Professional Documents
Culture Documents
Manual Mtto Rams
Manual Mtto Rams
PAGE
Ram BOPs ii
PREFACE
Hydril makes no warranties of any kind, expressed or sembly, inspection, reassembly, and testing of the
implied, including any warranty of mechanical fitness blowout preventer. The customer also is solely re-
for any particular purpose, that the work performed sponsible for providing competent and qualified per-
pursuant to this manual will be free from defects in sons, equipment and facilities to perform such opera-
workmanship or material. tions, and for workmanship and safety. If at any time
Hydril retains for itself all proprietary rights in and the customer is unable to understand recommenda-
to all designs, engineering details, data, and proce- tions made in this manual or is unable to follow those
dures set forth herein. This manual is intended for the recommendations, they should consult the nearest
sole use of Hydril customers, and they shall strictly Hydril Authorized Repair Facility or Hydril Headquar-
control copying of same, as this manual and all copies ters. The addresses, telephone numbers, FAX num-
thereof may be recalled by Hydril at any time. bers of the repair facilities as well as Hydril Headquar-
This manual makes recommendations only. The ters are listed in Section 10 of this manual.
customer is at all times responsible for actual disas-
Inspection Manual
R
PAGE
Ram BOPs iii
CONTENTS
PAGE
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Please contact Hydril Pressure Control Products for any assistance or questions concerning the information in this
manual. All information contained in this manual is the exclusive property of Hydril Company LP.
©2001 Hydril Company LP Printed In The U.S.A. July 1994 Rev. A, April 2002
Inspection Manual
R
PAGE
Ram BOPs iv
REVISION RECORD
1.0 INTRODUCTION
PAGE
Ram BOPs Introduction 1-1
PAGE
Ram BOPs Introduction 1-2
1.1 General
A. Purpose
The purpose of this manual is to provide detailed
instructions on how to perform scheduled inspections
of Hydril ram blowout preventers when they are not in
service. For in-service inspections, refer to the BOP
operator's manual.
PAGE
Ram BOPs Introduction 1-3
A. Normal Use
This manual is designed to be used in conjunction with
the BOP operator's manual for disassembly and as-
sembly instructions, operation specifications, bolt
torques, and part numbers. If an operator's manual is
not available, contact Hydril Headquarters in Hous-
ton, Texas for a copy (refer to Section 10 for address
information). This manual is divided into sections for
ease of use. The section headings are listed in the
Table Of Contents at the front of this manual.
To use this manual, turn first to the inspection
schedule in Section 2. Find the desired inspection
interval on the schedule. The procedure for each
inspection on the schedule is found in Sections 3
through 8. Find the inspection form in Section 9,
photocopy it, and use it as you follow the correspond-
ing inspection procedure. If the BOP requires major
repairs that cannot be made in the field, contact Hydril
at one of the Hydril Repair Facilities listed in Section
10.
B. Revision
Occasionally, Sections 1 through 10 of this manual
may be revised. Revisions are identified in two ways.
First, by a letter of the alphabet (Rev. A, B, C, etc.) on
page 1 of each section and in the Revision Record.
The Revision Record follows the Table Of Contents in
the front of this manual.
Second, the revised portion will be indicated by an
8-pt. grey bar in the margin (see example in the left
margin). This bar is intended to aid the user in finding
the parts of the section that have been changed from
the previous version.
Furthermore, to make the updating of this manual
easier when revisions are made, whole sections will
be replaced rather than individual revised pages.
NOTE: The revision letter indicated in the revision box
on page 1 of each section should match with the letter
shown in the Revision Record. If not, contact Hydril
Inspection Manual
R
PAGE
Ram BOPs Inspection Schedule 2-1
PAGE
Ram BOPs Inspection Schedule 2-2
2.1 General
The inspection schedule provides the inspection in- performing the first inspection listed. Perform the
terval and type of inspection required in tabular form. inspection using the inspection form and the corre-
The procedures for performing the inspections are sponding procedure. Continue to perform each in-
located in Sections 3 through 8 (see Table Of Con- spection in the same manner until all inspections
tents for listing). To use the schedule, find the have been completed.
inspection interval on the schedule and the associ-
ated inspections. Next, photocopy the inspection
form(s) from Section 9. Begin the inspections by 2.2 Inspection Schedule
turning to the section that contains the procedure for Refer to Table 2-1.
TABLE 2-1
INSPECTION SCHEDULE
2. Inspect Visually. 3
a. Replace All BOP Seals.**
b. Replace Ram Packers And Seals.**
3. Assemble BOP. *
2. Inspect By Gauge. 4
a. Replace BOP Spare Parts.**
Inspection Manual
R
PAGE
Ram BOPs Inspection Schedule 2-3
3. Assemble BOP. *
PAGE
Ram BOPs Visual Inspection 3-1
PAGE
Ram BOPs Visual Inspection 3-2
3.1 General
The procedures in this section cover the visual in-
spection of the Hydril ram BOP.
A. Inspection Records
During the inspection of the ram BOP, keep records
of the inspections and the actions taken. Use the
inspection form(s) in Section 9.
B. Repairs
Minor repairs can be performed in the field. However,
major repairs requiring welding must be performed at
an approved Hydril Repair Facility. Refer to Section
10 for a list of facility locations.
C. Cleaning
Prior to inspection, clean caked drilling mud, loose
rust, and scale from the exterior of the ram BOP with
high pressure water or steam.
D. Handling
Lift the ram BOP using two slings of adequate strength
in a basket configuration. Position the slings one on
each side of the ram BOP from just inside the hinges,
under the BOP body, and up the off hinge side (refer
to Figure 3-1). CAUTION: To prevent damage, do
not position slings under the multiple position locks or
the manual locks when lifting the ram BOP.
PAGE
Ram BOPs Visual Inspection 3-3
TOP VIEW
Bolt Heads
PAGE
Ram BOPs Visual Inspection 3-4
PAGE
Ram BOPs Visual Inspection 3-5
6. Inspect the pipe ram, shear ram, variable Repair Facility. Record findings on the
ram as follows: inspection form.
NOTE: If replacement of parts is required, b. Shear Ram:
refer to the disassembly and assembly pro- 1) Inspect shear blades for wear and
cedures in the BOP operator's manual. Re- damage. Replace if necessary. Record
fer to the operator's manual for part numbers. findings on the inspection form.
a. Pipe Ram and Variable Ram: 2) Inspect lateral T-Seal for wear, crack-
1) Inspect front packer on ram assem- ing, and hard skin. Replace if neces-
bly for wear, cracking, and hard skin. sary. Record findings on the inspection
Check variable ram packers for insert form.
separation. Replace if necessary. 3) Inspect upper seal on shear ram
Record findings on the inspection form. assembly for wear, cracking, and hard
2) Inspect top seal groove and vertical skin. Replace if necessary. Record
packing slots for burrs. Remove burrs findings on the inspection form.
with 240-grit emery cloth. Wipe clean 4) Inspect bottom surface of shear ram
with rag soaked in light machine oil. for wear and pitting. Minor damage can
3) Inspect upper seal on pipe ram as- be removed by polishing with 240 grit or
sembly for wear, cracking, and hard skin. finer emery cloth. After polishing, wipe
Replace if necessary. Record findings surfaces with light machine oil. Any
on the inspection form. damage requiring welding or machining
4) Inspect bottom surface of pipe ram must be repaired at a Hydril Authorized
for wear and pitting. Minor damage can Repair Facility. Record findings on the
be removed by buffing. After buffing, inspection form.
wipe surfaces with light machine oil. Any 5) Inspect sealing surface of lower car-
damage requiring welding or machining rier for scaring and pitting. Minor dam-
must be repaired at a Hydril Authorized age can be removed by polishing with
Top
Seal
Top Seal
Packer
Top Seal
Figure 3-4. Hydril Pipe Ram, Variable Pipe Ram, And Shear Ram
Inspection Manual
R
PAGE
Ram BOPs Visual Inspection 3-6
PAGE
Ram BOPs Gauge Inspection 4-1
PAGE
Ram BOPs Gauge Inspection 4-2
3.1 General
The procedures in this section cover the gauge in-
spection of the Hydril ram BOP. To complete this
inspection, the ram BOP operator's manual is re-
quired for disassembly, assembly, and part number
identification. If a manual is not available, contact the
nearest Hydril Repair Facility for a copy. Refer to
Section 10 for a list of locations.
A. Inspection Records
During the inspection of the ram BOP, keep records
of the inspections and the actions taken. Use the
inspection form(s) in Section 9.
B. Repairs
Minor repairs can be performed in the field. However,
major repairs requiring welding must be performed at
an approved Hydril Repair Facility. Refer to Section
10 for a list of locations.
C. Cleaning
Prior to inspection, clean caked drilling mud, loose
rust, and scale from the exterior of the ram BOP with
high pressure water or steam.
D. Handling
Lift the ram BOP using two slings of adequate strength
in a basket configuration. Position the slings one on
each side of the ram BOP from just inside the hinges,
under the BOP body, and up the off hinge side (refer
to Figure 4-1). CAUTION: To prevent damage, do
not position slings under the multiple position locks or
the manual locks when lifting the ram BOP.
PAGE
Ram BOPs Gauge Inspection 4-3
PAGE
Ram BOPs Gauge Inspection 4-4
PAGE
Ram BOPs Gauge Inspection 4-5
PAGE
Ram BOPs Gauge Inspection 4-6
52
PAGE
Ram BOPs Gauge Inspection 4-7
PAGE
Ram BOPs Gauge Inspection 4-8
PAGE
Ram BOPs Gauge Inspection 4-9
4
1
1
3
PAGE
Ram BOPs Gauge Inspection 4-10
* Use only Hydril replacement parts. Commercial grade fasteners will fail
in service due to the loads experienced.
** Quantity varies per BOP. Refer to ram BOP operator's manual.
PAGE
Ram BOPs Gauge Inspection 4-11
PAGE
Ram BOPs Gauge Inspection 4-12
PAGE
Ram BOPs Gauge Inspection 4-13
PAGE
Ram BOPs Gauge Inspection 4-14
PAGE
Ram BOPs Gauge Inspection 4-15
PAGE
Ram BOPs Gauge Inspection 4-16
PAGE
Ram BOPs Gauge Inspection 4-17
PAGE
Ram BOPs Gauge Inspection 4-18
Bearing
Surfaces
PAGE
Ram BOPs Gauge Inspection 4-19
PAGE
Ram BOPs Gauge Inspection 4-20
PAGE
Ram BOPs Gauge Inspection 4-21
Ring
pitting, and scratches (refer to Figure 4-25). OPEN CLOSE
Grooves
Remove any corrosion, minor scratches, or
minor pitting with emery cloth. Nicks and Bolt
scratches exceeding .015 in (.38 mm) must Holes
be repaired at a Hydril Repair Facility (refer to
Section 10 for a list of locations). Check
flatness of areas with a straight edge and Flanged
feeler gauges. Record findings on the in- Bottom Connection
spection form.
e. Inspect hydraulic operator fluid passages
and flush out to ensure full flow. Bolt
Holes
BOTTOM
VIEW
Ring
Groove
PAGE
Ram BOPs Gauge Inspection 4-22
LEGEND:
A – Maximum Rails to Seat Pocket
B – Maximum Rails to Seal Seat
C – Maximum Bore
F
B A D – Side Outlet Erosion
E – Side Outlet Erosion
F – Seal Seat Sealing Surfaces
D E
Rails
PAGE
Ram BOPs Gauge Inspection 4-23
PAGE
Ram BOPs Gauge Inspection 4-24
C. Wear Limits
The wear limits discussed in this section are listed in
Table 4-1.
Inspection Manual
R
PAGE
Ram BOPs Gauge Inspection 4-25
TABLE 4-1
RAM BOP WEAR LIMITS
7 1/16" – 3000 PSI
PAGE
Ram BOPs Gauge Inspection 4-26
TABLE 4-1
RAM BOP WEAR LIMITS
7 1/16" – 5000 PSI
PAGE
Ram BOPs Gauge Inspection 4-27
TABLE 4-1
RAM BOP WEAR LIMITS
7 1/16" – 10,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-28
TABLE 4-1
RAM BOP WEAR LIMITS
7 1/16" – 15,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-29
TABLE 4-1
RAM BOP WEAR LIMITS
9" – 3000 PSI
PAGE
Ram BOPs Gauge Inspection 4-30
TABLE 4-1
RAM BOP WEAR LIMITS
9" – 5000 PSI
PAGE
Ram BOPs Gauge Inspection 4-31
TABLE 4-1
RAM BOP WEAR LIMITS
11" – 3000 PSI
PAGE
Ram BOPs Gauge Inspection 4-32
TABLE 4-1
RAM BOP WEAR LIMITS
11" – 5000 PSI
PAGE
Ram BOPs Gauge Inspection 4-33
TABLE 4-1
RAM BOP WEAR LIMITS
11" – 10,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-34
TABLE 4-1
RAM BOP WEAR LIMITS
13 5/8" – 3000 PSI
PAGE
Ram BOPs Gauge Inspection 4-35
TABLE 4-1
RAM BOP WEAR LIMITS
13 5/8" – 5000 PSI
PAGE
Ram BOPs Gauge Inspection 4-36
TABLE 4-1
RAM BOP WEAR LIMITS
13 5/8" – 10,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-37
TABLE 4-1
RAM BOP WEAR LIMITS
13 5/8" – 15,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-38
TABLE 4-1
RAM BOP WEAR LIMITS
16 3/4" – 10,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-39
TABLE 4-1
RAM BOP WEAR LIMITS
18 3/4" – 10,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-40
REV A
TABLE 4-1
RAM BOP WEAR LIMITS
18 3/4" – 15,000 PSI
PAGE
Ram BOPs Gauge Inspection 4-41
TABLE 4-1
RAM BOP WEAR LIMITS
20 3/4" – 3000 PSI
PAGE
Ram BOPs Gauge Inspection 4-42
TABLE 4-1
RAM BOP WEAR LIMITS
21 1/4" – 2000 PSI
PAGE
Ram BOPs Gauge Inspection 4-43
TABLE 4-1
RAM BOP WEAR LIMITS
21 1/4" – 5000 PSI
PAGE
Ram BOPs BOP Operating Test 5-1
PAGE
Ram BOPs BOP Operating Test 5-2
5.1 General tion 4-Way valve (Open, Block, Close) and a hydrau-
lic regulator should be installed in the output line of the
A. Purpose test pump. An opening and closing line is required to
The procedures in this section cover the BOP operat- operate each set of rams. These control lines are
ing test of the Hydril ram BOP. This test verifies that connected to the one-inch NPT ports on the hinge
the Open and Close functions of the ram BOP operate side of the BOP. The regulated pressure source to
properly. operate the ram BOP should be from a regulator
separate from that used for the annular blowout
B. Inspection Records preventer(s).
During the BOP operating test of the ram BOP, Any clean, light petroleum hydraulic oil can serve
records should be kept of the results. Use the Ram as a hydraulic fluid. Fresh water may be used if water
BOP Inspection Form located in Section 9. soluble oil is added. Antifreeze must be added to
water based operating fluids to prevent serious dam-
C. Control System Requirements age to the operators when used in freezing condi-
The Hydril ram BOP may be tested with any oil field tions. CAUTION: Do not use synthetic fluids or fuel
test pump of sufficient pressure capacity. A 3-posi- oils. Serious seal damage will result.
Inspection Manual
R
PAGE
Ram BOPs BOP Operating Test 5-3
A. Testing Precautions
Take the following precautions to insure the safety of
all personnel during blowout preventer testing.
1. Use safety barrier during test operations.
2. Verify that test stump, blind flanges, mandrels,
blind hubs, piping, valves, gauges, and related
equipment are rated for the test pressures.
3. Check resolution and accuracy of pressure indi-
cating devices. A resolution of one percent of full
range and an accuracy of two percent is required.
4. Do the following if a leak occurs, or an unaccept-
able pressure loss occurs:
a. Stop the test.
b. Vent pressure from the BOP.
PAGE
Ram BOPs BOP Operating Test 5-4
Seal Seat
Ram Assy. Ring Groove
Ram BOP Body
Bonnet Bolts
MPL
Ram Compartment
Piston & Bonnet Seal
Piston Rod
Cylinder Piston Rod Mud Seal
Assy. Piston
Liner Weephole
Seals
PAGE
Ram BOPs BOP Operating Test 5-5
PAGE
Ram BOPs BOP Operating Test 5-6
PAGE
Ram BOPs Hydraulic System Test 6-1
PAGE
Ram BOPs Hydraulic System Test 6-2
PAGE
Ram BOPs Hydraulic System Test 6-3
A. Testing Precautions
Take the following precautions to insure the safety of
all personnel during blowout preventer testing.
1. Use safety barrier during test operations.
2. Verify that test stump, blind flanges, mandrels,
blind hubs, piping, valves, gauges, and related
equipment are rated for the test pressures.
3. Check resolution and accuracy of pressure indi-
cating devices. A resolution of one percent of full
range and an accuracy of two percent is required.
4. Do the following if a leak occurs of unacceptable
pressure loss occurs:
a. Stop the test.
b. Vent pressure from the BOP.
PAGE
Ram BOPs Hydraulic System Test 6-4
Seal Seat
Ram Assy. Ring Groove
Ram BOP Body
Bonnet Bolts
MPL
Ram Compartment
Piston & Bonnet Seal
Piston Rod
Cylinder Piston Rod Mud Seal
Assy. Piston
Liner Weephole
Seals
Figure 6-2. Typical Ram BOP Cutaway View
1) If a clamp is required to make up the installed in the same manner as end connec-
connection between the test stump and the tion clamps.
ram BOP, clean the clamp thoroughly and d. Connect test pump to the ram BOP. Refer to
coat the insides with light machine oil. Apply Paragraph 6.1.C.
Never-Seez thread lubricant to clamp nut 2. Open the ram BOP bonnets. Pressurize the
and bolt threads. Tighten clamp nuts and Close side of the BOP operator system. Begin-
bolts alternately, side to side, during installa- ning at zero, increase the pressure to 3000
tion to bring the clamp haves together uni- PSI(207 Bar) in increments of 500 PSI (34 Bar).
formly. Strike the clamp occasionally with a Isolate (Block) the pump from the ram BOP.
sledge hammer during tightening to ensure Observe the exterior of the BOP bonnets for
proper seating of the clamp on the hub. leakage for three minutes minimum. If no leaks
Contact clamp manufacturer for torque val- are present, continue to the next step. Do the
ues. following if a leak occurs or unacceptable pres-
2) If studs and nuts are required to make up sure loss occurs:
the connection between the test stump and a. Stop the test.
the ram BOP, apply Never-Seez thread lubri- b. Vent pressure from the BOP.
cant to the threads prior to installation. Refer
to the BOP operator's manual for the torque WARNING: STAND CLEAR OF VENTED PRES-
value. SURE TO AVOID INJURY.
c. Blind off all outlet connections with appropri-
ate hardware. Outlet clamps (if required) are c. Make necessary repairs. If repairs require
Inspection Manual
R
PAGE
Ram BOPs Hydraulic System Test 6-5
PAGE
Ram BOPs Wellbore Pressure Test 7-1
PAGE
Ram BOPs Wellbore Pressure Test 7-2
PAGE
Ram BOPs Wellbore Pressure Test 7-3
A. Testing Precautions
Take the following precautions to insure the safety of
all personnel during blowout preventer testing.
1. Use safety barrier during test operations.
2. Verify that test stump, blind flanges, mandrels,
blind hubs, piping, valves, gauges, and related
equipment are rated for the test pressures.
3. Check resolution and accuracy of pressure indi-
cating devices. A resolution of one percent of full
range and an accuracy of two percent is required.
4. Do the following if a leak occurs of unacceptable
pressure loss occurs:
a. Stop the test.
b. Vent pressure from the BOP.
PAGE
Ram BOPs Wellbore Pressure Test 7-4
Seal Seat
Ram Assy. Ring Groove
Ram BOP Body
Bonnet Bolts
MPL
Ram Compartment
Piston & Bonnet Seal
Piston Rod
Cylinder Piston Rod Mud Seal
Assy. Piston
Liner Weephole
Seals
Figure 7-2. Typical Ram BOP Cutaway View
1) If a clamp is required to make up the installed in the same manner as end connec-
connection between the test stump and the tion clamps.
ram BOP, clean the clamp thoroughly and d. Connect test pump to the ram BOP. Refer to
coat the insides with light machine oil. Apply Paragraph 7.1.C.
Never-Seez thread lubricant to clamp nut 2. Open the ram BOP bonnets and cycle the rams
and bolt threads. Tighten clamp nuts and using 200 PSI (14 Bar) pressure. Leave the rams
bolts alternately, side to side, during installa- in the Open (retract) position.
tion to bring the clamp haves together uni- 3. Close the bonnets and tighten the bolts using 100
formly. Strike the clamp occasionally with a percent of the torque value shown in the BOP
sledge hammer during tightening to ensure operator's manual. Also refer to the operator's
proper seating of the clamp on the hub. manual for the tightening sequence.
Contact clamp manufacturer for torque val- 4. If pipe rams are installed in the ram BOP, install
ues. a test mandrel into the bore of the ram BOP. Do
2) If studs and nuts are required to make up not install a test mandrel if shear rams are in-
the connection between the test stump and stalled.
the ram BOP, apply Never-Seez thread lubri- 5. Fill the bore of the ram BOP with clean tap water
cant to the threads prior to installation. Refer to a level six inches above the rams.
to the BOP operator's manual for the torque 6. Close the rams using 1500 PSI (103 Bar) for pipe
value. rams or 3000 PSI (207 Bar) for shear rams.
c. Blind off all outlet connections with appropri- 7. Vent the operator system to zero.
ate hardware. Outlet clamps (if required) are 8. Remove the excess water from above the rams
Inspection Manual
R
PAGE
Ram BOPs Wellbore Pressure Test 7-5
so that rams can be observed clearly. b. Vent pressure from the BOP.
9. Apply wellbore pressure of 200 - 300 PSI (14 - 21
Bar). Isolate (Block) test pump from ram BOP WARNING: STAND CLEAR OF VENTED PRES-
and allow pressure to stabilize. Hold pressure for SURE TO AVOID INJURY.
three minutes minimum. Observe for dramatic
pressure loss and leakage. Use a mirror or c. Make necessary repairs. If repairs require
boroscope suspended over the bore of the BOP disassembly of the BOP, perform the Wellbore
to observe for leakage between the ram packing Pressure Test again beginning with Step 2.
and the mandrel. 11. Vent wellbore pressure to zero. Allow a few
seconds to allow any residual pressure to bleed
WARNING: DO NOT EXTEND ANY PART OF off.
BODY OVER THE BOP WHILE PRESSURE IS 12. Open (retract) rams and remove mandrel.
IN THE WELLBORE. 13. Drain water from wellbore.
14. If further testing is required, leave the ram BOP
This low pressure test is satisfactory if no visable installed on the test stump. If testing is complete,
leaks occur. Record initial and final wellbore remove the BOP from the test stump as follows:
pressure on the inspection form. If no leaks a. Install the lifting apparatus onto the ram BOP
occur, continue to the next step. Do the following Lift the BOP using the sling arrangement
if a leak occurs: shown in Figure 7-1.
a. Stop the test. 1) If a clamp is required to make up the
b. Vent pressure from the BOP. connection between the test stump and the
ram BOP, remove the clamp.
WARNING: STAND CLEAR OF VENTED PRES- 2) If studs and nuts are required to make up
SURE TO AVOID INJURY. the connection between the test stump and
the ram BOP, remove the studs and nuts.
c. Make necessary repairs. If repairs require b. Remove blind hardware from outlet connec-
disassembly of the BOP, perform the Wellbore tions. Outlet clamps (if required) are re-
Pressure Test again beginning with Step 2. moved in the same manner as the end con-
10. Increase wellbore pressure to BOP rated working nection clamp.
pressure (refer to operator's manual for working c. Vent all pressure and disconnect the test
pressure of your particular ram BOP). Isolate pump from the ram BOP.
(Block) test pump from ram BOP and allow pres- d. Lift and remove the ram BOP from the test
sure to stabilize. Hold pressure for three minutes stump.
minimum. Observe for dramatic pressure loss
and leakage. Use a mirror or boroscope sus- WARNING: THE RAM BOP IS VERY HEAVY
pended over the bore of the BOP to observe for AND BULKY EQUIPMENT. TAKE EXTREME
leakage between the ram packing and the man- CARE WHEN LIFTING IT. DO NOT PLACE
drel. HANDS OR OTHER BODY MEMBERS WHERE
THEY CAN BE INJURED BY CONTACT WITH
WARNING: DO NOT EXTEND ANY PART OF OTHER EQUIPMENT DURING LIFTING AND
BODY OVER THE BOP WHILE PRESSURE IS INSTALLATION OPERATIONS. BE SURE THAT
IN THE WELLBORE. THE LIFTING APPARATUS IS ADEQUATE TO
HANDLE THE LOAD.
This high pressure test is satisfactory if the well
pressure does not drop more than 100 PSI (7 Bar) 15. Sign and date the inspection form.
in three minutes and no visable leaks occur.
Record initial and final wellbore pressure on the
inspection form. If pressure loss is less than 100
PSI (7 Bar) and no leaks occur, continue to the
next step. Do the following if a leak occurs or if an
unacceptable pressure loss occurs:
a. Stop the test.
Inspection Manual
R
PAGE
Ram BOPs MPL Lock Test 8-1
PAGE
Ram BOPs MPL Lock Test 8-2
PAGE
Ram BOPs MPL Lock Test 8-3
A. Testing Precautions
Take the following precautions to insure the safety of
all personnel during blowout preventer testing.
1. Use safety barrier during test operations.
2. Verify that test stump, blind flanges, mandrels,
blind hubs, piping, valves, gauges, and related
equipment are rated for the test pressures.
3. Check resolution and accuracy of pressure indi-
cating devices. A resolution of one percent of full
range and an accuracy of two percent is required.
4. Do the following if a leak occurs of unacceptable
pressure loss occurs:
a. Stop the test.
b. Vent pressure from the BOP.
PAGE
Ram BOPs MPL Lock Test 8-4
Seal Seat
Ram Assy. Ring Groove
Ram BOP Body
Bonnet Bolts
MPL
Ram Compartment
Piston & Bonnet Seal
Piston Rod
Cylinder Piston Rod Mud Seal
Assy. Piston
Liner Weephole
Seals
Figure 8-2. Typical Ram BOP Cutaway View
PAGE
Ram BOPs MPL Lock Test 8-5
7. Engage the lockout devices by rotating the stems connection between the test stump and the
clockwise approximately 6 1/2 turns or until they ram BOP, remove the clamp.
stop turning. Tighten the stems using 10 lb-ft (13 2) If studs and nuts are required to make up
N•m) torque. the connection between the test stump and
8. Bleed operator closing pressure to zero. the ram BOP, remove the studs and nuts.
9. Slowly increase operator opening pressure to b. Remove blind hardware from outlet connec-
1500 PSI (103 Bar) in increments of 500 PSI (34 tions. Outlet clamps (if required) are re-
Bar). Observe through the bore of the ram BOP moved in the same manner as the end con-
to see if the rams retract. nection clamp.
c. Vent all pressure and disconnect the test
WARNING: USE A MIRROR OR A BORE pump from the ram BOP.
SCOPE TO OBSERVE THE OPERATION OF d. Lift and remove the ram BOP from the test
THE RAMS THROUGH THE BORE. stump.
CAUTION: Do not exceed 1500 PSI (103 Bar) or WARNING: THE RAM BOP IS VERY HEAVY
damage to the MPL may occur). If the rams AND BULKY EQUIPMENT. TAKE EXTREME
remain closed, continue to the next step. If the CARE WHEN LIFTING IT. DO NOT PLACE
rams open (retract), do the following: HANDS WHERE THEY CAN BE INJURED BY
a. Stop the test. CONTACT WITH OTHER EQUIPMENT DUR-
b. Vent pressure from the BOP. ING LIFTING AND INSTALLATION OPERA-
TIONS. BE SURE THAT THE LIFTING APPA-
WARNING: STAND CLEAR OF VENTED PRES- RATUS IS ADEQUATE TO HANDLE THE LOAD.
SURE TO AVOID INJURY.
17. Sign and date the inspection form.
c. Make necessary repairs. If repairs require
disassembly of the BOP, perform the MPL
Lock Test again beginning with Step 2.
10. Apply 200 PSI (14 Bar) wellbore pressure and
hold for three minutes. NOTE: The application of
higher wellbore pressures do not test the locking
system because the ram blocks become well
pressure energized; therefore, the locks become
essentially passive.
11. Vent wellbore pressure to zero.
12. Apply 100 PSI (7 Bar) closing pressure to set the
cylinder liner forward and away from the lockout
segments.
13. Disengage lockout devices by turning the stems
6 1/2 turns counterclockwise until they are fully
retracted.
14 Set normal operating pressure and open the
rams.
15. Vent the operating pressure to zero.
16. If further testing is required, leave the ram BOP
installed on the test stump. If testing is complete,
remove the BOP from the test stump as follows:
a. Install the lifting apparatus onto the ram BOP
Lift the BOP using the sling arrangement
shown in Figure 8-1.
1) If a clamp is required to make up the
Inspection Manual
R
PAGE
Ram BOPs Inspection Forms 9-1
PAGE
Ram BOPs Inspection Forms 9-2
PAGE
Ram BOP 1
NOTE: This inspection form is written for a single ram BOP containing two bonnets and one ram
compartment. For models that have more than one ram compartment, photocopy this form as many
times as there are ram compartments in use.
Owner: User:
[ ] Drilling [ ] Stripping [ ]
o o
[ ] Carbon Dioxide (Stack Temperature): F C
o o
[ } Hydrogen Sulfide (Stack Temperature): F C
o o
[ ] High Temperature Well (Stack Temperature): F C
o o
[ ] Below Freezing Ambient Temperatures: F C
Inspection Form
R
PAGE
Ram BOP 2
1 Top Connection:
Bottom Connection:
Side Outlets:
2 Nut/Bolt Heads:
3 Stud Threads:
4 Body:
5 Bonnets:
6 Pipe Ram/HVR:
Shear Ram:
5 Pressure: Less than 200 PSI (14 Bar) — Left Bonnet Open And Right Bonnet Closed
Pressure: Less than 200 PSI (14 Bar) — Left Bonnet Closed And Right Bonnet Open
2,3 Pressure: 0-3000 PSI (207 Bar) In 500 PSI (34 Bar) Increments – Bonnets Open
PAGE
Ram BOP 3
Step
7 Operator Pressure: 1500 PSI (103 Bar) — Both Bonnets Closed — Pipe Rams or 3000 PSI (207
Bar) —Shear Rams
5 Operator Pressure: 1500 PSI (103 Bar) — Both Bonnets Closed — Pipe Rams or 3000 PSI (207
Bar) —Shear Rams; Reduce Pressure to 100 PSI (7 Bar).
9 Open Pressure: 0 - 1500 PSI (104 Bar) in 500 PSI (35 Bar) Increments.
PAGE
Ram BOP 4
4 MPL Locknut Assembly —Left Bonnet MPL Locknut Assembly — Right Bonnet
a. Locknut a. Locknut
3) Surface B: 3) Surface B:
1) Edges: 1) Edges:
5 MPL Cylinder Assembly — Left Bonnet MPL Cylinder Assembly — Right Bonnet
PAGE
Ram BOP 5
Step
6 Piston & Lock Screw —Left Bonnet Piston & Lock Screw — Right Bonnet
2) Entry Bevel and Seal Groove: 2) Entry Bevel and Seal Groove:
1) Surfaces: 1) Surfaces:
1) Radius: 1) Radius:
2) Threads: 2) Threads:
3) Edges: 3) Edges:
Inspection Form
R
PAGE
Ram BOP 6
Step
1) Surface A: 1) Surface A:
1) Surface A: 1) Surface A:
2) Straightness: 2) Straightness:
8 Bonnet Hinge Assembly — Left Bonnet Bonnet Hinge Assembly — Right Bonnet
PAGE
Ram BOP 7
Step
4) Threads: 4) Threads:
2) Threads: 2) Threads:
a. Bonnet a. Bonnet
8) Studs: 8) Studs:
1) Condition: 1) Condition:
2) Straightness: 2) Straightness:
10 Load Hinge Assemblies — Left Bonnet Load Hinge Assemblies — Right Bonnet
Inspection Form
R
PAGE
Ram BOP 8
Step
a. Seal Seat
1) O-Ring Grooves:
2) Lower Surface:
3) Flatness:
13 Body
a. Ring Grooves:
b. Threaded Holes:
c. Mounting Surfaces:
d. Sealing Surfaces:
e. Fluid Passages:
g. Wellbore Diameter:
14 Ram Assemblies
PAGE
Ram BOP 9
Step
COMMENTS
Inspection Form
R
PAGE
Ram BOP 10
COMMENTS CONTINED
Inspector:
Date
Inspection Form
R
PAGE
Pipe/Variable Ram 1
RAM IDENTIFICATION
NOTE: This inspection form is written for a single pipe/variable ram assembly containing two ram
blocks. Photocopy this form for as many ram assemblies that are to be inspected.
Owner: User:
o o
[ ] Carbon Dioxide (Stack Temperature): F C
o o
[ } Hydrogen Sulfide (Stack Temperature): F C
o o
[ ] High Temperature Well (Stack Temperature): F C
o o
[ ] Below Freezing Ambient Temperatures: F C
PAGE
Pipe/Variable Ram 2
X
B
LEGEND:
A: Overall Height
B: Top Seal Groove Depth
X: Area For NDE & Hardness Tests
PAGE
Pipe/Variable Ram 3
COMMENTS
Inspector:
Date:
Inspection Form
R
PAGE
Shear Ram 1
RAM INDENTIFICATION
NOTE: This inspection form is written for a single shear ram assembly containing an upper and
lower carrier. Photocopy this form for as many shear ram assemblies that are to be inspected.
Owner: User:
Ram Size:
o o
[ ] Carbon Dioxide (Stack Temperature): F C
o o
[ } Hydrogen Sulfide (Stack Temperature): F C
o o
[ ] High Temperature Well (Stack Temperature): F C
o o
[ ] Below Freezing Ambient Temperatures: F C
PAGE
Shear Ram 2
5) Distance Between the Top of the 8) Distance Between the Top of the
Ram Block to the Hard-Faced Ram Block to the Hard-Faced
Surface: Surface:
PAGE
Shear Ram 3
X UPPER CARRIER
B E
C D
LEGEND:
A: Overall Height
B: Top Seal Groove Depth
C: Guide Pin Diameter
D: Distance Between Bottom of Ram Block To Top of Guide Pins
E: Distance between Top of Ram Block to Hard-Faced Surface
X: Area for NDE and Hardness Tests
X
LOWER CARRIER
B G
A
LEGEND: F H
A: Overall Height
B: Top Seal Groove Depth
F: Guide Pin Hole Diameter
G: Distance between Top of Ram Block to Hard-Faced Surface
H: Distance Between Bottom of Ram Block To Top of Guide Pin Holes
X: Area for NDE and Hardness Tests
PAGE
Shear Ram 4
COMMENTS
Inspector:
Date:
Inspection Manual
R
PAGE
Ram BOPs Hydril Repair Facilities 10-1
PAGE
Ram BOPs Hydril Repair Facilities 10-2