;
Seal Ring: First check whether there are any abrasions at the lip of the sealing element and
whether there are any cut damages resulted from extrusions. The sealing element shall be
replaced if there are any damages or abrasions;
Piston: The piston shall be replaced if it is with an inhomogeneous abrasion deeper than
0.2mm at the moving sealing surface. And there shall not be any defects that can affect the
sealing performance on other surfaces.
7.2.3 Installation of hydraulic cylinder assembly
Repeat the disassemble operations reversely to mount the hydraulic cylinder and pay
attention to the following points：
Check whether there are any burrs or cusped edges on the components and remove them if
there are any to protect the seal rings from being scratched. Pay attention to keep them clean;
When mounting the seal ring, its surface shall be covered with lubricant and the
corresponding sealing surface shall also be smeared with lubricant to facilitate the mounting
operation;
Pay attention to the direction of the lip seal to make sure that the opening of the lip shall be
pointed to the pressure side;
Take care to allow the seal ring to pass through the threaded parts smoothly and avoid any
scratch.

7.3 Replacement of Bonnet sealing ring

When the rubber seal or the framework of the seal ring of the bonnet is damaged, it shall be
replaced. The specific procedures are described underbelow：

19
 Open the bonnet with the hydraulic pressure；
Screw two M12 grub screws into the bolt holes on the two sides of the seal ring of the
bonnet to prop up the seal ring . Pry the left side and the right side at the same time when
propping up the gasket；
Replace the sealing element. Attention shall be taken when mounting the sealing element.
The seal ring of the bonnet must be mounted in the correct direction. That is, the rubber spring
shall be mounted on the end side where there is a horizontal slot, this side shall be at the bottom
of the slot of the seal ring on the bonnet, and the lip side of the lip seal shall be on the same side
of the bottom of the slot for the seal ring of the bonnet；
Install the bonnet seal ring. Smear lubricant on the groove for the seal ring of the bonnet and
the seal ring it self. Place the seal ring of the bonnet into the groove, press the lip of the lip seal
into the groove with a screwdriver, press the seal ring of the bonnet into the groove at the left end
and the right end with two M10 screws and then take the screws out.

7.4 Maintenance of hydraulic wedge lock device

If there is oil leakage or can not normal lock or unlock of hydraulic wedge lock assembly,
maintenance should be carried out.
7.4.1 Procedure of disassembly:
Release hydraulic pressure；
Put a clean basin under the hydraulic wedge lock assembly to prevent oil flowing to the floor
during disassembly；
Take off the connection bolts of left (right) lock cylinder. Take off hydraulic lock assembly in a
whole；
Take off lock head and unlock head. Disassemble lock piston；
Take off the valve head of lock head and take off the non-return valve；
Lightly knock the wedge piston by copper bar to the direction of unlock head of lock cylinder；
Take off checking device；
7.4.2 Inspection of hydraulic wedge lock device
Inner hole of left (right) lock cylinder：When there is deep longitudingal pull scar on the inner
surface of lock cylinder, change new lock cylinder cause it can not prevent oil leakage when
change new seal ring. At the same time, inspect relative parts as the wedge piston and find pull
cause to settle it. If the pull scar is shallow linear scratch or dotted scar, repair it by superfine
sand paper and abrasive stick;
Wedge piston seal surface and bevel surface：When there is pull scar on seal surface,
determine and treatment methods are as lock cylinder. When there is pull scar on the bevel
surface, polish and repair it. If the scar is big, new parts should be changed;
Seal ring：Inspect O-ring if it is extruded or aging. If the seal parts are damaged, they should

20
be changed;
Lock piston：When the depth of uneven wear abrasion of movable seal surface of piston is
not more than 0.2mm, it should be changed. The other surfaces should not have obvious scar,
which will affect seal effect;
Non-return valve：Clean each parts of check valve and inspect seal ring and seal tapered
surface of valve body. Inspect elasticity of the spring and inspect surface and seal ring of the
valve rod. Inspect surface condition of steel ball. If there is need, it can separately change parts
or change the check valve and rod in a whole;
Check device：Inspect display rod for freely ejecting and resetting. The seal ring on the
display block is for dust-proof, not for sealing.
7.4.3 Installation of hydraulic wedge lock device
Assembling order is contrary to disassembling. Attention：
Inspect parts for burrs or sharp angles, it should be get rid of if there is some. It can ensure
the lip of seal ring from scratching. Pay attention to maintain clean。
When install seal ring, coat lubricating oil on the surface of seal ring and counter-seal surface
for easy to assembly。
Move the valve rod by hand till it can freely press down into the locking cylinder cap and can
eject to reset。

8 Storage of rubber element

All rubber parts must be stored as following:

Store rubber parts in a dark place (temperature:0~25℃): Definitely do not store rubber parts
out-of-doors in direct sunlight and keep items stored indoors away from windows and skylights to
avoid sunlight.
Keep storage area as cool as possible. Never store rubber part near heaters, radiators or
other hot equipment.
Store these items away from high-voltage equipments. High-voltage equipment frequently
produces ozone which attacks rubber.
Store rubber parts in a relaxed position. For example, do not bend a rubber part and force it
into a small box. This accelerates aging in the stressed (bent) area.
Rubber part should be checked periodically. If there is any problem in a rubber part, it cannot
be used.
Usually the storage term is 2 years.

21
9 Trouble shouting

No. Trouble phenomena Cause Settlements

a. Seal ring between the body Change damaged seal

and side door is damaged.
Fluids flow out from the ring.
1 clearance between the
body and side door. b. There is dust and damage CLEAR DUST AND
on the BOP body and side REPAIR DAMAGED
door seal surface. PARTS.

Ram movement direction

is not conformance with BOP pipes are wrong
2 Reverse BOP pipes.
plate mark of control
connected in control platform.
valve.

Hydraulic system is in There are other materials,

Wash ram, ram chamber
3 order, but ram can not sand and mud on ram contact
and bonnet.
closed fully. ends.

The seal ring on ram shaft

There is well medium REPLACE DAMAGED
close to body is damaged or
4 flowing from bonnet SEAL RING OR REPAIR
the surface of ram shaft is
observation hole DAMAGED RAM SHAFT.
scuffed.

5 THERE IS HYDRAULIC The seal ring on ram shaft

REPLACE DAMAGED
OIL FLOWING FROM close to cylinder is damaged
SEAL RING OR REPAIR
BONNET or the surface of ram shaft is
DAMAGED RAM SHAFT.
OBSERVATION HOLE scuffed.

BOP cylinder, piston, locking

BOP hydraulic part
shaft, oil tubing, opening and Replace all seal rings and
cannot hold pressure,
6 closing bonnet piston rod seal repair seal surface or
and open and close the
ring damaged, seal surface change new parts.
bonnet unhandy.
scratched.
Ram seal rubber damaged,
It cannot hold pressure Change ram rubber, and
7 upper seal surface of the ram
when ram closed. repair seal surface.
chamber damaged.
Clear sand and mud
Ram plugged with sand and
Control pipe is in order, increase hydraulic control
mud.
but ram or bonnet can't pressure.
8
be opened with hydraulic
The wedge lock device is not Check the wedge lock
pressure.
unlocked device

1)increase unlocking
There is dust in oil way； pressure appropriately
9 Ram cannot be unlocked.
Bevel face is damaged (≤2285psi) ； 2)Clean
non-return valve；3) Repair

22
 the end of ram shaft and
bevel face of wedge piston
There is hydraulic oil Disassembly wedge lock
The seal ring of wedge lock is
10 flowing from the bottom of assembly, replace seal
damaged
wedge lock cylinder ring.

23
10 Appendix

Table 1：Specifications of the Nuts of the Blowout Preventer

d
Weight
Part No. S(㎜) M(㎜) e(㎜)
kg
Metric British

11706.01 M12 1/2 22 12 25.4 0.03

11706.02 M16 5/8 27 15.5 31.1 0.05
11706.03 M20 3/4 31.8 19 34.7 0.09
11706.04 M22 7/8 36 22 41.6 0.1
11706.05 M24 1 41 25 47.3 0.19
11706.06 M27 41 28 47.3 0.19
11706.07 M30X3 1 1/8 46 28 53.1 0.25
11706.08 M33X3 1 1/4 50 31 57.7 0.32
11706.09 M36X3 1 3/8 55 34 63.5 0.42
11706.10 M39X3 1 1/2 60 37 69.3 0.54
11706.11 M42X3 1 5/8 65 41 75.1 0.7
11706.12 M45X3 1 3/4 68 44 78.5 0.8
11706.13 M48X3 1 7/8 74 47 85.4 1.12
11706.14 M50X3 2 77 50 88.9 1.67
11706.15 M52X3 77 50 88.9 1.67
11706.16 M58X3 2 1/4 88 56 101.6 1.78

24
11706.17 M64X3 2 1/2 98 63 113.1 2.32
11706.18 M70X3 2 3/4 105 68 121.2 2.78
11706.19 M76X3 3 115 75 132.8 3.7
11706.20 M80X3 3 1/4 125 81 144.3 4.89

Table 2：Specification of bolt & Nut connect with BOP body

Wrench Spec. Tighten Torque

Part No. Description Remark
S N·m
RS11882.03 Bonnet bolt 74 8411
RS11148.02A Nut M39X3 55 2272
Table 3：Recommended tightening torque for bolts and screw（Metric）
Tightening Tightening Tightening
Size of Bolts Size of Bolts Size of Bolts
Torque Torque Torque
and Screws and Screws and Screws
N·m N·m N·m
M12 80 M33×3 1292 M52×3 5505
M16 153 M36×3 1737 M58×3 7892
M20 266 M39×3 2272 M64×3 10885
M22 424 M42×3 2910 M70×3 14549
M27 643 M45×3 3654 M76×3 18957
M30×3 930 M48×3 4516 M80×3 21565
Table 4：Recommended tightening torque for bolts and screw（British）
Tightening Tightening Tightening
Size of Bolts Size of Bolts Size of Bolts
Torque Torque Torque
and Screws and Screws and Screws
ft•lb ft•lb ft•lb
1/2-13UNC 59 1 1/4-8UN 953 2-8UN 4060
5/8-11UNC 113 1 3/8-8UN 1281 2 1/4-8UN 5821
3/4-10UNC 196 1 1/2-8UN 1676 2 1/2-8UN 8028
7/8-9UNC 313 1 5/8-8UN 2146 2 3/4-8UN 10731
1-8UN 474 1 3/4-8UN 2695 3-8UN 13982
1 1/8-8UN 686 1 7/8-8UN 3331 3 1/4-8UN 17830

25
Schemic drawing for 21 1/4”-2000psi BOP Stack

26