Hydril - Gk Bop

Manual 6609EOPERATOR'S MANUAL GK® 11"-5000 PSI Annular Blowout Preventer R Pressure Control Equipment R Operator's Manual OPERATOR'S MANUAL GK® 11"-5000 PSI Annular Blowout Preventer 6609E PAGE iii GK® 11"-5000 PSI Annular Blowout Preventer R Hydril Company LP/ P.O. Box 60458 / Houston, Texas 77205 Phone: (281) 449-2000 / FAX: (281) 985-2828 / WEB: www.hydril.com © 2007 Hydril Company LP Printed in U.S.A., Rev E, October 2007 All Rights Reserved R Operator's Manual PAGE iv GK® 11"-5000 PSI Annular Blowout Preventer Preface This manual contains the information necessary to operate and maintain the Hydril® GK® 11"-5000 PSI Annular Blowout Preventer (ABOP). Hydril recommends that the information in this manual be studied thoroughly before any attempt is made to operate or perform maintenance or repair operations on this equipment and that all safety precautions be followed. Generic in construction, this manual is applicable for the operation and maintenance of all GK 11"-5000 ABOPs manufactured by Hydril. The illustrations of assemblies and operation and maintenance procedures in this manual are typical and represent most configurations. Variations in configuration are noted in the procedures where applicable. In addition, illustrated parts lists are provided for component replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . Annular BOP Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4. . . . . . . . . . . . . . . . . . . . . . . . . .2 4. . . .2 Weights and Dimensions . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-3 4-4 4-5 4-6 4-7 SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API Ring Joint Flange Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Packing Unit Selection . . . . . . . . . . . . . .Screwed Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . .2 Operating Data . . . . . . . . . . . . . . .5 Surface Operation and Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. . . . . . . . . . . . . . . . . . . . . . . . . . . . B. . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Surface Stripping Operations . . . . . . . . . . . . . . . . . . . . . . . .2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Troubleshooting . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .2 Seals . . . . . . . . . . . . . . . . . . . . . .1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . .0 – PACKING UNITS AND SEALS 3. . . . . . . . . . . . . . .0 – PHYSICAL DATA 2. . . . 3. . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . .4 4. . . . . . 2-1 2-1 2-1 2-2 2-3 2-4 2-5 SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . .3 Wear Bands . Assembly . . . . . . . . . . . . . . . . . . . . . . . 3. . . . .GK® With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 5. . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOP Modifications . . 1. . . . . . . . . . . . . . . . . . . Seal Testing . . . . . . .1. . . . . . . 1. . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . .0 – MAINTENANCE AND TESTING 4. .3 Packing Unit Replacement-Latch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . .3 Annular BOP Removal and Installation Procedures . . . . .GK® Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screwed Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Operation . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . Opening the Annular BOP . . . . . . . . . . . .2 Packing Unit Replacement-Screwed Head . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . .1 5.Screwed Head Without Wear Bands . . . . . . 5-1 5-3 5-6 5-8 . . . . . . . . . . . . . . . . . . . . A. . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-1 1-1 1-1 1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-6 1-7 SECTION 2. . 1. . . . . . . . . . .3 Operational Characteristics Summary . .1 Installation . . . . . . . .2. .3 5. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2 3-3 3-4 3-5 3-6 SECTION 4. . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Testing . . Annular BOP Removal Procedure . . . . Packing Unit Testing . . . . . . . . . . . .0 – INSTALLATION AND OPERATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 4. . . . . . . . . . . . . . . . . . iv vii OPERATOR QUICK REFERENCE . . . . . . . . Maintenance Schedule . . . . 1. . . . .6 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screwed Head Without Wear Bands . . . . . . . . . . . . . .R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE v CONTENTS PAGE Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Packing Units . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closing the Annular BOP . . . . . . . . . . . .Screwed Head . . . . . . . . . . . . . . . . . . . . . . . . .0 – DISASSEMBLY AND ASSEMBLY 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2. . .4 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . .1 Operating Procedures . . . . . . . . . . . . . . . .7 Engineering Data . . . . . . .3 2. . . . Clamp Hub Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2. . Bolt and Wrench Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. . . . . . . . . . . . . . . . . .Latch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . .8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 6. . . . . . . . . . . . . . 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 . . . Parts List . . . . . . . . . . . . . . . Parts List . . . .Latched Head With Wear Band Modification . . . . . . .Screwed Head With Wear Band Modification . . . . . . . . . . . . . . . . . . . .Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . .5B 6. 5-11 5-13 5-16 5-18 SECTION 6. . . . . . . . . .R Operator's Manual PAGE vi GK® 11"-5000 PSI Annular Blowout Preventer CONTENTS (CONTINUED) SECTION 5. . . . . . . . . . . . . . . . .0 – PARTS AND STORAGE 6. . . . . . . . . . . Preventor Storage .Screwed Head Wear Band Modification Kit . . . . . . .Screwed Head With Wear Bands At Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . .0 – DISSASSEMBLY AND ASSEMBLY (CONTINUED) 5. . . . . . . . . . .8 Parts List . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . .Latched Head With Wear Bands .4 6. . . . . . . . . . . . . . . . . . . .Latched Head With Wear Bands At Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 6. . . . . . .Latched Head Wear Band Modification Kit . . . . . . . . . . . . . . . . . . . . . .5A 6. . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . .1 6. . . . . . . . . . . . . . . . . . .7 5. . . . . . . . . . . . . . .6 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List .Latched Head With Wear Bands .Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2B 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . Disassembly . . . . . . . . . . . . . .2A 6. . Assembly . . . .Screwed Head Without Wear Bands . . . . . . .6 5. . . . . . . . . . . . . . . Rubber Goods Storage . .5 5. . . . . . . See Section 1 for control pressure graph. Well pressure will maintain closure after exceeding the required level.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer OPERATOR QUICK REFERENCE 1-vii PAGE vii Figure 1 Standard Hookup Closing Pressure Opening Pressure Control Pressures ▲ Surface Control Pressure —psi Initial* Closure 900 800 825 450 350 WELL PRESSURE—psi 500 825 725 450 375 275 1500 650 550 275 225 125 2500 475 375 100 100 50 3500 300 200 50 50 50 5000 50 50 50 50 50 Pipe Size 2 3/8” 2 7/8" 3 1/2" 4 1/2"-5 " 5 1/2"-8 5/8" Close cautiously to prevent collapse of casing. Optimum stripping is obtained by adjusting the control pressure to achieve a slight drilling fluid leakage as the tool joint passes through the packing unit. CSO 1150 1150 1150 1150 1150 1150 ▲ *Use closing pressure shown at initial closure to establish seal off and reduce closing pressure proportionally as well pressure is increased. Closing pressures are average and will vary slightly with each packing unit. The GK® blowout preventer is designed to be well pressure assisted in maintaining packing unit seal off once initial seal off has been effected. it is recommended that closing pressure be proportionally reduced as well pressure is increased in order to maintain the optimum closing OPERATIONAL DATA 3 force on the packing unit. Optimum closing forces for high well pressures may require careful application of pressure to the opening chamber.4 mm 37. 7 1/8 in. Once initial seal off is achieved.* The maximum and minimum distances from the top of the head to the top of the piston are stamped on the BOP head and are also listed in the table below. As well pressure exceeds the required level the packing unit is maintained closed on the recommended size test pipe by well pressure alone. 279.08 gal. the closing force on the packing unit also increases. Minimum packing unit stress is achieved by use of the minimum closing chamber pressure that will initiate and maintain seal off on the recommended size test pipe.9 mm 181 mm TAPE MEASURE 2 5/16" ROD 1 Distance From Top of Head To Top of Piston Maximum — Piston Full Down Minimum — Piston at Full Stroke 11 1/8 in.6 liters 88. Begin the test with the recommended initial closing pressure.) 3 1/2 in. Reliable seal off tests are made by initially closing the packing unit with prescribed closing chamber pressure on the recommended size test pipe. Closing pressure required to effect initial seal off may vary slightly between individual packing units. Bore Closing Chamber Volume Opening Chamber Volume Recommended Test Pipe Size Full Piston Stroke 11 in. A valid test on any annular BOP is only achieved when the remaining piston stroke is measured at test seal off. 4 in. Compare with previous results and with maximum piston stroke for the BOP to ensure subsequent seal offs. (U. Optimum packing unit life is obtained by testing at low rubber stress levels.81 gal.R PAGE viii Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer 1-viii ANNULAR BOP TESTING AND OPERATION Proper Procedure for pressure testing any annular blowout preventer (BOP) ensures subsequent seal off and maximum packing unit life. Piston stroke remaining at seal off is a direct indicator of remaining packing unit life. “Maintenance and Testing” for information on modification. and by determining the remaining piston travel after seal off is achieved. Initial seal off is effected by applying pressure to the closing chamber. As well pressure or test pressure is increased.S.1 liters 30. 283 mm 102 mm Figure 2 Piston Stroke Measurement . 9. See Section 4. *Older model BOPs may not have vertical passage in head. proportionally reducing closing pressure as well pressure is increased. Record the piston stroke and the closing pressure at seal off for each test.S.) 8. (U. Piston Stroke can be measured on GK® blowout preventers through a vertical passage in the top of the BOP head. 3. leaving only a film of oil on the surface. Inspect the ring groove in the mating flange. "Physical Data" for estimated weight. WARNING: DO NOT USE THE FOUR LIFT EYES MOUNTED ON THE ANNULAR BOP BODY TO LIFT THE BOP STACK ASSEMBLY. CAUTION: Ensure that the lifting apparatus is adequate to safely support the weight of the annular BOP assembly. CAUTION: Ensure that the lifting apparatus is adequate to safely support the weight of the annular BOP assembly. 1. 46" or Exxon "Coray 100") c. . Apply lightweight oil to the ring groove and wipe it clean. 240-grit or finer 2. Disconnect bottom connection and lift the annular BOP free. The procedures below are intended for those circumstances where the annular BOP would require removal from the BOP stack for inspection of the bottom connection or for other reasons and subsequently would require installation again. refer to Section 2. Lift and position the annular BOP over the mating connection. Attach lifting apparatus to the four padeyes/anchor shackles on the annular BOP (refer to Figure 1-1 for sling arrangement). 7. 8. the annular BOP does not require removal from the BOP stack and subsequent installation for field repair. Inspect the ring groove in the connection of the annular BOP. Normally. NOTE: Refer to Section 2. refer to “Surface Operation and Hookup” and “Surface Stripping Operations” in this section for information on connection of hydraulic operating lines to the blowout preventer. The GK 11"-5000 PSI Annular BOP is usually installed at the top of a BOP stack. 9. 4.1. Connect the Open and Close hydraulic lines to the annular BOP. Annular BOP Installation Procedure 1. b.0 INSTALLATION AND OPERATION 1. Emery cloth. Disassemble the BOP stack to the point where the annular BOP can be removed. Gather the following tools and materials: a. 10. Lifting apparatus for lifting the annular BOP assembly.1 Installation 1. Lower the annular BOP onto the mating connection. THESE LIFT EYES ARE FOR LIFTING THE GK 11"-5000 PSI ANNULAR BOP ASSEMBLY ONLY. Remove minor damage by polishing the groove with 240-grit or finer emery cloth. Disconnect all hydraulic lines. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS." 1. "Physical Data" for estimated weight. 4. Remove the lifting apparatus. leaving only a film of oil on the surface. 2. Apply lightweight oil to a new API ring gasket and wipe it clean. Apply light machine oil to the ring groove and wipe it clean.1. Annular BOP Removal Procedure 1. Make up the bottom connection. Remove minor damage by polishing the groove with 240-grit or finer emery cloth. 5. One new API ring gasket for bottom connection d.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 1-1 1.2 Weight and Dimensions For dimensions and weight. 6. Gather a lifting apparatus for lifting the annular BOP assembly. Attach the lifting apparatus to the four padeyes/anchor shackles on the body of the annular BOP (Refer to Figure 1-1 for sling arrangement). Lightweight oil (Gulf "Harmony No.1 Safety Precautions WARNING: THIS IS VERY HEAVY EQUIPMENT."Physical Data. B. Install the new ring gasket into the ring groove of the mating flange. 5. aligning the hydraulic connection ports with the hydraulic lines and taking care not to damage the ring gasket. 3. leaving only a film of oil on the surface. NOTE: Refer to Section 2.1. A.3 Annular BOP Removal and Installation Procedures NOTE: For initial installation. R Operator's Manual PAGE 1-2 GK® 11"-5000 PSI Annular Blowout Preventer Figure 1-1 Sling Arrangement for Lifting BOP . To open the annular BOP. 1.2. vent operating pressure from the Close chamber. contact Hydril.2 Operating Data Refer to Section 2.3 Operational Characteristics Summary The GK sucessfully passed the fatigue and stripping life tests. Refer to “Surface Operation and Hookup” in this section.2. . 2.1 Operating Procedures 2.2 Operation 1.2. vent operating pressure from the Open chamber. Head Wear Plate Packing Unit Clamping Screw Radial Latch Opening Chamber Piston Closing Chamber Inner Sleeve Body Figure 1-2 Cutaway view of GK® with packing unit fully open." 1. Apply closing pressure to the Close chamber. Opening the Annular BOP 1. Refer to “Surface Operation and Hookup” in this section. B. Closing the Annular BOP 1. A.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 1-3 1. "Physical Data. To close the annular BOP. Apply opening pressure to the Open chamber. For sealing characteristics test data. The optimum closing pressure is the minimum pressure that will maintain a complete seal under existing operational conditions. 53* (available from the American Petroleum Institute.P.hydril. casing. Northwest. If certification is desired.com for the nearest ARF. or wireline in the wellbore or completely seal off the open hole to full rated working pressure. NOTE: Some GK® assemblies manufactured before 1980 are not be certified to NACE.R Operator's Manual PAGE 1-4 GK® 11"-5000 PSI Annular Blowout Preventer 1. Use of these types of operating fluids will cause serious damage to seals. (CAUTION: Do not use synthetic fluids or fuel oils. . This blowout preventer has been developed primarily for use on surface installations. In addition. tool joints. tubing. Seal off is effected by raising the piston which causes the packing unit to be squeezed inward to a sealing engagement with anything in the bore or with itself on open hole (refer to Figures 1-3 through 1-7). the GK® meets the requirements of API Recommended Practices – R. DC 20005) as well as NACE 10-75-43. contact Hydril or visit Hydril Website www. refer also to Hydril Engineering Bulletin EB 99009 on the Hydril Website www. 1220 L Street. Any clean. The piston is raised by applying hydraulic pressure to the closing chamber. light petroleum hydraulic oil will serve as a hydraulic operating fluid. Figure 1-3 Upward force exerted by the piston squeezes packing unit rubber inward into a sealing engagement. drill pipe can be rotated and tool joints stripped through a closed packing unit while maintaining a full seal on the pipe.2. It will close and seal off on drill pipe.) For additional discussion and specific hydraulic fluid recommendations. Washington.4 Principle of Operation The Hydril® GK 11"-5000 PSI annular BOP (Figure 1-2) is an annular blowout preventer as defined by API Specification 16A. Production Department. Any normal closing unit having a separate regulator valve for the annular blowout preventer and sufficient accumulator volume can be used to operate the GK 11"-5000 PSI annular blowout preventer. During well control operations. Fresh water may be used in a 50/50 water and ethylene glycol mixture with a corrosion inhibitor added.com.hydril. Certification of these units must be performed at a Hydril Authorized Repair Facility (ARF). Figure 1-6 Cutaway view of GK® BOP with packing unit closed on square kelly. tubing. or wireline to rated pressure. drill pipe. The packing unit seals off on tool joints. Figure 1-5 Cutaway view of GK® BOP with packing unit closed on drill pipe. The packing unit seals off on square or hexagonal kellys to rated pressure. The Hydril® GK® opens to full bore to allow passage of large-diameter tools through open bore as well as maximum annulus flow of drilling fluids. . Complete closure of packing unit safely holds well pressure.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 1-5 Figure 1-4 Cutaway view of GK® BOP with packing unit fully open. Figure 1-7 Cutaway view of GK® BOP with packing unit closed on open hole. Packing unit always returns to the open position due to normal resiliency of rubber packing unit. without leakage. casing. Retention of opening chamber pressure will provide positive control of piston and reduce wear caused by vibration. equal to the rated working pressure of the preventer. The Control Pressure Graph. the preventer is maintained closed by well pressure alone. During normal drilling operations. 500 2 7/ 8" P IPE 23 /8" PIP E 4 1/ 2" th ru 5 " 5/8" PIPE **5 1 /2" th ru 8 PIP E 3 1/ 2" P IPE 0 0 1000 2000 3000 4000 5000 Figure 1-9 Average Control Pressure .2. shows the relationship of closing pressure and well pressure required to effect optimum seal off for the GK® 11”-5000 PSI BOP. Use closing pressure shown at initial closure to establish seal off and reduce closing pressure proportionally as well pressure is increased. closing pressure should be proportionally reduced as well pressure is increased.GK 11"-5000 PSI WELL PRESSURE-PSI . During BOP testing operations. Well pressure will maintain closure after exceeding the required level.R Operator's Manual PAGE 1-6 GK® 11"-5000 PSI Annular Blowout Preventer 1. As well pressure further increases. Figure 1-9. This 1500 Closing Pressure Opening Pressure Figure 1-8 Standard Hookup pressure will ensure that initial seal off is achieved should a “kick” be encountered. once initial seal off is achieved. **Close cautiously to prevent collapse of casing. Closing pressure should be proportionally reduced as well pressure is increased in order to maintain optimum closing force on the packing unit and prolong packing unit life. the closing force on the packing unit also increases. it is recommended that the pressure regulator valve for the GK® be set at the initial closing pressure shown for the size pipe being used. ▲ CLOSING PRESSURE-PSI CSO 1000 *Closing pressures are average and will vary slightly with each packing unit.5 Surface Operation and Hookup The surface hookup of the GK® shown in Figure 1-8 connects the hydraulic control lines to the opening and closing chambers of the BOP Pressure applied to the closing chamber raises the piston and effects the initial seal between the packing unit and drill pipe. As the well pressure or test pressure exceeds the required level. Well pressure or test pressure also acts on the piston below the sealed-off packing unit and further increases the closing force acting on the packing unit. Operating pressure may vary at temperatures other than 70oF. When rotating in a closed packing unit. If the pressure regulator valve does not respond fast enough for effective BOP control. Precharge the accumulator to one-half of the closing pressure required to effect a seal off at the existing well pressure for the pipe size in use.50 x 450 psi Precharge = 225 psi Figure 1-11 . 3 1/2" drill pipe Precharge = 0.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 1-7 1. Slow tool joint stripping speeds reduce surge pressures. The pressure regulator valve should be set to provide and maintain the proper control pressure. Surface Hookup Closing Pressure Closing Pressure Opening Pressure Opening Pressure Figure 1-10 Example Precharge Calculation: 500 psi well pressure.2. and thus prolong packing unit life. Longest life for the packing unit is obtained by adjusting the closing forces low enough to maintain a seal on the drill pipe with a slight amount of drilling fluid leakage as the tool joint passes through the packing unit. it is recommended that the pipe be reciprocated (moved up and down) to minimize heat build up between the drill pipe and the packing unit.50 (Closing Pressure). a surge absorber (accumulator) shown in Figure 1-11 should be installed in the closing chamber control line adjacent to the blowout preventer. This drilling fluid leakage indicates optimum seal off for minimum packing unit wear and provides lubrication for the drill pipe motion through the packing unit.6 Surface Stripping Operations Drill pipe can be rotated and and tool joints stripped through a closed GK® packing unit (Figure1-10) while maintaining a full seal off on the pipe. From Figure 1-8: Closing Pressure = 450 psi Precharge = 0. R Operator's Manual PAGE 1-8 GK® 11"-5000 PSI Annular Blowout Preventer . . . . . . .4 mm 351. .. . .065 Coefficient of Friction) or Equivalent Nonpetroleum Base Oil Corrosion Inhibitor Grease Vapor Phase Corrosion Inhibitor Castor Oil Cortec VCI 369 Cortec VCI 609 . . . . . . . .0 PHYSICAL DATA 2. . . . 46" or Exxon "Coray 100" or Equivalent Neverseez (0. . . . . . Piston x 10" Lg. . . . . . . . . . . . . . . 5000 PSI Volume—Closing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protector Plate Screw 1/2" NPT 1/2"-13UNC 1"-8UNC 1/2-13UNC 5/8"-11UNC 1 1/4"-7NC 1/2"-13UNC LATCHED HEAD ONLY 22 23 Jaw Clamping Screw Spacer Sleeve Screw 2 1/4"-8UN 5/8"-18 UNF 2 1/2" Hex 3/4" Hex Key 350-475 150 475-644 203 2. . . . . . . . . . . . . . 3/4" Hex Recommended Torque Lb/Ft N•m 50 55-75 100 70 Snug Snug Snug 69 75-102 136 95 Snug Snug Snug Pipe Plug—Piston Indicator Inner Sleeve Screw Head Lock Screw Wear Plate Cap Screw Eyebolt. . . . . Eyebolt. . . . . . . . . . No. . . . . . . . .3 Lubricant List Type Lightweight Oil Thread Lubricant Source Gulf "Harmony No. . .5 5 kg/cm2 351.. . .81 gallons Volume—Opening Chamber . . . . . . . . . . . .1 Engineering Data English Bore . . . . . . .000 PSI Closing Chamber Test Pressure (Factory Test Only) . . . .. . . . .2 Bolt and Wrench Data Ref. . . . . . . . .. . . . . . . . . .1 kg/cm2 351. . . . 17 18 19 30 . . . . . . 9. . . . . . . . . . 8. .069 Coefficient of Friction) or Equivalent Moly Paste 503 (0. . . . . . . . . . 11 inches Working Pressure . . . . . . . . . . . 5000 PSI Opening Chamber Test Pressure (Factory Test Only) . . . .. . 1” NPT* Weight-Single (Approximate—varies with connectors) . . . . . . . . . . . . . . . . .. . . . . . . Socket . . . . .. . . . . . . . 8. . . . . . . . . . . . . . . .55 kg/cm2 37. . Description Thread Wrench Size 3/8" Hex Key 3/4" Hex 1 1/4" Hex 1/2" -12pt. . . . 10. . . . . . . . . . . . . . . . . . .200 lb * 1 1/4" or 1 1/2" NPT available on request Metric 279. .. . . . . . . . . . . . . . .. . . .. . . . . . Head x 1 3/4" Lg. . . . . . . . .08 gallons Piston Stroke . . . 7 1/8 inches Port Size .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720 kg 2. . . . . . . . . . . . . . . . . . . . . .6 liters 181 mm — 3. .R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 2-1 2. . . . . . . .1 liters 30. . . .55 kg/cm2 703. . . . . . . . . . . . 5000 PSI Shell Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . . . R Operator's Manual PAGE 2-2 GK® 11"-5000 PSI Annular Blowout Preventer 2.75 G 11.69 O 36..25 ▲5M 44.4 Dimensions . Nominal Dimensions — Inches A ▲5M 47.50 B ▲10M ..Screwed Head H AS CAST J K E F *OPENING PORT D AS CAST B CLAMP HUB C STUDDED A AS CAST G *CLOSING PORT M AS CAST N AS CAST O AS CAST Figure 2-1 Outside DimensionsScrewed Head * 1" NPT.00 19. C ▲10M 40. K 35.88 J 37.00 5..75 13 3/16 D E F ▲ Lower Connector Pressure Rating . NOTE: Lifting lugs split lower connection stud holes and are equally spaced 90o apart.75 ▲5M 39. Lifting lugs are 1-1/4" thick with 1-1/2" diameter holes..81 ▲10M 48.50 H 44. 45o from lifting lug unless otherwise specified.63 L . 1 set of ports.25 M 2.06 N 32. 25 ▲5M 45.25 B ▲10M . 1 set of ports.Latched Head H AS CAST J K E F *OPENING PORT D AS CAST C STUDDED *CLOSING PORT R L AS CAST M AS CAST N AS CAST *1” NPT.19 D E F ▲ Lower Connector Pressure Rating On BOPs built after serial number 69730: D= 27..00 19.75” diameter holes.06 L 2..00 H 44. Figure 2-2 Outside Dimensions Latched Head Nominal Dimensions — Inches A ▲5M 48.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 2-3 2.75 4.25 G 11.25 ▲10M 49.5 Dimensions .69 M 32. NOTE: Lifting lugs are equally spaced 90o apart.00 C ▲10M 40.50 A FLANGED g B CLAMP HUB . 18” from lifting lug. K 36.00 14.88 N 36.38 ▲5M 40.31 J 42.12” thick with 1. Lugs are 2. . Lengths shown herein are overall lengths. . . Bolt material shall be of a quality and strength not less than specified by ASTM A-193. . . . . . Over 1 1/8 to 1 5/8 . . . . Using Stud Bolts. . . .R Operator's Manual PAGE 2-4 GK® 11"-5000 PSI Annular Blowout Preventer 2.000 O. . . Inches Max. . . Over 7/8 to 1 1/8 . . . . . . (Inches) 19 22 1/4 12 16 1 7/8 1 3/4 14 1/2 15 3/4 POINT HEIGHT OF STUD BOLTS Bolt Diameter. . b † . including point at both ends. Using Studs.6 API Ring Joint Flange Connections C C B A Bolted Flange. . . . in case of 6B grooves. . . . . or pitch dim. . . . . . (Inches) 11 11 Max. . . C (Inches) API Ring 23 25 3/4 BOLTS & STUDSa 4 11/16 5 9/16 12 3/4 14. . . . . . Dimensions shown are outside diameters of 6BX flange grooves. . . . Nuts shall be of a quality not less than ASTM A-194. Figure 2-3 Bolted and Studded Flange Specifications Studded Flange. . . . . . . . (Inches) Thickness (Inches) SEAL RING † Dia. . . . . . .D. . Grade B7. . Grade 2H. as shown in table. Stud bolts are threaded full length. . Over 1 5/8 to 1 7/8 . Size Lengthb (Inches) Stud Bolts A Studs B 10 1/4 10 1/4 Bolt Circle Dia. . . . . . . Req. Over 1 7/8 to 2 1/2 .064 RX-54 BX-158 No. API Service Pressure Rating (PSI) 5000 10. . . . FLANGE Nominal Size (Inches) 11 11 Bore Dia. . . . Point Height Inches 1/8 3/16 1/4 5/16 3/8 a 1/2 to 7/8 . . ....7 Clamp Hub Connections J A G C A G B E F B E F H H Figure 2-4 Hub Connection Specifications HUB Hub Size (Inches) 11 11 Bore Size A (Inches) 11 11 Rated Working Pressure (PSI) 5000 10.. Hub Dimensions (Inches) RX Only Standoff D C 3 3/4 .R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 2-5 2. ▲ Clamp dimensions may vary from those shown.. 3 5/8 NOTE: API 16A 1st Edition Nov 1. .. Clamp Dimensions (Inches) ▲ E 20 13/16 20 13/16 F 28 1/2 28 1/2 G 6 3/4 6 3/4 H . 1986 Does Not Include Clamps... 158 B 16 1/4 16 1/4 J .. .000 Seal Ring No. 15/32 .... BX . RX 53 .. R Operator's Manual PAGE 2-6 GK® 11"-5000 PSI Annular Blowout Preventer . The unit is manufactured by Hydril from high quality rubber.0 PACKING UNITS AND SEALS 3. Since the rubber is confined and kept under compression. The design of the Hydril® GK® blowout preventer causes closure wear to occur on the outside of the packing unit while stripping wear occurs on the inside. The molded-in steel segments have flanges at the top and bottom These segments anchor the packing unit within the blowout preventer and control rubber extrusion and flow when sealing off well pressures. Each unit has a large volume of tough. Figure 3-1 Cutaway drawing showing how rubber is molded around steel segments. . feedable rubber to meet any requirement.1 Packing Units The heart of the GK® blowout preventer is the packing unit.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 3-1 3. Because the packing unit uses the principle of feeding rubber from the back of the packing unit to the bore. reinforced with flanged steel segments. All annular blowout preventer packing units are subjected to wear during closure and stripping. stripping life may be affected by a packing unit that is worn on the backside. it is resistant to tears and abrasion. Performance of elastomeric materials can vary significantly. This all-black packing unit is identified by a serial number with the suffix "R" or "NR. only genuine Hydril® packing units should be used as replacements for original equipment. Expected H2S Service does not affect selection of packing unit material. When properly operated. Natural Rubber is compounded for drilling with waterbase drilling fluids. Storage Conditions such as light. as covered in Section 6. Packing units for Hydril® blowout preventers are manufactured from compounded natural rubber or nitrile rubber. H2S service will reduce the service life of rubber products. All Hydril® packing units are tested to full rated pressure inside a test blowout preventer as part of standard performance tests before being furnished to the consumer. depending on the nature and extent of exposure to hydrogen sulfide. heat or adverse conditions are significant factors in the storage life of packing units." Seals for Hydril® blowout preventers are manufactured from a special nitrile rubber material which provides dependable service in sealing against oil gas. but the longest service life is obtained by matching the packing unit material with the requirements of the specific drilling fluid. when operated at temperao o tures below 20 F (–7 C). The nitrile rubber packing unit is identified by a red colored band and a serial number with the suffix "S" or "NBR.1 Packing Unit Selection Because of the importance of the packing unit to the operation of the blowout preventer and to the safety of the crew and rig.R Operator's Manual PAGE 3-2 GK® 11"-5000 PSI Annular Blowout Preventer 3." Nitrile Rubber (a synthetic compound) is for use with oilbase or oil-additive drilling fluids.3 and should be avoided.1. the compounded natural rubber packing unit will usually provide the longest service life. The operator should monitor pressure sealing integrity by frequently performing a packing unit seal test on the pipe diameter currently in use to assure no performance degradation has occurred. No Band Figure 3-2 Natural Rubber Packing Unit – No Band Red Band Figure 3-3 Synthetic Rubber Packing Unit – Red Band . or water. Natural rubber can be used at operating o o temperatures down to –30 F (–35 C). It provides reliable service with oil-base muds. R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 3-3 3.1.2 Packing Unit Replacement– Screwed Head To replace the packing unit, use the following procedure: NOTE: The procedure that follows is the short version of more detailed procedure in Section 6. 1. Remove head lock screw. 2. Install eyebolts and unscrew blowout preventer head counter-clockwise (Figure 3-4). 3. Lift off blowout preventer head (Figure 3-5). 4. Lift out packing unit (Figure 3-6). 5. Lubricate piston bowl with castor oil. 6. Install new packing unit, lubricated with castor oil. 7. Clean and lubricate head and body threads with Neverseez lubricant. 8. Replace head and tighten to align hole for lock screw. 9. Install head lock screw and torque to 100 lb-ft. NOTE: If the head was improperly installed at last reassembly, it may be necessary to apply considerably more torque on the head by the use of a catline or winch while alternately applying and releasing pressure to the opening chamber (1500 psi maximum). CAUTION: Do not attempt to loosen the head by applying heat. Refer to Section 5, “Disassembly and Assembly” for further information. OPENING TORQUE Figure 3-4 Figure 3-5 Figure 3-6 R Operator's Manual PAGE 3-4 GK® 11"-5000 PSI Annular Blowout Preventer 3.1.3 Packing Unit Replacement – Latched Head The latched head design of the GK® blowout preventer allows for easy replacement of the packing unit and eliminates loose parts that can be lost downhole or overboard. To replace the packing unit, use the following procedure: NOTE: The procedure that follows is the short version of more detailed procedurew in Section 6. 1. Retract jaw clamping screws four turns to release the jaws from the head (see Figures 3-8 and 3-9). 2. Remove head clamps and screws from top of head. 3. Lift off preventer head (see Figures 3-5 and 3-10). 4. Lift out the packing unit (see Figure 3-6) and lubricate the piston bowl with castor oil. 5. Install the new packing unit (see Figure 3-6), lubricated with castor oil. 6. Install the head (see Figure 3-11). HEAD 7. Tighten jaw clamping screws four turns and torque to 350 - 475 lb-ft (475-644 N•m). See Figure 3-7. Figure 3-9 Head in place but jaw and jaw clamping screws have been retracted (four turns). Head Clamp Screw Head Clamp Clamping Screw Pipe Plug SleeveScrew Spacer Sleeve Jaw Head Figure 3-10 Head removed, but all latching mechanisms remain in body. Standoff Figure 3-7 Head latched in place and jaw clamping screws tightened. Figure 3-11 Figure 3-8 Retract jaw clamping screws (4-turns counterclockwise). On assembly, if standoff between head and body occurs, use head clamps to pull head fully into place and eliminate standoff. R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 3-5 3.2 Seals The seals for Hydril® blowout preventers are manufactured from a special synthetic rubber material for long troublefree sealing service. The hydraulic operating fluid may be clean, light petroleum hydraulic oil, or water with soluble oil added. In cold climates, antifreeze should be added to prevent freezing (CAUTION: To prevent seal damage, Do Not use synthetic fluids in the hydraulic operating system). For additional discussion and specific hydraulic DYNAMIC SEALS DOUBLE U-SEAL cross-section with nonextrusion rings fluid recommendations, refer also to Hydril Engineering Bulletin EB 99009 on the Hydril Website www.hydril.com. The dynamic seals are all molded, lip-type, pressureenergized rings. The static seals are of O-ring and square ring configuration. For seal replacement procedure, see Section 5, “Diassembly and Assembly.” For seal maintenance and testing, refer to Section 4. STATIC SEALS U-SEAL cross-section O-RING cross-section SQUARE RING cross-section Figure 3-12 seal life is increased and wear to the sealing surfaces on the piston and body is reduced significantly. Contact Hydril or refer to Hydril Website www. Models not equipped with wear bands can be modified at a Hydril Authorized Repair Facility (ARF). hydril.com for the nearest ARF. the rubber wiper ring prevents drilling mud and debris from entering the space between the upper piston and the head and possibly damaging the wear bands. Refer also to Section 4.R Operator's Manual PAGE 3-6 GK® 11"-5000 PSI Annular Blowout Preventer 3. Installed on models with wear bands. As a result.7 for additional modifications available. wear bands improve the performance of the GK® BOP by protecting sealing surfaces on the piston and body from metal to metal contact.3 Wear Bands Manufactured from tough durable thermoplastic and installed on new and modified models. Wiper Ring Head Wear Band Head to Piston Seal Piston Sealing Surface Body Sealing Surfaces Wear Band Lower Piston Seal Figure 3-13 . T = Pressure Test: P = Inspect Precharge Item Equipment/Component Service Interval & Maintenance Operations As Required 1 2 3 4 a b c Refa Yearly Between Wellsc I 4. R = Replace. MODIFICATIONS. If the packing unit fails to close and seal. OR PRIOR TO POST REPAIR START UPS.0 GK Annular BOP Packing Unit Seals Wear Bands T T Rb Rb Rb I I I Paragraph where maintenance procedure is located.0 5. TABLE 4-1 MAINTENANCE SCHEDULE Maintenance Operations I = Inspect.0.3. WARNING: BEFORE THE INITIAL START UP. UNAUTHORIZED ALTERATIONS. VERIFY CONTAMINANTS. but it will also help to eliminate unnecessary down time.0 4.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 4-1 4. REPAIRS OR USE OF PARTS OTHER THAN THOSE SUPPLIED BY HYDRIL WILL VOID THE STANDARD WARRANTY OF THE BOP AS OUTLINED IN THE TERMS AND CONDITIONS AGREEMENT. it may not be possible to inspect the BOP between wells. AND OTHER FOREIGN MATERIALS HAVE BEEN FLUSHED FROM THE FLUID SUPPLY LINES.5. OR REPAIRS PERFORMED OTHERWISE MAY RESULT IN DAMAGE TO THE BOP OR FAILURE OF THE BOP TO OPERATE AS DESIGNED AND MAY RESULT IN SERIOUS PROPERTY DAMAGE. PERSONAL INJURY OR DEATH. DEBRIS. Depending on the drilling program.2 Maintenance Schedule Periodic maintenance is a very important part of keeping the Hydril® GK 11"-5000 PSI Annular BOP in good operating condition. Hydril only provides recommendations for inspections and maintenance. This section contains a maintenance schedule (Table 4-1) that is designed to help maintain the annular BOP by displaying in tabular form the recommended service interval for each required maintenance operation. Not to exceed 24 calendar months.1 Troubleshooting Troubleshooting the annular BOP is provided in the form of a fault analysis tree.0 MAINTENANCE AND TESTING WARNING: HYDRIL IS NOT RESPONSIBLE FOR ANY ALTERATIONS. refer to Figure 4-1. . 4. MODIFICATIONS. UNLESS PERFORMED WITH HYDRIL SUPPLIED PARTS AND THE WORK PERFORMED BY A HYDRIL AUTHORIZED REPRESENTATIVE. Not only will regular maintenance extend the service life of the equipment. PERSONAL INJURY OR DEATH. ITS INTERCONNECTS AND COMPONENTS. 4. MODIFICATIONS OR REPAIRS TO THE BLOWOUT PREVENTER (BOP). FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE BOP OR FAILURE OF THE BOP TO OPERATE AS DESIGNED AND MAY RESULT IN SERIOUS PROPERTY DAMAGE. ALTERATIONS.0.3 4. Latched Head PISTON STROKE LATCH FAILURE CLAMPING SCREW FAILURE Check piston stroke. Refer to operations and maintenance manual.Packing Unit Fails to Close and Seal . Inspect wear plate and replace as necessary. Latched Head & Screwed Head GALLED WEAR PLATE BENT PACKING UNIT INSERTS Inspect packing unit and replace if necessary. Inspect latch and make repairs. Inspect latch and make repairs. Inspect wear plate and make repairs.R Operator's Manual PAGE 4-2 GK® 11"-5000 PSI Annular Blowout Preventer PACKING UNIT FAILS TO CLOSE & SEAL PACKING UNIT FAILS TO SEAL PACKING UNIT FAILS TO CLOSE PACKING UNIT LEAKAGE WORN WEAR PLATE CONTROL SYSTEM PROBLEMS SEAL LEAKAGE MECHANICAL PART FAILURE Increase closing pressure or replace as necessary. Figure 4-1 GK 11"-5000 Annular BOP Fault Analysis Tree . GALLED PISTON Inspect piston and make repairs. Test seals and replace as necessary. com for the nearest ARF. See Section 3 for packing unit information and this section for packing unit testing. Check slots in sleeve for cuttings which may restrict piston movement. Worn or damaged stud bolt holes can be drilled and tapped to the next larger size and fitted with step-studs. Field welding is not recommended as it. If wear is excessive. 8. Minor pits and scores on the walls can be removed in the field with emery cloth. and abrasion.hydril. stress relieving or NACE certification must be performed at a Hydril Authorized Repair Facility (ARF). especially in ring grooves and stud bolt holes. Welding. Pits and gouges in the tapered bowl should be filled with a permanent type adhesive. Contact Hydril or go to Hydril Website www. especially in the internal cylinder walls for pits and vertical scores. Hydril recommends that all seals and wear bands be replaced after one year service or whenever the BOP is disassembled. and stress relieved (see “NOTE” above). Worn or damaged seals and wear bands should be replaced. cracking. 7. 6. Inspect the vertical bore for excessive wear and damage from drill string and drill tools. Prior to placing the GK® blowout preventer into service. The inner bottom face of the head serves as a wall to prevent upward movement of the packing unit. See Section 4 for pressure testing of seals. 4. cuts. especially the inner and outer walls for pits and vertical scores and the tapered bowl for pits and gouges. especially in the area of the ring grooves. it may not be certified to NACE. Repair of this surface is accomplished by replacing the wear plate. damage. but may be modified. 1 3 6 8 7 8 5 2 8 8 4 3 1 Figure 4-2 . machined. hardness. 2. and damage. Check the body for wear and damage. Repaired surface should be coated with castor oil. machining. Check the wear plate on the inner bottom face of the head for wear. Friction between these metal surfaces is controlled at a level which does not impair lateral movement of the packing unit. scores. and cracks may require machining and/or welding (see “NOTE” above). Some model BOPs have a welded body sleeve and may be modified by conversion to a bolted sleeve.3 Inspection NOTE: The Hydril® GK® blowout preventer is a primary pressure vessel. Severe pits and scores may require machining and/or welding. These forces are generated each time the packing unit is closed. Contact the nearest Hydril ARF (see “NOTE” above) for repair. Contact the nearest Hydril ARF (see “NOTE” above) for modification. In addition to the aging process of time and use. Severe pits. 3. Sharp or rolled edges should be removed with emery cloth or a grinder. fraying of lips. Inspect the packing unit for wear. Repaired surface should be coated with castor oil. the following visual inspections should be performed (step numbers match Figure 4-2): 1. and looseness. 1) induces undesirable stresses which must be relieved by proper heat treating procedure or controlled by special welding procedures and 2) negates certification to NACE . see “NOTE” above. 5. Some models of this BOP do not have the wear plate. Check seals and wear bands (if equipped) for nicks. and correct elastomer composition. wear. Contact the nearest Hydril ARF (see “NOTE” above) for modification. Inspect upper and lower connections for pitting. Check the inner body sleeve for wear. The blowout preventer surfaces exposed to wellbore fluids will meet NACE Standard MR-01-75. Proper handling and repair are required to maintain any original integrity. Check for piston damage and wear.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 4-3 4. Minor pits and scores can be removed in the field with emery cloth. If your assembly was manufactured before 1980. Repair is satisfactory when the surface is relatively smooth. Worn or damaged ring grooves must be welded. such as epoxy. wear of this metal surface is produced by the combination of vertical (upward thrust) and lateral forces. Severe wear is exhibited in the form of grooves or channels shaped by the steel segments of the packing unit. if only the seal in question is to be replaced. it must first be determined which seal is leaking. Drain wellbore fluid. it is recommended that all seals be replaced. a. 9. IF: Fluid is seen coming into the wellbore—seal 8 (lower) is leaking. Test packing unit or return the BOP to service. 10. Test seals 8 (lower). 6 1. 6. b. Gather the following tools and materials: a. 3 1/2-inch test pipe c.4 Seal Testing . RX-54 ring gasket 2. IF: Fluid is seen at closing chamber—seal 9 (upper) is leaking. 3. see procedure in this section. 4. a.R Operator's Manual PAGE 4-4 GK® 11"-5000 PSI Annular Blowout Preventer 4. 9 (upper). Reduce wellbore pressure to zero. Test seals 8 (upper) and 10 (lower). 11”-5000 PSI d. The following procedure is provided: Refer to Figure 4-3 while following this procedure. Open opening chamber to atmosphere. Pressurize opening chamber (1500 PSI). Remove blind flange. WARNING: THE RATED WORKING PRESSURE OF THE GK ANNULAR BOP IS 5000 PSI (345 BAR). 7. and 6. IF: Closing fluid is seen at opening chamber—seal 9 (lower) is leaking. Blind flange. Test seals 9 (lower) and 10 (upper). TAKE EVERY PRECAUTION TO PROTECT PERSONNEL FROM COMING IN CONTACT WITH PRESSURE DURING TESTING OPERATIONS. c. Pressurize closing chamber. IF: Fluid is seen coming from area between body and head—seal 6 is leaking. Install test pipe into test stump. Open closing chamber to atmosphere. Open opening chamber to atmosphere. Install blind flange on top and pressurize wellbore (5000 PSI/345 Bar maximum).GK® Without Wear Bands When it is known or suspected that a seal within the GK blowout preventer is leaking. IF: Closing chamber pressure gauge is dropping and no fluid is seen at opening chamber—seal 10 (upper) is leaking. . Install the annular BOP onto test stump with hydraulic pressure source connected to the Open and Close ports. 8 UPPER 8 LOWER 9 UPPER 9 LOWER 10 UPPER 10 LOWER 5. The test pressure to be used in the closing chamber should be the initial closing pressure required using the recommended test mandrel if a packing unit is installed (1500 PSI/ 104 Bar if no packing unit is installed). b. 5000 PSI (345 Bar) pressure source b. 8. IF: Fluid is seen coming from the opening chamber— seal 8 (upper) is leaking. However. b. USE EXTREME CAUTION WHEN WORKING WITH HIGH PRESSURE. Figure 4-3 IF: Fluid is seen coming from the closing chamber— seal 10 (lower) is leaking. Open closing chamber to atmosphere. a. For packing unit testing. However. Test head to piston seal. or both the head to piston seal and head gasket are leaking. IF: Wellbore fluid coming from the Open port indicates that head to piston seal is leaking. Figure 4-4 6. . 9. For packing unit testing. IF: Closing fluid seen in the wellbore indicates that lower piston seal is leaking. Fill wellbore with tap water. Reduce opening pressure to zero and open the opening and closing chambers to atmosphere. ING WITH HIGH PRESSURE. using rated working pressure: a. 11”-5000 PSI d. Drain wellbore fluid. WARNING: THE RATED WORKING PRESSURE OF THE GK ANNULAR BOP IS 5000 PSI (345 BAR). IF: Closing fluid seen coming from the Open port indicates that middle piston seal (B) is leaking. 7. or the head gasket seal is leaking. Testing of the head O-ring. Apply 1500 PSI (104 Bar) operating pressure to the opening chamber to open the packing unit.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 4-5 4. 3 1/2-inch test pipe c. and wiper seal is not required. Remove blind flange. Open opening chamber to atmosphere. 4. Gather the following tools and materials: a. if only the seal in question is to be replaced. b. Reduce wellbore pressure to zero. Refer to Figure 4-4 while following this procedure. Apply 1500 psi (104 Bar) operating pressure to the closing chamber to close the packing unit around the test pipe. 1. b. Remove test pipe and attach a blind flange to top of annular BOP. b. Install blind flange on top and pressurize wellbore (5000 PSI/345 Bar) maximum.GK® With Wear Bands When it is known or suspected that a seal within the GK Annular BOP is leaking. it is recommended that all seals be replaced. NOTE: The relief valve is a spring check valve which allows venting of pressure which could be trapped in the latching mechanism. 12. 3. d. it must first be determined which seal is leaking. This valve is reusable provided the spring is not frozen or damaged. Reduce closing pressure to zero and open the closing chamber to atmosphere. IF: Wellbore fluid coming from the Close port indicates that lower piston seal is leaking.5 Seal Testing . RX-54 ring gasket 2. USE EXTREME CAUTION WHEN WORK- Head O-Ring Seal Clamping Screw O-Ring Seal Wiper Seal Head Gasket Wear Band Head to Piston Seal Middle A Piston Seals B Wear Band Lower Piston Seal 5. Install test pipe into test stump. Blind flange. see procedure in this section. 5000 PSI (345 Bar) pressure source b. IF: Opening fluid seen in wellbore or coming from relief valve indicates that the head to piston seal is leaking. Test packing unit or return the BOP to service. clamping screw O-ring. IF: Opening fluid coming from the Close port indicates that middle piston seal (A) is leaking. and middle piston seal (A) using opening operating pressure: a. Test middle piston seal (B) and lower piston seal using closing operating pressure: a. Install the annular BOP onto test stump with hydraulic pressure source connected to the Open and Close ports. c. 11. 10. TAKE EVERY PRECAUTION TO PROTECT PERSONNEL FROM COMING IN CONTACT WITH PRESSURE DURING TESTING OPERATIONS. head gasket. Use the following procedure for testing the seals in the GK Annular BOP. Test head to piston seal and lower piston seal . Themodification to add the piston indicator hole must be performed at a Hydril Authorized Repair Facility (ARF). Figure 4-5 Piston Stroke Measurement .6. As well pressure or test pressure increases. Piston stroke remaining at seal off is a direct indicator of remaining packing unit life. closing pressure should be proportionally reduced as well pressure is increased (see the Control Pressure Graph. once initial seal off is achieved. the closing force on the packing unit also increases. Reliable pressure seal off tests are made by closing the packing unit with prescribed closing chamber pressure on recommended size test pipe and by determining the remaining piston travel after seal off is achieved.6 Packing Unit Testing Proper procedure for pressure testing any annular blowout preventer ensures subsequent seal off and maximum packing unit life. 4. Optimum packing unit life is obtained by testing at low rubber stress levels. A valid test on any annular BOP is only achieved when the remaining piston stroke is measured at test seal off. The maximum and minimum distances from the top of the head to the top of the piston are stamped on the BOP head and are also listed in the table below. As well pressure exceeds the required level.1 Packing Unit Testing—Surface The GK® blowout preventer is designed to be well pressure assisted in maintaining packing unit seal off once initial seal off has been effected. Figure 1-9). Compare with previous results and with maximum piston stroke for the BOP to ensure subsequent seal offs. Initial seal off is effected by applying pressure to the closing chamber.hydril. 3 TAPE MEASURE 2 5/16" ROD 1 Distance From Top of Head to Top of Piston Maximum (piston in full down position) Minimum (piston at full stroke) 11-1/8" 4" * Older model BOPs may not have the piston indicator hole as shown in Figure 4-5. the packing unit is maintained closed on pipe by well pressure alone. Minimum packing unit stress is achieved by use of the minimum closing chamber pressure that will initiate and maintain a seal off on the recommended size test pipe. depending on the style packing unit installed. Record the piston stroke and the closing pressure at initial seal off for each test. Contact Hydril or go to Hydril Website www. Begin the test with the recommended initial closing pressure shown in Figure 1-8. See “BOP Modifications” in this section for piston indicator hole modification as well as other modifications available. Piston Stroke can be measured on GK® blowout preventers through a vertical passage* in the top of the BOP head. Closing pressure required to effect initial seal off may vary between packing units. During routine BOP testing.R Operator's Manual PAGE 4-6 GK® 11"-5000 PSI Annular Blowout Preventer 4.com for the nearest ARF. com for the nearest ARF.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 4-7 4. . or wear bands can be modified at a Hydril Authorized Repair Facility (ARF). bolted inner sleeves.hydril.7 BOP Modifications Older model BOPs without piston indicator holes. Contact Hydril or visit Hydril Website www. wear plates. R Operator's Manual PAGE 4-8 GK® 11"-5000 PSI Annular Blowout Preventer . Unscrew the head counterclockwise from the BOP body. Hydril Part No. A vertical lift.). Numbers in figure correspond to items numbers in procedure. 32006 (for lifting head) 3. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. 1. Vent Pressure. Gather Tools and Materials. 1900076-08 (for lifting packing unit). AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. If the head 17 19 1 6 8 29 30 2 1 3 9 10 4 18 5 Figure 5-1: Screwed Head GK® 11"-5000 PSI Without Wear BandsDisassembly . 2.). Hydril Part No. using the chain sling. Hydril Part No. C. Vent the closing and opening chambers to atmosphere. Hydril Part No. may be applied to the eyebolts to take the weight of the head off of the threads while applying torque to the head. This lift will reduce the required turning torque. Chain sling. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. A. 1.0 DISASSEMBLY AND ASSEMBLY 5. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off.) 4. NOTE: Use a piece of strong pipe or rod (3" to 4" in diameter x 10' to 12' long) as a lever against the eyebolts to apply counterclockwise (left hand) torque on the head (refer to Figure 5-2). NOTE: Except for the tools listed below. Three eyebolts (5/8”-11UNC x 10” Lg. Remove Head. Do not use the chain sling to lift the annular BOP assembly.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-1 5. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD.). WARNING: THIS IS VERY HEAVY EQUIPMENT. Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.) into the head (Item 1) 3. 33565-M (CAUTION: The chain sling is for disassembly and assembly purposes only. 1. 2. B. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. Remove head lock screw (Item 19). 30952 (for lifting piston) 2.1 Disassembly .Screwed Head Without Wear Bands Refer to Figure 5-1 while following this procedure. ensuring that no trapped pressure exists which will cause injury to personnel and/or damage the equipment. disassembly of the GK® annular BOP can be performed with standard tools. 3. Remove the capscrews (Item 18) from around the inner sleeve (4).) into packing unit (Item 2). Remove the chain sling. Install two eyebolts (5/8"-11UNC x 1 3/4” Lg. slowly apply low (50 PSI) hydraulic pressure to the closing chamber. Remove Packing Unit. Using the Hydril chain sling. Head Installation Head Removal D. 1. 7. E. 3. 2. Attach the Hydril chain sling and lift the head straight up and off the body. lift the packing unit out of the piston. it may be necessary to apply considerable more torque on the head by the use of a winch or catline while alternately applying and releasing pressure to the opening chamber (1500 PSI/104 Bar maximum). Remove the capscrews (Item 30) and the wear plate (Item 29). Install three eyebolts (5/8”-11UNC x 10” Lg. WARNING: DO NOT USE AIR OR GAS. . Remove chain sling from eyebolts. 1. NOTE: This step is not applicable to model BOPs that have a welded body sleeve which is not removable. Remove Piston. 3. 6. 4. 5. Remove middle U-seals (Items 9) and lower Useals (Items 10). 1. Remove the sling and eyebolts from the piston.R Operator's Manual PAGE 5-2 GK® 11"-5000 PSI Annular Blowout Preventer 4. If a vertical lift is not possible or the piston does not lift out freely. Remove Inner Sleeve. was improperly installed at the last assembly. 2. Remove the head gasket (Item 6) and upper Useals (Items 8). Insert the hooks of the Hydril chain sling (equally spaced) in the slots of the inner sleeve and lift the sleeve out of the annular BOP. Remove sling and eyebolts. gently lift piston out of the preventer body. Using Hydril chain sling. 2. ) into the piston (Item 3). Figure 5-2: Head Removal/Installation F. CAUTION: Do not loosen the head by applying heat to the thread area. NOTE: Some models do not have a wear plate. ).065) or equivalent 7. bolts.).). A. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. Moly Paste 503 thread lubricant (Coefficient of Friction is . Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. seals. 33565-M (CAUTION: The chain sling is for disassembly and assembly purposes only. Hydril Part No. 1. WARNING: THIS IS VERY HEAVY EQUIPMENT. Coat interior surfaces with castor oil except wear band grooves in the head and piston ." B. Three eyebolts (5/8”-11UNC x 10” Lg. Coat packing unit. 3. Gather Tools and Materials. Inspect all seals installed in the head and piston. NOTE: Except for the tools listed below. Spare parts including seal kit. 6. 1. (NOTE: Hydril recommends that all seals be replaced whenever a BOP is disassembled and assembled. "Maintenance and Testing". CAUTION: Use of petroleum base oil or grease will reduce seal life. Refer to Section 6. Hydril Part No. Do not use the chain sling to lift the annular BOP assembly. Neverseez lubricant 8. 32006 (for lifting head) 3.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-3 5.) 5.Screwed Head Without Wear Bands Refer to Figure 5-3 and 5-4 while following this procedure. 7. 1900076-08 (for lifting packing unit) 4. Chain sling. and replace any damaged seals in use over one year. rough edges. 2. Lubricate the threads of nuts. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. Inspect BOP.) Seals must be installed as shown in Figure 5-3 and 5-4.Without Wear BandsAssembly . 17 19 1 6 8 29 30 2 1 3 9 10 4 18 5 Figure 5-3: Screwed Head GK® 11-5000 PSI. 30952 (for lifting piston) 2. Ensure that working surfaces are free of burrs. Castor oil 6. Clean all components thoroughly. Hydril Part No. or other defects. and capscrews with Moly Paste 503 thread lubricant. NOTE: Seal Rings MUST BE installed in position shown by cross-section. Hydril Part No. and Lubricate. assembly of the GK® annular BOP can be performed with standard tools. 5. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. and non-extrusion rings with castor oil before installation. 4. "Parts and Storage.2 Assembly . Perform the inspection procedures that are applicable in Section 4. Lubricate body threads on the head and body with Neverseez lubricant. Numbers in figures correspond to item numbers in procedure. Clean. D. Install the lower U-seals (Item 10). Install the upper U-seals (Item 8) on the inside bottom diameter of the head. Tighten the lock screw using 60 lb-ft (80 N•m) torque. 4. Insert hooks of Hydril chain sling (equally spaced) into slots in inner sleeve (Item 4) and install the sleeve into the bore of the body." . Install Packing Unit. 1. 2. Using Hydril chain sling. just below the major diameter. 6. Attach the Hydril chain sling to the eyebolts and install the piston over the inner sleeve (Item 4) and into the body. Install the middle U-seals (Items 9) on the upper segment of the piston. F. Install three eyebolts (5/8”-11UNC x 10” Lg. using the pipe or rod from Step C of the disassembly procedure. Install Head. Remove the chain sling and eyebolts from the piston. Install Piston. Align the head lock bracket with the hole in the body. 3. Ensure that the piston is aligned vertically with the body prior to lowering. 4. CAUTION: Be careful not to damage the seals during assembly. Install the head gasket (Item 6) in the seal groove on the outside diameter of the head. Install two eyebolts (5/8"-11 UNC x 1 3/4” Lg. Install Inner Sleeve. 3. Vent Close port. E. 1. on the lower segment of the piston (Item 3). With proper vertical alignment.R Operator's Manual PAGE 5-4 GK® 11"-5000 PSI Annular Blowout Preventer C. Torque the capscrews to 50 lb-ft (68 N•m). 8. 2. A vertical lift. Lubricate the bowl of the piston (Item 3) and packing unit (Item 2) with castor oil. using the chain sling attached to the eyebolts. 1. will reduce the weight on the threads and reduce the required turning torque. Remove the chain sling and eyebolts from the packing unit. Remove chain sling. "Maintenance and Testing. 1. 7. Remove the chain sling and eyebolts from the head. 2. Install the wear plate (Item 29) and capscrews (Item 30) on the inner face of the annular head (Item 1). Lubricate the lock screw threads (Item 19) with Moly Paste 503 and install.) into the head. NOTE: This step is not applicable to models that do not have a wear plate. NOTE: This step is not applicable for models that have a welded body sleeve . Tighten the head clockwise (right hand) as shown in Figure 5-2. 3. 5. Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. Install the capscrews (Item 18) and torque to 150 lbft (203 N•m). the piston will slide its normal full stroke to the bottom of the preventer body. Install the head into the body so that the body threads on the head engage the threads of the body.) into packing unit. 9. Perform seal and packing unit test procedures in Section 4. 2. lift the packing unit and set it into the bowl of the piston. Remove the chain sling. until the shoulder on the head engages the body.) into the piston. Lubricate the body threads on the outside diameter of the head and the inside diameter of the body (Item 5) with Neverseez lubricant. Lower (10) Inner Sleeve Capscrew (18) Figure 5-4 Cutaway of Screwed Head GK® 11-5000 PSI BOP Without Wear Bands Showing Position of Parts. Upper (8) Packing Unit (2) Piston (3) U-Seal.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-5 Pipe Plug (17) Head Lock Screw (19) BOP Head – Screwed (1) Head Gasket (6) Wear Plate Capscrew (30) Wear Plate (29) U-Seal. Middle (9) Body (5) Inner Sleeve (4) U-Seal. . Three piston lift assemblies. disassembly of the GK® annular BOP can be performed with standard tools. Chain sling. Vent Pressure. Hydril Part No. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg.) into the head (Item 1) 3.Screwed Head With Wear Bands Refer to Figure 5-5 while following this procedure. Remove head lock screw (Item 19). If the head was improperly installed at the last assembly.R Operator's Manual PAGE 5-6 GK® 11"-5000 PSI Annular Blowout Preventer 5. ensuring that no trapped pressure exists which will cause injury to personnel and/or damage the equipment. B. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. NOTE: Except for the tools listed below. C. 3105638-6 2. Hydril Part No. may be applied to the eyebolts to take the weight of the head off of the threads while applying torque to the head. 1. 2. Unscrew the head counterclockwise from the BOP body. Gather Tools and Materials. 3112077 (for lifting head) 3.3 Disassembly . Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. Hydril Part No. 1900179-0354 (CAUTION: The chain sling is for disassembly and assembly purposes only. it 17 19 1 6 15 13 12 30 2 11 29 3 14 34 33 4 18 9 5 Figure 5-5: Screwed Head GK® 11"-5000 PSI With Wear BandsDisassembly .) 4. This lift will reduce the required turning torque. Remove Head. 1. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. A vertical lift. Hydril Part No. NOTE: Use a piece of strong pipe or rod (3" to 4" in diameter x 10' to 12' long) as a lever against the eyebolts to apply counterclockwise (left hand) torque on the head (refer to Figure 5-2). Vent the closing and opening chambers to atmosphere. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY.). WARNING: THIS IS VERY HEAVY EQUIPMENT. 2. using the chain sling. 1900076-08 (for lifting packing unit). Do not use the chain sling to lift the annular BOP assembly. 1. Numbers in figure correspond to item numbers in procedure. Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.). BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. A. Remove middle U-seals (Items 9). 1. 2. Insert the hooks of the Hydril chain sling (equally spaced) in the slots of the inner sleeve and lift the sleeve out of the annular BOP. gently lift piston out of the preventer body. If a vertical lift is not possible or the piston does not lift out freely. 1. 3. wiper ring (Item 15) and wear band (Item 13) .) into packing unit (Item 2). lift the packing unit out of the piston. 3. Eyebolt Lift Device D. lower piston double-U-seal (Items 33 and 34). Remove Packing Unit. Remove the head gasket (Item 6). Install two eyebolts (5/8"-11UNC x 1 3/4” Lg. CAUTION: Do not loosen the head by applying heat to the thread area. Screw each eyebolt into the piston. Using the Hydril chain sling. 3. Remove sling and eyebolts. Remove Piston. Remove Inner Sleeve. Attach the Hydril chain sling and lift the head straight up and off the body. 2. Install three piston lift assemblies onto the piston (Item 3) as follows and as shown in Figure 5-6: a. Remove the sling and the lifting assemblies from the piston. Remove the chain sling. 2. head to piston double U-seal (Items 11 and 12). 5. c. b. E. Remove the capscrews (Item 18) from around the inner sleeve (4). 6. may be necessary to apply considerable more torque on the head by the use of a winch or catline while alternately applying and releasing pressure to the opening chamber (1500 PSI/104 Bar maximum). Piston Lift Device 4. Remove chain sling and eyebolts. 7. WARNING: DO NOT USE AIR OR GAS. Tighten the eyebolts until the retaining ring and spacer block are snug against the piston. Using Hydril chain sling. Remove the capscrews (Item 30) and wear plate (Item 29). F. Piston Shoulder Piston Figure 5-6. Check the tightness of the eyebolts prior to lifting.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-7 4. 1. and wear band (Item 14). . slowly apply low (50 PSI) hydraulic pressure to the closing chamber. 4 Assembly . BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD.065) or equivalent 7. 1. Ensure that working surfaces are free of burrs. Spare parts including seal kit." B. C. Hydril Part No. Coat interior surfaces with castor oil. Hydril Part No. and capscrews with Moly Paste 503 thread lubricant. 31056386 2.). Insert hooks of Hydril chain sling (equally spaced) NOTE: Seal Rings MUST BE installed in position shown by cross-section. or other defects. WARNING: THIS IS VERY HEAVY EQUIPMENT. 6. CAUTION: Use of petroleum base oil or grease will reduce seal life. Hydril Part No. NOTE: Except for the tools listed below.R Operator's Manual PAGE 5-8 GK® 11"-5000 PSI Annular Blowout Preventer 5. Chain sling. Clean all components thoroughly. 3112077 (for lifting head) 3. 17 19 1 6 15 13 12 30 2 11 29 3 9 14 34 33 4 18 5 Figure 5-7: Screwed Head GK® 11"-5000 PSI With Wear BandsAssembly . (NOTE: Hydril recommends that all seals and wear bands be replaced whenever a BOP is disassembled and assembled. and replace any damaged seals and wear bands in use over one year. Moly Paste 503 thread lubricant (Coefficient of Friction is . 1. Hydril Part No. Numbers in figures correspond to item numbers in procedure. 2. Perform the inspection procedures that are applicable in Section 4. Do not use the chain sling to lift the annular BOP assembly. bolts.Screwed Head With Wear Bands Refer to Figure 5-7 and 5-8 while following this procedure. nonextrusion rings. and wear bands with castor oil before installation. Install Inner Sleeve. seals. assembly of the GK® annular BOP can be performed with standard tools. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. "Parts and Storage. 1900077-08 (for lifting packing unit) 4. rough edges. Lubricate the threads of nuts. 4. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. Inspect BOP. Lubricate body threads on the head and body with Neverseez lubricant. Neverseez lubricant 8. Gather Tools and Materials. "Maintenance and Testing". Coat packing unit. Castor oil 6. 2. 1900179-0354 (CAUTION: The chain sling is for disassembly and assembly purposes only. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS.). 1. 3. A.) Seals must be installed as shown in Figures 5-7 and 5-8. Clean.) 5. 5. Refer to Section 6. Inspect all seals and wear bands installed in the head and piston. and Lubricate. Three piston lift assemblies . 1. Install the capscrews (Item 18) and torque to 150 lbft (203 N•m). 3." . Install two eyebolts (5/8"-11 UNC x 1 3/4” Lg.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-9 2.) into packing unit. E. 9. Align the head lock bracket with the hole in the body. the wear band (Item 13). 4. Perform seal and packing unit test procedures in Section 4. Ensure that the piston is aligned vertically with the body prior to lowering.) into the head. Tighten the lock screw using 60 lb-ft (80 N•m) torque. 2. Install Head. Install Piston. Using Hydril chain sling. "Maintenance and Testing. Install the head into the body so that the screw threads on the head engage the threads of the body. 6. F. Install the head to piston seal. Torque the capscrews to 50 lb-ft (68 N•m). the disassembly procedure. Remove the chain sling and eyebolts from the head. consisting of a double U-seal (Item 11) and two non-extrusion rings (Item 12). 3. until the shoulder on the head engages the body. 3. Lubricate the body threads on the outside diameter of the head and the inside diameter of the body (Item 5) with Neverseez lubricant. into slots in inner sleeve (Item 4) and install the sleeve into the bore of the body. Install the lower piston double U-seal (Items 33 and 34). Install the head gasket (Item 6) in the seal groove on the outside diameter of the head. Install Packing Unit. the piston will slide its normal full stroke to the bottom of the preventer body. Remove the chain sling and eyebolts from the packing unit. just below the major diameter and above the body threads. Tighten the head clockwise (right hand) as shown in Figure 5-2. and the wiper ring (Item 15) into the grooves on the inside bottom diameter. With proper vertical alignment. CAUTION: Be careful not to damage the seals during assembly. D. Vent Close port. Install the middle U-seals (Item 9) on the upper segment of the piston. Remove the chain sling. 1. 7. Remove the chain sling and piston lift assemblies from the piston. will reduce the weight on the threads and reduce the required turning torque. Lubricate the bowl of the piston (Item 3) and packing unit (Item 2) with castor oil. using the chain sling attached to the eyebolts. Install the wear plate (Item 29) and capscrews (Item 30) on the inner face of the annular head (Item 1). 1. Lubricate the lock screw threads (Item 19) with Moly Paste 503 and install. A vertical lift. 2. Install the piston lift assemblies onto the piston as shown in Figure 5-6. lift the packing unit and set it into the bowl of the piston. 5. Remove chain sling. 2. 4. Attach the Hydril chain sling to the eyebolts and install the piston over the inner sleeve (Item 4) and into the body. and the wear band (Item 14) on the lower segment of the piston (Item 3). using the pipe or rod from Step C of 8. Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. R Operator's Manual PAGE 5-10 GK® 11"-5000 PSI Annular Blowout Preventer Pipe Plug (17) Head Lock Screw (19) BOP Head – Screwed (1) Head Gasket (6) Wear Plate Capscrew (30) Wear Plate (29) Wiper Ring (15) Wear Band (13) Head to Piston Double U-Seal (11 and 12) Packing Unit (2) Piston (3) Middle Piston Seals (9) Body (5) Inner Sleeve (4) Wear Band (14) Lower Piston Double U-Seal (33 and 34) Inner Sleeve Capscrew (18) Figure 5-8 Cutaway of Screwed Head GK® 11 5000 PSI BOP with Wear Bands. Showing Position of Parts. . Hydril Part No. Hydril Part No. 23 22 17 32 31 1 7 6 8 29 30 2 3 9 10 18 4 25 24 26 21 5 27 Figure 5-9: Latched Head GK 11"-5000 PSI Without Wear BandsDisassembly . Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. Three piston lift assemblies. disassembly of the GK® annular BOP can be performed with standard tools. Gather Tools and Materials. 2. 3112077 (for lifting head) 3.). 1. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD.) 4. NOTE: Except for the tools listed below. C. 1. tighten the shoulder screw to approximately 50 lb-ft (68 N•m). Hydril Part No. Remove the four head clamp screws and head clamps (Items 31 and 32) from the annular head. Vent Pressure from Annular BOP Assembly.). Excessive torque at shouldering may cause thread damage.5 Disassembly . ensuring that no trapped pressure exists in the BOP which will cause injury to personnel and/or damage the equipment.Latched Head Without Wear Bands Refer to Figure 5-9 while following this procedure. 3.1900077-08 (for lifting packing unit). Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. Chain sling. Do not use to lift the annular BOP assembly. NOTE: If a jaw does not retract as described due to the lack of engagement with spacer sleeve screw (Item 23). AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. Vent the closing and opening chambers. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. Numbers in figure correspond to item numbers in procedure.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-11 5. Hydril Part No.) into head. 31056386 2. CAUTION: Take care not to continue turning the screws after the jaws have shouldered. B. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. NOTE: Alternately loosen the screws on opposite sides to unload the head evenly. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Release the annular head (Item 1) by backing off the jaws (Item 21). 1. 2. Unscrew the clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws shoulder against the body (Item 5). WARNING: THIS IS VERY HEAVY EQUIPMENT. A. Three eyebolts (1-1/4"-7UNC x 1 3/4’ Lg. Remove Head. lift the head out of the body. Remove the six cap screws (Item 30) and the wear plate (Item 29). Remove the lift devices from the piston. 2. Install two eyebolts (5/8"-11UNC x 1 3/4” Lg. Remove Jaws. Remove the capscrews (Item 18) from around the inner sleeve (Item 4). Using Hydril chain sling 1900179-0354. b. 1. Remove sling and eyebolts. 3. Position each lift device over the top edge of the piston above the eyebolt holes in the piston shoulder. 4.) into packing unit (Item 2). 3. taking care not to damage the sealing surface on the outside diameter. lift the packing unit out of the piston (Item 3). Remove sling and eyebolts. E. Remove sling. Remove the middle U-seals (Items 9) and the lower U-seals (Items 10). . Using Hydril chain sling . and upper U-seals (Items 8). Remove spacer sleeve from the clamping screw. Remove the head dirt seal (Item 7). Tighten the eyebolts until the lift devices are snug against the piston shoulder.R Operator's Manual PAGE 5-12 GK® 11"-5000 PSI Annular Blowout Preventer 4. slowly apply low (50 PSI) hydraulic pressure to the closing chamber. 3. Head gasket (Item 6). 2. 1. taking care not to damage the sealing surface on the outside diameter. attach the hooks (equally spaced) into the slots in the sleeve and lift the inner sleeve out of the annular BOP. Check the tightness of the eyebolts prior to lifting. 1. 2. Using Hydril chain sling. Using Hydril chain sling 1900178-0354. 1. Install three piston lifting devices onto the piston (Item 3) as follows and as shown in Figure 5-6: a. 2. 6. Remove the jaw (21) from the inside of the body. Remove Inner Sleeve. Remove the clamping screw and spacer sleeve (Item 24) from the body (Item 5). Perform the following procedure for each jaw (Item 19). 5. F. c. gently lift piston out of the preventer body. NOTE: Keep the jaws in sequence so that they can be returned to their original position. G. Remove pipe plug (Item 25). D. Remove Packing Unit. 3. WARNING: DO NOT USE AIR OR GAS. Remove Piston. If a vertical lift is not possible or the piston does not lift out freely. Hold clamping screw (Item 22) and remove spacer sleeve screw (Item 23) from the clamping screw. Lubricate all threads of fasteners with Moly Paste 503 thread lubricant except where noted in this procedure. Inspect BOP. 2. Refer to Section 6. Hydril Part No. 3. Ensure that working surfaces are free of burrs.Latched Head Without Wear Bands Refer to Figure 5-10 and 5-11 while following this procedure. or other defects. 5. 1900077-08 (for lifting packing unit) 5. 4. Hydril Part No. A. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. 17 32 31 WARNING: THIS IS VERY HEAVY EQUIPMENT. assembly of the GK® annular BOP can be performed with standard tools.6 Assembly . Three piston lift assemblies.065) or equivalent 7. Inspect all seals installed in the head and piston. CAUTION: Use of petroleum base oil or grease will reduce seal life. Spare parts including seal kit. Clean.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-13 5.). 1. Replace any damaged seals in use over one year.). and Lubricate. rough edges. Do not use to lift the annular BOP assembly.) Seals and must be installed as shown in Figures 5-10 and 5-11. (NOTE: Hydril recommends that all seals be replaced whenever a BOP is disassembled and assembled. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS.) 4. NOTE: Except for the tools listed below. and non-extrusion rings with castor oil before installation. Neverseez lubricant 8. "Parts and Storage. Castor oil 6. Hydril Part No. Chain sling. Moly Paste 503 thread lubricant (Coefficient of Friction is . "Maintenance and Testing"." B. seals. Hydril Part No. Numbers in figures correspond to item numbers procedure. 3105638-6 2. 1. Gather Tools and Materials. Clean all components thoroughly. 3112077 (for lifting head) 3. 1 7 6 8 29 30 2 3 9 10 18 4 22 23 25 24 26 21 5 27 Figure 5-10: Latched Head GK 11"-5000 PSI Without Wear BandsAssembly . Three eyebolts (1-1/4"-7UNC x 1 3/4” Lg. Coat packing unit. Perform the inspection procedures that are applicable in Section 4. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. 4. NOTE: If a new jaw is installed within a set of well worn jaws. install the head into the annular body (Item 5). the jaws have shouldered. attach the three hooks (evenly spaced) into the slots in 2. Using of each clamping screw (Item 22). 2. Install the jaws (Item 21) into the annular body taking care not to damage the sealing surface on with the short side of the teeth down and in the the outside diameter. CAUTION: To prevent unequal clearfore lowering the piston over the inner sleeve. of the preventer head and apply 350 lb-ft (475 N•m) Lubricate all mating surfaces with castor oil beof torque. into head. lift the packing Install the clamping screws and screw them allunit and set it into the bowl of the piston. Coat interior surfaces with castor oil. Install Packing Unit. 3. or the jaw will unit. Turn the clamping screws (Item 22) clockwise to shown in Figure 5-6. 6. Using Hydril chain sling 1900179-0354. D. shouldering may cause thread damage. 3. 32) to secure the head fully into place. 4. head gasket (6). lb-ft (203 N•m). Remove the sling and lift devices from the piston. segment of the piston. tighten the Ensure that the piston is aligned vertically with jaws/latches alternately on opposite sides or in a the inner sleeve prior to lowering. screw. Install Jaws. Install the wear plate (Item 29) on the inner face of the sleeve and install the inner sleeve (Item 4) the annular head (1) and install the capscrews into the body. careful not to damage the sealing surfaces on the inside diameter of the body and the seals on the outside diameter of the piston during assembly. Install the head dirt seal (Item 7). until the jaws are shouldered against the body. Vent the Close crisscross pattern. 4. ance between the head and the body. 2. Install the middle U-seals (Item 9) onto the upper Remove the sling and eyebolts. E. 2. Excessive torque at Install pipe plugs (Item 25) into clamping screws. 1. Remove the sling and eyebolts from the packing to overtighten the clamping screws. 5. Install Head. Insert the spacer sleeve (Item 24) and spacer sleeve screw (Item 23) through each clamping G. 1. Lubricate the bowl of the piston (Item 3) and packensure equal load sharing. C. Install thelower U-seals (Item 10) on the lower 5. ing unit (Item 2) with castor oil. With proper vertical alignment. CAUTION: Be careful not 2. 3. the piston will slide its normal full stroke to the bottom of the preventer body. CAUTION: PORTANT: Do not lubricate the threads of the Take care not to continue turning the screws after spacer sleeve screws. devices. the-way in hand tight. lift and segment of the piston (Item 3). Using Hydril chain sling 1900179-0354. NOTE: If Ensure that all of the jaws are retracted fully by a jaw does not retract as described due to the lack turning the clamping screws counterclockwise of engagement with spacer sleeve screw (Item 23). 3. Hydril chain sling 1900179-0354. N•m). same sequence as disassembled. taking care not to damage engage the jaws (Item 21) fully into the locking rings the sealing surface on the outside diameter. Install two eyebolts Install the O-ring (Item 26) in the external groove (5/8"-11UNC x 1 3/4” Lg. Tighten the Install the piston into the body using the piston lift head clamp screws until tight. Install three eyebolts (1-1/4"-7UNC x 1 3/4” Lg. 1. polish the new jaw to match existing jaws to F.) into packing unit.) Install Piston. IMshoulder against the body (Item 5). extend beyond the sides of the body. Torque the capscrews to 50 lb-ft (68 Install the capscrews (Item 18) and torque to 150 N•m). (Item 30). tighten the spacer sleeve screw counterclockwise (left hand thread) to approximately 150 lb-ft (203 Install Inner Sleeve. 1. and upper U-seals (Items 8) onto the head. CAUTION: Be .R Operator's Manual PAGE 5-14 GK® 11"-5000 PSI Annular Blowout Preventer 6. Orient the seal lips as 8. Turn the screws into the jaws (Item 21) 1. Install four head clamps (item 31) and screws (Item shown in Figure 5-9 and/or 5-10. ports to atmosphere. Install each device onto the piston as 9. Remove chain sling. Unscrew the clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws until tight (approximately 50 lb-ft/68 N•m). Showing Position of Parts.23.26) Wear Plate (29) Head Gasket (6) U-Seal.24.22. Lower (10) Inner Sleeve Capscrew (18) Figure 5-11 Cutaway of GK® 11-5000 PSI Latched Head BOP Without Wear Bands. Upper (8) Packing Unit (2) Piston (3) U-Seal. .R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-15 Pipe Plug (17) Head Clamp Screw (31) Head Clamp (30) Head Dirt Seal (7) Wear Plate Capscrew (30) BOP Head – Latched (1) Jaw Mechanism (21.25. Middle (9) Body (5) Inner Sleeve (4) U-Seal. WARNING: THIS IS VERY HEAVY EQUIPMENT. tighten the shoulder screw to approximately 50 lb-ft (68 N•m). 1900077-08 (for lifting packing unit).). CAUTION: Take care not to continue turning the screws after the jaws have shouldered.R Operator's Manual PAGE 5-16 GK® 11"-5000 PSI Annular Blowout Preventer 5. ensuring that no trapped pressure exists in the BOP which will cause injury to personnel and/or damage the equipment. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Remove the four head clamp nuts and head clamps (Items 31 and 32) from the annular head. NOTE: If a jaw does not retract as described due to the lack of engagement with spacer sleeve screw (Item 23). B. Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg. Vent Pressure from Annular BOP Assembly. 3. Chain sling. 1. 2. 31056386 2. Unscrew the clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws shoulder against the body (Item 5). Hydril Part No. Release the annular head (Item 1) by backing off the jaws (Item 21). Three eyebolts (1-1/4"-7UNC x 1 3/4’ Lg. 2. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. Do not use to lift the annular BOP assembly. Remove Head. Numbers in figure correspond to item numbers in procedure.) 4. Gather Tools and Materials.) into head. Three piston lift assemblies. 1. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS.). Hydril Part No. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to bleed off. WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID INJURY. Vent the closing and opening chambers. Hydril Part No.Latched Head With Wear Bands Refer to Figure 5-12 while following this procedure. disassembly of the GK® annular BOP can be performed with standard tools. NOTE: Alternately loosen the nuts on opposite sides to unload the head evenly. NOTE: Except for the tools listed below. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. Excessive torque at shouldering may cause thread damage. C. 1. 17 32 31 1 7 15 6 13 12 30 2 11 29 3 9 14 34 33 18 4 22 23 25 24 26 21 5 27 Figure 5-12: Latched Head GK 11"-5000 PSI With Wear BandsDisassembly . A.7 Disassembly . 3112077 (for lifting head) 3. Hydril Part No. Remove sling. lower piston double U-seal (Items 33 and 34). Using Hydril chain sling 1900178-0354.) into packing unit (Item 2). wiper ring (Item 15). Remove the six cap screws (Item 30) and the wear plate (Item 29). Using Hydril chain sling . head to piston double Useal (Items 11 and 12). Remove the lift devices from the piston. Remove the head dirt seal (Item 7). head gasket (Item 6). taking care not to damage the sealing surface on the outside diameter. Install three piston lifting devices onto the piston (Item 3) as follows and as shown in Figure 5-6: a. Position each lift device over the top edge of the piston above the eyebolt holes in the piston shoulder. 2. Using Hydril chain sling. 1. sleeve screw (Item 23) from the clamping screw. D. If a vertical lift is not possible or the piston does not lift out freely. Remove the capscrews (Item 18) from around the inner sleeve (Item 4). Remove Inner Sleeve. 4. Remove the jaws (Item 21) from the inside of the body. Tighten the eyebolts until the lift devices are snug against the piston shoulder. WARNING: DO NOT USE AIR OR GAS. 1. G. 3. lift the head out of the body. and the wear band (Item 14) from the piston.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-17 4. E. NOTE: Keep the jaws in sequence so that they can be returned to their original position. 5. Remove Piston. Remove pipe plug (Item 25). 1. 3. taking care not to damage the sealing surface on the outside diameter. Remove Packing Unit. Check the tightness of the eyebolts prior to lifting. attach the hooks (equally spaced) into the slots in the sleeve and lift the inner sleeve out of the annular BOP. F. 1. Remove sling and eyebolts. Perform the following procedure for each radial latch (Item 19). Remove the middle U-seals (Item 9). b. Remove sling and eyebolts. Using Hydril chain sling 1900179-0354. lift the packing unit out of the piston (Item 3). 2. gently lift piston out of the preventer body. Remove spacer sleeve from the clamping screw. 3. 4. Install two eyebolts (5/8"-11UNC x 1 3/4” Lg. Remove Radial Latches. Hold clamping screw (Item 22) and remove spacer . Remove the O-ring (Item 26) from the clamping screw. 3. 6. slowly apply low (50 PSI) hydraulic pressure to the closing chamber. 2. Remove the clamping screw and spacer sleeve (Item 24) from the body (Item 5). c. and the wear band (Item 13) from the head. 2. rough edges." B.) Seals and must be installed as shown in Figures 5-13 and 5-14. 1900179-0354 (CAUTION: This chain sling is for disassembly and assembly purposes only. Castor oil 6. BE SURE THAT LIFTING EQUIPMENT IS IN GOOD CONDITION AND CAPABLE OF HANDLING THE LOAD. 3105638-6 2.) 4. 1. Hydril Part No. and Lubricate. 3112077 (for lifting head) 3.). and non-extrusion rings with castor oil before installation. ). Inspect BOP. Three piston lift assemblies. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. NOTE: Except for the tools listed below. (NOTE: Hydril recommends that all seals and wear bands be replaced whenever a BOP is disassembled and assembled. Hydril Part No. Numbers in figures correspond to item numbers in procedure. "Maintenance and Testing". Neverseez lubricant 8.8 Assembly . Replace any damaged seals and wear bands in use over one year. seals. Ensure that working surfaces are free of burrs. Moly Paste 503 thread lubricant (Coefficient of Friction is . 1900077-08 (for lifting packing unit) 5. "Parts and Storage. Hydril Part No. Coat packing unit.Latched Head With Wear Bands Refer to Figure 5-13 and 5-14 while following this procedure. Refer to Section 6. Do not use to lift the annular BOP assembly. CAUTION: Use of petroleum base oil or grease will reduce seal life. Inspect all seals and wear bands installed on the head and piston. Spare parts including seal kit. 1. Gather Tools and Materials. assembly of the GK® annular BOP can be performed with standard tools. 1 7 15 6 13 12 29 2 11 28 3 9 14 34 33 18 4 22 23 25 24 26 21 5 27 Figure 5-13: Latched Head GK 11"-5000 PSI With Wear BandsAssembly .R Operator's Manual PAGE 5-18 GK® 11"-5000 PSI Annular Blowout Preventer 5. 4. Three eyebolts (1-1/4"-7UNC x 1 3/4” Lg. 17 32 31 WARNING: THIS IS VERY HEAVY EQUIPMENT. Perform the inspection procedures that are applicable in Section 4. Clean. 2. Chain sling. AND EXTREME SAFETY PROCEDURES MUST BE FOLLOWED DURING LIFTING OPERATIONS. A. 3. or other defects. Clean all components thoroughly.065) or equivalent 7. Hydril Part No. devices. 4. Install Install the capscrews (Item 18) and torque to 150 the head to piston double U-seal (Items 11 and 12).) Install the lower piston double U-seal (Items 33 into head. hand thread) to approximately 150 lb-ft (203 N•m). Refer to Figures 5-13 and 5-14 for seal orientation. lift the packing Install the clamping screws and screw them allunit and set it into the bowl of the piston. 2. Coat interior surfaces with castor oil. 2. not retract as described due to the lack of engageEnsure that all of the jaws are retracted fully by ment with spacer sleeve screw (Item 23). Lubricate all threads of fasteners with Moly Paste 503 thread lubricant except where noted in this procedure. attach the annular head (1) and install the capscrews the three hooks (evenly spaced) into the slots in (Item 29). Install Inner Sleeve. preventer head and apply 350 lb-ft (475 N•m) of Lubricate all mating surfaces with castor oil betorque. Lubricate the bowl of the piston (Item 3) and packjaws to ensure equal load sharing. may cause thread damage. lift and segment of the piston (Item 3). Install the head gasket (6) and head dirt seal (Item into the body. the sleeve and install the inner sleeve (Item 4) 3. D. 4. 3. 7) on the lower outside diameter of the head. lb-ft (203 N•m). NOTE: If a new jaw is installed within a set of well worn latches. CAUTION: To prevent unequal clearance fore lowering the piston over the inner sleeve.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 5-19 5. Install three eyebolts (1-1/4"-7UNC x 1 3/4” Lg. Install Packing Unit. Install Jaws. Install the middle U-seals (Item 9) onto the middle Remove the sling and eyebolts. install the head into the annular body (Item 5). Using Hydril chain sling 1900179-0354. tighten the jaws alterEnsure that the piston is aligned vertically with nately on opposite sides or in a crisscross pattern. Using of each clamping screw (Item 22). or the jaw will extend beyond the sides of the body. CAUTION: Be careful not 2. 1. and wear band (Item 13) onto Remove chain sling. With proper vertical alignment. Install the jaws (Item 21) into the annular body taking care not to damage the sealing surface on with the short side of the teeth down and in the the outside diameter. polish the new jaw to match existing F. 1. Torque capscrews to 50 lb-ft (68 N•m). NOTE: If a jaw does Install pipe plugs (Item 25) into clamping screws. CAUTION: Take until tight (approximately 50 lb-ft/68 N•m). 2. Turn the screws into the jaws (Item 21) shoulder against body (Item 5). 2. 5. Vent the Close . between head and the body. 4. Excessive torque at shouldering spacer sleeve screws.) into packing unit. the piston will slide its normal full stroke to the bottom of the preventer body. 1. to overtighten the clamping screws. Tighten the Install the piston into the body using the piston lift screws until tight. Unscrew clamping screws (Item 22) by rotating them counterclockwise four turns or until the jaws screw. Install each device onto the piston as 7 Turn clamping screws (Item 22) clockwise to enshown in Figure 5-6. E. and 34) and wear band (Item 14) on lower 5. 1. Install two eyebolts Install the O-ring (Item 26) in the external groove (5/8"-11UNC x 1 3/4” Lg. the lower inside diameter of the head. Remove sling and eyebolts from packing unit. segment of the piston. Install the wear plate (Item 28) on the inner face of Using Hydril chain sling 1900179-0354. 3. 6. IMcare not to continue turning screws after the jaws PORTANT: Do not lubricate the threads of the have shouldered. ing unit (Item 2) with castor oil. the inner sleeve prior to lowering. CAUTION: Be careful not to damage the sealing surfaces on the inside diameter of the body and the seals on the outside diameter of the piston during assembly. 32) to secure the head fully into place. 3. the-way in hand tight. wiper ring (Item 15). C. taking care not to damage gage jaws (Item 21) fully into locking rings of the sealing surface on the outside diameter. Orient the seal lips as 6. ports to atmosphere. 6. Install four head clamps (item 31) and screws (Item shown in Figures 5-13 and 5-14. sleeve screw (Item 23) through each clamping 1. Hydril chain sling 1900179-0354. same sequence as disassembled. Install Head. Remove the sling and lift devices from the piston. Install Piston. Insert the spacer sleeve (Item 24) and spacer G. tighten turning the clamping screws counterclockwise the spacer sleeve screw counterclockwise (left until the jaws are shouldered against the body. 25.R Operator's Manual PAGE 5-20 GK® 11"-5000 PSI Annular Blowout Preventer Pipe Plug (17) Head Clamp Screw (31) Head Clamp (30) Head Seal (7) Wear Plate Capscrew (30) BOP Head – Latched (1) Wear Plate (29) Jaw Mechanism (21. 34) Inner Sleeve Capscrew (18) Figure 5-14 Cutaway of Latched Head GK® 11-5000 PSI BOP with Wear Bands.22. 12) Packing Unit (2) Piston (3) U-Seal.23. . Middle (9) Body (5) Inner Sleeve (4) Wear Band (13) Lower Piston Double U-Seal (33.24.26) Wiper Ring (15) Head Gasket (6) Wear Band (14) Head to Piston Double U-Seal (11. Showing Position of Parts. R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 6-1 6.. ** Some BOPs are equipped with Sleeve P/N 1004075 and Capscrew 1920026-12016. 4. .19 24. 5 10 1 3 6 8 29 17 19 2▲ Packing UnitNatural (NR) 3 Nitrile (NBR) Piston 4** Inner Sleeve 5 Body 6 8 9 10 17 Head Gasket U-Seal. * Requires head conversion to accept wear plate. Upper U-Seal.880 305 311 1.200 1.. Piston Eyebolt. Part Name BOP Assembly 1 BOP Head Screwed No.15 0. Check P/N stamped on bottom of sleeve for replacement.. Req. Middle U-Seal.94 4..13 .380 .25 66 0. Sleeve does not interchange with Item 4. 1..13 33565-M 30952 32006 31406 1900043 08010 ▲ Recommended spares for one year service.75 . (Lb) 8.Complete 4 • For converting welded sleeve on some model BOPs to bolted sleeve only.. 1 1/4”-7NC Protector Plate Protector Plate Screw 1 3 2 1 4 45 1. 14. Head.1 Parts List — Screwed Head Without Wear Bands Item No.41 Part Number 1002140 1 1002143 1003260-01 1003260-02 1002145-1 1004201 1002141 31402 31403 30736 32599 190006505 192002612012 1002149 1004203 192002608007 1006100 1002150 18 ACCESSORIES Chain Sling Assy Eyebolt..645 2 2. Piston Indicator 30 2 18** Inner Sleeve Screw 9 • ▲ Field Replacement Sleeve Kit Seal Kit. Net Wt.. some models of this BOP do not have the wear plate.0 PARTS AND STORAGE 6. 1 1 1 1 1 1 1 1 2 2 2 1 12 19 Head Lock Screw 29* Wear Plate 30* Wear Plate Capscrew 1 1 6 1 1 Approx. Figure 6-1: Screwed Head GK® 11"-5000 PSI without Wear Bands .13 2 1. Lower Pipe Plug. 1 1/4”-7UNC Protector Plate Protector Plate Screw 1 2 2 1 4 45 1. Head. 4...Screwed Approx..R Operator's Manual PAGE 6-2 GK® 11"-5000 PSI Annular Blowout Preventer 6. The abbreviation “WB” will be stamped on the name plate after the BOP assembly number (XXXXXXX-WB) to indicate wear band Figure 6-2: Screwed Head GK® 11"-5000 PSI with Wear Band Modification modification.2A Parts List — Screwed Head With Wear Band Modificationa Item No.2B (PNI04-007-02 Rev A1) for modification kit parts.. .. Head Wear Band... Part Number 1002140-WB 3136824 1003260-01 1003260-02 3136680 1004201 1002141 31402 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 1004201 14 34 33 4 3 a 17 19 1 2▲ Packing UnitNatural (NR) 3 Nitrile (NBR) Piston 1 6 15 13 12 30 2 11 29 4** Inner Sleeve 5 Body 6 9 11 12 13 14 15 17 Head Gasket U-Seal... .645 2 .880 305 311 1. some models of this BOP do not have the wear plate. Sleeve does not interchange with Item 4. .. 2. • For converting welded sleeve on some model BOPs to bolted sleeve only.25 66 0.380 ..13 . Net Wt. ..13 .. . No. (Lb) 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 6 1 2 1 1 8. See Parts List 6. a Wear band modification at Hydril Authorized Repair Facility (ARF). ** Some BOPs are equipped with Sleeve P/N 1004075 and Capscrew 1920026-12016. Head Non Extrusion Ring Wear Band. Check P/N stamped on bottom of sleeve for replacement.15 1004203 0... 14.19 1002149 24. Middle Piston Double U-Seal.. .13 33565-M 30952 32006 31406 1900043 08010 5 ▲ Recommended spares for one year service. Piston 5/8”-11UNC Eyebolt.. Req. Piston Indicator 18** Inner Sleeve Screw 19 Head Lock Screw 29* Wear Plate 30* Wear Plate Capscrew 33 34 Double U-Seal. Piston Wiper Ring Pipe Plug. Part Name BOP Assembly Head .Complete 1. Piston Non Extrusion Ring Field Replacement Sleeve Kit Seal Kit.200 1.94 4.41 192002608007 3136746 3136745 1006100 3137431 9 • ▲ 18 ACCESSORIES Chain Sling Assy Eyebolt... * Requires head conversion to accept wear plate. .. .380 ... (Lb) 1. 1 1 1 1 1 Approx..Screwed Piston Wear Band.41 Part Number 3136824 3136680 1931099-05 1931099-04 3137431 Item number refers to Parts List 6-2A and Figure 6-2.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 6-3 6.. Req. Piston Seal Kit. a Part Name Head .880 1..a 1 3 13 14 . Net Wt..Complete No. Head Wear Band.2B Parts List — Screwed Head Wear Band Modification Kit PNI04-007-02 Rev A1 Item No. . 14. This parts list is generic in construction and part numbers are listed for all components that are standard except for non-standard components or those that require regulatory certification. a * Wear bands are installed at manufacture. Head Non Extrusion Ring Wear Band. 14.380 .41 * * 1003260-01 1003260-02 * 1004201 * 31402 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 192002612012 1002149 3123805 192002608007 3136746 3136745 3137431 19001790354 3112077 3113411-37 3105638-6 5 4 14 34 33 9 3 6 15 13 12 30 2 11 29 17 19 1 2▲ Packing UnitNatural (NR) 3 4 5 6 9 11 12 13 14 15 17 18 19 29 30 33 34 ▲ Nitrile (NBR) Piston Inner Sleeve Body Head Gasket U-Seal. Piston Non Extrusion Ring Seal Kit. If name plate is missing or damaged.3 Parts List — Screwed Head With Wear Bands At Manufacturea Item No.13 . 1 1/4-7UNC Protector Plate Piston Lift Device 3 2 3 .13 . the serial number is stamped on the body.25 66 . 4. contact Hydril. Include the assembly part number and/or serial number from the name plate. . Piston Wiper Ring Pipe Plug..13 1.. Part No. If you want a complete parts list specific to your equipment... Head. 4.. .. . (Lb) 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 6 1 1 6 1 2 1 8. which may change from one assembly to another.0 . Piston Indicator Inner Sleeve Screw Head Lock Screw Wear Plate Wear Plate Capscrew Double U-Seal. ▲ Recommended spares for one year service.. Head Wear Band. These parts are specific to the assembly part number stamped on the BOP name plate... 0.880 305 311 1...200 1.15 0.R Operator's Manual PAGE 6-4 GK® 11"-5000 PSI Annular Blowout Preventer 6. Part Name BOP Assembly Head . Figure 6-3: Screwed Head GK® 11"-5000 PSI with Wear Bands . Number* Req.. Middle Piston Double U-Seal.. Net Wt....19 24... ... .645 2..Screwed Approx..Complete 1 18 ACCESSORIES Chain Sling Assembly 1 Eyebolt. 2. .85 0..R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 6-5 6. Piston Indicator 18 Inner Sleeve Screw 21 22 23 24 25 26 27 29 30 31 32 Jaw Jaw Clamping Screw Spacer Sleeve Screw Spacer Sleeve Pipe Plug Jaw Clamping Screw O-Ring Relief Fitting Wear Plate Wear Plate Capscrew Head Clamp Head Clamp Screw 2 3 9 10 18 4 22 23 ▲ Seal Kit..200 1900 305 311 1380 . 1 1/4”-7UNC Protector Plate Protector Plate Screw 3 2 1 4 .. Req.4 Parts List — Latched Head Without Wear Bands Item No...02 0. 0.. (Lb) 1 1 1 1 1 1 1 1 1 2 2 2 1 12 16 16 16 16 16 16 1 1 6 4 4 .. .13 19001790354 3105638-6 3112077 31406 190004308010 25 24 26 21 5 27 ▲ Recommended spares for one year service. Net Wt.75 .67 18 Part Number 1004060 1002223 1003260-01 1003260-02 1002145 1004201 1004061-02 31402 51189 31403 30736 32599 1900065-05 192002612012 1004065 1004067 190018410024 1004068 1900065-08 1900001329 1900086-03 1004203 192002608007 1002351 190004914024 1004074 1 7 6 8 29 30 17 32 31 BOP Assembly 1 BOP Head-Latched 2▲ Packing Unit Natural Rubber (NR) Nitrile (NBR) 3 Piston 4 Inner Sleeve 5 Body 6 Head Gasket 7 Head Dirt Seal 8 U-Seal .03 ..13 2 1. .. Lower 17 Pipe Plug. 4. 4645 2. Middle 10 U-Seal.Upper 9 U-Seal. ....75 .44 .. Head. Part Name Approx... . . No..Complete ACCESSORIES Chain Sling Assembly 1 Piston Lift Device Eyebolt.. Figure 6-4: Latched Head GK 11"-5000 PSI Without Wear Bands .....09 0. 0..25 66 0.. 2. 3. 8. Middle Piston 11 Double U-Seal.... 0..02 0.85 0..25 66 0..... ....75 ..Complete 25 24 26 21 5 ACCESSORIES Chain Sling Assembly 1 Piston Lift Device Eyebolt.. Head. 1 1/4”-7UNC Protector Plate Protector Plate Screw 3 2 1 4 . 18 Part Number 1004060-WB* 3136678 1003260-01 1003260-02 3136680 1004201 1004061-02 31402 51189 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 192002612012 1004065 1004067 190018410024 1004068 1900065-08 1900001329 1900086-03 1004203 192002608007 1002351 190004914024 3136746 3136745 3137417 17 32 31 BOP Assembly 1 BOP Head-Latched 2▲ Packing Unit Natural Rubber (NR) Nitrile (NBR) 3 Piston 4 Inner Sleeve 5 Body 6 Head Gasket 7 Head Dirt Seal 9 U-Seal.5A Parts List — Latched Head With Wear Band Modification* Item No.13 19001790354 3105638-6 3112077 31406 190004308010 27 ▲ Recommended spares for one year service.. No.. ... . 4645 2. .R Operator's Manual PAGE 6-6 GK® 11"-5000 PSI Annular Blowout Preventer 6.. Figure 6-5: Latched Head GK 11"-5000 PSI With Wear Band Modification .. * Wear band modification at Hydril Authorized Repair Facility (ARF).... .. ..200 1900 305 311 1380 . 4. See parts list 6. The abbreviation “WB” will be stamped on the name plate after the BOP assembly number (XXXXXXX-WB) to indicate modification..09 0.. 3. Part Name Approx. Head 12 Non Extrusion Ring 13 Wear Band.. 0. .... 8.67 .. . Head 14 Wear Band. . . Req. Net Wt..03 . Piston 34 Non Extrusion Ring ▲ Seal Kit.. .. (Lb) 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 12 16 16 16 16 16 16 1 1 6 4 4 1 2 .. Piston 15 Wiper Ring 17 Pipe Plug. ..5B (PNI04-007-03 Rev A1) for modification kit parts..44 . Piston Indicator 18 Inner Sleeve Screw 21 22 23 24 25 26 27 29 30 31 32 Jaw Jaw Clamping Screw Spacer Sleeve Screw Spacer Sleeve Pipe Plug Jaw Clamping Screw O-Ring Relief Fitting Wear Plate Wear Plate Capscrew Head Clamp Head Clamp Screw 1 7 15 6 13 12 30 2 11 29 3 9 14 34 33 18 4 22 23 33 Double U-Seal. .380 . 14.5B Parts List — Latched Head Wear Band Modification Kit PNI04-007-03 Rev A1 Item No. .880 1. (Lb) 1.41 Part Number 3136678 3136680 1931099-05 1931099-04 3137417 Item number refers to Parts List 6-5A and Figure 6-5. a Part Name Head .R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 6-7 6. Head Wear Band. Net Wt. Piston Seal Kit. . 1 1 1 1 1 Approx. Req...Screwed Piston Wear Band..Complete No.a 1 3 13 14 ... 4645 2. .03 ..85 * * 1003260-01 1003260-02 * 1004201 * 31402 51189 30736 1002921 1002922 1931099-05 1931099-04 3136747 1900065-05 192002612012 3136678 1004067 190018410024 1004068 1900065-08 1900001329 1900086-03 1004203 192002608007 1002351 190004914024 3136746 3136745 3137417 19001790354 3105638-6 3112077 31406 190004308010 Part Number 17 32 31 BOP Assembly 1 BOP Head-Latched 2▲ Packing Unit Natural Rubber (NR) Nitrile (NBR) 3 Piston 4 Inner Body Sleeve 5 Body 6 Head Gasket 7 Head Dirt Seal 9 U-Seal. Head 14 Wear Band. Figure 6-6: Latched Head GK 11"-5000 PSI With Wear Bands Include the assembly part number and/or serial number from the name plate.13 25 24 26 21 5 27 ▲ Recommended spares for one year service. 18 ACCESSORIES Chain Sling Assembly 1 .....09 0. Piston Lift Device Eyebolt. 4.44 . 3.. (Lb) 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 12 16 16 16 16 16 16 1 1 6 4 8. Net Wt.. These parts are specific to the assembly part number stamped on the BOP name plate.... the serial number is stamped on the body.Complete .. . .. contact Hydril.. Piston 15 Wiper Ring 17 Pipe Plug.75 . If name plate is missing or damaged.R Operator's Manual PAGE 6-8 GK® 11"-5000 PSI Annular Blowout Preventer 6.. No. Req. .... If you want a complete parts list specific to your equipment.Head 12 Non Extrusion Ring 13 Wear Band..... Piston 1 34 Non Extrusion Ring 2 .. Part Name Approx.02 0. .. .. .. Head Protector Plate Protector Plate Screw 3 2 1 4 .. a * Wear bands are installed at manufacture....6 Parts List — Latched Head With Wear Bands At Manufacturea Item No.67 . 33 Double U-Seal. Middle Piston 11 Double U-Seal . which may change from one assembly to another... .. ▲ Seal Kit... . This parts list is generic in construction and part numbers are listed for all components that are standard except for non-standard components or those that require regulatory certification.200 1900 305 311 1380 .. 0.25 66 0.. Piston Indicator 18 Inner Sleeve Screw 21 22 23 24 25 26 27 29 30 31 32 Jaw Jaw Clamping Screw Spacer Sleeve Screw Spacer Sleeve Pipe Plug Jaw Clamping Screw O-Ring Relief Fitting Wear Plate Wear Plate Capscrew Head Clamp Head Clamp Screw 1 7 15 6 13 12 30 2 11 29 3 9 14 34 33 18 4 22 23 4 0. .. . 0.. . Use silicone cauk if necessary. Install a protective cover on the top connection. 9. 6.2 Depreservation Procedure and Return to Service Remove the end connection covers and blow or rinse out the vapor phase corrosion inhibitor. 4. Install pipe plugs into Open and Close ports. inspect.7. A. 11. Cortec VCI 369 grease (for unpainted machined face surfaces) 2. Contact Hydril for paint specifications. Disassemble. Materials Required 1. The protection period is dependent primarily upon the sealing integrity of the end connections and sealing of other pressure boundary penetrations. 8. Apply Cortec VCI 369 grease to bottom connection mating surface . Drop 10 ounces of Cortec VCI 609 vapor phase corrosion inhibitor into the bore of the BOP. Refer to the maintenance procedure in Section 4. refer to Hydril Engineering Bulletin EB9909A on Hydril Website www. 2.7. Drain the bore and rinse thoroughly behind the packing unit and inner sleeve with water displacement oil. Allow the bore. 10. Witco Macco 1961. Install a protective cover on the bottom connection. Two protective covers for the end connections. using a 50/50 mix of fresh water (DO NOT USE SEA WATER OR BRINE) and glycol mixed with corrosion inhibitor or BOP hydraulic fluid as an operating fluid. Hydril recommends the replacement of all seals when the annular BOP is disassembled. 3. Ensure that a tight seal exists between the BOP and the cover. "Disassembly and Assembly. Coat unpainted exterior surfaces with Cortec VCI 369 grease. Refer to Section 4.1 Preservation Procedure 4." Replacement of worn packing units. 13. 12. Test the packing unit and seals. NOTE: For additional discussion on operating fluid and specific fluid recommendations.7 Preventer Storage The following preservation procedure protects the Hydril® 11 5/8"-5000 PSI annular BOP for up to two years of storage. 5. Touch up paint where necessary. operating fluid paths and chambers (Open and Close) to dry. "Maintenance and Testing" for testing procedures. 7.R Operator's Manual GK® 11"-5000 PSI Annular Blowout Preventer PAGE 6-9 6. 6. Cortec VCI 609 vapor phase corrosion inhibitor. and assemble the annular BOP. One tube of silicone caulk (additional sealing for protective covers) B. Ensure that a tight seal exists between the BOP and the cover. Procedure 1. Water displacement oil such as Hougton Rust Veto 4221 or Stack Guard 180. 6.com. Use silicone cauk if necessary. clean. and other parts can be made conveniently at this time. lubricate. or any AW Hydraulic Oil 46 (required for removal of water after hydrostatic testing) 5.hydril. "Maintenance and Testing" and Section 5. 10 ounce (for bore and exposed interior surfaces) 3. Drain the operating fluid and flush out the operating fluid paths and chambers (Open and Close) with water displacing oil. Apply Cortec VCI 369 grease to the top connection mating surface. seals. Rubber goods storage areas should be kept as dry as possible. and direct blasts of space heaters. The practice of first-in. dry. . sealed containers are recommended. Do not keep assemblies in stretched attitudes. or any high voltage equipment producing corona and ozone). do not hang O-rings on nails. Remove oil. Store rubber goods in a relaxed position in their normal shape. Keep the rubber storage area as dark as possible — preferably indoors. For example. and users of oil field equipment to maximize normally available storage facilities for rubber goods: 1. stoves. switch gear.g. and direct artificial lighting. The ideal storage situation for rubber goods would be in air tight containers maintained 4. away from heaters. Avoid locations susceptible to drafts that will carry the atmosphere from electrical machinery to the rubber goods storage area. e. and operator parts. The following recommendations will allow vendors 5. Keep rubber goods away from electrical machinery (motors. Impervious surface coverings such as waxing will increase shelf life. Select a cool location (approximately 65oF) that is 7. 3. direct sunlight. If storage for extended periods is anticipated.8 Rubber Goods Storage The term rubber goods includes synthetic compounds such as Nitrile Copolymers and Neoprene. dark storage area. skylights. windows. first-out is essential with rubber goods. in a cool. grease or other foreign materials from the storage area to preclude spillage on rubber goods.R Operator's Manual PAGE 6-10 GK® 11"-5000 PSI Annular Blowout Preventer 6. O-rings on glands. as well as natural rubber parts. 2. not outdoors. BOP testers. and away from 6.. OPERATOR'S MANUAL R Pressure Control Equipment .