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1562+Fz35 35闸板防喷器+用户手册a0 英文
1562+Fz35 35闸板防喷器+用户手册a0 英文
No.1562
Trademarks ○
R ○
R ○
R
16A-0111, , XK14-001-0002 .
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd hereby declares that by check the contents of the
manual are consistent with the product and cannot in the nature of things be free from error, the consistency is
maximized. The contents of the manual will be reviewed at fixed period and modified in the next version. Suggestions
for improvements are highly welcomed.
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd holds the copyright ○c 2015. No inform will be made for
any change.
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd Contract No.
Technical Support Department
Customer Hotline: +86(21)64290467 Fax: +86(21) 64290467
Website: www.shenkai.com Postal Code: 201114
Catalogue
1 Application ........................................................................................................................................... 1
2 Model & Specification and Technical Parameters ............................................................................... 2
2.1 Model......................................................................................................................................... 2
2.1.1 Bore Code ....................................................................................................................... 2
2.1.2 Rated working pressure .................................................................................................. 2
2.1.3 Temperature grade ......................................................................................................... 2
2.2 Ram BOP Technical Parameters .............................................................................................. 3
3 Working Principles and Structure Characteristics ............................................................................... 5
3.1 Working principle....................................................................................................................... 5
3.1.1 Hydraulic control principle .............................................................................................. 5
3.1.2 Principle of Sealing ......................................................................................................... 5
3.2 Structural features of main parts ............................................................................................... 6
3.2.1 Pipe ram assembly ......................................................................................................... 7
3.2.2 Side Door Seal Structure ................................................................................................ 8
3.2.3 Ram Shaft Seal Assembly .............................................................................................. 8
3.2.4 Secondary Seal System ................................................................................................. 9
3.2.5 Locking Shaft Seal Assembly ....................................................................................... 10
3.2.6 Manual locking mechanism of ram ............................................................................... 10
3.2.7 Hinge Structure ..............................................................................................................11
3.2.8 Piston Assembly ........................................................................................................... 13
3.3 Parts List ................................................................................................................................. 14
4 Installation and Use ........................................................................................................................... 17
4.1 Preparation before Use ........................................................................................................... 17
4.2 Usage and matters needing attention ..................................................................................... 18
5 Dismounting and Maintenance of BOP ............................................................................................. 20
5.1 Opening Door of BOP ............................................................................................................. 20
5.2 Replacement of ram and its sealing rubber core .................................................................... 21
5.3 Replacement of Seal Ring between Door and Body .............................................................. 22
5.4 Repair and replacement of cylinder assembly........................................................................ 22
5.6 Installation Notes..................................................................................................................... 24
5.7 Daily Maintenance................................................................................................................... 24
5.8 Operating Period Maintenance ............................................................................................... 25
6 Preservation procedures ................................................................................................................... 27
6.1 Storing for periods greater than 30 days ................................................................................ 27
6.2 Storage of Rubber Parts ......................................................................................................... 27
7 Common Troubles and Troubleshooting ........................................................................................... 28
1 Application
Ram BOP with hydraulic control is a key part of well-control equipment. It's used for
controlling wellhead pressure during well drilling, workover and testing etc., preventing
well blowout effectively and realizing safe construction. It can be used for the
following:(Figure 1-1):
With proper pipe ram sealing the annular space between casing and drilling
string when there is pipe in the hole.
With blind ram sealing the well head completely.
When the well head is closed, use the kill manifold and choke manifold
connected to the spool and the outlet of the body doing mud circulating, choking
and releasing, well killing etc.
When ram BOP is used together with the choke manifold and kill manifold, it can
effectively control the bottom hole pressure and achieve near-balanced drilling
operation.
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FZ35-35 Ram BOP Manual Rev.A0
BOP type
Bore code Bore size (in) Bore code Bore size (in)
1
18 7 /16 " 48 18 3/4"
23 9" 53 20 3/4"
28 11" 54 21 1/4"
35 13 5/8" 68 26 3/4"
43 16 3/4" 76 30"
The BOP has rated working pressure at six grades, as shown in Table 2-2.
Synthetic rubber materials in the equipment, contacting with the liquid in the well,
work at the temperature grade as shown in Table 2-4.
Code of
API code Range of working temperature
temperature grade
T-75 75 -59℃~121℃(-75 ºF ~250 ºF)
T-20 20 -29℃~121℃(-20 ºF ~250 ºF)
T-0 00 -18℃~121℃(0 ºF ~250 ºF)
Table 2-4 Temperature grade of nonmetal sealing material in contact with liquid in well
Model
FZ35-35 2FZ35-35
Single BOP Double BOP
Bore 346.1mm(13 5/8 in)
Rated working pressure 35MPa(5000psi)
Hydrostatic test pressure 52.5MPa (7500psi)
Hydraulic control rated
working pressure
21 MPa(3000psi)
Recommended hydraulic
control operation pressure
8.4-10.5MPa(1200-1500psi)
Open 7.4 L×2=14.8 L 7.4 L×4=29.6 L
Hydraulic Fluid
Close 8.3 L×2=16.6 L 8.3 L×4=33.2 L
Closing Ratio 5.7 5.9
Locking Screw turns
(each end)
23 23
Temperature grade
of metal material
T-20
Weight 3430kg 6310kg
Instructions:
a. The BOP is designed and manufactured according to specifications API Spec 16A.
b. The part in the BOP, in contact with liquid in well is resistant to hydrogen sulfide stress corrosion, and the
requirements of NACE MR-0175 are met.
c. The weight of BOP in the connection mode of upper flanged, lower flanged and side bolted is showed in the table
(see Fig.2-1, Fig.2-2, including ram assembly). The actual weight shall change with the change of the upper and the
lower connection and the side port.
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FZ35-35 Ram BOP Manual Rev.A0
A Length
B-1 Height-flange connection
C Width-not including side port
Table 2-6 Size of appearance of ram BOP
Overall dimension
Model A B-1 C
mm mm mm
FZ35-35 Single Ram BOP 2468 950 887
2FZ35-35 Double Ram BOP 2468 1430 887
Instructions: The actual size shall change with the change of the upper and the lower connection and
the side port.
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Floating performance of the ram is good. Because the ram seat (ram holder) and the
ram body (block) are separated, the ram can move slightly in the holder to ensure
positive alignment of the rubber faces as face seal contact occurs. There is 3mm
installation clearance between the ram body and the ram seat. When shutting off the ram,
the holder extrudes top rubber and makes it deform and bulge up to enhance
effectiveness of sealing and reduces the wear of the ram packer.
Note: The sign of "HO" (Hang-Off) on the ram body indicates that drilling tools could be
hanged on. Drilling tools shall not be hanged on the ram assembly without the sign of
"HO".
Table 3-1 Part Numbers for Rams
Qty Qty
No. Description Part No./Model
(Single) (Double)
4 Door Seal 2FZ3535-15 2 4
Body Door
Qty. Qty.
No. Description Part No./Model
(Single) (Double)
14-1 Retainer ring DFZ5414-33 2 4
14-2 Wiper ring 100 Q/ZB336-77 2 4
14-3 Bushing 2FZ5414B-07 2 4
14-4 O-ring 105×3.1 4 8
14-5 Packing Bearing Ring DFZ5414-31 4 8
14-6 O-ring 120×3.1 4 8
14-7 Backup ring SKZF100.02 8 16
14-8 Y-ring SKZF100.01 4 8
14-9 Washer DFZ5414-28 4 8
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The sealing part between the door and the Ram Shaft is comprised of two parts. The
first one is the sealing wellhead. And the other one is the oil pressure for sealing the
hydraulic control. The secondary seal is at the middle of the two parts. Generally, the
sealing is highly reliable by the sealing ring of several structure. But the sealing ring may
be damaged due to not being maintained for a long term or other reasons, leakage may
happen during well sealing. The secondary seal will be needed for emergency handling.
At the condition of well sealing, if any fluid flows from the access hole (at the bottom
of the door), the sealing ring shall have been damaged. Whether the sealing ring for well
sealing pressure or that for the oil sealing pressure is damaged can be damaged
according to the property of fluid. Now remove the Z1″ external hex blocking for greasing
hole at the top immediately. Rotate the hole screws clockwise by a socket head wrench.
Eject the secondary sealing grease in bar shape to the annular space via a one-way
valve, so as to reinforce the sealing ring and make sealing compensation.
To prevent the secondary sealing grease from being solidified and invalid when
the BOP is not used for a long term, the secondary sealing grease bar shall not
be mounted when the BOP leaves out of factory, and our company also doesn't
recommend to install the secondary sealing grease bar when the BOP is not
used. It shall not be mounted before being inserted to the well, and removed
after well completion and maintenance. It shall be washed to keep clean.
Special tools shall be prepared in advance for urgent need.
Observe frequently from the access hole (internal hexagonal plug screws with
hole) at the bottom whether drilling fluid or oil fluid flows during usage of BOP.
After the sealing ring becomes invalid, the secondary
7-1
sealing grease shall not be ejected excessively,
which shall be subject to the standard that the
7-2
observation hole would not be leaked. Because the
friction resistance of secondary sealing grease is
high and particles are adhered, a major damage may
7-3
happen to the Ram Shaft.
Fig.3-4 Secondary Seal System
Qty. Qty.
No. Description P/N
(Single) (Double)
Z1″ External
7-1 SFZ2835-38 2 4
hexagonal blocking
7-2 Cock SFZ2835-37 2 4
7-3 Secondary sealing grease EM-09-1 2 4
7-4
Z1/2″ Internal hexagonal
7-4 SFZ2835-40 2 4
plug screw with hole
Table 3-5 Parts list of
Secondary Seal System
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FZ35-35 Ram BOP Manual Rev.A0
Direction of hydraulic
control pressure
Qty. Qty.
No. Description Part No./Model
(Single) (Double)
18-1 Retainer Ring GB/T893.1 95 2 4
18-2 Thrust Shaft Sleeve 2FZ3535-17A 2 4
18-3 W-ring DFZ5414-25 6 12
18-4 Back –up ring DFZ5414-24 2 4
18-5 Wiper Seat Retainer DFZ5414-23 2 4
18-6 Wiper Ring DFZ5414-22 2 4
The manual locking mechanism of ram is comprised of locking shaft, ram shaft,
manual-operated rod and hand wheel etc. (The length is generally 3.38m and 3.8m, or
customized).
The effect of manual locking mechanism is when it takes a long time to have well
sealing, and after the ram is closed hydraulically, rotate the hand wheel by manual force,
and lock the ram at the closed position. At this time, the hydraulic pressure may be
released.
Locking -- When it is locked manually, rotate the hand wheel clockwise, and drive
the locking shaft for rotation by a joystick. Because the locking shaft locates at
the clamp seat, rotate the locking shaft to push it at the rear of cylinder head,
forcing the ram shaft moving toward the center of wellhead and locking the ram
assembly. (The rotation number is shown in Table 2-5 ).
Unlocking -- The manual locking device can just close the ram instead of opening
the ram. If to open the ram that has been locked manually, firstly reset and
unlock the locking device manually, and open the ram by hydraulic pressure.
This is the only way. The detailed operation method is:
Firstly rotate the hand wheel to the terminal point counter-clockwise (The
rotation number is shown in Table 2-5 ).;
And then rotate back for 1/8~1/4 turns, to prevent the lock screw from
jamming during change of temperature;
And then the ram is opened by hydraulic pressure.
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FZ35-35 Ram BOP Manual Rev.A0
The aquare
Connect the
Manual control
assembly
Door hinge are designed that the hinge separates from the fluid hinge. This structure
has following features:
1. Load hinges support the full weight of doors; self-lubricated radial needle bearing
and palm thrust are installed on the load hinges for quick and easy opening and closing
the doors.
2. The fluid hinges only connect with oil pipe and seal oil pressure, they don't support
the weight of the side door, the can prolong the life of seal assembly and change the seal
assembly directly on the body without disassembly the side door.
3. The up and down position of side door can be adjusted with load hinges.+
▲ ! Note: Generally, the hinge brackets and doors do not have
interchangeability. If there is need to replace the hinge brackets and doors for
special requirement, shall choose SHENKAI's parts and do some adjustments
when assembly. Drill and ream the hinge positioning pin hole(9-12 or 9-15) again to
make sure the interchangeability.
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9-1 9-2 9-3 9-4 9-5 9-6 9-2 9-7 9-8 9-9 9-10 9-11
9-12 9-13 9-14 9-15 9-16 9-17 9-18 9-19 9-20 9-21
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Table 3-9 Spare Parts list for one year for FZ35-35
Qty. Qty.
No. Description Part No./Model
(Single) (Double)
4 Door seal 2FZ3535-15 2 4
6 O-ring 250×5.7 4 8
7-3 Secondary sealing grease EM-09-1 2 4
9-2 O-ring 70×3.1 4 8
9-3 O-ring 55×3.1 12 24
9-6 O-ring 40×3.1 4 8
9-11 O-ring 25×2.4 4 8
9-17 O-ring 30×3.1 4 8
9-18 O-ring 35×3.1 4 8
10 O-ring 50×3.1 2 4
14-2 Wiper ring 100 Q/ZB336-77 2 4
14-4 O-ring 105×3.1 4 8
14-6 O-ring 120×3.1 4 8
14-8 Y-ring SKZF100.01 4 8
14-7 Back up ring SKZF100.02 8 16
17-2 Piston Seal DFZ5414-13 4 8
17-3 O-ring 95×3.1 2 4
18-3 W-ring DFZ5414-25 6 12
18-4 Back –up ring DFZ5414-24 2 4
18-6 Wiper ring DFZ5414-22 2 4
19 O-ring 32×3.1 4 8
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FZ35-35 Ram BOP Manual Rev.A0
Check if BOP is correctly installed: the hoisting bolt of the body is on the top; the
manual lock device is well installed and fixed with the hanger in the hand wheel
indicating the opening and closing cycles; the opposite angles of the attachment
bolts at all position are even and tightening.
Check whether the size of mounted ram rubber cores and the size of drilling tools
under the well;
Check whether the blowout control, the well control, and the choke manifold are
well connected;
Use the control device to open and close all rams respectively twice by
2-3MPa(300psi~500psi) control pressure for test run.
Remove air in the oil line.
Check if the connection pipeline of the oil road is consistent with opening and
closing as indicated by BOP. In the case that the ram's opening and closing
action is not consistent with that as indicated by the console handle, adjust
the connection pipeline.
Check whether the manual locking device is well connected, and whether it is
flexible to open and close the ram by manual lever, and record the rotating turns
of hand wheel during the well shut-in, and hang a sign on the hand wheel. After
the trial run, rotate the hand wheel leftward to return and unlock. Open the ram
by the hydraulic pressure;
Have complete pressure test to the wellhead device, and the pressure test
standard shall be executed according to the well control regulations. After the
pressure test, tighten again the connection bolt, to prevent the loosening or
uneven. The tightening torque of flange bolt is showed at Table 4-1 or Table 4-2;
When the BOP is performed with ground inspection and test, the BOP shall be
filled with water, and then open and close the ram for once to release the air in
the rear of ram chamber.
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FZ35-35 Ram BOP Manual Rev.A0
Table 4-1 Recommended value (Metric system) of connecting and tightening torque of stud and screw
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5.1.2 Release the hydraulic pressure. Loosening the door bolts (▲! Caution: If the
BOP is mounted on the well, the door bolts shall not be uninstalled if any pressure
in the well)
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FZ35-35 Ram BOP Manual Rev.A0
5.2.2 Replace the rubber part of the ram. Unscrew the two ram bolts and take down
the holder. Remove the two ram rubber bolts.Take out the top seal from the groove of the
ram block with a screwdriver.Remove the whole rubber from the rams.▲!Note:It must
clean up the ram and the holder of mud or cement before install new rubber parts. It shall
be applied with lubricating oil during install ram rubber bolts. Tighten the screws
manually.
5.2.3 The procedure of assembling is in the opposite order. Use hydraulic oil to Open
the ram to pull the ram into of the door before close the door.
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FZ35-35 Ram BOP Manual Rev.A0
5.3.2 When replacing a seal, pay attention on the position of sealing ring that shall be
applied with lubricating oil during installation of sealing part.
5.4.2 Remove nuts. Remove cylinder head , hydraulic cylinder and bolts.
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FZ35-35 Ram BOP Manual Rev.A0
5.4.5 Firstly remove the locking screw ,secondly unscrew the lock nut, finally remove
the piston; (Note: The installing steps is contrary to the steps of removing. When
screwing the lock nut, should pay attention to align the hole of locking screw on the piston
and lock nut.
5.4.7 Open the door, pull out the ram shaft and replace the seal in the door;
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FZ35-35 Ram BOP Manual Rev.A0
Check if there is the burr or sharp edge on the parts. If any, remove them to
ensure no scratch caused to the seal ring. Note to clean parts.
Grease the seal ring while installing it. Grease the relative sealing surface to
facilitate installation.
Note the direction of the lip type seal ring and ensure opening of the lip to be
opposite the direction with pressure.
Make the seal ring to smoothly pass the guiding part of the shaft head and avoid
scratch
1. Disassemble all of the parts and clean up. In addition to examinations according to
the requirements of the one-year check, also should deal with important size
measurement of main parts. a) If the wear extent of inner diameter of the cylinder is more
than 0.4 mm or there is obvious scars and the solder peels off, the cylinder should be
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FZ35-35 Ram BOP Manual Rev.A0
remanufacture or replacement; b) If the wear extent of piston rod is more than 0.25 mm ,it
should be remanufacture or replacement; c) If the wear ring diameter is lower than the
metal body, the wear ring should be replace; d)If cladding material of the lock shaft is
corroded and appear pits that would affect sealing, the lock shaft is overall bending or
thread damaged that would affect the lock or unlock, or the quartet at end is damaged
that will affect the connection with manual assembly, etc., the lock shaft should be
replaced.
2. Hardness testing shall be carried out on the pressure-containing parts and the
pressure-controlling parts such as body and bonnet. If the hardness is abnormal(>
HRC22), contacting manufacturer is necessary.
Repair and remanufacture parts shall be carried out according to API Spec 16A
appendix B. Replacement of parts shall be design and manufacturing by the OEM. After
checking the Bop, if the pressure-containing parts need to be welded to restore the
performance, the bop is not suitable for easy maintenance in the field, must be
remanufactured by the API Spec 16A qualified remanufacturer or authorized
remanufacturer.
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FZ35-35 Ram BOP Manual Rev.A0
6 Preservation procedures
Prior to shipping and storage, all equipment should avoid direct sunlight, rain and
snow shower, keep them away from acid and alkali, organic solution etc, which would
affect the quality of rubber material.
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FZ35-35 Ram BOP Manual Rev.A0
Prepared by:
(Technical engineer)
Audited by:
(Chief engineer)
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Rev:A0