U BOP Manual Rev B
U BOP Manual Rev B
U BOP Manual Rev B
Operations and
Maintenance Manual
Part #:
Customer:
Customer Ref #:
Control Flow SO #:
Rev. B
Updated: August 17, 2004
Table of Contents
Section Page
1 Body connections and side outlets 5
2 BOP vertical bore 7
3 Bonnet bolting (including internal threads in the BOP body) 7
4 Bonnet sealing surfaces 9
5 Ram bores 10
6 Rams 12
7 Ram-to-ram-bore clearance 13
8 Connecting rod buttons 14
9 Components with plated, overlayed or coated surfaces 15
10 Piston heads 16
11 Through bores and counterbores 17
12 Ram locking devices 18
13 Care and Maintenance 20
14 Cold Weather Operation Precautions 21
15 Assembly Procedure 22
16 Storage and Aging of Rubber Goods 23
Revision: B
Updated: August 17, 2004
At each inspection, particular attention should be given to the items listed below. The order of
appearance of an item in the list does NOT indicate order of importance. The items to which
particular attention should be given are:
All seals should be replaced at each periodic inspection. It is recommended that seals which have
been in service not be reused.
It is recommended that a record of the periodic inspections of each BOP be kept in a permanent
file.
The machined surfaces of clamps (Figure 8) must Figure 6 The mating face of clamp
be free of galling, upsets, and raised edges. hubs must be free of upsets and
raised edges.
1.5 Clamp Bolting: Clean clamp studs, washers, and
nuts priorto inspection. Washers which show
signs of galling must be replaced. Studs which
have visible cracks must be replaced.
c. EXCESSIVE WEAR OR DAMAGE IN THE AREA OF THE RING GROOVES. In the area
of the ring grooves (ie: at the faces of the flanges or clamp hubs), the vertical bore
is keyseated, gouged, or worn deeper than 1/8" (0.125 inch) beyond the maximum
API bore dimension (Figure 10).
Note: The maximum API bore dimension, given in API 6A, is the nominal bore size plus
1/32" (0.031 inch),
Inspect bonnet bolts for thread galling and for impact damage to threads.
Minor localized damage may be corrected by chasing the threads with a triangular
file. If the threads are severely damaged or galled, the bolt must be replaced.
Inspect bonnet bolts for gall ing between the head of the bolt and the bonnet. If
galling is evident, remove raised metal, using a file on the underside of the bolt
head or 60 to 100 grit abrasive cloth on the face of the bonnet. When reassembling the
BOP, install a hardened washer (see the following table on next page) under the
head of each bonnet bolt.
Inspect bonnet bolts for visible cracks at the root of threads and at the junction of
the body and head of the bolt, using dye penetrant methods. Bonnet bolts which
have visible cracks must be replaced.
Use a thread profile template to inspect bonnet bolt threads for visible wear and for
deformation of the thread profile. If the threads are visibly worn or deformed, the
bonnet bolt must be replaced.
Inspect the threads on both ends of each bonnet stud for galling and impact
damage. Minor localized damage may be corrected by chasing the threads with a
triangular file. If the threads are severely damaged or galled, the stud must be
replaced.
Inspect studs for visible cracks at the root of threads. Bonnet studs which have
visible cracks must be replaced.
Use a thread profile template to inspect stud threads for visible wear and for
deformation of the thread profile. If the threads are visibly worn or deformed, the
bonnet bolt must be replaced.
Inspect the threads of bonnet stud nuts for galling. Minor damage may be corrected
by chasing the threads with a tap. If the threads are severely galled, the nut must
be replaced.
Use a thread profile template to inspect nuts for visible wear and for deformation of
the thread profile (Figure 11). If the threads are visibly worn or deformed, the
bonnet stud nut must be replaced.
The bonnet face of the BOP body should be checked for flatness. The recommended
check for flatness is to use a feeler gage to measure the gap, if any, between the
bonnet face of the BOP body and a straightedge placed across the center of the
face. A measurement should be taken in both the horizontal and vertical directions
(Figures 15 and 16). The face of the body is acceptably flat if the measured
gap in each direction does not exceed 0.015 inch.
Warning: The bonnet face of a BOP body may be repaired by a skim cut
only once. A skim cut must not be taken on either bonnet face of
the body unless it is known for certain that the body has not previously
been repaired in this manner.
5. Ram Bores
Inspect all surfaces of the ram bores for pitted or rough areas and for scratches,
gouges, and indentations with raised edges.
Remove ridges along scratches and gouges, and remove raised metal surrounding
indentations. Polish the surface of the ram bores to a 125 RMS finish, with the
exception of scratches, pitting, and other blemishes which are below the
surrounding surface.
Warning: (1) Don’t remove metal in order to clean up blemishes which are
below the surrounding surface (except on the sealing surface; see Section
5.3).
Warning: (2) If the ram bores have been severely gouged or enlarged by
careless or excessive polishing, filing, or grinding, resulting in excessive
ram bore clearance (see Section 7), it will be necessary to return the BOP
to a Control Flow, Inc. or authorized repair facility for repair.
Carefully inspect the upper half of the ram bore for sharp edges and rough surfaces
which can damage the ram top seal. Remove sharp edges from scratches and
gouges, and remove peaks from pitted or rough areas. A 125 RMS finish is required
on the upper surface of the ram bore, with the exception of scratches, gouges, and
pitted or rough areas.
Warning: Do not remove from the ram bore more metal than is absolutely
necessary to prevent damage to the ram top seal. Once sharp edges and
peaks are removed, further polishing is of no benefit.
Carefully inspect the sealing surface of the ram bore. The sealing surface of the BOP
ram bore is the surface of the bore in contact with the ram top seal and packer when the ram is
in the closed position. Contact is made on the upper surface of the bore within 4 inches of the
edge of the BOP vertical bore and on the sides (Figure 17).
A 125 RMS finish is required on the sealing surface of the ram bore. Polish the sealing
surface to remove scratches, pitting, and other blemishes. The ram top seal is tolerant of
indentations in the sealing surface if surface contours are smooth and if there are no sharp ridges
or deep, narrow grooves.
Warning: Do not remove from the ram bore more metal than is absolutely
necessary to achieve smooth contours and the required surface finish on
the sealing surface of the ram bore.
6.1 General
Inspect Shearing Blind Rams (SBRs) for visible cracks, particularly in the blade area.
BRs with visible cracks anywhere in the ram body or blade area must be replaced.
Inspect the cutting edges of SBRs for upset metal and blunted edges. The face of
the blades may be dressed to produce sharp cutting edges if the original face angles
are maintained.
7. Ram-to-Ram-Bore Clearance
Excessive clearance between the ram and the ram bore may
allow leakage at low wellbore pressures. Wellbore pressures
which are sufficient to force the rams upward against the top
of the ram bore help energize the top seal, resulting in a tighter
seal as wellbore pressure increases. Therefore, ram-to-ram-
bore clearance is not critical to high-pressure sealing.
Ram and ram bore dimensions vary from unit to unit due to
normal manufacturing tolerances, wear, and damage. Clear
ance between the ram and ram bore depends upon the
particular combination of ram and ram bore and upon the
Figure 20 Deformation of the
position of the ram in the ram bore. Forthis reason, separate
upper corners of the pipe
height measurements of the ram and ram bore may not bore may occur if a tool joint
provide a reliable indication of low-pressure sealing ability. A was landed on the ram.
direct measurement of clearance between the ram and the Remove upset metal flush
ram bore with the ram in the closed position is best. This with the original contour of
measure-ment can most readily be made after the bonnets are the bore.
removed.
(2) Insert the ram into the ram bore, and push the ram toward the vertical bore until it is
approximately in the fully-closed position (Figure 21).
Proprietary Information of Control Flow, Inc. ** Pg 13 **
7. Ram-to-Ram-Bore Clearance, continued
Clearance between the top of the ram and the ram bore
should not exceed 0.060 inch. The total side clearance
(right side clearance and left side clearance combined)
Figure 22 Vertical clearance between
should not exceed 0.080 inch. If clearances are in
the ram and the ram bore is
excess of these values, low-pressure sealing may not
measured at the top of ram.
be assured. If low pressure leaks are experienced,
substitution of other rams and the use of new top seals
and packers may result in acceptable low-pressure tests.
Connecting rod buttons may be overstressed by application of more than 1500 psi RAM
OPEN pressure to the BOP while the rams are holding bore pressure or when they are
prevented from opening fully by an obstruction. Overstress will be indicated by deformation
or cracking of the button.
Note: API RP 53 contains a recommended field acceptance test procedure for testing the
strength of the ram and the connecting rod button, to verify that both are in good
condition. To ensure against overstress during this test, operating pressure must never be
allowed to exceed or 1500 psi.
On the Class U BOP, the connecting rod button is integral with the connecting rod. Control
Flow, Inc. repairs the BOP operating pistons with damaged connecting rod buttons by
installing a threaded-in replacement button. Threaded-in connecting rod buttons have a
preparation for installation and removal with a spanner wrench and are locked in place with
thread-locking compound.
Use a machinist's square to visually inspect connecting rod buttons for deformation (Figure
24). Use dye penetrant methods to inspect connecting rod buttons for cracks. Pay particular
attention to the junction of the head and the neck of the button and to the junction of the
neck with the connecting rod.
PTFE coating is used on the ID of some ram change cylinders and operating
cylinders.
Inspect the cylinder ID for areas which are rough, corroded, or otherwise damaged.
Cylinders with coating worn through in one or more areas may be returned to
service if the exposed surface and the adjacent coating are smooth and free from c
orrosion. If the PTFE coating is rough, the
exposed surfaces corroded, or scratches
penetrate the coating, the cylinder
should be returned to a Control Flow, Inc.
or an authorized repair facility for repair.
10.1 General
On lip seal and bearing ring type piston heads, the non-metallic bearing ring
prevents contact between the piston head and the cylinder (Figure 28). In normal
service and with the bearing ring intact and undamaged, the piston head should
experience no wear.
Proprietary Information of Control Flow, Inc. ** Pg 16 **
10. Piston Heads, continued
10.3 Lip Seal and Bearing Ring Type Piston Heads, coninued
A bearing ring must be replaced if any of the following conditions are present:
(3) The bearing ring stands out less than 0.015 inch (approximately 1/64") from
the head of the piston. Standout may be measured with a machinist's scale
or a caliper (Figure 29).
A gap of at least 1/8 inch is required between the ends of the bearing ring, to allow
for thermal expansion. The gap should be measured with the ring wrapped tightly in
the ring groove, to correspond with the installed position of the ring (Figure 30).
11.1 General
Through bores and counterbores in the bonnets and intermediate flanges will not
wear in normal service, but they can be damaged by corrosion or by chipped or
peeling plating on the piston rods running through them.
Inspect the bonnets and the intermediate flanges for corrosion and mechanical
damage to the through bores through which the ram change piston rods, the
connecting rods, and the tail rods pass. Rough or damaged surfaces should be
smoothed to a 125 RMS or better finish.
Check the clearance between the through bore or counterbore and the rod or
piston. The clearance should be determined by separate micrometer measurements
of the bore and the rod or piston. The maximum allowable diametral clearances are
as follows:
If scoring, galling, corrosion, or other damage has increased the clearance in a bore
beyond the allowable value, the bonnet or intermediate flange should be returned to
a Control Flow, Inc. facility for repair. This damage must be corrected before the
unit is returned to service. In the case of mechanical damage, carefully inspect the
piston rod (see Section 9, "Components with Plated, Overlayed, or Coated
Surfaces").
Carefully inspect sealing surfaces in the intermediate flange for corrosion and
mechanical damage. The required surface finish is 63 RMS. If sealing surfaces are
corroded or otherwise damaged, the intermediate flange should be returned to a
Control Flow, Inc. or an authorized repair facility for repair. This damage must be
corrected before the unit is returned to service.
12.1 Wedgelocks
WEDGELOCK HOUSING: The tail rod bore and the plated portion of the wedge
piston bore in the Wedgelock housing must be free from galling, cracks, and
corrosion. Damaged Wedgelock housings should be returned to Control Flow, Inc.
or an authorized repair facility for possible repair.
WEDGE PISTON: The OD of the wedge piston should be inspected for galling and
corrosion. Remove raised edges, and polish the OD of the piston to a 63 RMS finish,
with the exception of scratches and other blemishes which are below the
surrounding surface.
The locking surface of the wedge piston is the surface which bears against the end
of the operating piston tail rod or tail rod extension, to lock the rams. The locking
surface must be free from galling. Remove raised edges, and polish the
locking surface to a 63 RMS finish, with the exception of scratches and other
blemishes which are below the surrounding surface.
SEQUENCE CAP: Internal components of the sequence cap must show no sign of
corrosion, wear, or mechanical damage. Components which are damaged, worn, or
corroded must be replaced.
Inspect the ram locking screws for damage from bending, impact, and corrosion.
Screws which are bent must be straightened or replaced. Use a file to remove upset
metal from threads damaged by impact. Run the entire length of each screw
through the locking screw housing, in order to ensure proper operation.
13.1 DAILY OR TRIP CARE: All blowout preventers should be operated daily. Many
owners require that they be operated at the beginning of each tour. Blind rams
should be operated every time pipe is out of the hole. Pipe rams should not be
closed except when pipe is in the blowout preventer, to avoid extruding the packer.
If operation of the rams requires more than 500 psi control pressure when there is
no pressure in the well bore, the cause should be determined and remedial
measures taken.
13.2 CARE BETWEEN WELLS: Whenever a blowout preventer is removed from a drilling
hookup, it should be carefully cleaned, the rams should be removed, cleaned,
inspected and lubricated, Also, the ram bore should be cleaned, inspected and
lubricated. Any burrs or galled spots should be smoothed. Rams may be stored in
the blowout preventer or separately. The operating system should be thoroughly
flushed to remove sediment or foreign material.
The Class U Blowout Preventers should be transported with rams closed and locking
screws run in to avoid accidental bending of the locking screws.
13.3 PERIODIC OVERHAUL: Annually, or more often depending on the type of service, a
preventer should be completely dissassemblied and all parts cleaned, inspected and
reconditioned or replaced. All rubber seals should be replaced except ram packings
which should be replaced according to condition. Any metal parts which show
damage, such as scored pistons or cylinders, should be replaced or repaired.
Blowout preventer parts in some cases can be repaired; however, this should be be
done only at a Control Flow, Inc. repair shop or under supervision of Control Flow,
Inc. personnel. After the blowout preventer is rebuilt, the body should be tested to
maximum rated working pressure and the operating system to 4500 psi.
The Class U Blowout Preventer has been designed especially for ease of field
servicing and reconditioning. Ram change pistons and cylinders, and operating
pistons and cylinders can be quickly replaced on location, providing a completely
rebuilt bonnet assembly.
13.4 TESTING: At regular intervals, weekly if possible, the complete drilling hookup and
choke manifold should be tested for pressure holding ability and correct operation.
Blowout preventer, operating unit and all control piping should also be pressure
tested and inspected. Pipe rams should not be closed except when pipe is in
the blowout preventer, to avoid extruding the packing.
Note: Failure can result to some of the components if the Class “U” Blowout
preventer is locked in and inadvertently operated with maximum hy
draulic operating pressure and maximum working pressure in the body
cavity.
13.5 LUBRICANTS:
a. Ram lubricant: Any water resistant grease or heavy oil can be used as a ram
and ram bore lubricant.
13.6 STORAGE: When a blowout preventer is put in storage, the rams should be
removed and the blowout preventer thoroughly cleaned, all moving parts greased,
and all machined surfaces oiled and greased, particularly the ram bores and the
flange ring grooves. Preferbly, the blowout preventer should be provided with flange
protectors. BOPs in storage should have the operating system full of light weight oil.
Packed rams should not be stored out of doors. (See Section16.)
13.7 SPARE PARTS: It is recommended that spare drill pipe rams plus replacement
packers and top seals for all sizes of rams being used be kept at the rig. Other
spare parts, recommended for a year of operation, are shown in the table below.
Spare parts are available from Control Flow, Inc.
The operation of the Class U Blowout Preventer is sub-zero temperatures requires special
precautions not normally necessary in the more temperate climates such as that of the Gulf
Coast area. Some of these precautions are:
14.1 The blowout preventer should be kept as warm as possible as the rams are
susceptible to freezing in place since water-base drilling fluids freeze quickly and
solidyly when they come to rest at such temperatures.
14.2 Lubricants should be selected on their low temperature properties since some
lubricants congeal at sub-zero temperatures and prevent the operations which they
were intended to facilitate.
14.3 Avoid impact loads on rubber parts as they become very brittle and may shaffer.
14.4 Use metallic hose in lieu of rubber hose hue to rubber embrittlement.
14.5 Light hydraulic oil should be used in the Class U Blowout Preventer hydraulic system
since some medium-weight oils become semi-solid at temperatures in the neighbor
hood of fifty degrees below zero.
14.6 Keep the equipment clean and free of water-based fluids where at all possible.
14.8 Water is satisfactory operating fluid provided a soluble oil is used for corrosion
protection and sufficient antifreeze is added to prevent freezing.
15.1 Place the two ram change piston rod o-rings in the intermediate flange piston rod
bores. Place the operating piston rod o-ring in the central bore. Install the plastic
packing ring and the energizing ring. In 10,000 and 15,000 psi wp BOPs only,
install the back-up ring. Then install the lip seal, retainer washer and snap ring
combination. Place the ram change piston rod o-rings on rods. Screw the ram
guide pins into the intermediate flange. Tighten with a small pipe wrench.
15.2 Slip the ram change pistons and through the intermediate flange. The threads on
the end of each rod are different and must match the threads in the body. Note
holes through the piston which screws in open side. Tighten the rods securely
against body, using a crescent wrench on flats provided. Place o-rings on ram
change pistons. Note the tool for handling intermediate flange made by welding
studs on the back of a 1” NPT pipe plug.
15.3 Install the cylinder o-rings and on the ram change cylinders. Slip the cylinders over
the pistons and seat them into the intermediate flange.
15.4 Place the operating piston o-ring on the operating piston. Push rod end of the
piston through the intermediate flange. At this point it will be helpful to place a
wood block between the intermediate flange and the body.
15.5 Place the operating cylinder o-rings on the operating cylinder. Slip the cylinder over
the piston and seat it into the intermediate flange.
15.6 In the bonnet insert the lip seal ring and wiping o-ring. Handling with a lifting eye,
guide the bonnet onto the tail rod, over the cylinders and against the intermediate
flange. (To guide the tail rod through the hole in the bonnet, it is possible to screw
a 1”-8NC stud into the end of the tail rod. This stud will extend through the bonnet
and provide a handle.) Install the cap screws to assemble the intermediate flange
to the bonnet.
5.7 Insert the bonnet bolts through the bonnet and the intermediate flange. Push the
bonnet bolt o-ring over the bonnet bolt threads onto the undercut. Thoroghly grease
the bonnet seal ring and groove in face of the intermediate flange. Place the seal
ring in the groove.
5.8 Screw the plastic packing check valve all the way into preparation in the
intermediate flange. Insert one stick of packing. Partially force plastic packing
into place with the plastic packing screw. Do not build up a high pressure in the
packing. Install a 1” NPT pipe plug to close the hole. Install the bleeder gland
with plug in the bonnet.
15.9 Install the studs in the bonnet. The short threaded ends screw into the bonnet.
These studs can be tightened with a small pipe wrench used close to the bonnet.
Install the locking screw into the locking screw housing.
15.10 Install the locking screw housing over studs with flats on the housing flange vertical.
Install and tighten the locking screw housing nuts.
15.11 Screw the lifting eye normally carried in top of the bonnet into the rams. Set
assembled ram onto the operating piston rod.
15.12 After assembling both bonnets, applying hydraulic pressure to rams “open”
connection to close bonnets. Screw in and sledge up the bonnet bolts.
16.1 General
There is very little published information on the storage and care of rubber goods as
used in the oil field. The term rubber goods includes synthetic packings of Nitril
Copolymers and Neoprene as well as natural rubber parts. Natural rubber parts
have become relatively rare, but the same things that are harmful to natural rubber
are also harmful to synthetics in varying degrees.
Generally speaking, light and air are bad for rubber goods. The exact chemical
action is not fully understood and what has been written by various writers is not in
agreement on the mechanism involved.
Ozone is known to be bad for rubber goods. Ozone is a very active form of oxygen.
As far as we know two principal sources contribute the ozone that reaches rubber
goods. One is atmospheric ozone which is generated in the stratosphere, carried
downward by convection currents and eventually absorbed by organic matter. The
other source is electrical discharges, such as lightening, high voltage corona, but
more commonly, electrical machinery. Ozone attack is characterized by fairly deep
cracks in the rubber parts.
Astrong direct light, especially sunlight, has deleterious effects on rubber goods.
This is attributed to the ultraviolet content of the spectrum which accelerates
cracking. Whatever the mechanism, however, light, particularly sunlight, is
undesirable.
In extreme cold climates some rubber goods will become so brittle that upon
dropping or rough handling they will shatter.
In very warm humid climates, particularly those found in parts of the tropics, fungi
and bacteria find their way to the rubber goods and attack the organic content.
This is especially true on duck reinforced rubber parts. However, parts reinforced
with synthetic fabrics will not be attacked in the reinforcement.
Heat also has a bad effect on rubber. This could be the result of sunlight or artificial
heating of any type. Heat results in a gradual hardening of the part and, if ozone or
oxygen is present, will accelerate their action.
Any stretching or bending of rubber in storage will result in very accelerated aging.
The term aging means the cumulative effects of all the above mentioned attacking
agents over a period of time. Ozone attacks rubber preferentially at points of strain.
Rubber goods, both natural and synthetic, all possess some degree of susceptibility
to various solvents including water, but especially the liquid hydrocarbons. These
materials cause swelling or shrinkage of the rubber goods with which they are in
contact.
16.2 Storage
From the preceding section a few rules governing storage of rubber goods can be
drawn. Briefly put – a cool, dry, dark storage place would be the best that could
normally be managed. The ideal would be to store the packings in vacuum sealed
containers. The following rules, however, should not be difficult to follow under the
average storage conditions experienced by vendors or users of oil field equipment.
a. Keep the rubber storage area as dark as possible – certainly not out of doors
and, if indoors, away from sky lights or windows and with subdued or
indirect artificial lightening.
b. Select the coolest location possible and be sure that no heaters or stoves are
nearby and particularly that the direct blast from a space heater does not
blow on the rubber parts
e. Store rubber goods in a relaxed position. For example, do not hang o-rings
on nails. Where possible, do not keep assemblies in stock where the rubber
goods are stretched in order to assemble them on the part; for example,
o-rings on glands, BOP testers and operator parts.
On parts where there is known the rubber parts will be stretched in storage,
the best age resistant compounds obtainable should be used.
f. Keep storage as dry as possible and remove any oil, grease or other foreign
material that may accidentally get on the rubber.
g. Do not store the rubber goods on top shelves near galvanized roofs. There
are several reasons for this – one is that heat is passed through galvanized
roofing and also there is some opinion that ozone may be generated in this
area.
No general rule can be drawn regarding usability. The final measure is whether or
not the cumulative effects of aging have affected the physical properties of the part
to such an extent that it will no longer perform the function for which it is designed.
Thus, a large heavy part might suffer the same total amount of aging as a small,
light, thin piece, and still be useable, whereas the small part is rendered useless. In
these cases some judgment must be used in deciding useaility. Prior to use out of
stock, rubber goods should be examined to see that no chalking or barking is
present, that there is not a hard skin on the rubber and that there are no cracks.
Sometimes cracks will be obvious; stretch or bend the part in question so that any
incipient cracks or very thin cracks will reveal themselves. Where a part is suspect,
a check of hardness should be run. In the event that the hardness runs 15 points
higher than the nominal hardness of the part, it is considered non-usable. Hardness
is affected by temperature and readings should be taken with the rubber part at
70O – 100OF.
1.3 Repeat 1.2 until all bolts have been tightened to the 10% recommended torque.
Note: It is recognized that applied torque to a nut member is only one of several ways to approximate
tension and unit stress in a stud bolt. Tabulated values are presented for convenience and guidance
only.
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Proprietary Information of Control Flow, Inc. ** Pg 27 **
CONTROL FLOW, INC.
Headquarters & International Offices
CFI International
c/o Control Flow, Inc. U.S.A.
WesTech/HMD
1220 East 29th Street, Signal Hill, California 90755
Phone 562-528-3300 / Fax 562-988-0351
E-Mail sales@westech-cfi.com
Website www.westech-cfi.com / westech.com