Bop cameron

Blow Out reventor Cameron

1. U BLOWOUT PREVENTERS
FOR SURFACE APPLICATIONS

CAMERON

2. All the information contained in this manual is the exclusive property of
Cooper Cameron Corporation, Cameron Division. Any reproduction or use
of the calculations, drawings, photographs, procedures or instructions,
either expressed or implied, is forbidden without the written permission of
Cameron or its authorized agent.

Initial Release A,
March 1999

Revision 02
December 2003

Copyright © 2003 all rights reserved
By
Cooper Cameron Corporation
Cameron Division

ru 2

3. PREFACE

‘The procedures included in this book are to be performed in conjunction with
the requirements and recommendations outlined in API Specifications. Any re-
pairs to the equipment covered by this book should be done by an authorized
Cameron service representative. Cameron will not be responsible for loss or ex-
pense resulting from any failure of equipment or any damage to any property or
injury or death to any person resulting in whole or in part from repairs per-
formed by other than authorized Cameron personnel. Such unauthorized re-
pairs shall also serve to terminate any contractual or other warranty, if any, on
the equipment and may also result in equipment no longer meeting applicable
requirements.

File copies of this manual are maintained. Revisions and/or additions will be
made as deemed necessary by Cameron. The drawings in this book are not
drawn to scale, but the dimensions shown are accurate.

‘This book covers Cameron U Blowout Preventers, which are products of Cooper
Cameron Corporation.

Cooper Cameron Corporation
Cameron Division

P.O. Box 1212

Houston, Texas 77251-1212
713-939-2211
httpy//www.coopercameron.com

5. Contents

Single Open-Face Flange or Clamp Hub Dimensions

Double Open-Face Flange or Clamp Hub Dimensions.

Part Numbers
Hydraulic Control System
Specifications and Accessories
Large Bore Shear Bonnets
‘Tandem Boosters

Ram Hang-Off Weights and Shear Requirements

Pipe Rams
Shearing Blind Rams . .

DSI and DVS Shear Rams

Variable Bore Rams

Flexpackers

CAMRAM™ 350 Packers and Top Seals.
Rams for Multiple Completions .
Bonnet Rebuild Softgoods Kits

Bonnet Seals and Connecting Rod Seals
Bonnet Seal Carriers. ...

U BOP Operation and Maintenance

1. Physical Data... 0...
11. Applicable Operating Characteristics
Il. Disassembly Procedure . B
IV. Assembly Procedure

V. Operation and Installation Procedures - -

VI. Maintenance Procedures
Vil. Testing.
VIIL Storage

Bonnet Bolt Torque Requirements.

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7. Single Open-Face Flange or Clamp Hub U BOP Dimensions*

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9. Double Open-Face Flange or Clamp Hub U BOP Dimensions*

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revs 9

10. revs 10

11. 7-1/16" 3000 - 11” 10,000 psi WP U BOP Part Numbers

12. revs 2

13. 11” 15,000 - 16-3/4” 5000 psi WP U BOP Part Numbers

5

14. revs 14

15. 16-3/4" 10,000 -

-3/4" 3000 psi WP U BOP Part Numbers

16. U BOP Hydraulic Control System

‘The U blowout preventer is designed so that hydraulic pressure opens and closes the rams
and provides the means for quick ram change-out.

Ram closing pressure closes the rams. When the bonnet bolts are removed, closing
pressure opens the bonnet. After the bonnet has moved to the fully extended position,
the ram is clear of the body. An eyebolt can be installed in the top of each ram to lift it
out of the preventer.

Ram opening pressure opens the rams. Following ram change-out, this pressure closes
the bonnets. The rams are pulled outward, near the bonnets before the bonnets begin
moving toward the preventer body. This assures that the rams never obstruct the bore or
interfere with the pipe in the hole. Hydraulic pressure draws the bonnets tightly against
the preventer body and the bonnet bolts are reinstalled to hold the bonnets closed.

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Feu 7

18. U BOP Specifications and Accessories

‘The following specifications apply to typical Cameron U type BOPS. Your Cameron repre
sentative can provide information on non-standard BOP assemblies.

+ Side outlets to 4-1/16" (7-1/16" on 26-3/4" BOPs) can be provided beneath each set
of rams on either or both sides of U BOPs. Side outlets can be studded, open-face
flange or clamp hub with the same pressure rating as the vertical run connections.

+ Flanges conform to API standard 6A and/or 16A. Hubs conform to API 16A or
applicable standards. Type 6BX flanges are standard for 10,000 and 15,000 psi
working pressures and for 5000 psi for 13-5/8" and larger bore BOPs.

+ Hydraulic control connections for operation of rams and bonnets are 1” NPT. There
are two connections for each set of rams. Wedgelock connections are Y" NPT.

UBOP Standard Accessories

revs 18

19. Large Bore Shear Bonnets

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revs 19

20. Tandem Boosters for U BOPs

A BOP equipped with tandem boosters can deliver increased shearing force while not in-
creasing the wear and tear on the packers. Tandem boosters approximately double the
force available to shear pipe. Since the tailrod of the tandem booster has the same stroke
as the BOP's operating piston, the standard shear locking mechanism can be installed on
the outside end of the booster. For information on lock screws and the required spacers,
see pages 11, 13, and 15,

For information concerning applications where a tandem booster is required, consult
your Cameron representative.

revs 20

21. U BOP Ram Hang-Off Weights and
Shear Requirements

Hang-Off Weights

Hang-off weights are estimated capacities with : :
hardened top corners of the hang-off rams. This ares
enables the rams to dig into the tool joint and sms
provide superior hang-off capacity while still een sa
meeting NACE requirements,

For variable bore rams (VBRs) and
FLEXPACKER rams, hang-off weights up to 300,000 Ib (136,078 kg) on hang-off rams for
the lower pipe size in the range, 600,000 Ib (272,155 ka) for the larger pipe size in the
range.

Drill Pipe Shearing Requirements

The minimum shearing configurations needed for each size U BOP to meet the require-
ments of the second edition of API 16A are listed in the following chart. Each shearing
configuration is capable of shearing the corresponding pipe at a closing pressure equal to
or less than 2800 psi. For further information on shearing requirements for different pipe
sizes and grades, contact your Cameron representative.

Minimum Shearing Configurations forte U BOP

cios a

22. U BOP Pipe Rams

Pipe rams are available for use in Cameron U BOPS to fit all commonly used sizes of tub-
ing, drill pipe, dril collar or casing within the ranges in the charts on pages 23, 24, and 25.
Cameron pipe rams include the following features:

+ Cameron pipe rams are self-feeding and incorporate a large reservoir of packer
rubber to ensure a long-lasting seal under all conditions.

+ Ram packers lock into place and are not dislodged by well flow.

+ All Cameron pipe rams are suitable for HS service per NACE MR-01-75.

+ CAMRAM?™ top seals are standard for all U BOP pipe rams from 7-1/16" through
18-3/4" sizes. Packer part numbers beginning with 644xx indicate the CAMRAM
lipped-plate design. All other packers use standard elastomer material and
reinforcement plates.

+ CAMRAM 350™ packers and top seals are available for high temperature service and
for service in which concentrations of HS are expected.

Feu 2

26. U BOP Shearing Blind Rams

Cameron shearing blind rams shear the pipe in the hole, then bend the lower section of
sheared pipe to allow the rams to close and seal. Shearing blind rams can be used as blind
rams during normal drilling operations.

The DS shearing blind ram can cut larger diameter tubulars or multiple tubing strings
regardless of their orientation to the centerline of the ram. A blade seal between the up-
per and lower faces eliminates the need for moving pipe after shearing,

Features of shearing blind rams and DS rams include:

+ Large frontal area on the blade face seal reduces pressure on the rubber and
increases service life.

+ Cameron SBRs can cut pipe numerous times without damage to the cutting edge.

+ The single-piece body incorporates an integrated cutting edge.

+ CAMRAMM top seals are standard for all U BOP shearing blind rams through
18-3/4". Part numbers beginning with 644xxx indicate CAMRAM. All other top seals

are standard elastomer material.

+ H¿5 SBRs are available for critical service applications and include a blade material of
hardened high alloy suitable for H:S service.

+ The Cameron shearing blind ram has a single-piece body with an integrated cutting
edge.

revs 26

27. U BOP HS Shearing Blind Ram Part Numbers

28. U BOP DS Shearing Blind Ram**

29. ing Blind Ram Part Numbers

U BOP Sheari

30. U BOP DSI and DVS Shear Rams

Dual string interlocking (DSI) shear rams and double V shear (DVS) rams are also available
for the U BOP. The interlocking feature of these rams provides the capability of shearing
wireline and braided cable with zero tension in the line, while still maintaining a seal. The
blades are interlocked by using pockets in the lower ram and arms on the upper ram to.
prevent any gap between blade surfaces.

DSI rams are similar to standard DS shear rams except for the interlock feature. DSI
shear rams are capable of shearing tubing, small pipe, braided cable, slickline and solid
sinker bar.

DVS rams are similar in design to the standard shearing blind rams except that both
blades are V shaped and interlocked. The DVS rams are capable of shearing tubing, small
pipe, braided cable and slickline.

revs 30

32. U BOP Variable Bore Rams

One set of Cameron variable bore rams seals on several sizes of pipe or hexagonal kelly
Variable bore rams are available in the size ranges listed in the chart below. All rams listed
are suitable for H;S service per NACE MR-01-75.

‘CAMRAM top seals are standard for all U BOP variable bore rams. CAMRAM packers
are available in most sizes. Packer part numbers beginning with 644xx indicate
CAMRAM. All other packers are standard elastomer material.

The variable bore ram packer contains steel reinforcing inserts similar to those in the
Cameron annular BOP packer. The inserts rotate inward when the rams are closed so the
steel provides support for the rubber which seals against the pipe.

revs 2

33. Flexpackers for U BOPs

‘The Cameron FLEXPACKER ram is designed to close and seal around several diameters of
tubing and pipe. These packers can be used in existing Cameron BOPs. Features include:

+ Stacks of metal inserts bonded into the elastomer move radially in the elastomer as
the BOP rams are closed

+ As rams are energized, the proper set of metal inserts is forced against the pipe. The
top plate of the packer fits the largest diameter of pipe.

FLEXPACKER Sizes and Pat Numbers

revs 3

34. CAMRAM 350 Packers and Top Seals for U BOPs

CAMRAM 350 U BOP pipe ram packers and top seals are available for applications which

require high temperature capabilities and greater HS resistance than standard CAMRAM
packers and top seals.

CAMRAM 350 is available in all U BOP sizes in which standard CAMRAM packers and
top seals are offered. At present, only pipe sizes (up to 5-1/2") are manufactured.

Top Sel

U BOP Cam 350 Pacer an To Sl

cios 34

35. U BOP Rams for Multiple Completions

Non-sealing centralizing rams and companion subsea dual rams and packers for use with
two strings of the same diameter are available for the U BOP. Also available are offset
bore rams for 7-1/16" and 11" BOPs. Contact a Cameron representative for more informa-

tion.

‘Blowout Preventer Ofsel Bare Ram Pat Numbers

cios 35

36. Bonnet Rebuild Softgoods Kits

For popular size U BOPs, a bonnet rebuild softgoods kit is available to provide all parts re-
quired to reseal the operating system.

kit parts are shrink-film packed to prevent loss and assure long shelf life. The kits are
less expensive than individual parts. All parts in each kit are identified with part numbers
and parts list index numbers.

"OP Bonne Songs Compares

37. Kit Part Numbers

U BOP Bonnet Rebuild Softgoods Kit Components

revs 37

38. Bonnet Seals and Connecting Rod Seals

For applications where only bonnet and/or connecting rod seals are required, Cameron of-
fers individually packaged components. Connecting rod seals are nitrile rubber. Bonnet
seals beginning with 644197 are the newest design.

When high temperature and/or high concentrations of H3$ are expected, Cameron rec-
‘ommends the used of CAMLAST bonnet and connecting rod seals along with CAMRAM
350 packers and top seals.

BOP Bonnet and Connecting Rad Seals

UBOP CAMLAST Bonnet and Connecting Rod Seals.

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cios 38

39. Bonnet Seal Carriers for U BOPs

‘The bonnet seal carrier is a bore-type
sealing assembly which replaces the face
seal used as the previous bonnet seal.
Sealing capability is not dependent upon
bonnet bolt torque. One seal is captured
in a machined bore in the BOP body
while the other seal is captured in a ma-
chined bore in the intermediate flange.
The seal carrier was designed, devel-
oped and performance-verified for use in
newly manufactured BOPs or as a re-
placement seal assembly for BOPs where
either the BOP body or the intermediate
flange requires weld repair on the seal-
1g surfaces.

revs 39

40. U BOP Operation and Maintenance 617.159

1. Physical Data

A. Lubricants.

1. Ram lubricant, PIN 705725 (CHEMLOA #681 BOP oil) or a water resistant non
petroleum base grease.

2. Thread lubricant - which meets the requirements of the latest revision of API
Bulletin SA or Moly #503, (P/N 705444, 4 Ib can)

3. Multi purpose lubricant or grease.
4. Multi-purpose lubricant or grease for cold weather operation
5. Hydraulic operating system:

a. Storage - PIN 718100 (Marston Bentley Preservation Fluid.)

b. Standard operation - Use a fresh water lubricant that forms a true solu-
tion rather than an emulsion when mixed with water and/or antifreeze.

6. Seals and sealing surfaces - Hydraulic Oil (10-15 wt) PIN 203497.

B. Dimensional Drawings
1. SD-017499, Single U BOP.
2. $D-017498, Double U BOP.

Bills of Mat

© Drawings
1. $0-017500, Double U BOP.
5D-017503, Large Bore Shear Bonnet Assembly.
. 5D-017504, Tandem Booster Assembly,
|. $0-017508, Pipe Ram.
5D-017509, H3$ Shearing Blind Ram.

. $D-017513, Shearing Blind Ram.
. $D-017525, DSI Shear Ram,

2
3.
4
5.
6. 5D-017512, DS Shearing Blind Ram.
7
a.
9. SD-017525, DVS Shear Ram.

revs 40

41. 10. $D-5129, Variable Bore Ram.

11. SD-10315, Flexpacker.

12. $D-017514, CAMRAM™ 350 Packer and Top Seal
13. $D-017515, Bonnet Softgoods Components.

D. Weights,

Refer to pages 7 and 9.

E. Lifting and Handling

1. Lift BOP assemblies only with slings appropriately rated for the maximun

weight of the BOP.

2. Lift ram assemblies by installing a lifting eye, P/N 011849, in the threaded

preparation in the ram.

3. Handle all other subassemblies using appropriately rated slings.

F. External Thread Connections

Open Port

1er

BOP Body, Right Side

Close Port

ner

BOP Body, Left side

G. Hydraulic Operating System Requirements

1. Use a freash water lubricant in the hydraulic system that forms a true solu-

tion rather than an emul

n when mixed with water and/or antifreeze.

2. Refer to page 17 for fluid requirements.

3. Normal pressure for the hydraulic operating system is 1500 psi (103 Bars)

4, Maximum pressure to shear drill pipe is 2800 psi (193 Bars).

5. The maximum hydraulic operating pressure limit is 3000 psi (207 Bars) to op-

erate rams.

42. H. API 16A Drift Diameter

Size and Worki

7-16" 3000 pa 7.032" (179 mm) | 16:34" 3000 & 5000 psi_| 16,720" (425 mm)
7.1167 5000 ps 7.932" (179 mm) | 16-44" 10,000 psi 16720" (425 mm) |
7.1167 10,000 & 15,000 psi_| 7.032" (179 mm) | 18-347 10,000 psi 18.7207 (475 mm)
117 3000, 5000 & 10,000 ps 10.970: (279 mm) | 20:314" 3000 ps 20720 (526 mm) |

13:5/8" 3000 & 5000 psi | 13,595" (345 mm) | 21-14" 5000 psi

707 (279 mm) | 21-14" 2

4539 mm) |

1539 mm) |
13-58" 10,000 ps 13.595" (245 mm) | 21-1/4" 10,000 psi (539 mm)
13-578" 15,000 psi 13.595" (345 mm) | 26-3/4" 10,000 psi 26.720" (679 mm) |

11. Applicable Opera

1g Character

À. Subasemblies

1

Pipe ram operating characteristics.
a, Seals around dril pipe or casing

Variable bore rams.

2. Seals and holds low or high pressure on drill pipe

b. Supports 300,000 Ib (136, 078 kg) of pipe size at the lower end of the
range, 600,000 Ib (272,155 kg) at the higher end of the range.

Shear rams

a. Shearing capabilities are dependent upon the size and working pressure
of the BOP and the shearing configuration associated with that BOP.

Bonnet
a. Houses the BOP hydraulic operating system.
b. Provides access to the rams.

€. Provides mounting for the wedgelock assembly.

a

43. I. Disassembly Procedure

A. Part Preparation Prior To Disassembly

‘The work area should be clean and well lighted.

BOP

sembly

Reference page 10.

10.
1.

12.
13,

14,

Use an air wrench to break and unscrew the bonnet bolts (12) on both sides
of the BOP.

Apply hydraulic closing pressure to the rams CLOSE connection on the BOP to
open the bonnet assembly.

Screw the lifting eye (38) into the top of the ram.

. Use a hoist to lift up on the ram to remove it from the operating piston rod
. Remove the seal (22) that resides in the seal bore of the BOP body.

With a spanner wrench and a hammer, break loose the locking screw hous-
ing nuts. (14).

.. Remove the nuts, the locking screw housing (7), and the locking screw (8).

Remove the locking screw housing studs (13) with a small pipe wrench.
On the top of the bonnet, remove:

a. The tubing gland (36) and blind plug (37).

b. The 1” NPT pipe plug (17).

©. The plastic packing screw (16) and packing (39).

Unscrew the plastic packing check valve (15).

Remove the O-ring (34) from each bonnet bolt and remove the bolts from
the bonnet asembly.

Insert the lifting eye (38) into the intermediate flange or into the bonnet.

‘Attach a hoisting cable to the lifting eye and apply tension to the cable to
hold up the bonnet asembly.

Using a crescent wrench, loosen the ram change pistons (9) and (10) on the
flats provided.

a

44. 15. Once the ram change pistons are completely loose, move the assembly to the
side away from the main body of the BOP.

©. Bonnet Disassembly
1. Remove the ram guide pins (23) from the intermediate flange (2)

2. Remove the cap screws (35) to disassemble the intermediate flange from the
bonnet.

3. Separate the bonnet (3) from the intermediate flange (2)

4. Remove the ram change cylinder O-rings (31) and (32) from the cylinders, and
remove the cylinders from the bonnet.

5. Remove the operating cylinder O-rings (24) from the operating cylinder, and
remove the cylinder from the bonnet. These O-rings are for standard bonnets
only. The large bore shear bonnets do not have a separate operating cylin-
der.

6. Remove the operating piston seal ring (26) and the operating piston wear
ring (42) from the operating piston, and remove the piston from the bonnet.

7. Pull out the remaining seals in the bonnet bore, including the wiping O-ring
(28) and the lip seal for the tail rod (27).

8. Remove the following seals from the intermediate flange:

spirolox retaining ring (41)

lip seal retainer (40)
back-up ring (21)

lip seal (connecting rod) (20)
energizing ring (19)

plastic packing ring (18)

operating piston rod O-ring (25)

45. IV. Assembly Procedure

A. Part Preparation Prior to Assembly

‘The work area should be clean and well lighted.

1. Remove all dirt, grit, oil, and contaminates from the ram bore, ram change
piston holes, bonnet stud holes, all fluid passageways in the body, and inter-
‘mediate flange. Clean water and detergent should be used for cleaning.
High pressure air may also be used if itis dry air.

2. Clean all internal surfaces of bonnets using clean water and detergent. Lubri-
cate internal sealing surfaces.

3. Clean pistons, cylinders, and intermediate flanges, using clean water and de-
tergent. Lubricate areas that will come in contact with other parts.

4. Lubricate sealing surfaces behind the threads in the bonnet stud holes in the
BOP body after cleaning this area.

5. Sealed elastomer containers should not be opened until they are required for
assembly. This is to prevent contamination and damage to the seal.

B. Bonnet Assembly

Reference page 10.
1. Place each bonnet (3) on stands or pallets with the bore side up.
2. Install the tail rod lip seal (27) and the wiping O-ring (28) into the bonnet (3).

3. Place the operating cylinder O-rings (24) on the operating cylinder (6). These
O-rings are for standard bonnets only. The large bore shear bonnets do not
have a separate operating cylinder.

4. Insert the operating cylinder (6) into the standard bonnet bore.
5. Install the ram change cylinders (11) into the bonnet.

6. Place ram change piston O-rings (33) and the ram change piston to body
(O-rings (29) on the both ram change pistons.

7. Insert the assembled ram change pistons (9) and (10) into the bonnet so that
‘the pistons with side holes are on the OPEN side, and the pistons with center
holes are on the CLOSE side.

Caution: Ensure that the threaded end of the ram change piston does not contact the

floor.

45

46. Caution:

8. Place the operating piston wear ring (42) and the seal ring (26) onto the op-
erating piston (5).

ion the assembled operating piston into the bonnet.

10. Place the intermediate flange (2) on the assembly table with the threaded.
holes for the guide pins (23) in the bottom position,

11. Place the operating piston rod O-ring (25) in the central bore.
12. Install the plastic packing ring (18) and energizing ring (19).

13. Install the connecting rod lip seal (20), lip seal retainer (40), the back-up ring
(21), and spirolox retaining ring (41).

14, Install the O-ring (30) onto the intermediate flange.
15. Install the cylinder O-rings (31) and (32) onto the ram change cylinder.

16. Apply a light coat of oil on the O-rings and inside the corresponding seal
bores in the bonnet (3) and the intermediate flange (2).

17. Install the assembled intermediate flange onto the assembled bonnet.

18, Install the cap screws (35) from the bottom side of the intermediate flange
and tighten them securely. Be sure that the plastic packing port on the inter-
mediate flange is on the same side of the assembly as the lifting eye hole on
the bonnet.

a. Ensure the the tail rod seals are not damaged.
b. Ensure that the seals are not damaged during the bonnet seating process.

Important: The threaded holes for the lifting eyes in both the bonnet and the intermedi-

ate flange must be on the same side of the connecting rod.

19. Tighten the cap screws in a crisscross pattern so that the intermediate flange
pulls down straight and level with respect to the face of the bonnet. Torque
‘the cap screws between 3350 and 3670 ft-lb (4542 and 4976 Nem).

20. Screw the ram guide pins (23) into the intermediate flange. Tighten the
guide pins with a pipe wrench to a maximum of 400 ft-lb (542 Nem).

21. Install the lifting eye (38) into the intermediate flange or into the bonnet.

22. Position the bonnet assembly next to the body and thread the ram change
pistons onto the body.

23. Tighten the rods securely against the body, using a crescent wrench on the
flats provided.

47. Warning: Make sure that the open and close pistons are in the appropriate location with
respect to the body.

24. Insert the bonnet bolts (12) through the bonnet and intermediate flange

25. Push the bonnet bolt O-
dercut,

ings (34) over the bonnet bolt threads onto the un-

26. Screw the plastic packing check valve (15) all the way into the preparation in
the intermediate flange.

27. Insert one stick of plastic packing (39) above the check valve and install the
plastic packing screw (16). Do not apply any torque to the plastic packing
screw.

28. Instala 1° NPT pipe plug (17) to close the hole,
29. install the bleeder gland (36) with the plug (37) into the bonnet.

30. Install the double ended locking screw studs (13) into 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.

31. Install the locking screw (8) into the locking screw housing (7).

32. Install the locking screw housing over the studs with the flats on the housing
flange vertical. Install and tighten the locking screw housing nuts (14).

Note: All hydraulic lines must be in place. Install the seal carrier before the rams are in-
stalled.

33. Lubricate the seal bores for the bonnet seal in both the BOP body (1) and the
intermediate flange (2).

34. Install the bonnet seal (22) that will reside in the seal bore of the intermedi-
ate flange.

35. Lubricate the seal with ram lubricant.

36. Close the bonnet asembly with 200 to 500 psi (13.8 to 34.5 Bars) operating
presure, trapping the seal carrier.

Caution: Keep hands out of the way during this operation.
37. Lubricate the seal with ram lubricant.

38. Once the bonnet seals are securely installed, connect the hydraulic lines to
‘the OPEN and CLOSE ports on the sides of the preventer body.

revs a

48. 39. With the bleed gland (36) loose, on the top of the bonnets, apply 200-300 psi
(13.8 - 20.7 Bars) OPEN and CLOSE operating pressure alternately to expel air
from the operating system.

40. After the air is bled from the system, tighten the bleed plugs (37).
41. Install the appropriate ram assemblies (4) onto the operating piston rod.

42. After assembling both bonnets, apply 1500 psi (103 Bars) hydraulic pressure
to the rams OPEN connection to close the bonnets.

43. Apply thread lubricant to the threads and below the head of the bolt.

44, Screw in and torque the bonnet bolts to according to the charts on page 54
and 55.

V. Operation and Installation Procedures

A. Preparation

Prior to the installation of the preventer, ensure that the following requirements
are met:

1. The capacity and the pressure rating of the accumulators and the pressure
pumps must comply with the API RPS3 recommendations or appropriate reg-
latory agency requirements.

2. Ensure that the ring gaskets are correct for the preventer flange, the hub
size, and the pressure rating.

B. Installation

1. Install the preventer, ensuring that the preventer is rightside-up (outlets are
below the center of the preventer).

2. Inspect the preventer, the ram subassemblies, and all rubber parts during in-
stallation.

Remove the external mechanical protectors.
Lift the BOP with slings installed around the body of the BOP.
5. Install the BOP on a test stumplfixture.

. Drain the fluid from the operating system.

Remove the 1” ball valves or pipe plugs from the inlet and outlet connec-
tions.

revs 48

49. 8. Connect the hydraulic control lines, and flush the operating system with
lean fluid,

9. Test for leaks in the operating system (refer to Part Vil, TESTING.)

10. Install the rams in accordance with the assembly procedure described in Part
IV, ASSEMBLY.

11. While installing the rams, inspect the ram bore and bonnet.
a. Inspect the vertical bore for key seating.
b. Inspect the intersection between the vertical bore and the ram bore.

Grind out any raised metal surfaces. Do not remove any metal below the
original surface.

VI. Maintenance Procedures

A. Routine Maintenance

1. If more than 500 psi (34.5 Bars) hydraulic pressure is required to operate the
ram subassemblies when there is no pressure in the well bore, determine the
cause and correct any irregularities.

To avoid damage to the packers, close pipe and variable bore rams only when
pipe is in the preventer,

2. Pressure test and operate the preventer once a week per API RP53 “Periodic
Field Testing” or appropriate regulatory agency requirement.

B. Per

Maintenance

1. Once a year, or every six months in cold weather conditions, completely dis-
assemble the preventer.

Note: For detailed description of disassembly, see Part Il, DISASSEMBLY.
a. Clean all parts. Do not use a wire brush on sealing areas.
b. Replace all rubber seals, gaskets, and O-rings
«Replace ram packing according to its physical condition.

d. Repair or replace damaged metal parts.

revs “9

50. 2. Reassemble the preventer.
Note: For a detailed description of assembly, see Part IV, ASSEMBLY.

a. After reassembling the preventer, test the rams and operating system. Re-
fer to Part Vil, TESTING for the correct procedure.

Vil. Testing

A. Hydraulic Operating System
1. Test the hydraulic operating system after installation.
a. Flush the hydraulic operating system with clean operating fluid
b. Test for proper stroking of the rams and operating system.

1) Apply a maximum of 300 psi (20.7 Bars) hydraulic pressure to the OPEN
port.

2) Ensure that the rams open.
3) Reduce hydraulic pressure to zero psi

4) Apply a maximum of 300 psi (20.7 Bars) hydraulic pressure to the CLOSE
port

5) Ensure the rams close.
6) Reduce hydraulic pressure to zero ps.

©. Test for leaks in the operating system.
1) Remove the hydraulic line from the OPEN port.

Note: If testing pipe, casing, flex packers, or variable bore rams, be sure that an appropri-
ate size test mandrel is installed into the preventer. DO NOT close the rams on an
‘open hole unless closing pressure is less than 300 psi (20.7 Bars). Flex Packers and
VBRs should be tested with the largest pipe size for that packer.

2) Apply 300 psi (20.7 Bars) hydraulic pressure to the CLOSE port, and ob-
serve the OPEN port for leaks.

3) Increase the pressure to 3000 psi (207 Bars) and observe the OPEN port
for leaks.

4) Inspect for leaks between the intermediate flange, the bonnet, and the
BOP body. Bleed all pressure from the BOP closing line.

5) Replace the hydraulic line to the OPEN port.

revs so

51. 6) Remove the hydraulic line from the CLOSE port.

7) Apply 300 psi (20.7 Bars) hydraulic pressure to the OPEN port, and ob-
serve the CLOSE port for leaks.

8) Increase the pressure to 3000 psi (207 Bars) and observe the CLOSE port
for leaks.

9) Inspect for leaks between the intermediate flange, body, and bonnet.
Bleed all pressure from the BOP opening line.

10) Replace the hydraulic line to the CLOSE port.

11) Replace the seals if leaks were observed and repeat the test with new
seals.

12) Repeat the procedure for each preventer.

B. Ram Test

(After installation and as required by API RP53 or appropriate regulatory
agency)

1. Hydraulicall test ram packers with water using the following procedure:

a. Install the BOP stack on a prepared test stump or install a test plug below
the BOP if on the wellhead.

b. Inspect for ram packer leaks at low pressure by closing rams on an appro-
priate size test mandrel (none if blinds or shears are used) with 1500 psi
(103 Bars) operating pressure, and apply 200 psi (13.8 Bars) pressure under
the rams. Hold pressure for 3 minutes. Maximum pressure drop is 10 psi
(7 Bars) in 3 minutes.

Increase pressure slowly to the rated working pressure of the preventer.
Hold pressure for 3 minutes. Maximum pressure drop is 100 psi (6.9 Bars)
in 3 minutes.

4. If rams leak at low pressure or at working pressure, inspect for worn ram
packers and replace if necessary.

e. Repeat the above procedure for each set of casing, pipe and shear rams.

revs st

52. Vill, Storage

A. Preventer
1. Open the bonnets and remove the ram subassemblies
2. Remove the top seals and packers, then wash the ram subasemblies.
3. Lubricate the ram bodies, covering them with a heavy grease.
Caution: DO NOT lubricate the top seals or packers
4. Do not store the ram subassemblies inside the preventer.

Note: Rubber products that have been put into service and that are subsequently stored,
will have an unpredictable shelf life. This is attributable to their varied physical con-
dition when returned to storage, due to the inability to completely remove
elastomeric solvents (hydrocarbon contaminates, etc) and storage in a container
filled with air (chemically active gases).

5. Clean the inside and outside machined surfaces of the preventer.

6. Dry with an air blaster until no moisture is left inside or outside the
preventer.

7. Inspect the ram bores and the vertical bores for burrs.

8. Remove burrs by touching the surface lightly with a grinder using 36 to 60
grit paper.

9. Lubricate the ram bore with a heavy grease.

10. Lubricate the end and outlet connection faces with a heavy grease, and cover
‘them with flange protectors.

11. Flush the operating system using clean operating fluid.
12. Fill the operating system with preservation fluid Cameron PIN 718100.
13. Install the 1” NPT pipe plugs into the OPEN and CLOSE connections.
Caution: DO NOT use the bonnet lifting eyes to lft a preventer.

14. To lift the preventer, use appropriately rated slings around the ends of the
body.

revs 5

53. B. Elastomers

1

6.

Important:

Store rubber products inside a cool, dark, and dry storage area.

a. The preferred storage temperature range for rubber goods is from 40°F to
80°F (4.4*Cto 26.7°C).

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

<. Store rubber parts in a relaxed position. Do not stretch or hang O-rings
and seals. Labels should not be attached to seals with string, wire, or tape,
as these items may deform the sealing surface.

Use airtight containers when possible to protect against circulating air.

Ozone is extremely harmful to rubber. Ensure that there is no equipment in
‘the storage area which may generate ozone, such as mercury vapor lamps,
high-voltage electrical equipment, electric motors, or any electric apparatus
which produces arcing.

Keep the rubber products clean and free of solvents, oil, greases, or any
other semi-solid or liquid materials during storage. Rubber goods should spe-
cifically be protected against direct contact with: manganese, copper, copper
alloys (including brass), polyvinyl chloride (PVC) creosote-impregnated tim-
ber, other rubber goods of different rubber compounds, sulphur, and copper
napthenate.

. When cleaning is necessary, rubber goods may be cleaned with either soap

and water or methyl alcohol. After cleaning, the rubber goods should be
dried at room temperature.

Examine the part before installation.

Rubber goods taken from storage must ALWAYS be inspected before installa-
tion. Rubber goods should not be flexed at temperatures below 40°F (44°C).
Rubber goods in storage should be inspected every 12 months to ensure that
they are still serviceable.

a. Ensure that the part does not have a tacky surface or noticeable softening
or hardening of the surface,

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

€. Replace items which show any of the aging signs mentioned above.

5

54. Bonnet Bolt Torque Requirements for Seal Carrier BOP Bonnets

7.1167 3000 | 30312-06 71311408

1116" 5000 | 3032-02 71311408. E
7.116" 10,000 | 30312.07 71311410 1002 | 1413,
7-116" 15,000 | 30312.01 71311419 1201 | 1628 |
1173000 [| 30312.04 | 2-10” 7aaiva-10 | 1279 1736 | 1918 | 2600

zianao | 1306 | 1679 | 2079 | 2819 |
manso [1616 | 2272 | 2514 | 200

117 5000 | 30312.03 | 2-12"
117 10,000__| 30312-05 | 3-18"

SONO af 230] rindo | mes | 17 | te 2203
of na | iso | en | 27 |

13:58" 3000

[nasser so00 | 3031201] 228 | 230" | an
13-518" 10000 | 30312-12 | 3-20" | 302° | munies | 1534 | 2080 | 2300 | 31e
3815000 | 3031218 | 212° | asar 93 [ons | 7030 | 1002 |

16340" 3000 | 30312-17| 2008 [apr | rinvteus | 1802 | 2097 | 2163 | 3706
1631475000 | 30312-16 | 310" | 3-12" | names | 2211 | 2908 | 3316 | ass |
16-38" 10000 | 3031224 | 4127 | as" B som | wer | 86 | 12061

a) aaa | ase a 44 T ]

20.3 3000 [0312510] 2.12 | 2.38 | Tiss | 1923 | 207 | 28 | 3910
21-114" 2000 | 30312-11 | 2-14" | 2-3/4" | 713114-10 | 1690 291 2534 | 3036 |
aie" 5000 | 3031226 | aa” | aser ans | sos2 | ssee | 757
Corarzsco Tosz2r] se Pase] Tes | ose |iou6e | 0107 |
26-314" 2000 | 30312-10 | 2-12" | 238” | 713114-08 | 1907 2586 2860 3878 |

26.310" 3000 [0312-13 | 3-58 | 3027 | zısmaıs | 3079 | ams | asia | 6261

cios sa

55. Bonnet Bolt Torque Requirements for U BOPs without Seal Carriers

Bonnet Hex | Cameron Torque
Thread | across | ‘Wrench Moy tubs

EE lb | nem
Zn" 3000 | 2031206 | 134" | 238" | riamaos | 1600 | 2169 | mo | 1220
is" 5000 | 30312-02 | 2 | 2-38" | 71311408 | 2200 | 2963 | 1200 | 1687 |
7-116" 10,000 | 30312-07 | 2-1/2 | 2:34" | 71311410 | 4200 5694 2300 3118
7-16" 15,000 | 30312-01 | 2.7/8" | 2.3/4" | 713114-10 | 6000 8135 3300 aaa |
“113000 [3031204 | 20107 | 2-318" | 713114-10 | 3000 | 41067 | 1600 | 2160
1170002031203 2347 [12110] azoo | sone | 2300 | ame]
11710000 | 01205 2347 [mama | 7900 | 10711 | ano | 5559
Ts 3000 | 3031200) 237 12.07 | 71311610 7593 | 3000 | 4067
[3585 12.01 | 278 | 23" | ameno. 8135 | 3300 | ar |
1358" 0000 | 3031.12 | aa | 3.19" | 7180213 19659 | 7500 | 10.169
13.56" 15000 [3032-18 em Lese: así | 13,000 12626 |
3630" 3000 [031271 278° [312° | 712013 es | 300 | sara
ir sooo [3031216 | 3172 | 310" | nanas | 12500 | 16908 | 6500 | een]

Lors]

6-34" 10000! 3031224 [au [ass | 25500 | 34573 | 1500 | 17626
Fr y ese 1915]
zou 3000 | 0312-10] 2-12" 238" 713112081 2200 | 560% | 2300 | ame
21-14" 2000 | 30312-11 [amer | 2-347 | 713114-10 | 3000 | 4067 | 1600] 2169 |
rar 5000 | 30312-26 | asia" | 258" 29,500 | 39.997 | 15500 | 21,015
[ara 7500 [3031221 | 5° [ese] 34000 | 46,098 | 17,500 | 23,727 |

26.314" 2000 | 30312-10 | 202 | 2387 | 71311808 | 4200 | sesa | 2300 | 3118 |
26.314" 3000 | 30312-13 | 33107 | 3177 | 71311013 | 14500 | 19659 | 7500 | 10,169

cios ss