TC9009 Op & Maint Man 13in 10k DL

DL Blowout Preventer 13-5/8" 10,000 psi WP Operation and Maintenance Manual

TC9009

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

All the information contained in this manual is the exclusive property of Cameron International Corporation. 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 01 February 2007

Copyright © 2007 all rights reserved by Cameron International Corporation

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PREFACE The procedures included in this book are to be performed in conjunction with the requirements and recommendations outlined in API Specifications. Any repairs to the equipment covered by this book should be done by an authorized Cameron service representative. Cameron will not be responsible for loss or expense resulting from any failure of equipment or any damage to any property or death or injury to any person resulting in whole or in part from repairs performed by other than authorized Cameron personnel. Such unauthorized repairs 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 products, which are products of Cameron International Corporation. Cameron P.O. Box 1212 Houston, Texas 77251-1212 713-939-2211 http://www.c-a-m.com

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Table Of Contents DL BOP, 13-5/8" 10,000 psi WP . . . . . . . . . . . . . . . . . . . . . . . 7 P/N 699341-30-00-03 (Illustration and Parts List) Standard Spare Parts, 13-5/8" 10,000 psi WP DL BOP . . . . . . . . . . . 11 P/N 046064-30-00-01 (Parts List) Seals, Bearings and Scrapers, 13-5/8" 10,000 psi WP DL BOP . . . . . . . 12 P/N 049742-12 (Parts List) I. Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 II. Applicable Operating Characteristics . . . . . . . . . . . . . . . . . . 15 III. Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 16 IV. Assembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 19 V. Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 25 VI. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . 28 VII. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 VIII. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Parts List: DL BOP, 13-5/8" 10,000 psi WP P/N 699341-30-00-03 Rev. 01 Item 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 29 30 31 32 33 34 35 36 37 38 39 40 41 42 45 46

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Part Number 046088-30-00-03 046054-30-00-04 699333-06-00-03 699334-30-00-03 699335-30-00-03 699336-06-00-03 644856-07-00-01 699337-30-01 699338-30-00-01 049089-02 699343-02 614350-01 049416-01 2010341-06 046045-09 644868-02 2032175-02 049047-03 049052-01 049051-01 049050-01 663311-13 046037-20 049800-05 219065-17-10-71 2709000-17-01 235539-63 005930-06-10 046052-09 046052-02 11849 700649 012185-01 012185-03 700446 702514-25-20-08 700594

Qty 1 1 1 1 1 1 1 1 1 4 4 3 1 1 1 8 1 1 4 2 2 4 12 12 20 20 2 2 24 4 4 4 2 4 2 4 4

Description Body Top Piston Inner Cylinder Head Outer Cylinder Head Pusher Plate Packing Element Subassembly Lock Ring, Split Actuator Ring Actuator Screw Subassembly Insert, Actuator Screw Lock Segment, Outer Cylinder Head Ring, Outer Cylinder Head Locking Segment Support Plate Top Trash Seal Bearing, Actuator Screw Name Plate, Annular BOP, API 16A Name Plate, Type D BOP, 10,000# Pressure Rating Name Plate, Vent Name Plate, Close Port Name Plate, Open Port Shackle, Anchor, Fits Body Lifting Lugs Stud, Double Ended, Inner Cylinder Head Nut, Modified Heavy Hex, Inner Cylinder Head Stud, Double Ended Nut, Heavy Hex Plug, Hex Head, Special Pipe Plug, Hex Head Screw, Socket Head Cap Screw, Socket Head Cap, Special Lifting Eye Eyebolt Eyebolt Eyebolt Eyebolt Screw, Socket Head Set Fitting, Grease-Straight

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Item 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 75 76

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Part Number 049122-06 2010196-23 2010196-11 2010196-12 2010196-24 699345-03 700319 700320 615850-32-01 615850-33-01 615847-40-01 615850-30-01 615846-22-01 615850-31-01 615846-23-01 615846-24-01 615850-34-01 706258-10 615851-28-01 615846-25-01 702645-33-01 230266-02-00-16

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4

Description Wear Ring Bearing Bearing Bearing Bearing Wear Ring Wiper Ring Wiper Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring O-Ring Screw, Hex

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Parts List: Standard Spare Parts, 13-5/8" 10,000 psi WP DL BOP P/N 046064-30-00-01 Rev. A01 Item 7 16 66 67

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Part Number 644856-07-00-01 046045-09 615850-34-01 706258-10

Qty 1 1 1 2

Description Packing Element Subassembly Top Trash Seal Seal Ring Seal Ring

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Parts List: Seals, Bearings and Scrapers, 13-5/8" 10,000 psi WP DL BOP P/N 049742-12 Rev. H20 Item 16 17 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

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Part Number 046045-09 644868-02 049122-06 2010196-23 2010196-11 2010196-12 2010196-24 699345-03 700319 700320 615850-32-01 615850-33-01 615846-25-01 615850-30-01 615846-22-01 615850-31-01 615846-23-01 615846-24-01 615850-34-01 706258-10 615851-28-01 615847-40-01

Qty 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description Top Trash Seal Bearing, Actuator Screw Wear Ring Bearing Bearing Bearing Bearing Wear Ring Wiper Ring Wiper Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring Seal Ring

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

I. PHYSICAL DATA A. Lubricants: 1. Thread lubricant - API-5A-Lub, Fel-Pro Paste #670, or SLECT-A-TORQ Paste #503 (4 lb can P/N 705444). 2. Multi-purpose lubricant or grease. 3. Multi-purpose lubricant or grease for cold weather operation. 4. Hydraulic operating system: a. Storage - P/N 718100 (Marston Bentley Preservation Fluid). b. Standard Operation - use a fresh water lubricant that forms a true solution rather than an emulsion when mixed with water and/or antifreeze.

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

C. Drawings with Bills of Material 1. SD-035682 13-5/8"-10,000 psi WP DL Annular BOP

D. Weights and external dimensions 1. Total estimated weight: 27,262 lb. 2. Lifting Lug capacity for each lug: 35 tons 3. Maximum capacity of all four lugs used together: 140 tons

E. Lifting and Handling 1. Lift BOP assemblies only with slings appropriately rated for the maximum weight of the BOP. 2. Handle all other sub-assemblies using appropriately rated slings.

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F. External Thread Connections NPT Fitting Size for Open and Close Ports: 1"-11-1/2 NPT

G. Hydraulic Operating System Requirements US Gallons to Open US Gallons to Close

15.22 17.10

1. Normal pressure for the hydraulic operating system is 1500 psi. 2. Maximum pressure for the hydraulic operating system is 3000 psi.

H. Torque Specifications 1. Inner Cylinder Nuts (Item #31): 2220 ft-lb. 2. Pusher Plate Screws (Item #36): 68 ft-lb.

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

J. Service Tools and Equipment Item No. 11 31 33 34 35 36 37 45 46

Description Actuator Screw Assembly Inner Cylinder Nut Flange Nut Lock Ring Access Port Plug Hydraulic Port Plug Pusher Plate Screw Actuator Ring Stop Screw Insert Retaining Screw Oil Injection Fitting

Wrench Size 1-7/16" Socket 2" Socket 2-15/16" Wrench 2" Wrench 1-7/16" Wrench 5/8" Allen 1" Allen 3/8' Allen 7/16" Socket

K. Temperature Rating of Annular BOP Packers: 1. Continuous Service — 70 - 180 deg. F (21 - 82 deg. C) 2. Extreme Service — 30 - 200 deg. F (-1 - 93 deg. C) Note: There is no industry accepted method of establishing BOP temperature ratings at this time. These are estimates based on lab testing and field performance. Temperature ratings for rubber components must take into account the environmental exposure history, the chemical environment while at temperature, and other factors. Therefore, a single number rating can be misleading if all conditions are not understood. TC9009

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II. APPLICABLE OPERATING CHARACTERISTICS AND PRINCIPLES OF OPERATION

A. Packer/Donut Assembly 1. The packer is a cylinder of molded rubber combined with sixteen steel reinforcing inserts. 2. The donut is made of homogeneous molded rubber that surrounds the packer. 3. The packer inserts are flanged on the top and bottom. 4. The shape of the flanges have been designed to maintain an unbroken barrier of steel above and below the packer rubber as the packer is closed, regardless of the size or shape of the pipe or tool in the bore. 5. The uninterrupted barrier reduces rubber extrusion, even under high bore pressure. 6. The rubber on the ID of the packer forms a pressure tight seal against the pipe or the tool in the BOP bore.

B. Hydraulic Operating System 1. The annular BOP does not depend upon wellbore pressure to close the packer. 2. Closing pressure must be maintained to the operating system to hold the packer in the closed position. 3. This independence of wellbore pressure gives the operator control of the rubber pressure on the pipe, reduces packer extrusion, and can significantly increase packer life when the BOP is used for stripping.

C. Closing the Annular BOP 1. Hydraulic fluid is pumped into the closing chamber to force the piston and the pusher plate upward against the donut. 2. The pusher plate squeezes the donut, forcing the donut to expand inward. 3. The inward displacement of the donut forces the packer inward toward the center of the bore. TC9009

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III. DISASSEMBLY PROCEDURE A. Part Preparation Prior to Disassembly The work area should be clean and well lighted.

B. BOP Disassembly 1. Clean the outside of the BOP body (1). Use high pressure water and detergent to clean mud and debris from the outside of the BOP. 2. Make sure the BOP is fully open. Apply opening pressure and allow pressure to build up to the regulator pressure and make sure that the packer is completely open. 3. Remove and bleed all operating pressure. 4. Vent the operating system. Remove the plugs from the unused open and close ports on the BOP body. This will eliminate the possibility of accidental operation of the BOP once the quick release Top is unlocked. 5. Inspect the Top trash seal (16). If the seal is damaged, it should be replaced as soon as possible, to keep mud and debris out of the mechanism of the quick-release top (2). 6. Open the access flaps on the Top trash seal (16). Clean out the cavity around the head of each actuator screw. Do not reuse the grease removed from these cavities. 7. Grease the Actuator Screws (11). Inject a molybdenum disulfide or graphite-loaded grease fitting in the head of each actuator screw, until grease is forced up through the threads and comes out underneath the head of the actuator screw. Note: The actuator screws should be greased before unlocking the quick release top. This should be done EVERY time the top is unlocked. This will make the screws turn more easily and reduce the possibility of thread galling. 8. To prepare for the removal of the quick-release top (2), install eye bolts in the tapped holes in the top. 9. Using two wrenches, operate the actuator screws (11) in pairs of two adjacent (NOT OPPOSITE!) screws, alternately lifting first one side of the actuator ring and then the other. Turn each actuator screw counter-clockwise, a few turns at a time, or until the screw starts to bind. A socket wrench with a 12-inch handle works well for turning these screws.

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Note: If only one wrench is used, the wrench should be moved from one screw to the next, moving in the same direction around the ring. 10. When the actuator screws can no longer be turned using a wrench with a 12-inch handle, the actuator ring (10) has reached its uppermost position, and the quick release top should be fully unlocked. 11. Clean out the vent ports using a stiff wire or rod. Attach lifting chains to the lifting eyes in the top and lift the quick-release top out of the BOP body. If the top is pulled at an angle instead of straight out, the top may bind in the BOP body. Danger:

Dried mud or clogged vent ports may cause the quick release top to stick in the BOP body. When lifting force is applied, the top may break loose suddenly. Use safe rigging and lifting procedures to avoid injury.

Danger:

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

Note: If the donut (7) hangs in the quick release top, lower the top to the floor, then insert a pry bar through the bore FROM ABOVE and pry the donut loose. 12. Set the quick release top (2) down on a flat, clean surface. 13. Remove and inspect the top trash seal (16), being careful not to damage the seal. 14. Remove the actuator ring stop screws (37). 15. To remove the actuator ring/lock ring assembly, install eye bolts in the tapped holes in the actuator ring (10), and lift the assembly off the quick release top. 16. Pull each actuator screw (11) from its slotted recess in the actuator ring (10). Remove the pair of actuator screw bearings (17) from each actuator screw. DO NOT remove the grease fitting from the head of the actuator screw unless it is damaged. 17. Remove and inspect the Top ID (66) and Top OD (67) seal rings. Warning: To remove seals, use a dull tool, such as a screwdriver blade with the sharp edges removed. Insert the tool under the seal at one point, and carefully stretch the seal out of the groove by pulling the tool around the entire circumference of the groove. A sharp tool may damage the seal or the seal groove.

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18. Install eye bolts in the tapped holes in the top of the packer, attach lifting chains, and lift the packer out of the BOP body. If the donut does not come out with the packer, use a pry bar to lift the donut in order to get a lifting strap around the donut. 19. Install eye bolts in the tapped holes in the support plate (15) and remove it from the BOP. 20. Remove the outer cylinder lock ring (14). Note: Older model BOPs may not be equipped with this lock ring. If this is the case, move on to step 22. 21. Remove the outer cylinder lock segments (13). Use a pry bar or a long flat head screwdriver to assist in the removal of the lock segments. 22. Use an air wrench to remove the inner cylinder nuts (31). 23. Remove the pusher plate screws (36). 24. Install lifting eyes into the pusher plate (6) and remove it from the BOP. 25. Apply low pressure hydraulic fluid (up to 300 psi) to the BOP close port. Release the pressure as soon as the seal leaks. 26. Install lifting eyes into the tapped holes in the top of the inner cylinder (4). Attach lifting chains and lift the operating system out of the BOP body (1).

C. Disassembly of the Operating System Outside the BOP Note: In order to disassemble the operating system after it has been removed from the BOP, low pressure hydraulic fluid (up to 300 psi) is used to pump the inner and outer cylinders off the piston. The ports in the outer cylinder and the ports in the piston must first be tapped with a pipe tap. All but one of the ports are then plugged with pipe plugs, and low pressure hydraulic fluid is applied to the remaining port to pump the assembly apart. 1. If the pusher plate has not been removed, remove the pusher plate screws (36) and then lift the pusher plate (6) off the piston (3). 2. Tap the ports in the outer cylinder so the outer cylinder may be pumped off the piston. It is not necessary to tap and plug the small vent holes. 3. Plug all but one of the ports in the outer cylinder. Use NPT pipe plugs, and use TFE thread sealing tape on the threads.

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4. Slowly apply low pressure hydraulic fluid (up to 300 psi) to the remaining port. To prevent damage to the components, the assembly is suspended an inch or two above a sheet of plywood on the floor using lifting eyes installed in the outer cylinder. 5. The piston/inner cylinder assembly will drop onto the wood without being damaged. 6. Remove all pipe plugs from the outer cylinder. 7. Tap the ports in the Piston. 8. Plug all but one of the ports in the piston. 9. Pump the assembly apart as in step 4. 10. Remove all pipe plugs from the piston. 11. Inspect the bearing rings, the seals, and the wiper rings.

IV. ASSEMBLY PROCEDURE A. Part Preparation Prior to Assembly The work area should be clean and well lighted. 1. Remove all dirt, grit, oil, and contaminants from the ID sealing surfaces of the Body and all fluid passageways. Clean detergent and fresh water should be used for cleaning. High pressure air may also be used if it is dry air. 2. Clean the piston, the outer and inner cylinder, and the quick- release top using clean detergent and fresh water. Lubricate areas that will come in contact with other parts. 3. Sealed elastomer containers should not be opened until they are required for assembly. This is to prevent contamination and damage to the seals.

B. Assembly of the Quick-Release Top Outside the BOP 1. Place the top (2) on a pallet with the flange stud holes looking up. 2. Apply anti-seize to the outside threads of the four actuator screw inserts (12) and install them into the tapped holes of the quick-release top until the top of the insert is flush with the top of the hole. The top of each insert is slotted, to allow the insert to be turned with a screwdriver blade.

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Note: The easiest way to install an insert is to first thread it onto an actuator screw and then use the actuator screw as an insertion tool. 3. Apply anti-seize to the threads of the four insert retaining screws (45). Install the retaining screws and tighten them securely with an Allen wrench. 4. Apply a light coat of grease to the outside surface (the teeth) of the lock ring (9) and apply a heavy coat of grease to the inside surface of the lock ring. Also, completely fill the axial grooves on the inside of the ring. 5. Position the actuator ring (10) inside the lock ring (9). 6. Install the actuator screws (11) into the actuator ring by first suspending the actuator ring/lock ring assembly above the quick-release top. Apply grease to the threads of the actuator screws and to the actuator screw bearings (17). Install a bearing on the top side and another on the bottom side of the actuator screw head. Slide each actuator screw into its recess in the actuator ring. 7. Install the actuator ring/lock ring assembly on the quick release top. Slowly lower the actuator ring/lock ring assembly into place on the quick release top, until the actuator screws can be started in the threads of the actuator screw inserts. 8. When all four actuator screws are started (at least two threads) in the actuator screw inserts without binding, remove the lifting chains. 9. Using two wrenches, operate the actuator screws in pairs of two adjacent (NOT opposite!) screws, alternately lowering first one side of the actuator ring and then the other. Turn each screw clockwise, a few turns at a time, or until the screw starts to bind. A socket wrench with a 12-inch handle works well for turning these screws. 10. If only one wrench is used, the wrench should be moved from one screw to the next, moving in the same direction around the ring. 11. Using the actuator screws, lower the actuator ring approximately one inch, so that the actuator ring stop screws (37) can be installed. 12. Apply anti-seize compound to the threads of the actuator stop screws (37) and seat all four screws fully before tightening any of them. 13. Install the quick-release top OD seal (67) with the sealing lips face up. 14. Using lifting chains, raise the entire top assembly and install the top ID seal ring (66). Do not lubricate this seal or seal groove with grease. TC9009

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C. Assembly of the Hydraulic Operating System Outside the BOP 1. Install the bearing rings, seal rings, and wiper rings on the piston. a. Install the piston ID seal ring (61). The lip faces down. b. Install the piston ID bearing ring (51). c. Install the piston OD seal ring (62). The lip faces down. d. Install the piston OD bearing ring (54). 2. Install the bearing rings, seal rings, and wiper rings on the outer cylinder. a. Install the outer cylinder ID wiper ring (56). The scraper end is up. b. Install the outer cylinder ID bearing ring (53). c. Install the outer cylinder ID seal ring (upper) (68). The lip faces up. d. Install the outer cylinder ID seal ring (lower) (63). The lip faces down. e. Install the outer cylinder OD seal ring (upper) (64). The lip faces down. f. Install the outer cylinder OD seal ring (lower) (65). The lip faces down. 3. Install the bearing rings, seal rings, and wiper rings on the inner cylinder. a. Install the inner cylinder ID seal ring (upper) (58). The lip faces up. b. Install the inner cylinder ID seal ring (lower) (59). The lip faces down. c. Install the inner cylinder OD wiper ring (57). The scraper end is up. d. Install the inner cylinder OD bearing ring (52). e. Install the inner cylinder OD seal ring (upper) (69). The lip faces up. f. Install the inner the cylinder OD seal ring (lower) (60). The lip faces down.

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D. Assembly of the Inner Cylinder onto the Piston. 1. Apply a light coat of light clean oil to the inner surface of the piston and to the outer surface of the inner cylinder. 2. Place the piston on a flat, clean surface. 3. Lower the inner cylinder onto the piston. 4. Keep the inner cylinder level, and make sure the seals do not slip out of the grooves and become pinched or cut as the inner cylinder slides into the piston. 5. Lower the inner cylinder slowly, and inspect each seal as it engages with the piston. 6. Seat the inner cylinder on the piston by placing a packer on the inner cylinder and then set the BOP body on top of the packer. The weight of the BOP body should be sufficient to seat the inner cylinder on the piston. 7. Remove the BOP body and the packer, then install lifting eyes in the piston. Lift the assembly, and inspect the underside of the piston to ensure that the piston ID seal ring and the piston ID bearing ring have not extruded out of the groove.

E. Assembly of the Outer Cylinder onto the Piston 1. Apply a light coat of light clean oil to the outer surface of the piston. 2. Place the piston/inner cylinder assembly on a flat, clean surface. 3. Apply a light coat of light clean oil to the inner surface of the outer cylinder. 4. Lower the outer cylinder onto the piston. Keep the outer cylinder level, and make sure the seals do not slip out of the grooves and become pinched or cut as the cylinder slides onto the piston. 5. Lower the outer cylinder slowly, and inspect each seal as it engages with the piston. 6. Seat the outer cylinder on the piston by placing the quick-release top on the outer cylinder, then place the BOP body on the quick-release top. The combined weight should be sufficient to seat the outer cylinder on the piston. 7. Remove the BOP body and the quick-release top, then install lifting eyes in the inner cylinder.

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8. Lift the assembly, and inspect the bottom of the piston to ensure that the piston OD seal ring and the piston OD bearing ring have not extruded.

F. Assembly of the Pusher Plate to the Operating System 1. Clean the tapped holes in the top of the piston. 2. Lower the pusher plate onto the top of the piston. 3. Apply anti-seize compound to the pusher plate screws and install them. 4. Fully seat all the pusher plate screws, then tighten them evenly to 68 ft-lb.

G. Installation of the Operating System as a Unit into the BOP body. 1. Lubricate the interior of the body by applying a light coat of light clean oil to the inside of the body below the locking grooves. Note: Make certain that any plugs installed in the vents of the BOP body have been removed, and that all control system lines have been disconnected from the BOP. Otherwise, it may be impossible to seat the operating system in the BOP body. 2. Install eye bolts in the tapped holes in the top of the inner cylinder. Do not attempt to lift the operating system using eye bolts installed in the outer cylinder. 3. Attach lifting chains and suspend the operating system above the BOP body. 4. Apply a light coat of light clean oil to the outer surface of the operating system. 5. Line up the holes in the inner cylinder with the studs in the BOP body, then slowly lower the operating system into place. 6. Make certain the lip seals on the outside of the outer cylinder are not forced out of the seal grooves, and use care not to pinch or cut them during the assembly process. 7. Remove the lifting eyes from the inner cylinder. 8. Apply anti-seize compound to the threads of the inner cylinder nuts (Not to the studs!). 9. Draw the inner cylinder into place with the inner cylinder nuts. TC9009

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Note: If the inner cylinder is sitting so high in the BOP body that the inner cylinder nuts cannot be started onto the inner cylinder studs, place a few nuts on top of the inner cylinder between the stud holes. Then place a packer on top of the nuts and use the quick-release top as a weight to force the inner cylinder down into the body. 10. Install the inner cylinder nuts and tighten them evenly to 2220 ft-lb. 11. Make sure the outer cylinder is properly seated. The shoulder of the outer cylinder should be level with or slightly lower than the adjacent inner shoulder of the BOP body. Note: If the outer cylinder is too high in the BOP body, place three heavy hex nuts of the same size on the outer shoulder of the outer cylinder. Stand the nuts on edge, if necessary, and space the nuts evenly around the cylinder. Do not allow the nuts to protrude beyond the outer edge of the outer cylinder. The inner cylinder nuts are suitable for this application. Use the quick-release top as a weight to seat the outer cylinder. Lower the top into the BOP body, and set it down on the nuts. 12. Install the outer cylinder lock segments in the groove on top of the outer cylinder. 13. Install the lock segment retaining ring next to the lock segments. 14. Lower the support plate into place inside the pusher plate. Make certain the recesses in the underside of the support plate fit down over the inner cylinder studs. The support plate should rest evenly on the inner cylinder nuts.

H. Final Assembly 1. Lubricate the inside of the BOP body by applying a light coat of light clean oil. 2. Apply a light coat of grease or light machine oil to the teeth of the lock ring and the lower surface of the quick-release top. 3. Lubricate the OD and ID of the donut (7) with a light coat of grease. Make certain the donut is installed top side up. The word “TOP” is molded into the rubber and the top side of the donut has a long, smooth bevel on the OD. Use a fabric sling to lift the donut into the BOP. 4. Attach eye bolts to the top of the inserts on the packer. Attach lifting chains to the eye bolts. Lift the packer into the BOP and position the packer inside the donut. Make sure the packer is installed top side up. 5. Lower the assembled quick-release top into the BOP body. TC9009

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Note: The quick-release top is designed to rest on the shoulder within the BOP body which is just below the locking grooves. When the top is resting on the shoulder, the upper surface of the top is flush with the upper surface of the BOP body. The top must be in this position before it can be locked. 6. Lock the quick-release top with the actuator screws. The quickest and easiest way to lock the quick-release top is to use two wrenches. 7. Operate the actuator screws in pairs of two adjacent (Not opposite!) screws, alternately lowering first one side of the actuator ring and then the other. 8. Turn each actuator screw clockwise, a few turns at a time, or until the screw starts to bind. A socket wrench with a 12-inch handle works well for turning these screws. 9. When the actuator screws can no longer be turned with the 12-inch wrench, the actuator ring should be in its lowermost position. When the actuator ring is in this position, the teeth of the lock ring are fully engaged in the locking grooves of the BOP body, and the upper surface of the top trash seal is approximately flush with the upper surface of the quick-release top. The quick-release top is now locked. 10. Grease the actuator screws with molybdenum disulfide or graphite-loaded grease in the grease fitting. 11. Pack the cavity around the head of each actuator screw with clean grease. 12. Close the access flaps of the top trash seal. 13. Reinstall the pipe plugs which were removed to vent the operating system. Use TFE thread-sealing tape on the plugs. 14. Verify operation of the BOP.

V. OPERATION PROCEDURES A. Normal Operation 1. Operating Pressure — General Recommendations a. A minimum closing pressure of 1500 psi is required to close and seal the BOP on pipe. Higher closing pressures (up to the rated working pressure of 3000 psi) may be necessary, depending upon packer condition, pipe size, and ambient temperature. Neither the operating system nor the packer will be damaged by application of up to 3000 psi closing pressure. TC9009

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b. Closing pressure should never be reduced below 1500 psi, except when stripping. It is only during stripping that reduced closing pressure is beneficial in prolonging packer life. c. A minimum opening pressure of 1500 psi is required for reliable operation. The operating system will not be damaged by repeated application of up to 3000 psi opening pressure. 2. Closing the BOP on pipe or tools a. To close the BOP on pipe or tools, apply closing pressure while venting the opening port. b. If well fluid leaks past the packer, increase closing pressure as necessary until the leakage stops, but do not exceed 3000 psi. c. Closing pressure must be continuously applied in order to hold the packer in the closed position. 3. Closing the BOP on open hole a. To close the BOP on open hole, apply the maximum available closing pressure (not to exceed 3000 psi) while venting the opening port. Note: Every annular packer (including replacement packers) has been tested on open hole with a wellbore pressure of one half the rated working pressure of the BOP, according to API 16A, latest edition. As a packer wears, its ability to close and seal on open hole will decrease, even though it may continue to hold full rated working pressure when closing on pipe. 4. Opening the BOP a. To open the BOP, apply opening pressure while venting the closing port. Opening pressure must never exceed 3000 psi. Warning: Operating system control valves may develop internal leakage. This leakage may cause either the opening or the closing line to be pressurized when the valve handle is set to “Neutral” or “No Pressure”. This could result in unintended closing of the BOP. It is therefore recommended that the control valve handle be left in the “Open” position at all times when the operator wishes the BOP to be open.

B. Stripping Pipe Through the Closed BOP 1. Before stripping pipe through the closed BOP, make certain the hydraulic control system and the control piping conforms to the following requirements: TC9009

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a. A nitrogen-precharged surge bottle of 10 gallon capacity b. A pneumatically-controlled or hydraulically-controlled self-relieving pressure regulator c. A control valve of the non-check type. Note: The purpose of these items is to reduce the pressure surge which occurs in the BOP closing chamber each time a tool joint enters the closed packer. High pressure surges cause excessive and unnecessary packer wear. 2. Stripping Procedure a. Check the surge bottle precharge pressure. A 10 gallon surge bottle, precharged to a pressure of 400 to 500 psi, will normally give proper stripping performance with all annular sizes. b. Open the valve between the surge bottle and the BOP closing line. c. Vent the opening chamber by removing the pipe plug from the unused opening port. d. Keep the packer lubricated while stripping to prevent excessive wear. Do not move dry pipe through the packer, except in an emergency. e. When stripping out of the hole, leakage of well fluid (if other than dry gas) will provide adequate lubrication. f. When stripping into the well, apply lubricant to the pipe, and especially to the tool joints or couplings. Suitable lubricants, in order of preference, are: 1) oil 2) oil-base drilling mud 3) water-base drilling mud 4) water with gel 5) plain water g. Control the closing pressure by using the lowest practical closing pressure when stripping. h. Reduce the closing pressure until well fluid leaks slightly between the pipe and the packer while the pipe is in motion. This leakage lubricates the packer, thus reducing packer wear.

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

1500

5000 psi BOP

1400 1300 1200 1100 1000

10,000 PSI BOP

900 800 700 600 500 400 300 200

9000

10,000

8000

7000

6000

5000

4000

3000

2000

100

1000

k. When the packer has become severely worn during stripping, leakage will begin to increase. When leakage cannot be controlled by increasing the closing pressure, the packer is nearly worn out, and arrangements should be made to replace the packer.

SD-10779-99

CLOSING PRESSURE (PSI)

j. As a new packer begins to wear during stripping, sealing is improved, and the closing pressure required to seal on pipe will decrease. For this reason, closing pressure should be reduced as often as is necessary to maintain slight leakage for lubrication of the packer.

WELL PRESSURE (PSI)

l. Observe the pressure gauge on the BOP closing port as a tool joint approaches and enters the packer. If the drill string is moved slowly enough, the pressure surge in the BOP closing chamber during entry of a tool joint should be 100 psi or less. The faster the tool joint enters the packer, the greater will be the pressure surge. If the pressure surge as tool joint enters the packer is greater than 100 psi, packer wear will be excessive.

VI. MAINTENANCE PROCEDURES A. Routine Maintenance 1. Preparation and Safeguards prior to maintenance a. Use high-pressure water to clean mud and debris from the outside of the BOP. TC9009

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b. Apply opening pressure and allow pressure to build up to the regulator pressure and make certain that the packer is completely open. c. Make certain all pressure is bled from both the opening and the closing lines. d. Vent the operating system by removing the plugs from the unused opening and closing ports on the BOP body. e. Inspect the top trash seal for damage. f. Clean out the cavity around the head of each actuator screw. g. Grease the actuator screws. Note: The actuator screws should be greased before unlocking the quick-release top. This should be done every time the top is unlocked. This will make the screws turn more easily and will reduce the possibility of thread galling. 2. Inspection and changeout of the packer and donut a. The packer should be inspected weekly, after every pressure test, between wells, after stripping, and in the event of a packer leak. b. The packer should be replaced if there are vertical cracks or tears across the full height of the sealing surface. Also, if a large portion of the sealing surface has been gouged away, or if the packer has been exposed to hydrogen sulfide at temperatures in excess of 200 deg. F., the packer should be replaced. 3. Between-well servicing a. Between-well servicing consists of cleaning debris from the inside of the BOP body and inspecting the packer and donut, followed by a test of the packer. The quick-release top, the packer, and the donut must be removed for this cleaning and inspection. b. Once the packer, the donut, and the quick-release top have been reinstalled, the API Hydraulic Test (Packer Test) in accordance with API RP 53 is performed. It is not necessary to open or service the operating system at this time, as long as the specified operating fluids have been used. 4. Disassembly and cleaning: a. Remove the quick-release top.

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b. Clean the quick-release top by using high-pressure water. Make certain the lower surface of the top, the lock ring, and the actuator are clean. c. Remove, clean, and inspect the top trash seal. d. Reinstall the top trash seal. e. Inspect the seals and the wiper rings on the quick-release top. Note: The quick-release top ID lip seal should be replaced at each between-well servicing. f. Remove, clean, and inspect the packer and donut. g. Remove the support plate. h. Clean out the inside of the BOP Body. i. Clean out the vent ports with a stiff wire or rod. 5. Reassembly: a. Check tightness of pusher plate screws. b. Make certain the outer cylinder is fully seated. c. Apply a light coat of grease or light machine oil to the inside of the BOP body. d. Lubricate the teeth of the lock ring and lower surface of the quick-release top. e. Install the support plate. f. Install the donut and packer. g. Replace and install the top ID lip seal with the sealing lip facing up. h. Install the quick-release top. i. Verify operation of the BOP and test the packer according to API RP 53.

B. Periodic Maintenance 1. Every two years, or as required by the appropriate regulatory agency, completely disassemble the preventer and: a. Clean all parts. Do not use a wire brush on sealing areas.

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b. Replace all rubber seals, gaskets, and O-rings. c. Replace the packer and donut according to its physical condition. d. Repair or replace damaged metal parts. e. After reassembly, test the packer and operating system in accordance with this manual.

VII. TESTING A. Function Test - With Pipe 1. Install the appropriate pipe mandrel into the test stump. a. For 9" diameter bores or less use 3.5" diameter pipe mandrel. b. For 11" diameter bore or greater use 5" diameter pipe mandrel. 2. Install the strip chart recorder and identify the device. 3. Apply 1500 psi +/- 200 psi to the close port as follows: a. Pump up the accumulator pressure to at least 2500 psi. b. Set the regulator to provide 1500 psi +/- 200 psi closing pressure. c. Move the control valve to the close position. The closing pressure at the BOP must be up to 1500 psi +/- 200 psi within five minutes after moving the control valve to the close position. Less than five minutes would be preferable. 4. Exercise the packer two times (open-close cycles). 5. Apply 200 psi wellbore test pressure. 6. After a minimum of 200 psi wellbore test pressure has been reached and has stabilized, hold for a period of at least five minutes. 7. Increase the wellbore pressure to full rated working pressure. 8. After full rated working pressure is reached and has stabilized, hold for a period of at least five minutes. 9. If the packer fails to hold pressure on the first test or develops a tear, discontinue the test. A new packer must be tested. 10. Bleed bore pressure to zero psi.

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11. Check the packer for 13.595" API drift within 30 minutes after opening the BOP. a. The 30-minute time period starts when the operating piston is fully open. This is the time period when opening pressure builds up and can normally be determined by watching the BOP open hose. 12. If the packer fails to drift within 30 minutes: a. Exercise the packer, (open-close cycles if required to achieve full drift). The exercise cycles should be performed immediately one after the other and should not exceed more than a total of 15 exercise cycles, including exercises performed per Paragraph A, step 4. b. The 30 minute drift time starts after the last packer exercise (open-close cycle).

B. Drift Test Drift Diameter Bore Size (Inch) 13-5/8

Drift Diameter (Inch) 13.595

1. Open the BOP using 1500 psi hydraulic pressure. 2. Drift BOP through bore with a drift of 13.595" in diameter.

VIII. STORAGE A. Preventer 1. If the BOP is to be stored for a period of a year or longer, the packer and donut should be removed from the BOP and stored separately, following the packaging and storage recommendations of section VIII B. 2. Clean the outside of the BOP body. 3. Disconnect the hydraulic hose at the close port and drain the operating fluid out of the BOP. 4. Attach a hydraulic line containing only preservation fluid to the close port. Use Marston Bentley preservation fluid, P/N 718100. 5. Disconnect the bottom open hydraulic port to allow the operating fluid to drain out of the BOP once closing pressure is applied to the close port.

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6. Apply pressure to the closing port, allowing the operating fluid to drain out of the bottom open port. Once the fluid has completely drained, plug the open port. 7. Apply pressure to the opening port to fill the operating system with the preservation fluid. 8. Release the pressure, disconnect the hydraulic lines, and install pipe plugs into the open and close connections.

B. Elastomers 1. Store rubber products inside a cool, dark, dry storage. a. The preferred storage temperature range for rubber goods is from 40 deg. F (5 deg. C) to 80 deg. F (25 deg. C) b. Rubber goods should be wrapped or otherwise protected from direct exposure 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. c. 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. 2. Use airtight containers when possible to protect against circulating air. 3. 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. 4. Keep the rubber products clean and free of solvents, oil greases, or any other semi-solid or liquid materials during storage. Rubber goods should specifically be protected against direct contact with: manganese, copper, copper alloys (including brass), polyvinyl chloride (PVC), creosote-impregnated timber, other rubber goods of different rubber compounds, sulphur, and copper napthenate. 5. 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. 6. Examine the part before installation.

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Important: Rubber goods taken from storage must always be inspected before installation. Rubber goods should not be flexed at temperatures below 40 deg. F (5 deg. C). Rubber goods in storage should be inspected every 12 months to ensure that they are still serviceable. a. Ensure that the part does not have a tacky surface or noticeable softening or hardening of the surface. b. Flex the part and inspect with a magnifying glass to ensure that there are no cracks. c. Replace items which show any of the aging signs mentioned above.

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