MANAUL-9407_B

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Inspection ManualRam BOPs PAGE

ii

PREFACE

Hydril makes no warranties of any kind, expressed orimplied, including any warranty of mechanical fitnessfor any particular purpose, that the work performedpursuant to this manual will be free from defects inworkmanship or material.

Hydril retains for itself all proprietary rights in andto all designs, engineering details, data, and proce-dures set forth herein. This manual is intended for thesole use of Hydril customers, and they shall strictlycontrol copying of same, as this manual and all copiesthereof may be recalled by Hydril at any time.

This manual makes recommendations only. Thecustomer is at all times responsible for actual disas-

sembly, inspection, reassembly, and testing of theblowout preventer. The customer also is solely re-sponsible for providing competent and qualified per-sons, equipment and facilities to perform such opera-tions, and for workmanship and safety. If at any timethe customer is unable to understand recommenda-tions made in this manual or is unable to follow thoserecommendations, they should consult the nearestHydril Authorized Repair Facility or Hydril Headquar-ters. The addresses, telephone numbers, FAX num-bers of the repair facilities as well as Hydril Headquar-ters are listed in Section 10 of this manual.

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Inspection ManualRam BOPs

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CONTENTS

PAGE

Please contact Hydril Pressure Control Products for any assistance or questions concerning the information in thismanual. All information contained in this manual is the exclusive property of Hydril Company LP.

HYDRIL COMPANY LP/P.O. BOX 60458/HOUSTON, TEXAS 77205TELEPHONE: (281) 449-2000FAX: (281) 985-2828

©2001 Hydril Company LP Printed In The U.S.A. July 1994 Rev. A, April 2002

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2.0 INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3.0 VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4.0 GAUGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5.0 BOP OPERATING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6.0 HYDRAULIC SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7.0 WELLBORE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8.0 MPL LOCK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9.0 INSPECTION FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10.0 HYDRIL REPAIR FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

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Inspection ManualRam BOPs

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SECTION DATE REVISION

1.0 INTRODUCTION

2.0 INSPECTION SCHEDULE

3.0 VISUAL INSPECTION

4.0 GAUGE INSPECTION 10-06-97 A

5.0 BOP OPERATING TEST

6.0 HYDRAULIC SYSTEM TEST

7.0 WELLBORE PRESSURE TEST

8.0 MPL LOCK TEST

9.0 INSPECTION FORMS

10.0 HYDRIL REPAIR FACILITIES

REVISION RECORD

PAGE1-1

Inspection ManualRam BOPs � Introduction

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1.0 INTRODUCTION

PAGE1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2B. Ram BOP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2C. Initial Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2D. Part Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2E. Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2F. BOP Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2G. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2H. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2I. Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2J. Inspection Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3A. Normal Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3B. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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1.1 General

A. PurposeThe purpose of this manual is to provide detailedinstructions on how to perform scheduled inspectionsof Hydril ram blowout preventers when they are not inservice. For in-service inspections, refer to the BOPoperator's manual.

B. Ram BOP ConfigurationInstructions in this manual are provided for single ramBOPs with one ram compartment . Therefore, if theBOP being inspected has more than one ram com-partment, repeat the instructions as many times asnecessary.

C. Initial Safety PrecautionsWARNING: DO NOT OPEN THE BONNETS OF ARAM BOP UNLESS THE RAM BOP IS INSTALLEDON THE TEST STUMP OR SECURED TO THEFLOOR. THE WEIGHT OF AN OPEN BONNET CANCAUSE AN UNSECURED BOP TO TURN OVER.

D. Part IdentificationParts referenced in this manual are identified byreferring to Figures 4-2 through 4-5 in Section 4 of thismanual. These figures contain exploded views andparts lists of typical ram blowout preventers, piperams, variable rams, and shear rams. However,these figures do not contain part numbers. For partnumbers, refer to the part number stamped in thesurface of the component. If the component does nothave the part number stamped in its surface, refer tothe parts list and assembly drawing in the BOPoperator's manual.

E. Required EquipmentAdequate facilities and equipment are required tosafely lift and move the assembled ram BOP and topressure test the BOP. Hydril recommends the liftingconfiguration shown in Figure 1-1.

F. BOP Control System RequirementsOpening and closing of the BOP rams is accom-plished by applying hydraulic pressure to the Open orClose port on the BOP. When pressure is applied tothe Open port, the Close port must be piped in amanner that allows the free flow of operator fluid fromthe BOP as the pistons move to open the rams. Thisrequirement is the same for the application of hydrau-lic pressure to the Close port.

Figure 1-1 Ram BOP Lifting Confinguration

Use light weight hydraulic oil or a mixture of cleanfresh water and a fluid concentrate composed ofsoluble oil and rust inhibitor. In freezing temperatures(below 0oC /32oF), add antifreeze (ethylene glycol) toany fluid concentrate and water mixtures. [CAU-TION: Do not use synthetic fluids or fuel oil. Use ofthese will result in damage to the seals.] Use clean tapwater as bore fluid.

G. CleaningClean the ram BOP(s) as soon as possible afterremoving the BOP stack from the wellhead. Removecaked drilling mud and cuttings from the ramcompartment(s) and exterior of the BOP with highpressure water or steam.

H. LubricationLubricate all metal surfaces with light machine oil suchas Gulf Harmony No. 46 or Exxon Coray 100 orequivalent. Use Never-Seez thread lubricant or equiva-lent with a coefficient of friction of .069. Coat all sealsand nonextrusion rings with silicone grease or castoroil. CAUTION: Use of petroleum base oil or greasewill reduce seal life.

I. Part ReplacementOnly Hydril replacement parts should be used toinsure expected performance and service life. Referto the part number stamped on the part or to the partslists in your BOP operator's manual.

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J. Inspection RecordsInspection forms are provided in Section 9. Theseforms are designed to be used along with the inspec-tion procedures. To make the recording of resultseasy, each form has step numbers that correspond tothe steps used in the inspection procedure. Eachform should be treated as a master for photocopying.Make as many copies as are needed.

1.2 How To Use This Manual

A. Normal UseThis manual is designed to be used in conjunction withthe BOP operator's manual for disassembly and as-sembly instructions, operation specifications, bolttorques, and part numbers. If an operator's manual isnot available, contact Hydril Headquarters in Hous-ton, Texas for a copy (refer to Section 10 for addressinformation). This manual is divided into sections forease of use. The section headings are listed in theTable Of Contents at the front of this manual.

To use this manual, turn first to the inspectionschedule in Section 2. Find the desired inspectioninterval on the schedule. The procedure for eachinspection on the schedule is found in Sections 3through 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 majorrepairs that cannot be made in the field, contact Hydrilat one of the Hydril Repair Facilities listed in Section10.

B. RevisionOccasionally, 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.) onpage 1 of each section and in the Revision Record.The Revision Record follows the Table Of Contents inthe front of this manual.

Second, the revised portion will be indicated by an8-pt. grey bar in the margin (see example in the leftmargin). This bar is intended to aid the user in findingthe parts of the section that have been changed fromthe previous version.

Furthermore, to make the updating of this manualeasier when revisions are made, whole sections willbe replaced rather than individual revised pages.NOTE: The revision letter indicated in the revision boxon page 1 of each section should match with the lettershown in the Revision Record. If not, contact Hydril

Company Headquarters. Refer to Section 10 of thismanual for the address, telephone, and FAX num-bers.

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Inspection ManualRam BOPs � Inspection Schedule PAGE

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2.0 INSPECTION SCHEDULE

PAGE2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.2 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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2-2

Inspection Interval Description Manual Section

AS REQUIRED 1. Inspect Visually. 3

2. Perform BOP Operating Test. 5

3. Perform Hydraulic System Test. 6

4. Perform Wellbore Pressure Test. 7

BETWEEN WELLS 1. Inspect Visually. 3




YEARLY 1. Disassemble BOP. *

2. Inspect Visually. 3a. Replace All BOP Seals.**b. Replace Ram Packers And Seals.**

3. Assemble BOP. *




FOUR YEARS 1. Disassemble BOP. *

2. Inspect By Gauge. 4a. Replace BOP Spare Parts.**

2.1 GeneralThe inspection schedule provides the inspection in-terval and type of inspection required in tabular form.The procedures for performing the inspections arelocated in Sections 3 through 8 (see Table Of Con-tents for listing). To use the schedule, find theinspection interval on the schedule and the associ-ated inspections. Next, photocopy the inspectionform(s) from Section 9. Begin the inspections byturning to the section that contains the procedure for

performing the first inspection listed. Perform theinspection using the inspection form and the corre-sponding procedure. Continue to perform each in-spection in the same manner until all inspectionshave been completed.

2.2 Inspection ScheduleRefer to Table 2-1.

TABLE 2-1INSPECTION SCHEDULE

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2-3

b. Replace Ram Spare Parts.**c. Replace parts as required.**

3. Assemble BOP. *




7. Perform MPL Lock Test (MPL Models 8Only).

* Refer to operator's manual for disassembly and assembly instructions.** Parts for a typical ram BOP are listed in Figures 4-2 through 4-5 in Section 4. Recommended spare

parts, including seals, are also indicated. Refer to the ram BOP operator's manual for part numbers.

Inspection Interval Description Manual Section

TABLE 2-1 CONTINUED

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Inspection ManualRam BOPs � Visual Inspection PAGE

3-1

3.0 VISUAL INSPECTION

PAGE3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

A. Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2B. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2C. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2D. Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2E. Inspection Criteria for Nuts, Studs, Bolts, and Threaded Holes . . . . . . . . . . . . . 3-2

3.2 Visual Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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3-2

3.1 GeneralThe procedures in this section cover the visual in-spection of the Hydril ram BOP.

A. Inspection RecordsDuring the inspection of the ram BOP, keep recordsof the inspections and the actions taken. Use theinspection form(s) in Section 9.

B. RepairsMinor repairs can be performed in the field. However,major repairs requiring welding must be performed atan approved Hydril Repair Facility. Refer to Section10 for a list of facility locations.

C. CleaningPrior to inspection, clean caked drilling mud, looserust, and scale from the exterior of the ram BOP withhigh pressure water or steam.

D. HandlingLift the ram BOP using two slings of adequate strengthin a basket configuration. Position the slings one oneach side of the ram BOP from just inside the hinges,under the BOP body, and up the off hinge side (referto Figure 3-1). CAUTION: To prevent damage, donot position slings under the multiple position locks orthe manual locks when lifting the ram BOP.

WARNING: USE EXTREME CAUTION WHEN LIFT-ING THE RAM BOP. THIS IS VERY HEAVY ANDBULKY EQUIPMENT. DO NOT PLACE HANDS OROTHR BODY MEMBERS WHERE THEY CAN BEINJURED BY CONTACT WITH OTHER EQUIPMENTDURING THE LIFTING OPERATION.

E. Inspection Criteria for Nuts, Bolts, and ThreadedHoles.Clean threads thoroughly because dirt and grit mayaccount for symptoms that otherwise appear to bedue to thread damage. Replace nuts and bolts ifthreads are damaged or if the hex surfaces areseriously rounded. A part with threaded holes withunacceptable threads may require replacement orrepair of the part. Contact Hydril for advice. Refer toSection 10 for a list of Hydril Authorized RepairFacilities.

Figure 3-1. Ram BOP Lifting Arrangement

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3-3

3.2 Visual Inspection Procedure

A. Tools and Materials Required1. Emery cloth, 240 grit or finer2. Light machine oil (Gulf Harmony No. 46 or

Exxon Coray 100)3. Never-Seez thread lubricant (coefficient of

friction is .069) or equivalent4. Inspection form(s) (refer to Section 9)

B. Inspection ProcedureRefer to Figure 3-2 while following this procedure.

1. Inspect the ring grooves and the matingfaces of the top connection, bottom connec-tion, and side outlets.a. Inspect the ring grooves for pitting,

scratches, indentations, and washouts.Minor damage to the grooves may berepaired in the field by polishing with 240grit or finer emery cloth. After polishing,wipe ring groove with a clean cloth soakedin light machine oil. Any damage requir-ing welding or machining must be re-paired at a Hydril Authorized Repair Fa-cility. Record findings on the inspectionform.

Figure 3-2. Typical Ram BOP — Visual Inspection

Bolt Heads

Ring Groove &Mating Surfaces(Top & Bottom)

Studs and Nuts

TOP VIEW

SIDE VIEWRing Grooves &Mating Surfaces(Side Outlets)

b. Inspect the mating faces for upset metaland raised edges. Minor metal upset orraised edges can be repaired in the fieldby grinding until flush. Major metal upsetor raised edges that require machining orwelding must be repaired at a HydrilAuthorized Repair Facility. Record find-ings on the inspection form.

c. Inspect outlets for interior wall collapse.2. Inspect nut and bolt heads for damage. Re-

place any nut or bolt that has hex corners onthe head that are rounded off. If a nut or boltrequires replacement, apply Never-Seezthread lubricant to the threads of the new nutor bolt before installing. Refer to BOPoperator's manual for torque specifications.

3. Clean the threads of any studs that are ex-posed and inspect the threads for cracks,galling, wear, and deformity. Replace asrequired. If a stud requires replacement,apply Never-Seez thread lubricant to thethreads of the new stud before installing.Refer to BOP operator's manual for torquespecifications.

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3-4

SealingArea

BonnetBolt Hole

Body

Figure 3-3. Ram BOP With Bonnet Open.

Ram Bore

BonnetBolt

RamBonnet

BonnetSeal

4. Open ram BOP bonnet and inspect the bodyas follows:.

WARNING: DO NOT OPEN A BONNETUNLESS THE RAM BOP IS INSTALLED ONA SECURED TEST STUMP OR SECUREDTO THE FLOOR. THE WEIGHT OF ANOPEN BONNET CAN CAUSE AN UNSE-CURED RAM BOP TO TIP OVER.

a. Inspect the area on the body where thebonnet seal contacts for pitting, scratches,and corrosion. Minor damage can beremoved by polishing with 240 grit orfiner emery cloth. After polishing, wipesurfaces with light machine oil. Anydamage requiring welding or machiningmust be repaired at a Hydril AuthorizedRepair Facility. Record findings on theinspection form.

b. Inspect bottom surface of ram bore fordamage and wear. Minor damage canbe removed by polishing with 240 grit orfiner emery cloth. After polishing, wipesurfaces with light machine oil. Anydamage requiring welding or machiningmust be repaired at a Hydril AuthorizedRepair Facility. Record findings on theinspection form.

5. Inspect the bonnet as follows:a. Remove the bonnet seal and Inspect the

bonnet seal groove for pitting, scratches,indentations, and washouts. Minor dam-age can be removed by polishing with240 grit or finer emery cloth. After polish-ing, wipe groove clean with light machineoil. Any damage requiring welding ormachining must be repaired at a HydrilAuthorized Repair Facility. Record find-ings on the inspection form.

b. Inspect front and back of bonnet seal forcracks, cuts, hard skin, and deformity.Replace seal if necessary. Record find-ing on inspection form.

c. Clean and inspect the threads of thebonnet bolts for cracks, galling, wear,and deformity. Replace any damagedbolt. Lubricate threads with Never-Seezthread lubricant.

d. Clean and inspect the threads of thebonnet bolt holes in the body of the ramBOP for damage and wear. If threadsare damaged or worn, contact a HydrilAuthorized Repair Facility.

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3-5

Pipe Ram Variable Ram

Packer

Top Seal

Shear Ram Assemblies

Packer

TopSeal

Upper Shear BladeLower Shear Blade Lateral T-Seal

Top Seal

6. Inspect the pipe ram, shear ram, variableram as follows:NOTE: If replacement of parts is required,refer to the disassembly and assembly pro-cedures in the BOP operator's manual. Re-fer to the operator's manual for part numbers.a. Pipe Ram and Variable Ram:

1) Inspect front packer on ram assem-bly for wear, cracking, and hard skin.Check variable ram packers for insertseparation. Replace if necessary.Record findings on the inspection form.2) Inspect top seal groove and verticalpacking slots for burrs. Remove burrswith 240-grit emery cloth. Wipe cleanwith rag soaked in light machine oil.3) Inspect upper seal on pipe ram as-sembly for wear, cracking, and hard skin.Replace if necessary. Record findingson the inspection form.4) Inspect bottom surface of pipe ramfor wear and pitting. Minor damage canbe removed by buffing. After buffing,wipe surfaces with light machine oil. Anydamage requiring welding or machiningmust be repaired at a Hydril Authorized

Repair Facility. Record findings on theinspection form.

b. Shear Ram:1) Inspect shear blades for wear anddamage. Replace if necessary. Recordfindings on the inspection form.2) Inspect lateral T-Seal for wear, crack-ing, and hard skin. Replace if neces-sary. Record findings on the inspectionform.3) Inspect upper seal on shear ramassembly for wear, cracking, and hardskin. Replace if necessary. Recordfindings on the inspection form.4) Inspect bottom surface of shear ramfor wear and pitting. Minor damage canbe removed by polishing with 240 grit orfiner emery cloth. After polishing, wipesurfaces with light machine oil. Anydamage requiring welding or machiningmust be repaired at a Hydril AuthorizedRepair Facility. Record findings on theinspection form.5) Inspect sealing surface of lower car-rier for scaring and pitting. Minor dam-age can be removed by polishing with

Figure 3-4. Hydril Pipe Ram, Variable Pipe Ram, And Shear Ram

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3-6

240 grit or finer emery cloth. After polish-ing, wipe surfaces clean with light ma-chine oil. For major damage, contact aHydril Authorized Repair Facility. Recordfindings on the inspection form.

7. Retract ram assembly and close the bonnet.Torque the bonnet bolts as per Section 10.

8. Open, visually inspect, and close the remain-ing bonnets as instructed above, beginningwith Step 4.

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Inspection ManualRam BOPs � Gauge Inspection PAGE

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4.0 GAUGE INSPECTION

PAGE4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

A. Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2B. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2C. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2D. Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2E. Part Identification and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Gauge Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11A. Tools And Materials Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11B. Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11C. Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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4-2

3.1 GeneralThe procedures in this section cover the gauge in-spection of the Hydril ram BOP. To complete thisinspection, the ram BOP operator's manual is re-quired for disassembly, assembly, and part numberidentification. If a manual is not available, contact thenearest Hydril Repair Facility for a copy. Refer toSection 10 for a list of locations.

A. Inspection RecordsDuring the inspection of the ram BOP, keep recordsof the inspections and the actions taken. Use theinspection form(s) in Section 9.

B. RepairsMinor repairs can be performed in the field. However,major repairs requiring welding must be performed atan approved Hydril Repair Facility. Refer to Section10 for a list of locations.

C. CleaningPrior to inspection, clean caked drilling mud, looserust, and scale from the exterior of the ram BOP withhigh pressure water or steam.

D. HandlingLift the ram BOP using two slings of adequate strengthin a basket configuration. Position the slings one oneach side of the ram BOP from just inside the hinges,under the BOP body, and up the off hinge side (referto Figure 4-1). CAUTION: To prevent damage, donot position slings under the multiple position locks orthe manual locks when lifting the ram BOP.

WARNING: USE EXTREME CAUTION WHEN LIFT-ING THE RAM BOP. THIS IS VERY HEAVY ANDBULKY EQUIPMENT. DO NOT PLACE HANDS OROTHER BODY MEMBERS WHERE THEY CAN BEINJURED BY CONTACT WITH OTHER EQUIPMENTDURING THE LIFTING OPERATION.

E. Part Identification and ReplacementThe parts of a typical Hydril ram BOP are illustrated inFigures 4-2 and 4-3 for the purpose of identifying thecomponents that are discussed in the Gauge Inspec-tion Procedure. Although the parts are identified byname, quantity, and recommended spares, no partnumbers are provided. Refer to the illustrated partslists in the ram BOP operator's manual for accuraterepresentation and part numbers.


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4-3

Figure 4-2. Typical Hydril Ram BOP With Manual Lock.

Qty.Per

Cavity**

Rec. Spare PartItemNo. Part Name*

1 Year 4 Year

1 Body, Single 12 Nameplate (not shown) 13 Screw, Drive (not shown) 44 Seat, upper Seal 15 Ring, Lock 16 O-Ring, Lower, Seat To Body 1 1 17 Backup Ring, Lower, Seat To Body 1 1 18 O-Ring, Upper, Seat To Body * 1 1 19 Screw, Socket Head Set, Seal Seat*** 4** 4**

10 Hydraulic Connection 111 O-Ring, Hydraulic Connection 2 2 212 Cap Screw, Socket Head *** 8

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4-4

Figure 4-2 Continued

13-20 Reserved For Future Use21 Hinge, Load 222 Pin, Locator 423 Cap Screw, Socket Head *** 824 Hinge, fluid 225 Sub, Fluid Hinge 426 O-Ring, Sub To Bonnet Hinge 4 4 427 Sub, Energizer 428 O-Ring, Sub To Energizer 4 4 429 Back-Up Ring, Sub To Energizer 4 4 430 O-Ring, Energizer To Fluid Hinge 4 4 431 Back-Up Ring, Energizer To Fluid Hinge 4 4 432 Spring 433 Screw, Socket Head Set, Fluid Hinge *** 434 Plug, Hex Head Pipe 435 O-Ring, Fluid Hinge To Body 4 4 436 Cap Screw, Hex Head *** 437 Bearing, Hinge Pin 4 4 438 Washer, Thrust 4 4 439 Washer, Fluid Hinge 440 O-Ring, Fluid Hinge To Bonnet Hinge 4 4 4

41-50 Reserved For Future Us51 Ram Assembly 1 set52 Bonnet 253 Bolt, Bonnet 2054 Retainer, Bonnet Bolt 20 20 2055 Seal, Bonnet 2 2 256 Pin, Ram Guide 457 Seal, Piston Rod Mud 2 2 258 Ring, Spacer 2 2 259 Ring, Retainer 2 2 260 Seal, Bonnet To Piston 2 2 261 Pin, Hinge 462 O-Ring, Hinge Pin 4 4 463 O-Ring, Pin 8 8 864 Screw, Socket Head Set, Hinge Pin 465 Ring, Plastic Packing ▼ 2 2 266 Ring, Plastic Energizing ▼ 2 2 267 Valve, Check ▼ 2 2 268 Packing, Plastic ▼ 2 2 269 Screw, Socket Head Set ▼ 2 270 Plug, Hex Head Pipe71 Hinge, Bonnet 272 Hinge, Bonnet 273 Cap Screw, Bonnet Hinge *** 1674 O-Ring, Bonnet Hinge 4 4 4

75-80 Reserved For Future Use 117-120 Reserved For Future Use

121 Piston, Manual Lock 2122 Seal, Piston 4 4 4123 Lock, Mechanical 2

Qty.Per

Cavity**


1 Year 4 Year

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4-5

124 Washer, Thrust 2125 O-Ring, Cylinder Liner To Bonnet 2 2 2126 Liner, Cylinder 2127 O-Ring, Cylinder To Bonnet 2 2 2128 Ring, Retaining 2 2 2129 Ring, Spacer 2 2 2130 Seal, Cylinder To Mechanical Lock 2 2 2131 Stud, Cylinder 12132 Nut, Heavy Hex 12133 Cylinder, Manual Lock 2134 Scraper 2 2 2

▼ Available on models used in surface applications only. * Item has been deleted on some BOPs.** Quantities vary per BOP. Refer to ram BOP operator's manual.*** Use only Hydril replacement parts. Commercial grade fasteners will fail

in service due to the loads experienced.


Qty.Per

Cavity**


1 Year 4 Year

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4-6

1 Body, Single 12 Nameplate (not shown) 13 Screw, Drive (not shown) 44 Seat, Upper Seal 15 Ring, Lock 16 O-Ring, Lower, Seat To Body 1 1 17 Backup Ring, Lower, Seat To Body 1 1 18 O-Ring, Upper, Seat To Body * 1 1 19 Screw, Socket Head Set, Seal Seat *** 4** 4**

10 Hydraulic Connection 111 O-Ring, Hydraulic Connection 2 2 212 Cap Screw, Socket Head *** 8

Figure 4-3. Typical Hydril Ram BOP With MPL

52

Qty.Per

Cavity**


1 Year 4 Year

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4-7


13-20 Reserved For Future Use21 Hinge, Load 222 Pin, Locator 423 Cap Screw, Socket Head *** 8 824 Hinge, fluid 225 Sub, Fluid Hinge 4 4 426 O-Ring, Sub To Bonnet Hinge 4 4 427 Sub, Energizer 4 4 428 O-Ring, Sub To Energizer 4 4 429 Back-Up Ring, Sub To Energizer 4 4 430 O-Ring, Energizer To Fluid Hinge 4 4 431 Back-Up Ring, Energizer To Fluid Hinge 4 4 432 Spring 433 Screw, Socket Head Set, Fluid Hinge *** 4 434 Plug, Hex Head Pipe 435 O-Ring, Fluid Hinge To Body 4 4 436 Cap Screw, Hex Head *** 4 437 Bearing, Hinge Pin 4 438 Washer, Thrust 4 439 Washer, Fluid Hinge 4 440 O-Ring, Fluid Hinge To Bonnet Hinge 4 4 4

41-50 Reserved For Future Us51 Ram Assembly 1 set52 Bonnet 253 Bolt, Bonnet 2054 Retainer, Bonnet Bolt 20 20 2055 Seal, Bonnet 2 2 256 Pin, Ram Guide 457 Seal, Piston Rod Mud 2 2 258 Ring, Spacer 2 2 259 Ring, Retainer 2 2 260 Seal, Bonnet To Piston 2 2 261 Pin, Hinge 462 O-Ring, Hinge Pin 4 4 463 O-Ring, Pin 8 8 864 Screw, Socket Head Set, Hinge Pin 465 Ring, Plastic Packing ▼ 2 2 266 Ring, Plastic Energizing ▼ 2 2 267 Valve, Check ▼ 268 Packing, Plastic ▼ 2 2 269 Screw, Socket Head Set ▼ 2 270 Plug, Hex Head Pipe71 Hinge, Bonnet 272 Hinge, Bonnet 273 Cap Screw, Bonnet Hinge*** 1674 O-Ring, Bonnet Hinge 4 4 4

75-80 Reserved For Future Use 117-120 Reserved For Future Use

135 Piston, MPL 2136 Seal, Piston 4 4 4

Qty.Per

Cavity**


1 Year 4 Year

R


4-8

137 Cylinder, MPL 2138 O-Ring, Cylinder To Bonnet 2 2 2139 Liner, Cylinder 2140 O-Ring, Cylinder Liner To Bonnet 2 2 2141 Stud, Cylinder 12142 Nut, Heavy Hex 12143 Nut, Lock 2144 Screw, Lock 2145 Plate, Retainer 2146 Plate, Front Clutch 2147 Capscrew, Sock. Hd. Front Clutch Plt.*** 16 16148 Plate, Rear Clutch 2149 Bearing, Lock Nut 4 4150 Spring, Clutch 16151 Key, Rear Clutch Plate 8152 O-Ring, Cylinder Head Dirt Seal 2 2 2153 Backup Ring, Cylinder Liner To Bonnet 4 4 4154 Head, Cylinder MPL 2155 O-Ring, Cylinder Head 2 2 2156 Cap Screw, Cylinder Head 16157 Pin, Locating, Bonnet (Not Shown) 2158 Pin, Locating, Retainer Plate 2159 Stem, Lockout 4160 Gland, Lockout 4161 Segment, Lockout 4162 O-Ring, Lockout Stem 4 4 4163 Backup Ring, Lockout Stem 4 4 4164 Ring, Transfer 2

Qty.Per

Cavity**


1 Year 4 Year


▼ Available on models used in surface applications only. * Item has been deleted on some BOPs.** Quantities vary per BOP. Refer to ram BOP operator's manual.*** Use only Hydril replacement parts. Commercial grade fasteners will fail in

service due to the loads experienced.

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4-9

VARIABLE RAM ASSEMBLY

1

2

4

3

PIPE RAM ASSEMBLY

Figure 4-4. Pipe Ram Assembly

1 Ram Assembly 22 Ram Block 23 Front Packer 2 1 14 Upper Seal 2 1 1

Qty.Per

Cavity

Rec. Spare PartItemNo. Part Name

1 Year 4 Year

2

4

1

3

R


4-10

1 Upper Blade Shear Ram Block 12 Upper Shear Blade 13 Upper Blade Cap Screw* 4** 44 Upper Blade Top Seal 1 1 15 Alignment Pin 26 Upper Blade Set Screw* 37 Alignment Pin Set Screw* 2 28 Lateral T-Seal 1 1 19 Not Used

10 Lower Blade Shear Ram Block 111 Lower Shear Blade 112 Lower Blade Cap Screw* 2 213 Lower Blade Top Seal 1 1 114 Anti-extrusion Block 2

Figure 4-5. Shear Ram Assembly

Qty.Per

Cavity

Rec. Spare PartItemNo. Part Name

1 Year 4 Year

* Use only Hydril replacement parts. Commercial grade fasteners will failin service due to the loads experienced.

** Quantity varies per BOP. Refer to ram BOP operator's manual.

UPPER BLADESHEAR RAMASSEMBLY

LOWER BLADESHEAR RAMASSEMBLY

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4-11

4.2 Gauge Inspection

A. Tools and Materials Required1. Emery cloth2. Light machine oil (Gulf Harmony No. 46 or

Exxon Coray 100)3. Never-Seez thread lubricant (coefficient of

friction is .069) or equivalent4. Inspection form(s) (refer to Section 9 )5. Spare parts (refer to Figures 4-2, 4-3, 4-4,

and 4-5)

B. Inspection ProcedureRefer to Figures 4-2, 4-3, 4-4, and 4-5 while followingthis procedure. Refer to the figure that correspondsmost closely to the ram BOP being inspected. Figure4-2 has a manual ram lock and Figure 4-3 has amultiple position ram lock (MPL).

1. Disassemble the ram BOP completely fol-lowing the procedure in the BOP operator'smanual. Replace all parts indicated as spareparts (refer to Figures 4-2 and 4-3).

2. Clean remaining parts thoroughly and pre-pare them for inspection.

3. If the ram BOP is equipped with a MPL(multiple position lock), continue with thenext step. If equipped with a manual lock,continue to step 7.

4. Inspect the MPL locknut assembly (items143, 149, 158, 145, 150, 148, 146, and 147 ofFigure 4-3).a. Inspect the lock nut (item 143 of Figure 4-

3). Refer also to Figure 4-61) Inspect the two bearing surfaces.The bearing surface should be smoothwith no gouges or scratches.2) Measure the thickness of the shoul-der. The thickness should not be lessthan minimum thickness listed in Table4-1.3) Inspect the threads in the threadholes for damage. Record the results onthe inspection form.4) Inspect the through bore threads fordamage. Minor ridging of the threadsdue to wear is acceptable, but not heavygalling or wear. Install the lock nut ontothe lock screw (item 144 of Figure 4-3)with timing marks aligned. The lock nutshould fit easily on the lock screw androtate down the length of the lock screwby hand. Record the condition on the

Figure 4-6. MPL Locknut (item 143, Figure 4-3)

MinimumThickness

BearingSurfaces

FrontRear

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4-12

inspection form.5) Replace the lock nut if damaged orworn beyond the conditions stated insteps 1) through 4) above. Refer to theram BOP operator's manual for the partnumber.

b. Inspect the retainer plate (item 145 of Figure4-3). Refer also to Figure 4-7.NOTE: Do not remove the retainer platelocating pin (item 158 of Figure 4-3). Inspectit for wear and straightness.1) Inspect the bearing surface. It should be

smooth and flat. Record condition oninspection form.

2) Inspect surface A and the key slots forburrs. It should be polished smooth withemery cloth. Record the condition on theinspection form.

3) Inspect Surface B for corrosion. Re-move corrosion with emery cloth. Recordcondition on inspection form.

c. Inspect front clutch plate (item 146 of Figure4-3). Refer also to Figure 4-8.1) Inspect all clutch teeth for dings anddents. CAUTION: Do not attempt repair ifdamage is present. Replace the clutch plate.Refer to BOP operator's manual for the partnumber.2) Measure clutch teeth. If any tooth is wornbelow the minimum height shown in Table 4-1, replace the clutch plate. Refer to BOPoperator's manual for the part number.3) Record the condition of the front clutchplate on the inspection form.

d. Inspect rear clutch plate (item 148 of Figure4-3). Refer also to Figure 4-8.1) Inspect all clutch teeth for dings anddents. CAUTION: Do not attempt repair ifdamage is present. Replace the clutch plate.Refer to BOP operator's manual for the partnumber.2) Measure clutch teeth. If any tooth is wornbelow the minimum height shown in Table 4-1, replace the clutch plate. Refer to BOPoperator's manual for the part number.3) Record the condition of the rear clutchplate on the inspection form.

BearingSurface

RetainerLocatingPin

Figure 4-7. Retainer Plate (Item 145 ofFigure 4-3)

Key Slot

Surface A

Surface B

MinimumTeethHeight

Figure 4-8. MPL Clutch Plate (items 146 and148 of Figure 4-3)

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4-13

e. Inspect retainer plate locating pin (item 158of Figure 4-3).1) Without removing the pin from the re-tainer plate (item 145), inspect the protrudingend for rounded-off edges. Replace if neces-sary. Refer to BOP operator's manual forpart number.2) Record results on inspection form.

5. Inspect the MPL cylinder assembly (items 137,142, 154, 156, 159, 160, 162, and 163 of Figure4-3).a. Inspect the MPL cylinder (item 137 of Figure

4-3). Refer also to Figure 4-9.1) Inspect the seal groove and the sealingsurfaces for smoothness. Remove minorpits and scores up to a depth of .015 in (.38mm) with emery cloth. If major pits andscores are present, contact a Hydril RepairFacility. Refer to Section 10 for a list oflocations.2) Inspect the threaded holes for threaddamage such as galling. If damage is present,contact a Hydril Repair Facility. Refer toSection 10 for a list of locations.3) Record results on the inspection form.

b. Inspect the lockout stem (item 159 of Figure4-3).1) Inspect the internal threads for damage.2) Inspect the seal groove for corrosion,nicks, and dings.3) Inspect square end for damage.4) Replace the lockout stem if any damageinspected for above is present. Refer to BOPoperator's manual for part number.5) Record the results on the inspection form.

c. Inspect the lockout gland (item 160 of Figure4-3).1) Inspect the threads on the outside diam-eter of the gland for burrs.2) Inspect the corners of the hex for rounded-off corners.3) Replace gland if damage above ispresent.

Figure 4-9. MPL Cylinder (Item 137 ofFigure 4-3)

Seal GrooveSealing Surfaces

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4-14

4) Dress the center bore of the gland withemery cloth as required to remove nicks.5) Record condition on inspection form.

d. Inspect the cylinder head (item 154 of Figure4-3). Refer also to Figure 4-10 .1) Inspect the O-ring seal groove and dirtseal groove. Both grooves should be smoothand flat. Remove minor dings, gouges, andpitting up to a depth of .015 in (.38 mm) withemery cloth. For major damage, contact thenearest Hydril Repair Facility. Refer to Sec-tion 10 for a list of locations.2) Smooth the bearing surface with emerycloth as necessary. Measure the depth of thebearing pocket. The depth should be lessthan shown in Table 4-1. If the depth is more,contact the nearest Hydril Repair Facility.Refer to Section 10 for a list of locations.3) Record the condition of the cylinder headon the inspection form.

6. Inspect the piston and lock screw assembly (items135, 136, 138, 139, 140, 144, 153, 161, and 164of Figure 4-3).a. Inspect the cylinder liner (item 139 of Figure

4-3). Refer also to Figure 4-11.1) Inspect the inside diameter for pits, dings,gouges, and wear. Repair minor damage upto a depth of .005 in (.13 mm) with emerycloth. Measure the inside diameter of thecylinder liner. The diameter should be lessthan the maximum inside diameter shown inTable 4-1. If the diameter is more, replacethe cylinder liner.2) Inspect the inside diameter of the pistonentry bevels and the seal groove for pits,handling damage, and gouges. Repair minordamage up to a depth of .015 in (.38 mm) withemery cloth.3) Inspect cylinder shoulder for burrs andflattened edges. Rework shoulder with a fileto return it to its original contour if necessary.Also inspect for line scores and chips in thechrome.4). Measure the outside diameter of the sealgroove. The diameter should be greater thanshown in Table 4-1. If less, replace thecylinder liner.5) For major damage, contact a Hydril Re-pair Facility. Refer to Section 10 for a list oflocations.6) Record condition of cylinder liner andany rework performed on the inspection form.

Bearing PocketMax. Depth

BearingPocket

O-Ring SealGroove (155)

Dirt SealGroove (152)

Min. SealGroove

O.D.

Figure 4-11. Cylinder Liner (Item 139 ofFigure 4-3)

Cylinder Shoulder

Max.I.D.

Seal Groove

EntryBevels

Figure 4-10. Cylinder Head (Item 154 ofFigure 4-3)

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4-15

b. Inspect the transfer ring (item 164 of Figure4-3). Refer also to Figure 4-12.1) Inspect transfer ring for corrosion anddeformity. Remove minor corrosion with fineemery cloth. Replace if deformed.2) Measure the thickness of the ring. Referto Table 4-1 for minimum thickness. Replaceif thickness is less.3) Record condition and thickness on in-spection form.

c. Inspect lockout segment (item 161 of Figure4-3). Refer also to Figure 4-13.1) Inspect radius at the base of the threadedstem for cracks.2) Inspect for damage to threads.3) Inspect both sides for rounded-off edges.4) Replace if any of the damage listed aboveis present.5) Record condition on inspection form.

d. Inspect piston (item 135) and lock screw(item 144 of Figure 4-3). Refer also to Figure4-14.1) Inspect surface A of the piston for pitting,dings, and gouges. Repair minor damage[less than .005 in (.13 mm) deep] with emerycloth. Replace piston if major damage ispresent.2) Inspect piston rod for straitness. The rodmust be perfectly straight. Verify that end ofpiston rod is perpendicular to shaft. Replaceif necessary. Measure the outside diameterof the piston rod. If it is less than shown inTable 4-1, replace it.3) Measure the large outside diameter ofthe piston on the center most land of the threelands. The diameter should not be less thanthe minimum piston diameter shown in Table4-1 . Replace if less.4) Inspect seal grooves for smoothness,pitting, and dings. Repair minor damage withemery cloth. Replace piston if major damageis present.5) Gauge the screw for wobble or wear bymeasuring the side to side movement of thematching nut. More than .060 inch move-ment is cause for replacement. NOTE: Nor-mally, it is nearly impossible to disassemblethe lock screw from the piston without theproper tools. Contact a Hydril Repair Facilityfor instructions. Refer to Section 10 for a listof locations.6) Inspect area around the lock screw shoul-der for cracks. Replace if cracks are present.

Figure 4-14. Piston And Lock Screw (Items 135and 144 of Figure 4-3)

Figure 4-12. Transfer Ring (Item 164 of Figure4-3)

MinimumThickness

InspectforCracks

Inspect BothSides For Rounded-off Edges

Figure 4-13. Lockout Segment (Item 161 ofFigure 4-3)

Min. Rod O.D.

Min. PistonO.D.

Lock Screw

InspectForCracks Seal

Grooves

Piston RodSurface A

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4-16

7) Record results of inspections on the in-spection form.

7. If the ram BOP is equipped with a manual lockassembly (items 121 through 134 of Figure 4-2),inspect it as follows. If the ram BOP is equippedwith a MPL, skip this step and continue to step 8.a. Inspect the manual lock cylinder (item 133 of

Figure 4-2). Refer also to Figure 4-15.1) Inspect the seal groove for the cylinder tobonnet seal (item 127 of Figure 4-2) forpitting, dings, and gouges. Repair minordamage with emery cloth. If major damage ispresent, replace the cylinder. Refer to theram BOP operator's manual for the part num-ber.2) Measure the inside diameter of the cylin-der. The inside diameter should be less thanthe maximum bore shown in Table 4-1. Ifgreater, contact a Hydril Repair Facility. Referto Section 10 for a list of locations.3) Record condition on inspection form.

b. Inspect the cylinder liner (item 126 of Figure4-2). Refer also to Figure 4-16.1) Inspect the seal groove for the cylinderliner to bonnet seal (item 125 of Figure 4-2)for pitting, dings, and gouges. Repair minordamage with emery cloth. If major damage ispresent, replace the cylinder liner. Refer tothe ram BOP operator's manual for the partnumber.2) Record condition on inspection form.

c. Inspect the mechanical lock piston assembly(items 121 and 123 of Figure 4-2). Refer alsoto Figure 4-17.1) Inspect the unthreaded surface of themechanical lock for scars, dings, and gouges.Make minor repairs with emery cloth. Re-place if major damage is present. NOTE:Normally, it is nearly impossible to disas-semble the lock screw from the piston withoutthe proper tools. Contact a Hydril RepairFacility for instructions. Refer to Section 10for a list of locations.2) Measure the diameter of the unthreadedrod of the mechanical lock screw. The diam-eter should be greater than the minimum rodoutside diameter shown in Table 4-1. If thediameter is less, replace the mechanical lockscrew. NOTE: Normally, it is nearly impos-sible to disassemble the lock screw from thepiston without the proper tools. Contact aHydril Repair Facility for instructions. Referto Section 10 for a list of locations.

InsideDiameter

Seal Groove

Figure 4-15. Manual Lock Cylinder (item 133 ofFigure 4-2)

Figure 4-16. Manual Lock Cylinder Liner(item 126 of Figure 4-2)

Seal Groove

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4-17

Figure 4-17. Manual Lock Piston and LockScrew Assembly (items 121 and 123 ofFigure 4-2)

Piston RodSurface A

Min. Rod Dia.

SealGrooves

Inspect forCracks

Lock Screw

MinimumPiston O.D.

Minimum Dia.

d. Inspect piston (item 121) and lock screw(item 123 of Figure 4-2). Refer also to Figure4-17.1) Inspect surface A of the piston for pitting,dings, and gouges. Repair minor damage[less than .005 in (.13 mm) deep] with emerycloth. Replace piston if major damage ispresent.2) Inspect piston rod for straitness. Therod must be perfectly straight. Verify thatend of piston rod is perpendicular to shaft.Replace if necessary. Measure the outsidediameter of the piston rod. If it is less thanshown in Table 4-1, replace it.3) Measure the large outside diameter ofthe piston on the center most land of thethree lands. The diameter should not be lessthan the minimum piston diameter shown inTable 4-1 . Replace if less.4) Inspect seal grooves for smoothness,pitting, and dings. Repair minor damagewith emery cloth. Replace piston if majordamage is present.5) Gauge the screw for wobble or wear bymeasuring the side to side movement of thematching nut. More than .060 inch move-ment is cause for replacement. NOTE:Normally, it is nearly impossible to disas-semble the lock screw from the piston with-out the proper tools. Contact a Hydril RepairFacility for instructions. Refer to Section 10for a list of locations.6) Inspect area around the lock screw shoul-der for cracks. Replace if cracks are present.7) Record results of inspections on theinspection form.

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4-18

Figure 4-20. Hinge Pin (Item 61 of Figures 4-2and 4-3)

SealingSurface

BonnetHingeMountingFace

SealingSurface

SealingSurface

Figure 4-18. Bonnet Hinge (Items 71 and 72 ofFigures 4-2 and 4-3)

BearingSurfaces

Figure 4-19. Bonnet Hinge Measurement

Upper BonnetHinge

Lower BonnetHinge

DistanceBetweenHinges

8. Inspect the bonnet hinge assembly (items61, 62, 63, 71, 72, 74, and 75 of Figures 4-2and 4-3).

a. Inspect bonnet hinges (items 71 and 72 ofFigures 4-2 and 4-3. Refer also to Figures 4-18 and 4-19.1) Measure the distance between the bon-net hinges. The distance should be less thanshown in Table 4-1. If the distance is more,replace the hinges.2) Inspect all sealing surfaces for corrosionand damage. Repair minor damage up to adepth of .015 in (.38 mm) with emery cloth.Replace hinges if major damage is present.3) Inspect hydraulic fluid passage for buildup. Clean as required to assure full fluid flow.4) Inspect threads for galling or tearing.Replace bonnet hinges that have damagedthreads.5) Inspect flatness of bonnet hinge mount-ing face. The face should be flat within .015in (.38 mm) after cleaning.6) Record inspection results on inspectionform.

b. Inspect hinge pin (item 61 of Figures 4-2 and4-3). Refer also to Figure 4-20.1) Inspect all seal grooves for corrosion.2) Inspect the threads for galling and tears.3) Inspect the hex head for rounded-offedges.4) Replace the hinge pin if any of the condi-tions listed above are present.5) Record the conditions on the inspectionform.

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4-19

9. Inspect the bonnet assembly (items 52, 53, 55,56, 57, 58, 59, and 60 of Figures 4-2 and 4-3).a. Inspect bonnet (item 52 of Figures 4-2 and 4-

3. Refer also to Figure 4-21.1) Inspect the bonnet seal groove for corro-sion, pitting, and dings. Repair minor dam-age with emery cloth. Measure the depth ofthe bonnet seal groove. The depth shouldnot exceed the maximum depth shown inTable 4-1.2) Inspect the piston rod bore for pitting,dings, and gouges. Repair minor damage ofless than .015 in (.38 mm) in depth withemery cloth.3) Measure the piston rod bore diameterwith pitting and corrosion removed. Thediameter should not exceed the maximumdiameter shown in Table 4-1.4) Measure the diameter of the cylinderliner bore. The diameter should not exceedthe maximum diameter shown in Table 4-1.5) Inspect the pilot surfaces for the cylinder(item 137 of Figure 4-3) and the cylinder liner(Item 126 of Figure 4-2 and item 139 ofFigure 4-3) for pitting, dings, and gouges.Repair minor damage of less than .010 in (.25mm) with emery cloth.6) Smooth the seal surface with emery clothwhere the bonnet hinge O-rings (item 74 ofFigures 4-2 and 4-3) contact the bonnet.7) Inspect all hydraulic fluid passages forany buildup. Clean as required to assure fullflow.8) Inspect the cylinder studs (item 131 ofFigure 4-2 and item 141 of Figures 4-3) fordamaged threads.Repair or replace as required.9) Clean and inspect the threaded holes forthread damage.10) If the bonnet cannot be repaired as di-rected above or wear exceeds specifica-tions, contact a Hydril Repair Facility. Referto Section 10 for a list of locations.11) Record conditions on the inspection form.

b. Inspect the ram guide pin (item 56 of Figures4-2 and 4-3).1) Inspect the pins for wear and damage.Repair minor nicks, burrs, and gouges with afile. If the sides that support the rams arewearing flat, measure the diameter of the pinacross the flat. The diameter should not beless than the minimum diameter shown inTable 4-1.

Figure 4-21. Bonnet (Item 52 of Figures 4-2 and4-3)

HINGE SIDE

Seal Surface

PilotSurfaces

CylinderLinerBoreDia.

MaximumPiston RodDia.

BonnetSealGroove

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4-20

}

2) Inspect the straightness of the pins. Thepins should be perpendicular to the bonnetface. If one is bent, lay a straightedge alongthe concave side of the bent pin and measurethe standoff distance with a feeler gauge.Straighten or replace the pin if the standoff isgreater than .060 in (1.52 mm).3) Record condition on the inspection form.

10. Inspect the load hinge assembly (items 21, 23,37, and 38 of Figures 4-2 and 4-3).a. Inspect the load hinge (item 21 of Figures 4-

2 and 4-3). Refer also to Figure 4-22.1) Inspect bearing and seal surfaces forcorrosion. Remove corrosion with emerycloth.2) Record condition on inspection form.

11. Inspect the remaining operator and bonnet com-ponents by repeating this procedure. Begin withStep 4 if the ram BOP is equipped with a MPL orwith Step 7 if the ram BOP is equipped with amanual lock. If both sets of operator and bonnetcomponents have been inspected, continue tothe next step.

12. Inspect seal seat assembly (items 4, 5, 6, 7, 8,and 9 of Figures 4-2 and 4-3).a. Inspect seal seat (item 4 of Figures 4-2 and

4-3). Refer also to Figure 4-23. Repair ifpossible. Otherwise, replace it.1) Inspect O-ring grooves for damage.Repair minor damage with emery cloth.NOTE: Some seats do not have an O-ringgroove in the top edge.2) Inspect lower surface finish for gouges,pitting, and dings. Repair damage less than.015 in (.38 mm) in depth with emery cloth.3) Inspect the flatness of the seal seat up-per surface. The upper surface should be flatwithin .005 in (.13 mm).4) Inspect the set screw threaded holes forcorrosion.5) Measure the maximum thickness of theram sealing flange. Refer to Table 4-1 for thedimension.6) Inspect and clean the groove for the lockring.7) Record condition inspection form.

SealSurface

Bearing Surfaces

Figure 4-23. Seal Seat (Item 4 of Figures 4-2and 4-3.

Ram SealingFlange

Figure 4-22 Load Hinge (Item 21 of Figures4-2 and 4-3)

UpperSurface

O-RingGroove

LowerSurface

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4-21

R

R

OPEN CLOSE

OPEN CLOSE

TopView

StuddedTop Connection

HydraulicConnections

RingGrooves

FluidHingeSealingArea

BoltHoles

FlangedBottom Connection

BOTTOMVIEW

SIDEVIEW

Figure 4-24. BOP Body (Item 1 of Figures 4-2and 4-3)

13. Inspect the body (item 1 of Figures 4-2 and 4-3).Refer also to Figures 4-24 through 4-26.

a. Inspect the ring grooves on the top, bottom,and side connections for wear and damage.Minor damage (nicks and scratches not ex-ceeding .015 in (.38 mm) to the grooves maybe polished with emery cloth. After polishing,wipe ring groove with a clean cloth soaked inlight machine oil. Nicks and scratches ex-ceeding .015 in (.38 mm) must be repaired ata Hydril Repair Facility (refer to Section 10 fora list of locations).

b. Inspect threaded stud and bolt holes forsigns of wear and damage. If wear or dam-age is present, contact a Hydril Repair Facil-ity for instructions. Refer to Section 10 for alist of locations.

c. Inspect sealing surfaces where fluid hinges,bonnet hinges, and hydraulic connectionsmount. Surfaces should be clean and free ofpits. Polish out any minor irregularities usingemery cloth. If major damage is present,contact a Hydril Repair Facility for instruc-tions. Refer to Section 10 for a list of loca-tions.

d. Inspect body where bonnet seal (item 55 ofFigures 4-2 and 4-3) contacts for corrosion,pitting, and scratches (refer to Figure 4-25).Remove any corrosion, minor scratches, orminor pitting with emery cloth. Nicks andscratches exceeding .015 in (.38 mm) mustbe repaired at a Hydril Repair Facility (refer toSection 10 for a list of locations). Checkflatness of areas with a straight edge andfeeler gauges. Record findings on the in-spection form.

e. Inspect hydraulic operator fluid passagesand flush out to ensure full flow.

StudHoles

RingGroove

RingGroove

BoltHoles

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4-22

f. Inspect the surface finish (refer to dimensionF of Figure 4-26) of the seal seat sealingsurfaces (item 4 of Figures 4-2 and 4-3) forflatness, pitting, dings, and gouges. Repairminor damage with emery cloth. The flat-ness should be within .010 in (.25 mm). Ifmajor damage is present, contact a HydrilRepair Facility. Refer to Section 10 for a listof locations.

g. Measure the wellbore diameter (dimensionC of Figure 4-26) of the ram BOP. Thediameter should not exceed the maximumbore in Table 4-1. If it does, contact a HydrilRepair Facility. Refer to Section 10 for a listof locations.

h. Measure the distance between the body railsand the seal seat pocket (refer to dimensionA of Figure 4-26). This measurement shouldnot exceed the maximum rails to seat pocketdimension in Table 4-1. If it does, contact aHydril Repair Facility. Refer to Section 10 fora list of locations.

i. Measure the distance between the body railsand the seal seat (refer to dimension B ofFigure 4-26). This measurement should notexceed the maximum rails to seal seat di-mension in Table 4-1. If it does, contact aHydril Repair Facility. Refer to Section 10 for

LEGEND:A – Maximum Rails to Seat PocketB – Maximum Rails to Seal SeatC – Maximum BoreD – Side Outlet ErosionE – Side Outlet ErosionF – Seal Seat Sealing Surfaces

a list of locations.j. Inspect the side walls of the body ram com-

partment for wear and damage. Repair mi-nor damage with emery cloth. If major dam-age is present, contact a Hydril Repair Facil-ity. Refer to Section 10 for a list of locations.

k. Inspect side outlet bores (areas D and E ofFigure 4-26) for erosion . Contact a HydrilRepair Facility if erosion is greater than .250in (6.4 mm).

AB

C

D E

F

Rails

Figure 4-26. Ram BOP Body

Bonnet SealContact Areas

Figure 4-25 Ram BOP Body, Bonnet Side

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4-23

14. Inspect the pipe ram, variable ram, and blind/shear ram assemblies (item 51 of Figures 4-2 and4-3). Refer also to Figures 4-4 and 4-5.a. Inspect pipe and variable ram blocks as

follows:1) Measure the overall height (refer todimension A of Figure 4-27). If the height isless than the minimum height given in Table4-1, contact a Hydril Repair Facility. Refer toSection 10 for a list of locations.2) Measure the depth of the top seal groove(refer to dimensions B of Figure 4-27). If thedepth is greater than the maximum depthgiven in Table 4-1, contact a Hydril RepairFacility. Refer to Section 10 for a list oflocations.3) Inspect the inlaid pipe hanging insertsfor cracks. If cracks are present, contact aHydril Repair Facility. Refer to Section 10 fora list of locations.4) Perform NDE and hardness tests onArea X of Figure 4-27.5) Record the results on the inspection form.

b. Inspect the shear ram assemblies as follows:1) Measure the overall height of the upperand lower carrier assemblies (refer to dimen-sion A of Figure 4-28). If it is less than themeasurement given in Table 4-1, contact aHydril Repair Facility. Refer to Section 10 fora list of locations.2) Measure the depth of the top seal groovein the upper and lower carrier assemblies(refer to dimensions B of Figure 4-28). If it isgreater than the measurement given in Table4-1, contact a Hydril Repair Facility. Refer toSection 10 for a list of locations.3) Measure the diameter of the guide pins(refer to dimension C of Figure 4-28) on theupper carrier assembly. If the diameter isless than the minimum diameter shown inTable 4-1, replace the guide pins. Part num-bers are iocated in the Ram BOP Operator'sManual.4) Measure the distance between the bot-tom of the upper carrier to the top of the guidepins (refer to dimension D of Figure 4-28). Ifthe distance is less than the measurementshown in Table 4-1, contact a Hydril RepairFacility. Refer to Section 10 for a list oflocations.5) Measure the distance between the top ofthe upper carrier to the hard-faced surface

UPPER CARRIER

LOWER CARRIER

A

B

C D

E

A

B

F

G

X

X

X

B

A

Figure 4-27. Pipe/Variable Ram Block Inspection

Figure 4-28. Shear Ram Inspection

H

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4-24

(refer to dimension E of Figure 4-28). If thedistance is less than the measurement shownin Table 4-1, contact a Hydril Repair Facility.Refer to Section 10 for a list of locations.6) Measure the diameter of the guide pinholes (refer to dimension F of Figure 4-28) onthe lower carrier assembly. If the diameter isgreater than the maximum diameter shownin Table 4-1, contact a Hydril Repair Facility.Refer to Section 10 for a list of locations.7) Measure the distance between the bot-tom of the lower carrier to the top of the guidepin holes (refer to dimension H of Figure 4-28). If the distance is greater than the mea-surement shown in Table 4-1, contact a HydrilRepair Facility. Refer to Section 10 for a listof locations.8) Measure the distance between the top ofthe lower carrier to the hard-faced surface(refer to dimension G of Figure 4-28). If thedistance is greater than the measurementshown in Table 4-1, contact a Hydril RepairFacility. Refer to Section 10 for a list oflocations.9) Inspect the hard-faced sealing surface ofthe lower carrier for cracks, corrosion, ero-sion, and scratches. If cracks are found,contact a Hydril Repair Facility. Refer toSection 10 for a list of locations.10) Inspect threaded holes for damage. Ifdamage is found, contact a Hydril RepairFacility. Refer to Section 10 for a list oflocations.11) Inspect the shear blades for nicks andcracks. Grind out any nicks that are presentand dress the blade. Replace blades withcracks. Refer to the BOP operator's manualfor the part number.12) Perform NDE and hardness tests onArea X of Figure 4-28.13) Record the results on the inspection form.

C. Wear LimitsThe wear limits discussed in this section are listed inTable 4-1.

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4-25

Component Description Wear LimitStandard ShearIn MM In MM

BOP Body Maximum Bore 7.126 181.00Maximum Rails to Seat Pocket Pipe Rams 6.246 158.65Maximum Rails to Seat Pocket Shear RamsMaximum Rails to Seat Pocket Variable RamsMaximum Rails to Seat Pipe Rams 5.583 141.81Maximum Rails to Seat Shear RamsMaximum Rails to Seat Variable Rams

Bonnet Maximum Bore Piston Rod 2.386 60.60Maximum Bore Cylinder Liner 6.512 165.40Maximum Depth Bonnet Seal Groove 0.344 8.74

Seal Seat MinimumThickness of Ram Sealing Flange 0.625 15.88Piston Minimum Piston O.D. 5.464 138.79

Minimum Rod O.D. 2.368 60.15Cylinder Maximum Bore, Manual Lock 1.769 44.93Cylinder Liner Maximum I.D. 5.511 139.98

Minimum Seal O.D. 6.484 164.69Cylinder Head Maximum Depth of Bearing Pocket 1.538 39.07Manual Lock Screw Minimum Rod O.D. 1.742 44.25MPL Lock Nut Minimum Shoulder Thickness 1.247 31.67MPL Clutch Minimum Teeth Height 0.045 1.14MPL Transfer Ring Minimum Thickness 1.423 36.14Bonnet Hinge Maximum Distance Between Hinges 3.530 89.66Pipe Rams Minimum Height 4.479 113.77

Maximum Depth of Top Seal Groove 0.655 16.64Variable Rams Minimum Height

Maximum Depth of Top Seal GrooveShear Rams Minimum Height

Maximum Depth of Top Seal GrooveUpper Carrier Minimum Diameter of Guide Pins

Minimum Height from Bottom of Rams toTop of Guide PinsMinimum Height from Top of Rams toHardface Surface

Lower Carrier Maximum Diameter of Guide Pin HolesMaxmum Height from Bottom of Rams toTop of Guide Pin HolesMaximum Height from Top of Rams toHardface Surface

TABLE 4-1RAM BOP WEAR LIMITS

7 1/16" – 3000 PSI

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7 1/16" – 5000 PSI

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BOP Body Maximum Bore 7.126 181.00 7.126 181.00Maximum Rails to Seat Pocket Pipe Rams 6.246 158.65 6.246 158.65Maximum Rails to Seat Pocket Shear Rams 6.239 158.47Maximum Rails to Seat Pocket Variable RamsMaximum Rails to Seat Pipe Rams 5.583 141.81 5.583 141.81Maximum Rails to Seat Shear Rams 5.566 141.38Maximum Rails to Seat Variable Rams

Bonnet Maximum Bore Piston Rod 2.637 66.98 3.640 92.46Maximum Bore Cylinder Liner 8.512 216.20 14.265 362.33Maximum Depth Bonnet Seal Groove 0.451 11.46 0.451 11.46

Seal Seat MinimumThickness of Ram Sealing Flange 0.663 16.84 0.663 16.84Piston Minimum Piston O.D. 7.486 190.14 12.714 322.94

Minimum Rod O.D. 2.618 66.50 3.618 91.90Cylinder Maximum Bore, Manual Lock 1.769 44.93 3.110 78.99Cylinder Liner Maximum I.D. 7.511 190.78 12.764 324.21

Minimum Seal O.D. 8.484 215.49 14.237 361.62Cylinder Head Maximum Depth of Bearing Pocket 1.538 39.07 1.241 31.53Manual Lock Screw Minimum Rod O.D. 1.742 44.25 2.992 76.00MPL Lock Nut Minimum Shoulder Thickness 1.247 31.67 1.042 26.50MPL Clutch Minimum Teeth Height 0.045 1.14 0.047 1.19MPL Transfer Ring Minimum Thickness 1.433 36.40 1.433 36.40Bonnet Hinge Maximum Distance Between Hinges 4.020 102.11 4.020 102.11Pipe Rams Minimum Height 5.479 139.17 5.479 139.17

Maximum Depth of Top Seal Groove 1.160 29.46 1.160 29.46Variable Rams Minimum Height

Maximum Depth of Top Seal GrooveShear Rams Minimum Height 5.492 139.50

Maximum Depth of Top Seal Groove 1.150 29.21Upper Carrier Minimum Diameter of Guide Pins

Minimum Height from Bottom of Rams toTop of Guide PinsMinimum Height from Top of Rams toHardface Surface 2.762 70.15

Lower Carrier Maximum Diameter of Guide Pin HolesMaxmum Height from Bottom of Rams toTop of Guide Pin HolesMaximum Height from Top of Rams toHardface Surface 2.776 70.51


7 1/16" – 10,000 PSI

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Minimum Seal O.D. 10.983 278.97 14.237 361.62Cylinder Head Maximum Depth of Bearing Pocket 1.241 31.53Manual Lock Screw Minimum Rod O.D. 2.493 63.32 2.992 76.00MPL Lock Nut Minimum Shoulder Thickness 1.042 26.50MPL Clutch Minimum Teeth Height .044 1.12MPL Transfer Ring Minimum Thickness 1.433 36.40Bonnet Hinge Maximum Distance Between Hinges 5.046 128.17 5.022 127.56Pipe Rams Minimum Height 5.479 139.17 5.479 139.17



Maximum Depth of Top Seal Groove 1.150 29.21Upper Carrier Minimum Diameter of Guide Pins

Minimum Height from Bottom of Rams toTop of Guide PinsMinimum Height from Top of Rams toHardface Surface 2.762 70.15

Lower Carrier Maximum Diameter of Guide Pin HolesMaxmum Height from Bottom of Rams toTop of Guide Pin HolesMaximum Height from Top of Rams toHardface Surface 2.776 70.51


7 1/16" – 15,000 PSI

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Minimum Seal O.D. 8.484 215.49Cylinder Head Maximum Depth of Bearing PocketManual Lock Screw Minimum Rod O.D. 2.992 76.00MPL Lock Nut Minimum Shoulder ThicknessMPL Clutch Minimum Teeth HeightMPL Transfer Ring Minimum ThicknessBonnet Hinge Maximum Distance Between Hinges 4.020 102.11Pipe Rams Minimum Height 5.729 145.52







9" – 3000 PSI

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Minimum Seal O.D. 8.484 215.49Cylinder Head Maximum Depth of Bearing PocketManual Lock Screw Minimum Rod O.D. 2.992 76.00MPL Lock Nut Minimum Shoulder ThicknessMPL Clutch Minimum Teeth HeightMPL Transfer Ring Minimum ThicknessBonnet Hinge Maximum Distance Between Hinges 4.020 102.11Pipe Rams Minimum Height 5.729 145.52







9" – 5000 PSI

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Minimum Seal O.D. 9.484 240.89 11.986 304.44Cylinder Head Maximum Depth of Bearing Pocket 1.241 31.52Manual Lock Screw Minimum Rod O.D. 2.992 76.00 2.992 76.00MPL Lock Nut Minimum Shoulder Thickness 1.042 26.47MPL Clutch Minimum Teeth Height 0.047 1.19MPL Transfer Ring Minimum Thickness 1.433 36.40Bonnet Hinge Maximum Distance Between Hinges 5.022 127.56 5.022 127.56Pipe Rams Minimum Height 6.604 167.74 6.604 167.74



Maximum Depth of Top Seal Groove 1.025 26.04Upper Carrier Minimum Diameter of Guide Pins 1.248 31.70

Minimum Height from Bottom of Rams toTop of Guide Pins 2.762 70.15Minimum Height from Top of Rams toHardface Surface 3.303 83.90

Lower Carrier Maximum Diameter of Guide Pin Holes 1.260 32.00Maxmum Height from Bottom of Rams toTop of Guide Pin Holes 2.766 70.26Maximum Height from Top of Rams toHardface Surface 3.336 84.73


11" – 3000 PSI

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11" – 5000 PSI

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Minimum Seal O.D. 10.986 279.04 14.237 361.62Cylinder Head Maximum Depth of Bearing Pocket 1.241 31.52 1.241 31.52Manual Lock Screw Minimum Rod O.D. 2.992 76.00 2.992 76.00MPL Lock Nut Minimum Shoulder Thickness 1.042 26.47 1.042 26.47MPL Clutch Minimum Teeth Height 0.002 0.05 0.047 1.19MPL Transfer Ring Minimum Thickness 1.433 36.40Bonnet Hinge Maximum Distance Between Hinges 5.022 127.56 5.022 127.56Pipe Rams Minimum Height 6.597 167.56 6.597 167.56







11" – 10,000 PSI

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BOP Body Maximum Bore 13.689 347.70 13.689 347.70Maximum Rails to Seat Pocket Pipe Rams 9.028 229.31 9.028 229.31Maximum Rails to Seat Pocket Shear Rams 9.021 229.13Maximum Rails to Seat Pocket Variable Rams 9.025 229.24 9.025 229.24Maximum Rails to Seat Pipe Rams 8.032 204.01 8.032 204.01Maximum Rails to Seat Shear Rams 8.023 203.78Maximum Rails to Seat Variable Rams 8.028 203.91 8.028 203.91





Maximum Depth of Top Seal Groove 1.040 26.42 1.040 26.42Variable Rams Minimum Height 7.961 202.21 7.961 202.21

Maximum Depth of Top Seal Groove 1.035 26.29 1.035 26.29Shear Rams Minimum Height 7.964 202.29





13 5/8" – 3000 PSI

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13 5/8" – 5000 PSI

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4-36


BOP Body Maximum Bore 13.689 347.70Maximum Rails to Seat Pocket Pipe Rams 9.280 235.71Maximum Rails to Seat Pocket Shear Rams 9.275 235.59Maximum Rails to Seat Pocket Variable Rams 9.278 235.66Maximum Rails to Seat Pipe Rams 8.290 210.57Maximum Rails to Seat Shear Rams 8.280 210.31Maximum Rails to Seat Variable Rams 8.285 210.44





Maximum Depth of Top Seal Groove 1.785 45.44Variable Rams Minimum Height 8.207 208.46

Maximum Depth of Top Seal Groove 1.780 45.21Shear Rams Minimum Height 8.211 208.56





13 5/8" – 10,000 PSI

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4-37





Minimum Rod O.D. 5.117 129.98Cylinder Maximum Bore, Manual LockCylinder Liner Maximum I.D. 14.264 362.31

Minimum Seal O.D. 15.734 399.64Cylinder Head Maximum Depth of Bearing Pocket 1.241 31.52Manual Lock Screw Minimum Rod O.D.MPL Lock Nut Minimum Shoulder Thickness 1.042 26.47MPL Clutch Minimum Teeth Height 0.047 1.19MPL Transfer Ring Minimum Thickness 1.433 36.40Bonnet Hinge Maximum Distance Between Hinges 5.034 127.86Pipe Rams Minimum Height 9.476 240.69







13 5/8" – 15,000 PSI

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BOP Body Maximum Bore 16.810 426.97Maximum Rails to Seat Pocket Pipe Rams 10.515 267.08Maximum Rails to Seat Pocket Shear Rams 10.510 266.95Maximum Rails to Seat Pocket Variable RamsMaximum Rails to Seat Pipe Rams 9.540 242.31Maximum Rails to Seat Shear Rams 9.530 242.06Maximum Rails to Seat Variable Rams











16 3/4" – 10,000 PSI

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18 3/4" – 10,000 PSI

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18 3/4" – 15,000 PSI

REV A

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20 3/4" – 3000 PSI

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21 1/4" – 2000 PSI

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21 1/4" – 5000 PSI

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Inspection ManualRam BOPs � BOP Operating Test PAGE

5-1

5.0 BOP OPERATING TEST

PAGE5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2B. Inspection Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2C. Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 BOP Operating Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

REV:

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5-2

5.1 General

A. PurposeThe procedures in this section cover the BOP operat-ing test of the Hydril ram BOP. This test verifies thatthe Open and Close functions of the ram BOP operateproperly.

B. Inspection RecordsDuring the BOP operating test of the ram BOP,records should be kept of the results. Use the RamBOP Inspection Form located in Section 9.

C. Control System RequirementsThe Hydril ram BOP may be tested with any oil fieldtest pump of sufficient pressure capacity. A 3-posi-

tion 4-Way valve (Open, Block, Close) and a hydrau-lic regulator should be installed in the output line of thetest pump. An opening and closing line is required tooperate each set of rams. These control lines areconnected to the one-inch NPT ports on the hingeside of the BOP. The regulated pressure source tooperate the ram BOP should be from a regulatorseparate from that used for the annular blowoutpreventer(s).

Any clean, light petroleum hydraulic oil can serveas a hydraulic fluid. Fresh water may be used if watersoluble oil is added. Antifreeze must be added towater based operating fluids to prevent serious dam-age to the operators when used in freezing condi-tions. CAUTION: Do not use synthetic fluids or fueloils. Serious seal damage will result.

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5-3

5.2 BOP Operating Test Procedure

A. Testing PrecautionsTake the following precautions to insure the safety ofall 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 relatedequipment are rated for the test pressures.

3. Check resolution and accuracy of pressure indi-cating devices. A resolution of one percent of fullrange 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.

WARNING: STAND CLEAR OF VENTED PRES-SURE TO AVOID INJURY.

c. Make necessary repairs and perform theBOP Operating Test again.

B. Tools and Materials required:1. New API metal ring gasket2. Light machine oil ( Gulf Harmony No. 46 or Exxon

Coray 100)3. Never-Seez thread lubricant (.069 coefficient of

friction) or equivalent4. Ram BOP Inspection Form (refer to Section 9)

C. BOP Operating Test1. If the ram BOP is already installed on the test

stump, continue to Step 2. Otherwise, install theBOP onto the test stump as follows:a. Wipe hubs/flanges, ring gasket, and ring

grooves clean with a rag soaked in lightmachine oil.

b. Install the BOP onto the test stump. Lift theBOP using the sling arrangement shown inFigure 5-1.

WARNING: THE RAM BOP IS VERY HEAVYAND BULKY EQUIPMENT. TAKE EXTREMECARE WHEN LIFTING IT. DO NOT PLACEHANDS WHERE THEY CAN BE INJURED BYCONTACT WITH OTHER EQUIPMENT DUR-ING LIFTING AND INSTALLATION OPERA-TIONS. BE SURE THAT THE LIFTING APPA-RATUS IS ADEQUATE TO HANDLE THE LOAD.

1) If a clamp is required to make up the


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5-4

Figure 5-2. Typical Ram BOP Cutaway View

connection between the test stump and theram BOP, clean the clamp thoroughly andcoat the insides with light machine oil. ApplyNever-Seez thread lubricant to clamp nutand bolt threads. Tighten clamp nuts andbolts alternately, side to side, during installa-tion to bring the clamp haves together uni-formly. Strike the clamp occasionally with asledge hammer during tightening to ensureproper seating of the clamp on the hub.Contact clamp manufacturer for torque val-ues.2) If studs and nuts are required to make upthe connection between the test stump andthe ram BOP, apply Never-Seez thread lubri-cant to the threads prior to installation. Referto the ram BOP operator's manual for thetorque value.

c. Blind off all outlet connections with appropri-ate hardware. Outlet clamps (if required) areinstalled in the same manner as end connec-

tion clamps.d. Connect hydraulic test pump to ram BOP.

Refer to Paragraph 5.1.C.2. Open the ram BOP bonnets. CAUTION: Open

and close bonnets with the rams fully retracted(Open position). Never apply operator closingpressure to open a bonnet with all bonnet boltsunscrewed. Otherwise, the ram will bind in theram compartment and damage the BOP.

3. Cycle the rams Open and Closed three times,using 200 PSI (14 Bar) operator pressure. Ob-serve for proper operation and hydraulic leaks.Record results on inspection form. Leave therams in the Open position. If a visible leak occurs:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs require

Bonnet Bolts

Ram Assy. Ring GrooveRam BOP Body

Side Outlets forChoke and Kill

WeepholePistonSeals

CylinderLiner

Piston &Piston RodAssy.

MPL

Seal Seat

Piston Rod Mud Seal

Ram CompartmentBonnet Seal

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5-5

disassembly of the BOP, cycle the ramsagain as instructed by Step 3.

4. Close one bonnet and tighten one bolt on the offhinge side. CAUTION: Ensure that the ram is inthe Open (retracted) position.

5. Slowly apply minimum operating pressure (lessthan 200 PSI (14 Bar) to the Close operator andobserve the ram stroke under the seal seat.

WARNING: STAND CLEAR OF THE OPEN BON-NET ON THE OTHER SIDE OF THE CLOSED BON-NET. THE RAM IN THE OPEN SIDE WILL BESTROKING ALSO.

Record the results on the inspection form. If ramcloses properly, continue to the next step. If anybinding and/or interference occurs, stop the clos-ing of the ram and find the cause of the problem.If disassembly is required:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, repeat Steps 2through 5 again.

6. Open (retract) the rams.7. Open the closed bonnet.8. Repeat Steps 4 through 7. Then, continue to

Step 9.9. Close the bonnets and tighten the bonnet bolts.

Refer to the BOP operator's manual for the tight-ening torque and sequence.

10. If further testing is required, leave the ram BOPon the test stump. Otherwise, remove the BOPfrom the test stump as follows:a. Install the lifting apparatus onto the ram BOP

Lift the BOP using the sling arrangementshown in Figure 5-1.1) If a clamp is required to make up theconnection between the test stump and theram BOP, remove the clamp.2) If studs and nuts are required to make upthe connection between the test stump andthe ram BOP, remove the studs and nuts.

b. Remove blind hardware from outlet connec-tions. Outlet clamps (if required) are re-moved in the same manner as the end con-nection clamp.

c. Vent all pressure and disconnect the test

Bonnet

Ram

BOP Body

Figure 5-3. Ram BOP With Bonnet Open

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5-6

pump from the ram BOP.d. Lift and remove the ram BOP from the test

stump.

WARNING: THE RAM BOP IS VERY HEAVYAND BULKY EQUIPMENT. TAKE EX-TREME CARE WHEN LIFTING IT. DO NOTPLACE HANDS OR OTHER BODY MEM-BERS WHERE THEY CAN BE INJURED BYCONTACT WITH OTHER EQUIPMENTDURING LIFTING AND INSTALLATION OP-ERATIONS. BE SURE THAT THE LIFTINGAPPARATUS IS ADEQUATE TO HANDLETHE LOAD.

11. Sign and date the inspection form.

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Inspection ManualRam BOPs � Hydraulic System Test PAGE

6-1

6.0 HYDRAULIC SYSTEM TEST

PAGE6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2


6.2 Hydraulic System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -3

REV:

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6-2

6.1 General

A. PurposeThe procedures in this section cover the hydraulicsystem test of the Hydril ram BOP. This test verifiesthe integrity of the hydraulic operator system.

B. Inspection RecordsDuring the hydraulic system test of the ram BOP,records should be kept of the results. Use the RamBOP Inspection Form located in Section 9.

C. Control System RequirementsThe Hydril ram BOP may be tested with any oil field

test pump of sufficient pressure capacity. A 3-posi-tion 4-Way valve (Open, Block, Close) and a hydrau-lic regulator should be installed in the output line of thetest pump. An opening and closing line is required tooperate each set of rams. These control lines areconnected to the one-inch NPT ports on the hingeside of the BOP.


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6-3

6.2 Hydraulic System Test Procedure




4. Do the following if a leak occurs of unacceptablepressure loss occurs:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the Hy-draulic System Test again.

B. Tools and Materials required:1. One new API metal ring gasket2. Light machine oil ( Gulf Harmony No. 46 or Exxon



C. Hydraulic System Test1. If the ram BOP is already installed on the test






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6-4


1) If a clamp is required to make up theconnection between the test stump and theram BOP, clean the clamp thoroughly andcoat the insides with light machine oil. ApplyNever-Seez thread lubricant to clamp nutand bolt threads. Tighten clamp nuts andbolts alternately, side to side, during installa-tion to bring the clamp haves together uni-formly. Strike the clamp occasionally with asledge hammer during tightening to ensureproper seating of the clamp on the hub.Contact clamp manufacturer for torque val-ues.2) If studs and nuts are required to make upthe connection between the test stump andthe ram BOP, apply Never-Seez thread lubri-cant to the threads prior to installation. Referto the BOP operator's manual for the torquevalue.

c. Blind off all outlet connections with appropri-ate hardware. Outlet clamps (if required) are

installed in the same manner as end connec-tion clamps.

d. Connect test pump to the ram BOP. Refer toParagraph 6.1.C.

2. Open the ram BOP bonnets. Pressurize theClose side of the BOP operator system. Begin-ning at zero, increase the pressure to 3000PSI(207 Bar) in increments of 500 PSI (34 Bar).Isolate (Block) the pump from the ram BOP.Observe the exterior of the BOP bonnets forleakage for three minutes minimum. If no leaksare present, continue to the next step. Do thefollowing if a leak occurs or unacceptable pres-sure loss occurs:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs require

Bonnet Bolts



WeepholePistonSeals

CylinderLiner


MPL

Seal Seat

Piston Rod Mud Seal


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6-5

disassembly of the BOP, perform the Hy-draulic System Test again beginning withStep 2.

3. Pressurize the Open side of the BOP operatorsystem. Beginning at zero, increase the pressureto 3000 PSI (207 Bar) in increments of 500 PSI(34 Bar).Isolate (Block) the pump from the ram BOP.Observe the exterior of the BOP for leakage forthree minutes minimum. If no leaks occur, con-tinue to the next step. Do the following if a leakoccurs of unacceptable pressure loss occurs:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the Hy-draulic System Test again beginning withStep 2.

4. Determine if the operator systems still functionssmoothly. With the bonnets open, cycle the ramsclosed and open using 200 PSI (14 Bar) pres-sure. Observe for binding and leakage. If theoperator system functions smoothly with no leaks,continue to the next step. If binding and/orleakage is/are present, do the following:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the Hy-draulic System Test again beginning withStep 2.

5. Hand start all bonnet bolts and then screw themin all the way until they are snug against the faceof the bonnet. Tighten the bolts using the torquevalue shown in the BOP operator's manual.Tighten the bolts in the sequence shown in theBOP operator's manual. CAUTION: To preventdamage to the BOP, be sure that rams areretracted (Open) before closing bonnets.

6. If further testing is required, leave the ram BOPinstalled 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 6-1.1) If a clamp is required to make up theconnection between the test stump and theram BOP, remove the clamp.2) If studs and nuts are required to make upthe connection between the test stump andthe ram BOP, remove the studs and nuts.


c. Vent all pressure and disconnect the testpump from the ram BOP.

d. Lift and remove the ram BOP from the teststump.

WARNING: THE RAM BOP IS VERY HEAVYAND BULKY EQUIPMENT. TAKE EXTREMECARE WHEN LIFTING IT. DO NOT PLACEHANDS OR OTHER BODY MEMBERS WHERETHEY CAN BE INJURED BY CONTACT WITHOTHER EQUIPMENT DURING LIFTING ANDINSTALLATION OPERATIONS. BE SURE THATTHE LIFTING APPARATUS IS ADEQUATE TOHANDLE THE LOAD.


R

Inspection ManualRam BOPs � Wellbore Pressure Test PAGE

7-1

7.0 WELLBORE PRESSURE TEST

PAGE7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2


7.2 Wellbore Pressure Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

REV:

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7-2

7.1 General

A. PurposeThe procedures in this section cover the wellborepressure test of the Hydril ram BOP. This test verifiesthe ability of the ram BOP to seal against wellborepressure.

B. Inspection RecordsDuring the wellbore pressure test of the ram BOP,records should be kept of the results. Use the RamBOP Inspection Form located in Section 9.

C. Control System RequirementsThe Hydril ram BOP may be tested with any oil field

test pump of sufficient pressure capacity. A 3-posi-tion 4-Way valve (Open, Block, Close) and a hydrau-lic regulator should be installed in the output line of thetest pump. An opening and closing line is required tooperate each set of rams. These control lines areconnected to the one-inch NPT ports on the hingeside of the BOP.


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7-3

7.2 Wellbore Pressure Test Procedure






c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the WellborePressure Test again.

B. Tools and Materials required:1. One new API metal ring gaskets2. Light machine oil ( Gulf Harmony No. 46 or Exxon



C. Wellbore Pressure Test1. If the ram BOP is already installed on the test






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7-4



c. Blind off all outlet connections with appropri-ate hardware. Outlet clamps (if required) are

installed in the same manner as end connec-tion clamps.

d. Connect test pump to the ram BOP. Refer toParagraph 7.1.C.

2. Open the ram BOP bonnets and cycle the ramsusing 200 PSI (14 Bar) pressure. Leave the ramsin the Open (retract) position.

3. Close the bonnets and tighten the bolts using 100percent of the torque value shown in the BOPoperator's manual. Also refer to the operator'smanual for the tightening sequence.

4. If pipe rams are installed in the ram BOP, installa test mandrel into the bore of the ram BOP. Donot install a test mandrel if shear rams are in-stalled.

5. Fill the bore of the ram BOP with clean tap waterto a level six inches above the rams.

6. Close the rams using 1500 PSI (103 Bar) for piperams or 3000 PSI (207 Bar) for shear rams.

7. Vent the operator system to zero.8. Remove the excess water from above the rams

Bonnet Bolts



WeepholePistonSeals

CylinderLiner


MPL

Seal Seat

Piston Rod Mud Seal


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7-5

so that rams can be observed clearly.9. Apply wellbore pressure of 200 - 300 PSI (14 - 21

Bar). Isolate (Block) test pump from ram BOPand allow pressure to stabilize. Hold pressure forthree minutes minimum. Observe for dramaticpressure loss and leakage. Use a mirror orboroscope suspended over the bore of the BOPto observe for leakage between the ram packingand the mandrel.

WARNING: DO NOT EXTEND ANY PART OFBODY OVER THE BOP WHILE PRESSURE ISIN THE WELLBORE.

This low pressure test is satisfactory if no visableleaks occur. Record initial and final wellborepressure on the inspection form. If no leaksoccur, continue to the next step. Do the followingif a leak occurs:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the WellborePressure Test again beginning with Step 2.

10. Increase wellbore pressure to BOP rated workingpressure (refer to operator's manual for workingpressure of your particular ram BOP). Isolate(Block) test pump from ram BOP and allow pres-sure to stabilize. Hold pressure for three minutesminimum. Observe for dramatic pressure lossand leakage. Use a mirror or boroscope sus-pended over the bore of the BOP to observe forleakage between the ram packing and the man-drel.

WARNING: DO NOT EXTEND ANY PART OFBODY OVER THE BOP WHILE PRESSURE ISIN THE WELLBORE.

This high pressure test is satisfactory if the wellpressure does not drop more than 100 PSI (7 Bar)in three minutes and no visable leaks occur.Record initial and final wellbore pressure on theinspection form. If pressure loss is less than 100PSI (7 Bar) and no leaks occur, continue to thenext step. Do the following if a leak occurs or if anunacceptable pressure loss occurs:a. Stop the test.

b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the WellborePressure Test again beginning with Step 2.

11. Vent wellbore pressure to zero. Allow a fewseconds to allow any residual pressure to bleedoff.

12. Open (retract) rams and remove mandrel.13. Drain water from wellbore.14. 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 arrangementshown in Figure 7-1.1) If a clamp is required to make up theconnection between the test stump and theram BOP, remove the clamp.2) If studs and nuts are required to make upthe connection between the test stump andthe ram BOP, remove the studs and nuts.






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Inspection ManualRam BOPs � MPL Lock Test PAGE

8-1

8.0 MPL LOCK TEST

PAGE8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2


8.2 MPL Lock Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

REV:

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8-2

8.1 General

A. PurposeThe procedures in this section cover the MPL lock testof the Hydril ram BOP. This test verifies the operationof the multiple position lock.

B. Inspection RecordsDuring the MPL lock test, records should be kept ofthe results. Use the Ram BOP Inspection Formlocated in Section 9.

C. Control System RequirementsThe Hydril ram BOP may be tested with any oil fieldtest pump of sufficient pressure capacity. A 3-posi-tion 4-Way valve (Open, Block, Close) and a hydrau-lic regulator should be installed in the output line of the

test pump. An opening and closing line is required tooperate each set of rams. These control lines areconnected to the one-inch NPT ports on the hingeside of the BOP.


Closing time of the ram BOP is determined by therate at which the hydraulic closing fluid can be deliv-ered to the operating cylinders. Minimum closing timewill result by short large-bore hydraulic control linesand large accumulator volume.

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8-3

8.2 MPL Lock Test Procedure






c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the MPLLock Test again.

B. Tools and Materials required:1. One new API metal ring gasket2. Light machine oil ( Gulf Harmony No. 46 or Exxon



C. MPL Lock Test1. If the ram BOP is already installed on the test






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8-4



c. Blind off all outlet connections with appropri-ate hardware. Outlet clamps (if required) areinstalled in the same manner as end connec-

tion clamps.d. Connect test pump to the ram BOP. Refer to

Paragraph 8.1.C.2. Open the ram BOP bonnets and cycle the rams

using 200 PSI (14 Bar) pressure. Leave the ramsin the Open (retract) position.

3. Close the bonnets and tighten the bolts using thetorque value shown in the BOP operator's manual.Also refer to the operator's manual for the tighten-ing sequence.

4. If pipe rams are installed in the ram BOP, installa test mandrel into the bore of the ram BOP. Donot install a test mandrel if shear rams are in-stalled.

5. Close the rams using 1500 PSI (103 Bar) operat-ing pressure, then reduce the closing pressure to100 PSI (7 Bar).

6. Inspect the MPL lockout devices (one on eachside of the MPLs) for freedom of movement byturning the stems alternately clockwise andcounter clockwise approximately 6 1/2 turns oruntil they stop turning.

Bonnet Bolts



WeepholePistonSeals

CylinderLiner


MPL

Seal Seat

Piston Rod Mud Seal


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8-5

7. Engage the lockout devices by rotating the stemsclockwise approximately 6 1/2 turns or until theystop turning. Tighten the stems using 10 lb-ft (13N•m) torque.

8. Bleed operator closing pressure to zero.9. Slowly increase operator opening pressure to

1500 PSI (103 Bar) in increments of 500 PSI (34Bar). Observe through the bore of the ram BOPto see if the rams retract.

WARNING: USE A MIRROR OR A BORESCOPE TO OBSERVE THE OPERATION OFTHE RAMS THROUGH THE BORE.

CAUTION: Do not exceed 1500 PSI (103 Bar) ordamage to the MPL may occur). If the ramsremain closed, continue to the next step. If therams open (retract), do the following:a. Stop the test.b. Vent pressure from the BOP.


c. Make necessary repairs. If repairs requiredisassembly of the BOP, perform the MPLLock Test again beginning with Step 2.

10. Apply 200 PSI (14 Bar) wellbore pressure andhold for three minutes. NOTE: The application ofhigher wellbore pressures do not test the lockingsystem because the ram blocks become wellpressure energized; therefore, the locks becomeessentially 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 lockoutsegments.

13. Disengage lockout devices by turning the stems6 1/2 turns counterclockwise until they are fullyretracted.

14 Set normal operating pressure and open therams.

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 arrangementshown in Figure 8-1.1) If a clamp is required to make up the

connection between the test stump and theram BOP, remove the clamp.2) If studs and nuts are required to make upthe connection between the test stump andthe ram BOP, remove the studs and nuts.






R

Inspection ManualRam BOPs � Inspection Forms PAGE

9-1

9.0 INSPECTION FORMS

PAGE9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2B. How To Use Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2 Inspection Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2A. Ram BOP Inspection FormB. Pipe/Variable Ram Inspection FormC. Shear Ram Inspection Form

REV:

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Inspection ManualRam BOPs � Inspection Forms PAGE

9-2

9.1 General

A. PurposeThe purpose of the inspection forms is to provide awritten record of the findings when scheduled inspec-tions of Hydril ram blowout preventers are performed.

B. How To Use FormsThe inspection forms in this section are intended to beused as a master for photocopying. The Ram BOPInspection Form is written for a single ram BOPcontaining two bonnets and one ram compartment.For models that have more than one ram compart-ment, photocopy this form as many times as there areram compartments in use. Each form is designed tobe used as you follow the corresponding inspectionprocedure outlined in the various sections of thismanual. The section and paragraph where the proce-dure is located is given on the form. The numberedsteps on the form correspond to the numbered stepsin the procedure.

The Ram BOP Inspection Form incorporates allof the scheduled inspections listed in Table 2-1 ofSection 2. However, not all of the inspections andtests are necessary for a given inspection interval. Touse the form correctly, check the box at the top of theform to select the desired inspection interval; fill outthe descriptive sections; perform the necessary in-spections and tests listed in Table 2-1; and skip theinspections and tests that do not apply. The inspec-tions and tests on the form that do not apply can becrossed out or marked as being not applicable.

NOTE: The Pipe/Variable Ram Form and theShear Ram Form are separate forms due to therequirement for unscheduled gauge inspection of therams that often occurs. However, the forms are usedas part of the Ram BOP Form during scheduledgauge inspection.

9.2 Inspection FormsThe inspection forms and the inspections containedon the forms are as follows:

Ram BOP Inspection FormVisual InspectionBOP Operating TestHydraulic System TestWellbore Pressure TestMPL Lock Test

Gauge Inspection

Pipe/Variable Ram Inspection FormGauge Inspection

Shear Ram Inspection FormGauge Inspection

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Inspection FormRam BOP PAGE

1

RAM BOP IDENTIFICATION

NOTE: This inspection form is written for a single ram BOP containing two bonnets and one ramcompartment. For models that have more than one ram compartment, photocopy this form as manytimes as there are ram compartments in use.

Owner: User:

Ram BOP Size: Pressure Rating (PSI):

Ram BOP Model: [ ] Single [ ] Dual [ ] Triple

Top Connection: [ ] Flange [ ] Clamp Hub [ ] Studded

Size: Pressure Rating (PSI):

Bottom Connection: [ ] Flange [ ] Clamp Hub [ ] Studded


Side Outlets: [ ] Flange [ ] Clamp Hub [ ] Studded


Ram Lock: [ ] Manual [ ] MPL MPL Size:

Hydril BOP Part No: Hydril Serial No:

Owner ID No: User ID No:

INSTALLATION & TYPE OF SERVICE

[ ] Land Stack [ ] Jackup [ ] Subsea

[ ] Drilling [ ] Stripping [ ]

SERVICE CONDITIONS OR ENVIRONMENT

[ ] Water Base Mud:

[ ] Oil Base Mud/Chemically Agressive Drilling Fluid:

[ ] Ester Base Mud:

[ ] Carbon Dioxide (Stack Temperature): oF oC

[ } Hydrogen Sulfide (Stack Temperature): oF oC

[ ] High Temperature Well (Stack Temperature): oF oC

[ ] Below Freezing Ambient Temperatures: oF oC

As Required Between Wells Yearly 4-Year

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2

VISUAL INSPECTI0N ( Section 3)

Step Paragraph 3.2.B

1 Top Connection:

Bottom Connection:

Side Outlets:

2 Nut/Bolt Heads:

3 Stud Threads:

4 Body:

5 Bonnets:

6 Pipe Ram/HVR:

Shear Ram:

BOP OPERATING TEST (Section 5)

Step Paragraph 5.2.C

3 Pressure: 200 PSI (14 Bar) — Both Bonnets Closed

1st Cycle: Close: Open: Leaks:

2ndCycle: Close: Open: Leaks:

3rd Cycle: Close: Open: Leaks:

5 Pressure: Less than 200 PSI (14 Bar) — Left Bonnet Open And Right Bonnet Closed

Cycle Under Seal Seat: Close: Open:

Pressure: Less than 200 PSI (14 Bar) — Left Bonnet Closed And Right Bonnet Open

Cycle Under Seal Seat: Close: Open:

HYDRAULIC SYSTEM TEST (Section 6)


2,3 Pressure: 0-3000 PSI (207 Bar) In 500 PSI (34 Bar) Increments – Bonnets Open

Hold Close Pressure 3 Minutes: Pressure Change: Leaks:

Hold Open Pressure 3 Minutes: Pressure Change Leaks:

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3

WELLBORE PRESSURE TEST (Section 7)


2 Pressure: 200 PSI (14 Bar) — Both Bonnets Open

Cycle Rams: Close: Open:

7 Operator Pressure: 1500 PSI (103 Bar) — Both Bonnets Closed — Pipe Rams or 3000 PSI (207 Bar) —Shear Rams

Close Rams: Close: Leaks:

10 Wellbore Pressure: 200 to 300 PSI (14 - 21 Bar)

Hold Wellbore Pressure 3 Minutes: Pressure Change: Leaks:

11 Wellbore Pressure: Working Pressure

Hold Wellbore Pressure 3 Minutes Pressure Change: Leaks:

MPL LOCK TEST (Section 8)


2 Pressure: 200 PSI (14 Bar) — Bonnets Open


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).

Close Rams: Close: Leaks:

6 MPL Lockout Device: Movement: Engagement:

9 Open Pressure: 0 - 1500 PSI (104 Bar) in 500 PSI (35 Bar) Increments.

Ram Movement: Close: Open:

10 Wellbore Pressure: 200 PSI (14 Bar)

Hold Wellbore Pressure 3 Minutes: Pressure Change: Leaks

HYDRAULIC SYSTEM TEST CONTINUED

Step

4 Pressure: 200 PSI (14 Bar) — Bonnets Open


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4

GAUGE INSPECTION (Section 4)


4 MPL Locknut Assembly —Left Bonnet

a. Locknut

1) Bearing Surfaces:

2) Shoulder Thickness:

3) Threaded Holes:

4) Through Bore Threads:

b. Retainer Plate

1) Bearing Surface:

2) Surface A and Key Slot:

3) Surface B:

c. Front Clutch Plate

` 1) Clutch Teeth:

2) Clutch Teeth Height:

d. Rear Clutch Plate

1) Clutch Teeth:


e. Retainer Plate Locating Pin:

1) Edges:

5 MPL Cylinder Assembly — Left Bonnet

a. MPL Cylinder

1) Seal Grooves/Surfaces:

2) Threaded Holes:

MPL Locknut Assembly — Right Bonnet

a. Locknut

1) Bearing Surfaces:

2) Shoulder Thickness:

3) Threaded Holes:

4) Through Bore Threads:

b. Retainer Plate

1) Bearing Surface:

2) Surface A and Key Slot:

3) Surface B:

c. Front Clutch Plate

1) Clutch Teeth:


d. Rear Clutch Plate

1) Clutch Teeth:


e. Retainer Plate Locating Pin:

1) Edges:

MPL Cylinder Assembly — Right Bonnet

a. MPL Cylinder

1) Seal Grooves/Surfaces:

2) Threaded Holes:

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5

GAUGE INSPECTION CONTINUED

Step

5 b. Lockout Stem — Left Bonnet

1) Internal Threads:

2) Seal Groove:

3) Square End:

c. Lockout Gland

1) Outside Diameter Threads:

2) Hex Corners:

d. Cylinder Head

1) Seal Grooves:

2) Bearing Pocket Depth:

6 Piston & Lock Screw —Left Bonnet

a. Cylinder Liner

1) Inside Diameter:

2) Entry Bevel and Seal Groove:

3) Cylinder Shoulder:

4) Seal Groove O.D:

b. Transfer Ring

1) Surfaces:

2) Ring Thickness:

c. Lockout Segment

1) Radius:

2) Threads:

3) Edges:

b. Lockout Stem — Right Bonnet

1) Internal Threads:

2) Seal Groove:

3) Square End:

c. Lockout Gland

1) Outside Diameter Threads:

2) Hex Corners:

d. Cylinder Head

1) Seal Grooves:

2) Bearing Pocket Depth:

Piston & Lock Screw — Right Bonnet

a. Cylinder Liner

1) Inside Diameter:

2) Entry Bevel and Seal Groove:

3) Cylinder Shoulder:

4) Seal Groove O.D:

b. Transfer Ring

1) Surfaces:

2) Ring Thicknesst:

c. Lockout Segment

1) Radius:

2) Threads:

3) Edges:

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6


Step

6 d. Piston — Left Bonnet

1) Surface A:

2) Rod Straightness:

Rod Diameter:

3) Large Piston Diameter:

4) Seal Grooves:

5) Threads (lockscrew):

6) Shoulder Cracks:

7 Manual Lock — Left Bonnet

a. Manual Lock Cylinder

1) Seal Groove:

2) Bore Diameter:

b. Cylinder Liner

1) Seal Groove

c. Mechanical Lock Piston Assembly

1) Surface A:

2) Straightness:


4) Seal Grooves:


8 Bonnet Hinge Assembly — Left Bonnet

a. Bonnet Hinges

1) Distance Between Hinges:

2) Sealing Surfaces:

d. Piston — Right — Bonnet

1) Surface A:

2) Rod Straightness:

Rod Diameter:


4) Seal Grooves:


6) Shoulder Cracks:

Manual Lock — Right Bonnet

a. Manual Lock Cylinder

1) Seal Groove:

2) Bore Diameter:

b. Cylinder Liner

1) Seal Groove

c. Mechanical Lock Piston Assembly

1) Surface A:

2) Straightness:


4) Seal Grooves:


Bonnet Hinge Assembly — Right Bonnet

a. Bonnet Hinges

1) Distance Between Hinges:

2) Sealing Surfaces:

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7


Step

8 a. Bonnet Hinges

3) Fluid Passages:

4) Threads:

5) Mounting Face:

b. Hinge Pins — Left Bonnet

1) Seal Grooves:

2) Threads:

3) Hex Head:

9 Bonnet Assembly — Left

a. Bonnet

1) Seal Groove :

Seal Groove Depth:

2) Piston Rod Bore Surface:

3) Piston Rod Bore Diameter:

4) Cylinder Liner Bore Diameter:

5) Pilot Surfaces:

6) Seal Surface:

7) Fluid Passages:

8) Studs:

9) Threaded Holes:

b. Ram Guide Pin

1) Condition:

2) Straightness:

10 Load Hinge Assemblies — Left Bonnet

a. Bonnet Hinges

3) Fluid Passages:

4) Threads:

5) Mounting Face:

b. Hinge Pins — Right Bonnet

1) Seal Grooves:

2) Threads:

3) Hex Head:

Bonnet Assembly — Right

a. Bonnet

1) Seal Groove:

Seal Groove Depth:

2) Piston Rod Bore Surface:

3) Piston Rod Bore Diameter:

4) Cylinder Liner Bore Diameter:

5) Pilot Surfaces:

6) Seal Surface:

7) Fluid Passages:

8) Studs:

9) Threaded Holes:

b. Ram Guide Pin

1) Condition:

2) Straightness:

Load Hinge Assemblies — Right Bonnet

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8


Step

10 a. Load Hinges

1) Bearing and Seal Surfaces:

a. Load Hinges

1) Bearing and Seal Surfaces:

12 Seal Seat Assembly

a. Seal Seat

1) O-Ring Grooves:

2) Lower Surface:

3) Flatness:

4) Set Screw Holes:

5) Ram Sealing Flange Thickness:

6) Lock Ring Groove:

13 Body

a. Ring Grooves:

b. Threaded Holes:

c. Mounting Surfaces:

d. Sealing Surfaces:

e. Fluid Passages:

f. Seal Seat Sealing Surface:

g. Wellbore Diameter:

h. Distance Between Body Rails and Seal Seat Pocket:

i. Distance Between Body Rails and Seal Seat:

j. Ram Compartment Side Walls:

k. Side Outlet Bores:

14 Ram Assemblies

a. Pipe/Variable Ram: (Use Pipe/Variable Ram Inspection Form.)

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9


Step

14 b. Shear Ram Assemblies (Use Shear Ram Inspection Form.)

COMMENTS

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10

Inspector:

Date

COMMENTS CONTINED

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Inspection FormPipe/Variable Ram PAGE

1

RAM IDENTIFICATION

NOTE: This inspection form is written for a single pipe/variable ram assembly containing two ramblocks. Photocopy this form for as many ram assemblies that are to be inspected.

Owner: User:

Ram Size: Pressure Rating (PSI):

Ram Model: [ ] Pipe [ ] Variable





[ ] Drilling [ ] Stripping [ ] Other


[ ] Water Base Mud:


[ ] Ester Base Mud:





GAUGE INSPECTION (SECTION 4)


14 a. Ram Block - Left a. Ram Block - Right

1) Overall Height: 1) Overall Height:

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2



14 a. Ram Block - Left a. Ram Block - Right

2) Top Seal Groove Depth: 2) Top Seal Groove Depth:

3) Pipe Hanging Inserts: 3) Pipe Hanging Inserts:

4) Hardness Value: 4) Hardness Value:

5) NDE Results: 5) NDE Results:

BX

LEGEND:A: Overall HeightB: Top Seal Groove DepthX: Area For NDE & Hardness Tests

Pipe/Variable Ram Block

A

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3

Inspector:

Date:

COMMENTS

R

Inspection FormShear Ram PAGE

1

RAM INDENTIFICATION

NOTE: This inspection form is written for a single shear ram assembly containing an upper andlower carrier. Photocopy this form for as many shear ram assemblies that are to be inspected.

Owner: User:

Ram Size:

Pressure Rating (PSI):





[ ] Drilling [ ] Stripping [ ] Other


[ ] Water Base Mud:


[ ] Ester Base Mud:





GAUGE INSPECTION (SECTION 4)


14 b. Upper Carrier Ram Block b. Lower Carrier Ram Block

1) Overall Height: 1) Overall Height:

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2

14 b. Upper Carrier Ram Block b. Lower Carrier Ram Block

2) Top Seal Groove Depth: 2) Top Seal Groove Depth:

3) Guide Pin Diameter 6) Guide Pin Hole Diameter

Left Pin: Left Hole:

Right Pin: Right Hole:

4) Distance Between the Bottom 7) Distance Between the bottomof the Ram Block and the Top of the Ram Block and the Topof the Guide Pins of the Guide Pin Holes

Left Pin: Left Hole:

Right Pin: Right Hole:

5) Distance Between the Top of the 8) Distance Between the Top of theRam Block to the Hard-Faced Ram Block to the Hard-FacedSurface: Surface:

9) Hard-Faced Sealing Surface:

10) Threaded Holes: 10) Threaded Holes:

11) Shear Blade: 11) Shear Blade:

12) Hardness Value: 12) Hardness Value:

NDE Results: NDE Results:



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3

LOWER CARRIER

B G

X

A

B

C D

E

X UPPER CARRIER


LEGEND:A: Overall HeightB: Top Seal Groove DepthC: Guide Pin DiameterD: Distance Between Bottom of Ram Block To Top of Guide PinsE: Distance between Top of Ram Block to Hard-Faced SurfaceX: Area for NDE and Hardness Tests

LEGEND:A: Overall HeightB: Top Seal Groove DepthF: Guide Pin Hole DiameterG: Distance between Top of Ram Block to Hard-Faced SurfaceH: Distance Between Bottom of Ram Block To Top of Guide Pin HolesX: Area for NDE and Hardness Tests

Shear Ram Assembly

F

A

H

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4

Inspector:

Date:

COMMENTS

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Inspection ManualRam BOPs � Hydril Repair Facilities PAGE

10-1

10.0 HYDRIL REPAIR FACILITIES

PAGE10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.2 Hydril Repair Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

A. United States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2B. Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2C. Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2D. Overseas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

REV:

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Inspection ManualRam BOPs � Hydril Repair Facilities PAGE

10-2

10.1 GeneralThis section contains a listing of Hydril repairfacilities.

10.2 Hydril Repair FacilitiesHydril repair facilities are located in the United

States, Canada, Mexico, and various countriesoverseas. Refer to the list below for their address,telephone, FAX, etc.

SingaporeHydril Private Ltd.Number 7 Gul CircleJurong TownSingapore 2262,Republic of SingaporeTel: (65) 861-2566FAX: (65) 861-4191

ABU Dhabi, U.A.E.WESCO(Authorized Rapair Facility)P.O. Box 4752ABU Dhabi, U.A.E.Tel: 554108/554436FAX: 553688

Saudi ArabiaArabian Metals Company(AMCO)(Authorized Repair Facility)P.O. Box 66, Dhahran AirportDhahran-31932 Saudi ArabiaTel: 8425639/8429588FAX: 8422249

IndonesiaP.T. FMC Santana PetroleumEquipment Indonesia(Authorized Repair Facility)JL. Cakung Cilincing RayaP.O. Box 1059Jakarta 14010IndonesiaTel: (6221) 4404151FAX: (6221) 4404050

C. Brazil

Rio De JanerioPWR MissionTel: 55 21 372 7979FAX: 55 21 372 5512

D. Overseas

Stavanger, NorwayWEPCO AS(Authorized Repair Facility)P.O. Box 5015 DusavikN-4001 Stavanger, NorwayTel: 47 (4) 54 1033FAX: 47 (4) 541226

Aberdeen, ScotlandHydril U.K. Ltd.Minto AvenueAltens Industrial EstateAberdeen, AB1 4JZ, ScotlandTel: (44) (224) 878-824FAX: (44) (224) 898-524

Hengelo, HollandStork IndustriesTel: (0) 74-407000FAX: (0) 74-426665

Pescaro, ItalyOMPATel: 0871/360898FAX: 0871/360997

A. United States

HeadquartersHYDRIL COMPANY LPP.O. Box 60458Houston, Texas 77205-04583300 Sam Houston ParkwayHouston, Texas 77032-3411Tel: (713) 449-2000FAX: (713) 985-2828

Houston, TexasHydril Valvcon Plant8641 Moers RoadHouston, Texas 77075Tel: (713) 941-6639FAX: (713) 941-5862

Anchorage, AlaskaEastern Electric(Authorized Repair Facility)568 E. Whitney Rd.Anchorage, AK 99501Tel: (907) 274-3523FAX: (907) 274-4155

B. Canada

Edmonton, Alberta CanadaHydril Canadian Company, Ltd.602 13th AvenueP.O. Box 202Nisku, Alberta TOC 2G0CanadaTel: (403) 955-2045FAX: (403) 955-7627

Documents

MANAUL-9407_B