Hydril GK Bop PDF

Manual 6609E
OPERATOR'S MANUAL
GK® 11"-5000 PSI
Annular Blowout Preventer
Pressure Control Equipment

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Operator's Manual
OPERATOR'S MANUAL PAGE
GK® 11"-5000 PSI Annular Blowout Preventer iii
6609E
GK® 11"-5000 PSI Annular Blowout Preventer
Hydril Company LP/ P.O. Box 60458 / Houston, Texas 77205

Phone: (281) 449-2000 / FAX: (281) 985-2828 / WEB: www.hydril.com
© 2007 Hydril Company LP Printed in U.S.A., Rev E, October 2007 All Rights Reserved
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Operator's Manual
iv GK® 11"-5000 PSI Annular Blowout Preventer
Preface
This manual contains the information necessary to operate and maintain the Hydril® GK® 11"-5000 PSI Annular Blowout
Preventer (ABOP). Hydril recommends that the information in this manual be studied thoroughly before any attempt
is made to operate or perform maintenance or repair operations on this equipment and that all safety precautions be
followed.
Generic in construction, this manual is applicable for the operation and maintenance of all GK 11"-5000 ABOPs
manufactured by Hydril. The illustrations of assemblies and operation and maintenance procedures in this manual
are typical and represent most configurations. Variations in configuration are noted in the procedures where
applicable. In addition, illustrated parts lists are provided for component replacement.
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Operator's Manual PAGE

GK® 11"-5000 PSI Annular Blowout Preventer v
CONTENTS
PAGE
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
OPERATOR QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
SECTION 1.0 – INSTALLATION AND OPERATION

1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.3 Annular BOP Removal and Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
A. Annular BOP Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
B. Annular BOP Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.1 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
A. Opening the Annular BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
B. Closing the Annular BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.2 Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.3 Operational Characteristics Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.4 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.5 Surface Operation and Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.6 Surface Stripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SECTION 2.0 – PHYSICAL DATA

2.1 Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Bolt and Wrench Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Lubricant List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Dimensions - Screwed Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5 Dimensions - Latch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.6 API Ring Joint Flange Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.7 Clamp Hub Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION 3.0 – PACKING UNITS AND SEALS

3.1 Packing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Packing Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.2 Packing Unit Replacement-Screwed Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.3 Packing Unit Replacement-Latch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SECTION 4.0 – MAINTENANCE AND TESTING

4.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Seal Testing - GK® Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 Seal Testing - GK® With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6 Packing Unit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7 BOP Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
SECTION 5.0 – DISASSEMBLY AND ASSEMBLY

5.1 Disassembly - Screwed Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Assembly - Screwed Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Disassembly - Screwed Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Assembly - Screwed Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
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Operator's Manual
vi GK® 11"-5000 PSI Annular Blowout Preventer
CONTENTS (CONTINUED)
SECTION 5.0 – DISSASSEMBLY AND ASSEMBLY (CONTINUED)

5.5 Disassembly - Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6 Assembly - Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.7 Disassembly - Latched Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.8 Assembly - Latched Head With Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
SECTION 6.0 – PARTS AND STORAGE

6.1 Parts List - Screwed Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2A Parts List - Screwed Head With Wear Band Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2B Parts List - Screwed Head Wear Band Modification Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Parts List - Screwed Head With Wear Bands At Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 Parts List - Latched Head Without Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5A Parts List - Latched Head With Wear Band Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5B Parts List - Latched Head Wear Band Modification Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6 Parts List - Latched Head With Wear Bands At Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.7 Preventor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.8 Rubber Goods Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
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Operator's Manual 1-vii

PAGE
GK® 11"-5000 PSI Annular Blowout Preventer vii
OPERATOR QUICK REFERENCE
Figure 1
Standard Hookup
Closing
Pressure
Opening
Pressure
Control Pressures
▲ Surface Control Pressure —psi
WELL PRESSURE—psi
Initial*
Pipe Size Closure 500 1500 2500 3500 5000
2 3/8” 900 825 650 475 300 50
2 7/8" 800 725 550 375 200 50
3 1/2" 825 450 275 100 50 50
4 1/2"-5 " 450 375 225 100 50 50
5 1/2"-8 5/8" 350 275 125 50 50 50

Close cautiously to prevent collapse of casing.
CSO 1150 1150 1150 1150 1150 1150
▲ *Use closing pressure shown at initial closure to establish seal off and reduce closing pressure proportionally as
well pressure is increased. Well pressure will maintain closure after exceeding the required level. See Section 1 for
control pressure graph. Closing pressures are average and will vary slightly with each packing unit.
Optimum stripping is obtained by adjusting the control pressure to achieve a slight drilling fluid leakage as the tool
joint passes through the packing unit.
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Operator's Manual 1-viii
viii GK® 11"-5000 PSI Annular Blowout Preventer
ANNULAR BOP TESTING AND OPERATION

Proper Procedure for pressure testing any annular blow- force on the packing unit. Optimum closing forces for high
out preventer (BOP) ensures subsequent seal off and well pressures may require careful application of pressure
maximum packing unit life. Reliable seal off tests are made to the opening chamber. Closing pressure required to
by initially closing the packing unit with prescribed closing effect initial seal off may vary slightly between individual
chamber pressure on the recommended size test pipe, packing units. Begin the test with the recommended initial
proportionally reducing closing pressure as well pressure closing pressure.
is increased, and by determining the remaining piston Piston Stroke can be measured on GK® blowout
travel after seal off is achieved. Optimum packing unit life preventers through a vertical passage in the top of the BOP
is obtained by testing at low rubber stress levels. Minimum head.* The maximum and minimum distances from the top
packing unit stress is achieved by use of the minimum of the head to the top of the piston are stamped on the BOP
closing chamber pressure that will initiate and maintain head and are also listed in the table below. Piston stroke
seal off on the recommended size test pipe. remaining at seal off is a direct indicator of remaining
The GK® blowout preventer is designed to be well packing unit life. Record the piston stroke and the closing
pressure assisted in maintaining packing unit seal off once pressure at seal off for each test. Compare with previous
initial seal off has been effected. Initial seal off is effected results and with maximum piston stroke for the BOP to
by applying pressure to the closing chamber. As well ensure subsequent seal offs. A valid test on any annular
pressure or test pressure is increased, the closing force on BOP is only achieved when the remaining piston stroke is
the packing unit also increases. As well pressure exceeds measured at test seal off.
the required level the packing unit is maintained closed on
the recommended size test pipe by well pressure alone. *Older model BOPs may not have vertical passage in head.
Once initial seal off is achieved, it is recommended that See Section 4, “Maintenance and Testing” for information
closing pressure be proportionally reduced as well pres- on modification.
sure is increased in order to maintain the optimum closing
OPERATIONAL DATA
3
Bore 11 in. 279.4 mm
TAPE
Closing Chamber 9.81 37.1
MEASURE 2 5/16" ROD
Volume gal. (U.S.) liters
Opening Chamber 8.08 30.6

Volume gal. (U.S.) liters 1
Recommended Test
Pipe Size 3 1/2 in. 88.9 mm
Full Piston Stroke 7 1/8 in. 181 mm
Distance From Top of Head To Top of Piston
Maximum — Piston Full

Down 11 1/8 in. 283 mm
Minimum — Piston at Full

Stroke 4 in. 102 mm
Figure 2
Piston Stroke Measurement
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GK® 11"-5000 PSI Annular Blowout Preventer 1-1
1.0 INSTALLATION AND OPERATION
1.1 Installation
1.1.1 Safety Precautions B. Annular BOP Installation Procedure
1. Gather the following tools and materials:
WARNING: THIS IS VERY HEAVY EQUIPMENT, AND a. Lifting apparatus for lifting the annular BOP as-
EXTREME SAFETY PROCEDURES MUST BE FOL- sembly. CAUTION: Ensure that the lifting appa-
LOWED DURING LIFTING OPERATIONS. BE SURE ratus is adequate to safely support the weight of
THAT LIFTING EQUIPMENT IS IN GOOD CONDITION the annular BOP assembly. NOTE: Refer to
AND CAPABLE OF HANDLING THE LOAD. Section 2, "Physical Data" for estimated weight.
b. Lightweight oil (Gulf "Harmony No. 46" or Exxon
WARNING: DO NOT USE THE FOUR LIFT EYES "Coray 100")
MOUNTED ON THE ANNULAR BOP BODY TO LIFT THE c. One new API ring gasket for bottom connection
BOP STACK ASSEMBLY. THESE LIFT EYES ARE FOR d. Emery cloth, 240-grit or finer
LIFTING THE GK 11"-5000 PSI ANNULAR BOP ASSEM- 2. Inspect the ring groove in the mating flange. Remove
BLY ONLY. minor damage by polishing the groove with 240-grit or
finer emery cloth. Apply light machine oil to the ring
1.1.2 Weight and Dimensions groove and wipe it clean, leaving only a film of oil on the
For dimensions and weight, refer to Section 2,"Physical surface.
Data." 3. Apply lightweight oil to a new API ring gasket and wipe
it clean, leaving only a film of oil on the surface. Install
1.1.3 Annular BOP Removal and Installation the new ring gasket into the ring groove of the mating
Procedures flange.
NOTE: For initial installation, refer to “Surface Operation 4. Attach lifting apparatus to the four padeyes/anchor
and Hookup” and “Surface Stripping Operations” in this shackles on the annular BOP (refer to Figure 1-1 for
section for information on connection of hydraulic operat- sling arrangement).
ing lines to the blowout preventer. 5. Lift and position the annular BOP over the mating
The GK 11"-5000 PSI Annular BOP is usually installed connection.
at the top of a BOP stack. Normally, the annular BOP does 6. Inspect the ring groove in the connection of the annu-
not require removal from the BOP stack and subsequent lar BOP. Remove minor damage by polishing the
installation for field repair. The procedures below are groove with 240-grit or finer emery cloth. Apply light-
intended for those circumstances where the annular BOP weight oil to the ring groove and wipe it clean, leaving
would require removal from the BOP stack for inspection of only a film of oil on the surface.
the bottom connection or for other reasons and subse- 7. Lower the annular BOP onto the mating connection,
quently would require installation again. aligning the hydraulic connection ports with the hy-
draulic lines and taking care not to damage the ring
A. Annular BOP Removal Procedure gasket.
1. Gather a lifting apparatus for lifting the annular BOP 8. Make up the bottom connection.
assembly. CAUTION: Ensure that the lifting appara- 9. Remove the lifting apparatus.
tus is adequate to safely support the weight of the 10. Connect the Open and Close hydraulic lines to the
annular BOP assembly. NOTE: Refer to Section 2, annular BOP.
"Physical Data" for estimated weight.
2. Disassemble the BOP stack to the point where the
annular BOP can be removed.
3. Attach the lifting apparatus to the four padeyes/anchor
shackles on the body of the annular BOP (Refer to
Figure 1-1 for sling arrangement).
4. Disconnect all hydraulic lines.
5. Disconnect bottom connection and lift the annular
BOP free.
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Operator's Manual
1-2 GK® 11"-5000 PSI Annular Blowout Preventer
Figure 1-1
Sling Arrangement for Lifting BOP
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1.2 Operation
1.2.1 Operating Procedures from the Open chamber.
2. Apply closing pressure to the Close chamber. Refer to
A. Opening the Annular BOP “Surface Operation and Hookup” in this section.
1. To open the annular BOP, vent operating pressure
from the Close chamber. 1.2.2 Operating Data
2. Apply opening pressure to the Open chamber. Refer Refer to Section 2, "Physical Data."
to “Surface Operation and Hookup” in this section.
1.2.3 Operational Characteristics Summary
B. Closing the Annular BOP The GK sucessfully passed the fatigue and stripping life
1. To close the annular BOP, vent operating pressure tests. For sealing characteristics test data, contact Hydril.
Head
Wear Plate
Packing Unit
Clamping
Screw
Radial Latch
Opening
Chamber
Piston
Closing
Chamber
Inner
Sleeve
Body
Figure 1-2
Cutaway view of GK®
with packing unit fully open.
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Operator's Manual
1.2.4 Principle of Operation

The Hydril® GK 11"-5000 PSI annular BOP (Figure 1-2) is an
annular blowout preventer as defined by API Specification
16A. It will close and seal off on drill pipe, tool joints, tubing,
casing, or wireline in the wellbore or completely seal off the
open hole to full rated working pressure. Seal off is effected
by raising the piston which causes the packing unit to be
squeezed inward to a sealing engagement with anything in
the bore or with itself on open hole (refer to Figures 1-3
through 1-7).
The piston is raised by applying hydraulic pressure to
the closing chamber. The optimum closing pressure is the
minimum pressure that will maintain a complete seal under
existing operational conditions. During well control opera-
tions, drill pipe can be rotated and tool joints stripped through
a closed packing unit while maintaining a full seal on the
pipe.
Any normal closing unit having a separate regulator
valve for the annular blowout preventer and sufficient accu-
mulator volume can be used to operate the GK 11"-5000 PSI
annular blowout preventer. Any clean, light petroleum
hydraulic oil will serve as a hydraulic operating fluid. Fresh
water may be used in a 50/50 water and ethylene glycol
mixture with a corrosion inhibitor added. (CAUTION: Do
not use synthetic fluids or fuel oils. Use of these types of
operating fluids will cause serious damage to seals.) For
additional discussion and specific hydraulic fluid recom-
mendations, refer also to Hydril Engineering Bulletin EB
99009 on the Hydril Website www.hydril.com.
This blowout preventer has been developed primarily
for use on surface installations. In addition, the GK® meets
the requirements of API Recommended Practices – R.P. 53*
(available from the American Petroleum Institute, Produc-
tion Department, 1220 L Street, Northwest, Washington, DC
20005) as well as NACE 10-75-43. NOTE: Some GK®
assemblies manufactured before 1980 are not be certified to
NACE. Certification of these units must be performed at a
Hydril Authorized Repair Facility (ARF). If certification is
desired, contact Hydril or visit Hydril Website www.hydril.com
for the nearest ARF.
Figure 1-3
Upward force exerted
by the piston squeezes
packing unit rubber inward into
a sealing engagement.
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Figure 1-4 Figure 1-5

Cutaway view of GK® BOP with packing unit fully open. Cutaway view of GK® BOP with packing unit closed on drill
The Hydril® GK® opens to full bore to allow passage of pipe. The packing unit seals off on tool joints, drill pipe,
large-diameter tools through open bore as well as maxi- casing, tubing, or wireline to rated pressure.
mum annulus flow of drilling fluids. Packing unit always
returns to the open position due to normal resiliency of
rubber packing unit. Retention of opening chamber pres-
sure will provide positive control of piston and reduce wear
caused by vibration.
Figure 1-6 Figure 1-7

Cutaway view of GK® BOP with packing unit closed on Cutaway view of GK® BOP with packing unit closed on
square kelly. The packing unit seals off on square or open hole. Complete closure of packing unit safely holds
hexagonal kellys to rated pressure. well pressure, without leakage, equal to the rated working
pressure of the preventer.
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Operator's Manual
1.2.5 Surface Operation and Hookup
The surface hookup of the GK® shown in Figure 1-8

connects the hydraulic control lines to the opening and
closing chambers of the BOP
Pressure applied to the closing chamber raises the
piston and effects the initial seal between the packing unit
and drill pipe. Well pressure or test pressure also acts on
the piston below the sealed-off packing unit and further
increases the closing force acting on the packing unit. As
the well pressure or test pressure exceeds the required Closing
level, the preventer is maintained closed by well pressure Pressure
alone. As well pressure further increases, the closing force
on the packing unit also increases. Closing pressure Opening
should be proportionally reduced as well pressure is Pressure
increased in order to maintain optimum closing force on
the packing unit and prolong packing unit life. Figure 1-8
The Control Pressure Graph, Figure 1-9, shows the Standard Hookup
relationship of closing pressure and well pressure re-
quired to effect optimum seal off for the GK® 11”-5000 PSI pressure will ensure that initial seal off is achieved should
BOP. a “kick” be encountered.
During normal drilling operations, it is recommended that During BOP testing operations, once initial seal off is
the pressure regulator valve for the GK® be set at the initial achieved, closing pressure should be proportionally
closing pressure shown for the size pipe being used. This reduced as well pressure is increased.
1500
▲ CLOSING PRESSURE-PSI
CSO
1000
*Closing pressures are average and will vary slightly with each
packing unit. Use closing pressure shown at initial closure to establish seal
off and reduce closing pressure proportionally as well pressure is increased.
Well pressure will maintain closure after exceeding the required level.
**Close cautiously to prevent collapse of casing.
Operating pressure may vary at temperatures other than 70oF.
500
23
/8"
PIP
E
2 7/
8" P
IPE
4 1/ 3 1/
2" th 2" P
**5 1 ru 5 IPE
/2" th " PIP
ru 8 E
5/8"
PIPE
0
0 1000 2000 3000 4000 5000
WELL PRESSURE-PSI
Figure 1-9
Average Control Pressure - GK 11"-5000 PSI
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1.2.6 Surface Stripping Operations

Drill pipe can be rotated and and tool joints stripped through packing unit.
a closed GK® packing unit (Figure1-10) while maintaining Slow tool joint stripping speeds reduce surge pressures,
a full seal off on the pipe. Longest life for the packing unit and thus prolong packing unit life. The pressure regulator
is obtained by adjusting the closing forces low enough to valve should be set to provide and maintain the proper
maintain a seal on the drill pipe with a slight amount of control pressure. If the pressure regulator valve does not
drilling fluid leakage as the tool joint passes through the respond fast enough for effective BOP control, a surge
packing unit. This drilling fluid leakage indicates optimum absorber (accumulator) shown in Figure 1-11 should be
seal off for minimum packing unit wear and provides installed in the closing chamber control line adjacent to the
lubrication for the drill pipe motion through the packing unit. blowout preventer. Precharge the accumulator to one-half
When rotating in a closed packing unit, it is recommended of the closing pressure required to effect a seal off at the
that the pipe be reciprocated (moved up and down) to existing well pressure for the pipe size in use.
minimize heat build up between the drill pipe and the
Surface Hookup
Closing Pressure Closing Pressure
Opening Pressure Opening Pressure
Figure 1-10
Example Precharge Calculation:
500 psi well pressure, 3 1/2" drill pipe
Precharge = 0.50 (Closing Pressure).
From Figure 1-8:
Closing Pressure = 450 psi
Precharge = 0.50 x 450 psi
Precharge = 225 psi
Figure 1-11
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Operator's Manual
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2.0 PHYSICAL DATA
2.1 Engineering Data

English Metric
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 inches 279.4 mm
Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5000 PSI 351.55 kg/cm2
Shell Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 PSI 703.1 kg/cm2
Closing Chamber Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . 5000 PSI 351.5 5 kg/cm2
Opening Chamber Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . 5000 PSI 351.55 kg/cm2
Volume—Closing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.81 gallons 37.1 liters
Volume—Opening Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.08 gallons 30.6 liters
Piston Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1/8 inches 181 mm
Port Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1” NPT* —
Weight-Single (Approximate—varies with connectors) . . . . . . . . . . . . . . . . . . . . . . . 8,200 lb 3,720 kg
* 1 1/4" or 1 1/2" NPT available on request
2.2 Bolt and Wrench Data
Ref. Description Thread Wrench Recommended Torque

No. Size Lb/Ft N•m
17 Pipe Plug—Piston Indicator 1/2" NPT 3/8" Hex Key 50 69

18 Inner Sleeve Screw 1/2"-13UNC 3/4" Hex 55-75 75-102
19 Head Lock Screw 1"-8UNC 1 1/4" Hex 100 136
30 Wear Plate Cap Screw 1/2-13UNC 1/2" -12pt. 70 95
Socket
... Eyebolt, Piston x 10" Lg. 5/8"-11UNC .... Snug Snug
... Eyebolt, Head x 1 3/4" Lg. 1 1/4"-7NC .... Snug Snug
... Protector Plate Screw 1/2"-13UNC 3/4" Hex Snug Snug
LATCHED HEAD ONLY

22 Jaw Clamping Screw 2 1/4"-8UN 2 1/2" Hex 350-475 475-644
23 Spacer Sleeve Screw 5/8"-18 UNF 3/4" Hex Key 150 203
2.3 Lubricant List

Type Source
Lightweight Oil Gulf "Harmony No. 46" or Exxon "Coray 100" or Equivalent
Thread Lubricant Neverseez (0.069 Coefficient of Friction) or Equivalent
Moly Paste 503 (0.065 Coefficient of Friction) or Equivalent
Nonpetroleum Base Oil Castor Oil
Corrosion Inhibitor Grease Cortec VCI 369
Vapor Phase Corrosion Cortec VCI 609
Inhibitor
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Operator's Manual
2.4 Dimensions - Screwed Head
H AS CAST
J
K
F
D
*OPENING AS
PORT CAST
B CLAMP HUB
C STUDDED
A AS CAST
G
*CLOSING
PORT
M AS
CAST
N AS CAST Figure 2-1

O AS CAST Outside Dimensions-
Screwed Head
* 1" NPT, 1 set of ports, 45o from lifting lug unless otherwise specified.
NOTE: Lifting lugs split lower connection stud holes and are equally spaced 90o apart.
Lifting lugs are 1-1/4" thick with 1-1/2" diameter holes.
Nominal Dimensions — Inches

A B C D E F
▲5M ▲10M ▲5M ▲10M ▲5M ▲10M
47.75 48.50 44.88 ... 39.63 40.25 19.06 5.69 13 3/16
G H J K L M N O
11.81 44.25 37.50 35.75 ... 2.00 32.00 36.75
▲ Lower Connector Pressure Rating

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2.5 Dimensions - Latched Head
H AS CAST
J
K
F
D
*OPENING AS
PORT CAST
C STUDDED
B CLAMP HUB
g
A FLANGED
*CLOSING
PORT R
L AS CAST
M AS CAST Figure 2-2

Outside Dimensions -
N AS CAST
Latched Head
*1” NPT, 1 set of ports, 18” from lifting lug.

NOTE: Lifting lugs are equally spaced 90o apart.
Lugs are 2.12” thick with 1.75” diameter holes.
Nominal Dimensions — Inches

A B C D E F
▲5M ▲10M ▲5M ▲10M ▲5M ▲10M
48.25 49.00 45.31 ... 40.06 40.69 19.88 4.00 14.19
G H J K L M N
11.25 44.25 42.25 36.38 2.00 32.00 36.75
▲ Lower Connector Pressure Rating

On BOPs built after serial number 69730: D= 27.50
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Operator's Manual
2.6 API Ring Joint Flange Connections
C C
B
A
Bolted Flange, Studded Flange,

Using Stud Bolts. Using Studs.
Figure 2-3
Bolted and Studded
Flange Specifications
FLANGE SEAL RING

Nominal Bore Max. API O.D. Thickness † Dia. C API
Size Dia. Service (Inches) (Inches) (Inches) Ring
(Inches) (Inches) Pressure
Rating (PSI)
11 11 5000 23 4 11/16 12 3/4 RX-54
11 11 10,000 25 3/4 5 9/16 14.064 BX-158

BOLTS & STUDSa
No. Size Lengthb Bolt

Req. (Inches) Circle
Dia.
Stud Bolts Studs
(Inches)
A B
12 1 7/8 14 1/2 10 1/4 19
16 1 3/4 15 3/4 10 1/4 22 1/4
POINT HEIGHT OF STUD BOLTS

a
Bolt Diameter, Inches Max. Point Height Inches Bolt material shall be of a quality and strength not
less than specified by ASTM A-193, Grade B7.
1/2 to 7/8 . . . . . . . . . . . . . . . . . . . . . . 1/8 Nuts shall be of a quality not less than ASTM
Over 7/8 to 1 1/8 . . . . . . . . . . . . . . . . 3/16 A-194, Grade 2H. Stud bolts are threaded full
Over 1 1/8 to 1 5/8 . . . . . . . . . . . . . . 1/4 length.
Over 1 5/8 to 1 7/8 . . . . . . . . . . . . . . 5/16 b
Lengths shown herein are overall lengths,
Over 1 7/8 to 2 1/2 . . . . . . . . . . . . . . 3/8 including point at both ends, as shown in table.
†
Dimensions shown are outside diameters of 6BX
flange grooves, or pitch dim. in case of 6B
grooves.
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2.7 Clamp Hub Connections
C A
J
A
G G
B B
E E
F F
H H
Figure 2-4
Hub Connection Specifications
HUB
Hub Bore Rated Seal Ring No. Hub Dimensions (Inches)

Size Size Working RX Only
(Inches) A Pressure Standoff
(Inches) (PSI) RX BX B C D J
11 11 5000 53 ... 16 1/4 3 3/4 15/32 ...
11 11 10,000 ... 158 16 1/4 ... ... 3 5/8
NOTE: API 16A 1st Edition Nov 1, 1986 Does Not Include Clamps.
Clamp Dimensions (Inches) ▲
E F G H
20 13/16 28 1/2 6 3/4 ...
20 13/16 28 1/2 6 3/4 ...
▲ Clamp dimensions may vary from those shown.

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Operator's Manual
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3.0 PACKING UNITS AND SEALS
3.1 Packing Units

The heart of the GK® blowout preventer is the packing resistant to tears and abrasion.
unit. The unit is manufactured by Hydril from high All annular blowout preventer packing units are sub-
quality rubber, reinforced with flanged steel segments. jected to wear during closure and stripping. The design of
Each unit has a large volume of tough, feedable rubber the Hydril® GK® blowout preventer causes closure wear to
to meet any requirement. occur on the outside of the packing unit while stripping wear
The molded-in steel segments have flanges at the top occurs on the inside. Because the packing unit uses the
and bottom These segments anchor the packing unit principle of feeding rubber from the back of the packing unit
within the blowout preventer and control rubber extru- to the bore, stripping life may be affected by a packing unit
sion and flow when sealing off well pressures. Since the that is worn on the backside.
rubber is confined and kept under compression, it is
Figure 3-1
Cutaway drawing showing
how rubber is molded around
steel segments.
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Operator's Manual
3.1.1 Packing Unit Selection

Because of the importance of the packing unit to the
operation of the blowout preventer and to the safety of the
crew and rig, only genuine Hydril® packing units should be
used as replacements for original equipment. All Hydril®
packing units are tested to full rated pressure inside a test
blowout preventer as part of standard performance tests
before being furnished to the consumer.
Packing units for Hydril® blowout preventers are manu-
factured from compounded natural rubber or nitrile rubber.
Natural Rubber is compounded for drilling with water-
base drilling fluids. Natural rubber can be used at operating No Band
o o
temperatures down to –30 F (–35 C). When properly
operated, the compounded natural rubber packing unit will Figure 3-2
usually provide the longest service life. This all-black Natural Rubber Packing
packing unit is identified by a serial number with the suffix Unit – No Band
"R" or "NR."
Nitrile Rubber (a synthetic compound) is for use with oil-
base or oil-additive drilling fluids. It provides reliable
service with oil-base muds, when operated at tempera-
o o
tures below 20 F (–7 C). The nitrile rubber packing unit is
identified by a red colored band and a serial number with
the suffix "S" or "NBR."
Seals for Hydril® blowout preventers are manufactured
from a special nitrile rubber material which provides de-
pendable service in sealing against oil gas, or water.
Expected H2S Service does not affect selection of
packing unit material. H2S service will reduce the service
life of rubber products, but the longest service life is
Red Band
obtained by matching the packing unit material with the
requirements of the specific drilling fluid. Figure 3-3
Performance of elastomeric materials can vary signifi- Synthetic Rubber Packing
cantly, depending on the nature and extent of exposure to Unit – Red Band
hydrogen sulfide. The operator should monitor pressure
sealing integrity by frequently performing a packing unit
seal test on the pipe diameter currently in use to assure no
performance degradation has occurred.
Storage Conditions such as light, heat or adverse
conditions are significant factors in the storage life of
packing units, as covered in Section 6.3 and should be
avoided.
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3.1.2 Packing Unit Replacement– Screwed Head

To replace the packing unit, use the following procedure: OPENING TORQUE
NOTE: The procedure that follows is the short version of
more detailed procedure in Section 6.
1. Remove head lock screw.
2. Install eyebolts and unscrew blowout preventer head
counter-clockwise (Figure 3-4).
3. Lift off blowout preventer head (Figure 3-5).
4. Lift out packing unit (Figure 3-6).
5. Lubricate piston bowl with castor oil.
6. Install new packing unit, lubricated with castor oil.
7. Clean and lubricate head and body threads with
Neverseez lubricant.
8. Replace head and tighten to align hole for lock screw.
9. Install head lock screw and torque to 100 lb-ft.
Figure 3-4
NOTE: If the head was improperly installed at last reassem-

bly, it may be necessary to apply considerably more torque
on the head by the use of a catline or winch while alternately
applying and releasing pressure to the opening chamber
(1500 psi maximum). CAUTION: Do not attempt to loosen
the head by applying heat. Refer to Section 5, “Disassembly
and Assembly” for further information.
Figure 3-5
Figure 3-6
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Operator's Manual
3.1.3 Packing Unit Replacement – Latched

Head
The latched head design of the GK® blowout preventer
allows for easy replacement of the packing unit and
eliminates loose parts that can be lost downhole or
overboard. To replace the packing unit, use the follow-
ing procedure: NOTE: The procedure that follows is the
short version of more detailed procedurew in Section 6.
1. Retract jaw clamping screws four turns to release

the jaws from the head (see Figures 3-8 and 3-9).
2. Remove head clamps and screws from top of head.
3. Lift off preventer head (see Figures 3-5 and 3-10).
4. Lift out the packing unit (see Figure 3-6) and lubri-
cate the piston bowl with castor oil.
5. Install the new packing unit (see Figure 3-6), lubri- Figure 3-9
cated with castor oil. Head in place but jaw and jaw clamping screws have
6. Install the head (see Figure 3-11). been retracted (four turns).
HEAD
7. Tighten jaw clamping screws four turns and torque to
350 - 475 lb-ft (475-644 N•m). See Figure 3-7.
Head Clamp Screw
Head Clamp
Clamping Screw
Pipe Plug
SleeveScrew
Spacer Sleeve
Figure 3-10
Jaw Head removed, but all latching mechanisms remain in
body.
Head Standoff
Figure 3-7
Head latched in place and jaw clamping screws
tightened.
Figure 3-11
Figure 3-8 On assembly, if standoff between head and body
Retract jaw clamping screws (4-turns counterclock- occurs, use head clamps to pull head fully into place
wise). and eliminate standoff.
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3.2 Seals
The seals for Hydril® blowout preventers are manufactured fluid recommendations, refer also to Hydril Engineering
from a special synthetic rubber material for long trouble- Bulletin EB 99009 on the Hydril Website www.hydril.com.
free sealing service. The hydraulic operating fluid may be The dynamic seals are all molded, lip-type, pressure-
clean, light petroleum hydraulic oil, or water with soluble energized rings. The static seals are of O-ring and square
oil added. In cold climates, antifreeze should be added to ring configuration. For seal replacement procedure, see
prevent freezing (CAUTION: To prevent seal damage, Section 5, “Diassembly and Assembly.” For seal mainte-
Do Not use synthetic fluids in the hydraulic operating nance and testing, refer to Section 4.
system). For additional discussion and specific hydraulic
DYNAMIC SEALS STATIC SEALS
DOUBLE U-SEAL
cross-section
with
nonextrusion U-SEAL O-RING SQUARE RING
rings cross-section cross-section cross-section
Figure 3-12
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Operator's Manual
3.3 Wear Bands

Manufactured from tough durable thermoplastic and in- ring prevents drilling mud and debris from entering the
stalled on new and modified models, wear bands improve space between the upper piston and the head and possibly
the performance of the GK® BOP by protecting sealing damaging the wear bands.
surfaces on the piston and body from metal to metal Models not equipped with wear bands can be modified at
contact. As a result, seal life is increased and wear to the a Hydril Authorized Repair Facility (ARF). Contact Hydril or
sealing surfaces on the piston and body is reduced signifi- refer to Hydril Website www. hydril.com for the nearest
cantly. ARF. Refer also to Section 4.7 for additional modifications
Installed on models with wear bands, the rubber wiper available.
Wiper Ring
Head
Wear Band
Head to
Piston
Seal
Piston
Sealing
Surface
Body
Sealing
Surfaces
Wear Band
Lower
Piston
Seal
Figure 3-13
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4.0 MAINTENANCE AND TESTING

WARNING: HYDRIL IS NOT RESPONSIBLE FOR FLUID SUPPLY LINES. FAILURE TO DO SO MAY
ANY ALTERATIONS, MODIFICATIONS OR RE- RESULT IN DAMAGE TO THE BOP OR FAILURE
PAIRS TO THE BLOWOUT PREVENTER (BOP), OF THE BOP TO OPERATE AS DESIGNED AND
ITS INTERCONNECTS AND COMPONENTS, UN- MAY RESULT IN SERIOUS PROPERTY DAMAGE,
LESS PERFORMED WITH HYDRIL SUPPLIED PERSONAL INJURY OR DEATH.
PARTS AND THE WORK PERFORMED BY A
HYDRIL AUTHORIZED REPRESENTATIVE. AL- 4.1 Troubleshooting
TERATIONS, MODIFICATIONS, OR REPAIRS PER- Troubleshooting the annular BOP is provided in the form of
FORMED OTHERWISE MAY RESULT IN DAMAGE a fault analysis tree. If the packing unit fails to close and
TO THE BOP OR FAILURE OF THE BOP TO OPER- seal, refer to Figure 4-1.
ATE AS DESIGNED AND MAY RESULT IN SERI-
OUS PROPERTY DAMAGE, PERSONAL INJURY
OR DEATH. UNAUTHORIZED ALTERATIONS, 4.2 Maintenance Schedule
MODIFICATIONS, REPAIRS OR USE OF PARTS Periodic maintenance is a very important part of
OTHER THAN THOSE SUPPLIED BY HYDRIL WILL keeping the Hydril® GK 11"-5000 PSI Annular BOP in
VOID THE STANDARD WARRANTY OF THE BOP good operating condition. Not only will regular main-
AS OUTLINED IN THE TERMS AND CONDITIONS tenance extend the service life of the equipment, but
AGREEMENT. it will also help to eliminate unnecessary down time.
This section contains a maintenance schedule (Table
WARNING: BEFORE THE INITIAL START UP, OR 4-1) that is designed to help maintain the annular BOP
PRIOR TO POST REPAIR START UPS, VERIFY by displaying in tabular form the recommended ser-
CONTAMINANTS, DEBRIS, AND OTHER FOREIGN vice interval for each required maintenance opera-
MATERIALS HAVE BEEN FLUSHED FROM THE tion.
TABLE 4-1
MAINTENANCE SCHEDULE
Maintenance Operations
I = Inspect; R = Replace;
T = Pressure Test: P = Inspect Precharge
Item Equipment/Component Service Interval & Maintenance Operations Refa
As Required Yearly Between Wellsc
1 GK Annular BOP I 4.3
2 Packing Unit T Rb I 4.0;3.0
3 Seals T Rb I 4.0;5.0
4 Wear Bands Rb I 5.0
a Paragraph where maintenance procedure is located.

b Not to exceed 24 calendar months.
c
Hydril only provides recommendations for inspections and maintenance. Depending on the drilling
program, it may not be possible to inspect the BOP between wells.
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Operator's Manual
4-2
PACKING UNIT
FAILS TO
CLOSE & SEAL
PACKING UNIT PACKING UNIT

FAILS TO FAILS TO
SEAL CLOSE
PACKING WORN MECHANICAL

CONTROL SEAL
UNIT WEAR PART
SYSTEM LEAKAGE
LEAKAGE PLATE FAILURE
PROBLEMS
Increase closing Inspect wear plate Refer to operations Test seals and
pressure or replace and replace as and maintenance replace as necessary.
as necessary. necessary. manual.
Latched Head
CLAMPING
PISTON LATCH
SCREW
STROKE FAILURE
FAILURE
Check piston stroke. Inspect latch and Inspect latch and

make repairs. make repairs.
Latched Head &

Screwed Head
BENT
GALLED PACKING
GALLED
WEAR UNIT
PISTON
PLATE INSERTS
Inspect piston Inspect wear plate Inspect packing unit and

and make repairs. and make repairs. replace if necessary.
Figure 4-1
GK 11"-5000 Annular BOP Fault Analysis Tree - Packing Unit Fails to Close and Seal
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4.3 Inspection
NOTE: The Hydril® GK® blowout preventer is a primary shaped by the steel segments of the packing unit.
pressure vessel. The blowout preventer surfaces exposed The inner bottom face of the head serves as a wall to
to wellbore fluids will meet NACE Standard MR-01-75. prevent upward movement of the packing unit. Friction
Proper handling and repair are required to maintain any between these metal surfaces is controlled at a level which
original integrity. Field welding is not recommended as it, 1) does not impair lateral movement of the packing unit.
induces undesirable stresses which must be relieved by Repair of this surface is accomplished by replacing the
proper heat treating procedure or controlled by special wear plate. Some models of this BOP do not have the wear
welding procedures and 2) negates certification to NACE . plate, but may be modified. Contact the nearest Hydril ARF
If your assembly was manufactured before 1980, it may not (see “NOTE” above) for modification.
be certified to NACE. Welding, machining, stress relieving 7. Inspect the packing unit for wear, cracking, hardness,
or NACE certification must be performed at a Hydril Autho- and correct elastomer composition. See Section 3 for
rized Repair Facility (ARF). Contact Hydril or go to Hydril packing unit information and this section for packing unit
Website www.hydril.com for the nearest ARF. testing.
8. Check seals and wear bands (if equipped) for nicks,
Prior to placing the GK® blowout preventer into service, the cuts, fraying of lips, and abrasion. Worn or damaged seals
following visual inspections should be performed (step and wear bands should be replaced. Hydril recommends
numbers match Figure 4-2): that all seals and wear bands be replaced after one year
1. Inspect upper and lower connections for pitting, wear, service or whenever the BOP is disassembled. See
and damage, especially in ring grooves and stud bolt holes. Section 4 for pressure testing of seals.
Worn or damaged ring grooves must be welded, machined,
and stress relieved (see “NOTE” above). Worn or dam- 1
aged stud bolt holes can be drilled and tapped to the next
larger size and fitted with step-studs. 3
2. Check the body for wear and damage, especially in the 6
internal cylinder walls for pits and vertical scores. Minor pits
and scores can be removed in the field with emery cloth. 8
Repaired surface should be coated with castor oil. Severe
pits, scores, and cracks may require machining and/or
7
welding (see “NOTE” above).
3. Inspect the vertical bore for excessive wear and dam-
age from drill string and drill tools, especially in the area of 8
the ring grooves. If wear is excessive, see “NOTE” above.
4. Check the inner body sleeve for wear, damage, and 5
looseness. Check slots in sleeve for cuttings which may
restrict piston movement. Some model BOPs have a welded
body sleeve and may be modified by conversion to a bolted
sleeve. Contact the nearest Hydril ARF (see “NOTE”
above) for modification. 2 8
5. Check for piston damage and wear, especially the inner
and outer walls for pits and vertical scores and the tapered
bowl for pits and gouges.
Minor pits and scores on the walls can be removed in
the field with emery cloth. Repaired surface should be
coated with castor oil. Severe pits and scores may require
8
machining and/or welding. Contact the nearest Hydril ARF
(see “NOTE” above) for repair.
Pits and gouges in the tapered bowl should be filled with
a permanent type adhesive, such as epoxy. Sharp or rolled 4
edges should be removed with emery cloth or a grinder.
Repair is satisfactory when the surface is relatively smooth.
3
6. Check the wear plate on the inner bottom face of the
head for wear. In addition to the aging process of time and
use, wear of this metal surface is produced by the combi-
nation of vertical (upward thrust) and lateral forces. These
forces are generated each time the packing unit is closed. 1
Severe wear is exhibited in the form of grooves or channels
Figure 4-2
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Operator's Manual
4-4
4.4 Seal Testing - GK® Without Wear Bands

When it is known or suspected that a seal within the GK
blowout preventer is leaking, it is recommended that all
seals be replaced. However, if only the seal in question is to
be replaced, it must first be determined which seal is
leaking. The following procedure is provided: Refer to
Figure 4-3 while following this procedure. 6
1. Gather the following tools and materials:
a. 5000 PSI (345 Bar) pressure source
b. 3 1/2-inch test pipe
c. Blind flange, 11”-5000 PSI 8 UPPER
d. RX-54 ring gasket
2. Install the annular BOP onto test stump with hy-
draulic pressure source connected to the Open
and Close ports.
3. Install test pipe into test stump. 8 LOWER
4. Test seals 9 (lower) and 10 (upper).
a. Pressurize closing chamber. The test pressure to
be used in the closing chamber should be the initial
closing pressure required using the recommended
test mandrel if a packing unit is installed (1500 PSI/
104 Bar if no packing unit is installed).
b. Open opening chamber to atmosphere.
IF: Closing fluid is seen at opening chamber—seal 9 9 UPPER
(lower) is leaking.
IF: Closing chamber pressure gauge is dropping and 9 LOWER
no fluid is seen at opening chamber—seal 10
(upper) is leaking.
5. Test seals 8 (lower), 9 (upper), and 6. 10 UPPER
a. Pressurize opening chamber (1500 PSI).
b. Open closing chamber to atmosphere. 10 LOWER
IF: Fluid is seen coming from area between body and
head—seal 6 is leaking.
IF: Fluid is seen coming into the wellbore—seal 8
(lower) is leaking.
IF: Fluid is seen at closing chamber—seal 9 (upper) is
leaking.
6. Test seals 8 (upper) and 10 (lower).
a. Open closing chamber to atmosphere.
b. Open opening chamber to atmosphere.
c. Install blind flange on top and pressurize wellbore Figure 4-3
(5000 PSI/345 Bar maximum).
WARNING: THE RATED WORKING PRESSURE OF

THE GK ANNULAR BOP IS 5000 PSI (345 BAR). USE
IF: Fluid is seen coming from the closing chamber—
EXTREME CAUTION WHEN WORKING WITH HIGH
seal 10 (lower) is leaking.
PRESSURE. TAKE EVERY PRECAUTION TO PRO-
TECT PERSONNEL FROM COMING IN CONTACT
7. Reduce wellbore pressure to zero.
WITH PRESSURE DURING TESTING OPERATIONS. 8. Drain wellbore fluid.
9. Remove blind flange.
IF: Fluid is seen coming from the opening chamber— 10. Test packing unit or return the BOP to service.
seal 8 (upper) is leaking. For packing unit testing, see procedure in this section.
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4.5 Seal Testing - GK® With Wear Bands

When it is known or suspected that a seal within the GK
Annular BOP is leaking, it is recommended that all seals
be replaced. However, if only the seal in question is to
be replaced, it must first be determined which seal is
leaking. Use the following procedure for testing the
seals in the GK Annular BOP. Refer to Figure 4-4 while
following this procedure. Head O-Ring
1. Gather the following tools and materials: Seal
a. 5000 PSI (345 Bar) pressure source
b. 3 1/2-inch test pipe Clamping
c. Blind flange, 11”-5000 PSI Screw
d. RX-54 ring gasket
2. Install the annular BOP onto test stump with O-Ring Seal
hydraulic pressure source connected to the
Open and Close ports. Wiper Seal
3. Install test pipe into test stump.
4. Test middle piston seal (B) and lower piston seal Head Gasket
using closing operating pressure:
a. Open opening chamber to atmosphere. Wear Band
b. Apply 1500 psi (104 Bar) operating pressure to
the closing chamber to close the packing unit Head to
around the test pipe. Piston Seal
IF: Closing fluid seen coming from the Open
port indicates that middle piston seal (B) is Middle A
leaking. Piston
IF: Closing fluid seen in the wellbore indi- Seals B
cates that lower piston seal is leaking.
5. Test head to piston seal, head gasket, and middle
piston seal (A) using opening operating pressure: Wear Band
a. Reduce closing pressure to zero and open the
closing chamber to atmosphere. Lower
b. Apply 1500 PSI (104 Bar) operating pressure Piston
to the opening chamber to open the packing Seal
unit.
IF: Opening fluid coming from the Close port
indicates that middle piston seal (A) is
leaking.
IF: Opening fluid seen in wellbore or coming
from relief valve indicates that the head to
piston seal is leaking, or the head gasket
seal is leaking, or both the head to piston
seal and head gasket are leaking. NOTE: Figure 4-4
The relief valve is a spring check valve
which allows venting of pressure which
could be trapped in the latching mecha-
nism. This valve is reusable provided the ING WITH HIGH PRESSURE. TAKE EVERY PRECAU-
spring is not frozen or damaged. TION TO PROTECT PERSONNEL FROM COMING IN
6. Test head to piston seal and lower piston seal , CONTACT WITH PRESSURE DURING TESTING OP-
using rated working pressure: ERATIONS.
a. Reduce opening pressure to zero and open
the opening and closing chambers to atmo- IF: Wellbore fluid coming from the Open port indi-
sphere. cates that head to piston seal is leaking.
b. Remove test pipe and attach a blind flange to IF: Wellbore fluid coming from the Close port indi-
top of annular BOP. cates that lower piston seal is leaking.
c. Fill wellbore with tap water. 7. Testing of the head O-ring, clamping screw O-ring, and
d. Install blind flange on top and pressurize wiper seal is not required.
wellbore (5000 PSI/345 Bar) maximum. 9. Reduce wellbore pressure to zero.
10. Drain wellbore fluid.
WARNING: THE RATED WORKING PRESSURE 11. Remove blind flange.
OF THE GK ANNULAR BOP IS 5000 PSI (345 12. Test packing unit or return the BOP to service. For
BAR). USE EXTREME CAUTION WHEN WORK- packing unit testing, see procedure in this section.
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Operator's Manual
4-6
4.6 Packing Unit Testing

Proper procedure for pressure testing any annular blowout achieved. Optimum packing unit life is obtained by
preventer ensures subsequent seal off and maximum testing at low rubber stress levels. Minimum packing
packing unit life. Reliable pressure seal off tests are made unit stress is achieved by use of the minimum closing
by closing the packing unit with prescribed closing cham- chamber pressure that will initiate and maintain a seal
ber pressure on recommended size test pipe and by off on the recommended size test pipe.
determining the remaining piston travel after seal off is
4.6.1 Packing Unit Testing—Surface

The GK® blowout preventer is designed to be well pressure 3
assisted in maintaining packing unit seal off once initial seal
off has been effected. Initial seal off is effected by applying
pressure to the closing chamber. As well pressure or test TAPE
pressure increases, the closing force on the packing unit MEASURE
also increases. 2 5/16" ROD
As well pressure exceeds the required level, the packing
unit is maintained closed on pipe by well pressure alone.
During routine BOP testing, once initial seal off is achieved,
closing pressure should be proportionally reduced as well
1
pressure is increased (see the Control Pressure Graph,
Figure 1-9).
Closing pressure required to effect initial seal off may
vary between packing units. Begin the test with the rec-
ommended initial closing pressure shown in Figure 1-8,
depending on the style packing unit installed.
Piston Stroke can be measured on GK® blowout pre-
venters through a vertical passage* in the top of the BOP
head. The maximum and minimum distances from the top
of the head to the top of the piston are stamped on the BOP
head and are also listed in the table below. Piston stroke
remaining at seal off is a direct indicator of remaining
packing unit life. Record the piston stroke and the closing
pressure at initial seal off for each test. Compare with
previous results and with maximum piston stroke for the
BOP to ensure subsequent seal offs. A valid test on any
annular BOP is only achieved when the remaining piston
stroke is measured at test seal off.
Distance From Top of Head to Top of Piston
Maximum (piston in full down position) 11-1/8"
Minimum (piston at full stroke) 4"
* Older model BOPs may not have the piston indicator hole
as shown in Figure 4-5. See “BOP Modifications” in this
section for piston indicator hole modification as well as Figure 4-5
other modifications available. Themodification to add the Piston Stroke Measurement
piston indicator hole must be performed at a Hydril Autho-
rized Repair Facility (ARF). Contact Hydril or go to Hydril
Website www.hydril.com for the nearest ARF.
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4.7 BOP Modifications
Older model BOPs without piston indicator holes, wear

plates, bolted inner sleeves, or wear bands can be modi-
fied at a Hydril Authorized Repair Facility (ARF). Contact
Hydril or visit Hydril Website www.hydril.com for the near-
est ARF.
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Operator's Manual
4-8
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5.0 DISASSEMBLY AND ASSEMBLY
5.1 Disassembly - Screwed Head

Without Wear Bands
Refer to Figure 5-1 while following this procedure. Num-
bers in figure correspond to items numbers in proce- 17
dure. 19
WARNING: THIS IS VERY HEAVY EQUIPMENT, AND

EXTREME SAFETY PROCEDURES MUST BE FOL- 1
LOWED DURING LIFTING OPERATIONS. BE SURE 6
THAT LIFTING EQUIPMENT IS IN GOOD CONDITION
AND CAPABLE OF HANDLING THE LOAD. 8
A. Gather Tools and Materials. 29

NOTE: Except for the tools listed below, disassembly
of the GK® annular BOP can be performed with standard
tools. 30
1. Three eyebolts (5/8”-11UNC x 10” Lg.), Hydril Part 2
No. 30952 (for lifting piston)
2. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.), Hydril
Part No. 32006 (for lifting head)
3. Chain sling, Hydril Part No. 33565-M (CAUTION: 1
The chain sling is for disassembly and assembly
purposes only. Do not use the chain sling to lift the 3
annular BOP assembly.)
4. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg.), Hydril Part
No. 1900076-08 (for lifting packing unit).
9
B. Vent Pressure.
1. Vent the closing and opening chambers to atmo- 10
sphere, ensuring that no trapped pressure exists
which will cause injury to personnel and/or damage
the equipment. 4
2. Open the valves in the control system to exhaust
the pressure and/or loosen the hydraulic connec-
tions to allow the pressure to bleed off. 18
WARNING: STAND CLEAR OF ESCAPING PRES-

SURE TO AVOID INJURY.
C. Remove Head.
1. Remove head lock screw (Item 19). 5
2. Install three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.) into
the head (Item 1)
3. Unscrew the head counterclockwise from the BOP
body. NOTE: Use a piece of strong pipe or rod (3"
to 4" in diameter x 10' to 12' long) as a lever against
the eyebolts to apply counterclockwise (left hand)
torque on the head (refer to Figure 5-2). A vertical
lift, using the chain sling, may be applied to the
eyebolts to take the weight of the head off of the
Figure 5-1:
threads while applying torque to the head. This lift
Screwed Head GK® 11"-5000 PSI Without Wear Bands-
will reduce the required turning torque. If the head
Disassembly
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PAGE
Operator's Manual
was improperly installed at the last assembly, it may

be necessary to apply considerable more torque on Head Installation
the head by the use of a winch or catline while
alternately applying and releasing pressure to the
opening chamber (1500 PSI/104 Bar maximum).
CAUTION: Do not loosen the head by applying
heat to the thread area.
4. Attach the Hydril chain sling and lift the head straight
up and off the body.
5. Remove the head gasket (Item 6) and upper U-
seals (Items 8).
6. Remove the capscrews (Item 30) and the wear
plate (Item 29). NOTE: Some models do not have
a wear plate.
7. Remove chain sling from eyebolts. Head Removal
D. Remove Packing Unit.
1. Install two eyebolts (5/8"-11UNC x 1 3/4” Lg.) into
packing unit (Item 2).
2. Using the Hydril chain sling, lift the packing unit out
of the piston.
3. Remove sling and eyebolts.
E. Remove Piston.
1. Install three eyebolts (5/8”-11UNC x 10” Lg. ) into
the piston (Item 3).
2. Using Hydril chain sling, gently lift piston out of the
preventer body. If a vertical lift is not possible or the Figure 5-2:
piston does not lift out freely, slowly apply low (50 Head Removal/Installation
PSI) hydraulic pressure to the closing chamber.
WARNING: DO NOT USE AIR OR GAS.
3. Remove middle U-seals (Items 9) and lower U-

seals (Items 10).
4. Remove the sling and eyebolts from the piston.
F. Remove Inner Sleeve.

NOTE: This step is not applicable to model BOPs that
have a welded body sleeve which is not removable.
1. Remove the capscrews (Item 18) from around the
inner sleeve (4).
2. Insert the hooks of the Hydril chain sling (equally
spaced) in the slots of the inner sleeve and lift the
sleeve out of the annular BOP.
3. Remove the chain sling.
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5.2 Assembly - Screwed Head

NOTE: Seal Rings MUST BE installed in position
Without Wear Bands shown by cross-section.
Refer to Figure 5-3 and 5-4 while following this proce-
dure. Numbers in figures correspond to item numbers in 17
procedure. 19

A. Gather Tools and Materials.

NOTE: Except for the tools listed below, assembly of the 29
GK® annular BOP can be performed with standard tools.
1. Three eyebolts (5/8”-11UNC x 10” Lg.), Hydril Part
30
No. 30952 (for lifting piston)
2. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.), Hydril 2
No. 1900076-08 (for lifting packing unit)
4. Chain sling, Hydril Part No. 33565-M (CAUTION:
1
The chain sling is for disassembly and assembly
purposes only. Do not use the chain sling to lift the
3
5. Castor oil
6. Moly Paste 503 thread lubricant (Coefficient of
Friction is .065) or equivalent 9
7. Neverseez lubricant
8. Spare parts including seal kit. Refer to Section 6,
10
"Parts and Storage."
B. Clean, Inspect BOP, and Lubricate.

4
1. Clean all components thoroughly.
2. Perform the inspection procedures that are appli-
cable in Section 4, "Maintenance and Testing".
18
3. Ensure that working surfaces are free of burrs,
rough edges, or other defects.
4. Inspect all seals installed in the head and piston,
and replace any damaged seals in use over one
year. (NOTE: Hydril recommends that all seals be
replaced whenever a BOP is disassembled and
assembled.) Seals must be installed as shown in 5
Figure 5-3 and 5-4. Coat packing unit, seals, and
non-extrusion rings with castor oil before installa-
tion. CAUTION: Use of petroleum base oil or
grease will reduce seal life.
5. Lubricate the threads of nuts, bolts, and capscrews
with Moly Paste 503 thread lubricant.
6. Coat interior surfaces with castor oil except wear
band grooves in the head and piston .
7. Lubricate body threads on the head and body with
Figure 5-3:
Screwed Head GK® 11-5000 PSI- Without Wear Bands-
Assembly
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Operator's Manual
C. Install Inner Sleeve. 7. Tighten the head clockwise (right hand) as shown in
NOTE: This step is not applicable for models that have Figure 5-2, using the pipe or rod from Step C of the
a welded body sleeve . disassembly procedure, until the shoulder on the head
1. Insert hooks of Hydril chain sling (equally spaced) engages the body. A vertical lift, using the chain sling
into slots in inner sleeve (Item 4) and install the attached to the eyebolts, will reduce the weight on the
sleeve into the bore of the body.
threads and reduce the required turning torque. Align the
2. Install the capscrews (Item 18) and torque to 150 lb-
head lock bracket with the hole in the body. Lubricate the
ft (203 N•m).
3. Remove chain sling. lock screw threads (Item 19) with Moly Paste 503 and
install. Tighten the lock screw using 60 lb-ft (80 N•m)
D. Install Piston. torque.
1. Install the lower U-seals (Item 10), on the lower 8. Remove the chain sling and eyebolts from the head.
segment of the piston (Item 3). 9. Perform seal and packing unit test procedures in Section
2. Install the middle U-seals (Items 9) on the upper 4, "Maintenance and Testing."
segment of the piston.
3. Install three eyebolts (5/8”-11UNC x 10” Lg.) into
the piston. Attach the Hydril chain sling to the
eyebolts and install the piston over the inner sleeve
(Item 4) and into the body. Ensure that the piston
is aligned vertically with the body prior to lowering.
Vent Close port. With proper vertical alignment, the
piston will slide its normal full stroke to the bottom
of the preventer body. CAUTION: Be careful not to
damage the seals during assembly.
4. Remove the chain sling and eyebolts from the
piston.
E. Install Packing Unit.

1. Lubricate the bowl of the piston (Item 3) and pack-
ing unit (Item 2) with castor oil. Install two eyebolts
(5/8"-11 UNC x 1 3/4” Lg.) into packing unit. Using
Hydril chain sling, lift the packing unit and set it into
the bowl of the piston.
packing unit.
F. Install Head.
1. Install the wear plate (Item 29) and capscrews (Item
30) on the inner face of the annular head (Item 1).
Torque the capscrews to 50 lb-ft (68 N•m). NOTE:
This step is not applicable to models that do not
have a wear plate.
2. Install the head gasket (Item 6) in the seal groove
on the outside diameter of the head, just below the
major diameter.
3. Install the upper U-seals (Item 8) on the inside
bottom diameter of the head.
the head.
5. Lubricate the body threads on the outside diameter
of the head and the inside diameter of the body
(Item 5) with Neverseez lubricant.
6. Install the head into the body so that the body
threads on the head engage the threads of the
body. Remove the chain sling.
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Pipe Plug (17)
Head Lock Screw (19)
BOP Head – Screwed (1)
Head Gasket (6)
Wear Plate Capscrew (30)
Wear Plate (29)
U-Seal, Upper (8)
Packing Unit (2)
Piston (3)
U-Seal, Middle (9)
Body (5)
Inner Sleeve (4)
U-Seal, Lower (10)
Inner Sleeve Capscrew (18)
Figure 5-4
Cutaway of Screwed Head GK® 11-5000 PSI
BOP Without Wear Bands Showing Position
of Parts.
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Operator's Manual
5.3 Disassembly - Screwed Head

With Wear Bands
Refer to Figure 5-5 while following this procedure.
Numbers in figure correspond to item numbers in proce- 17
dure. 19

THAT LIFTING EQUIPMENT IS IN GOOD CONDITION 15
A. Gather Tools and Materials. 12 11

NOTE: Except for the tools listed below, disassembly
of the GK® annular BOP can be performed with standard 29
30
tools.
1. Three piston lift assemblies, Hydril Part No. 2
3105638-6
2. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.), Hydril
3. Chain sling, Hydril Part No. 1900179-0354 (CAU-
TION: The chain sling is for disassembly and
assembly purposes only. Do not use the chain 3
sling to lift the annular BOP assembly.)
No. 1900076-08 (for lifting packing unit).
9
14
B. Vent Pressure.
1. Vent the closing and opening chambers to atmo- 34
sphere, ensuring that no trapped pressure exists
which will cause injury to personnel and/or damage 33
the equipment. 4
2. Open the valves in the control system to exhaust
the pressure and/or loosen the hydraulic connec-
tions to allow the pressure to bleed off. 18
WARNING: STAND CLEAR OF ESCAPING PRES-

SURE TO AVOID INJURY.
C. Remove Head.
1. Remove head lock screw (Item 19). 5
the head (Item 1)
3. Unscrew the head counterclockwise from the BOP
body. NOTE: Use a piece of strong pipe or rod (3"
to 4" in diameter x 10' to 12' long) as a lever against
the eyebolts to apply counterclockwise (left hand)
torque on the head (refer to Figure 5-2). A vertical
lift, using the chain sling, may be applied to the
eyebolts to take the weight of the head off of the
threads while applying torque to the head. This lift
will reduce the required turning torque. If the head
Figure 5-5:
Screwed Head GK® 11"-5000 PSI With Wear Bands-
was improperly installed at the last assembly, it
Disassembly
R

may be necessary to apply considerable more

torque on the head by the use of a winch or catline Eyebolt
while alternately applying and releasing pressure
to the opening chamber (1500 PSI/104 Bar maxi-
mum). CAUTION: Do not loosen the head by
Lift Device
applying heat to the thread area.
4. Attach the Hydril chain sling and lift the head
straight up and off the body.
5. Remove the head gasket (Item 6), head to piston
double U-seal (Items 11 and 12), wiper ring (Item
15) and wear band (Item 13) .
6. Remove the capscrews (Item 30) and wear plate
(Item 29).
7. Remove chain sling and eyebolts.
Piston
D. Remove Packing Unit. Shoulder
2. Using the Hydril chain sling, lift the packing unit out
of the piston. Piston
E. Remove Piston.
1. Install three piston lift assemblies onto the piston
Figure 5-6.
(Item 3) as follows and as shown in Figure 5-6: Piston Lift Device
a. Screw each eyebolt into the piston.
b. Tighten the eyebolts until the retaining ring and
spacer block are snug against the piston.
c. Check the tightness of the eyebolts prior to
lifting.
2. Using Hydril chain sling, gently lift piston out of the
preventer body. If a vertical lift is not possible or the
piston does not lift out freely, slowly apply low (50
PSI) hydraulic pressure to the closing chamber.
3. Remove middle U-seals (Items 9), lower piston

double-U-seal (Items 33 and 34), and wear band
(Item 14).
4. Remove the sling and the lifting assemblies from
the piston.

inner sleeve (4).
2. Insert the hooks of the Hydril chain sling (equally
spaced) in the slots of the inner sleeve and lift the
sleeve out of the annular BOP.
3. Remove the chain sling.
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Operator's Manual
5.4 Assembly - Screwed Head

NOTE: Seal Rings MUST BE installed in position
With Wear Bands shown by cross-section.
dure. Numbers in figures correspond to item numbers in
17
procedure. 19

EXTREME SAFETY PROCEDURES MUST BE FOL-
1
LOWED DURING LIFTING OPERATIONS. BE SURE
THAT LIFTING EQUIPMENT IS IN GOOD CONDITION 6
13
A. Gather Tools and Materials.
NOTE: Except for the tools listed below, assembly of the 12 11
GK® annular BOP can be performed with standard tools.
1. Three piston lift assemblies , Hydril Part No. 3105638- 29
6 30
2. Three eyebolts (1 1/4"-7UNC x 1 3/4” Lg.), Hydril 2
No. 1900077-08 (for lifting packing unit)
TION: The chain sling is for disassembly and
assembly purposes only. Do not use the chain sling
to lift the annular BOP assembly.) 3
5. Castor oil
6. Moly Paste 503 thread lubricant (Coefficient of Fric-
tion is .065) or equivalent 9
7. Neverseez lubricant 14
"Parts and Storage." 34
B. Clean, Inspect BOP, and Lubricate. 33

1. Clean all components thoroughly. 4
2. Ensure that working surfaces are free of burrs, 18
rough edges, or other defects.
3. Inspect all seals and wear bands installed in the
head and piston, and replace any damaged seals
and wear bands in use over one year. (NOTE:
Hydril recommends that all seals and wear bands be
replaced whenever a BOP is disassembled and
5
assembled.) Seals must be installed as shown in
Figures 5-7 and 5-8. Coat packing unit, seals, non-
extrusion rings, and wear bands with castor oil
before installation. CAUTION: Use of petroleum
base oil or grease will reduce seal life.
4. Lubricate the threads of nuts, bolts, and capscrews
with Moly Paste 503 thread lubricant.
5. Coat interior surfaces with castor oil.
6. Lubricate body threads on the head and body with
Figure 5-7:
C. Install Inner Sleeve. Screwed Head GK® 11"-5000 PSI With Wear Bands-
1. Insert hooks of Hydril chain sling (equally spaced) Assembly
R

into slots in inner sleeve (Item 4) and install the the disassembly procedure, until the shoulder on the
sleeve into the bore of the body. head engages the body. A vertical lift, using the chain
2. Install the capscrews (Item 18) and torque to 150 lb- sling attached to the eyebolts, will reduce the weight on
ft (203 N•m). the threads and reduce the required turning torque.
3. Remove chain sling. Align the head lock bracket with the hole in the body.
Lubricate the lock screw threads (Item 19) with Moly
D. Install Piston. Paste 503 and install. Tighten the lock screw using 60
1. Install the lower piston double U-seal (Items 33 and lb-ft (80 N•m) torque.
34), and the wear band (Item 14) on the lower 8. Remove the chain sling and eyebolts from the head.
segment of the piston (Item 3). 9. Perform seal and packing unit test procedures in Sec-
2. Install the middle U-seals (Item 9) on the upper tion 4, "Maintenance and Testing."
segment of the piston.
3. Install the piston lift assemblies onto the piston as
shown in Figure 5-6. Attach the Hydril chain sling to
the eyebolts and install the piston over the inner
sleeve (Item 4) and into the body. Ensure that the
piston is aligned vertically with the body prior to
lowering. Vent Close port. With proper vertical
alignment, the piston will slide its normal full stroke
to the bottom of the preventer body. CAUTION: Be
careful not to damage the seals during assembly.
4. Remove the chain sling and piston lift assemblies
from the piston.
E. Install Packing Unit.

1. Lubricate the bowl of the piston (Item 3) and pack-
ing unit (Item 2) with castor oil. Install two eyebolts
(5/8"-11 UNC x 1 3/4” Lg.) into packing unit. Using
Hydril chain sling, lift the packing unit and set it into
the bowl of the piston.
packing unit.
F. Install Head.
1. Install the wear plate (Item 29) and capscrews (Item
30) on the inner face of the annular head (Item 1).
Torque the capscrews to 50 lb-ft (68 N•m).
2. Install the head gasket (Item 6) in the seal groove
on the outside diameter of the head, just below the
major diameter and above the body threads.
3. Install the head to piston seal, consisting of a
double U-seal (Item 11) and two non-extrusion
rings (Item 12), the wear band (Item 13), and the
wiper ring (Item 15) into the grooves on the inside
bottom diameter.
the head.
5. Lubricate the body threads on the outside diameter
of the head and the inside diameter of the body
(Item 5) with Neverseez lubricant.
6. Install the head into the body so that the screw
threads on the head engage the threads of the
body. Remove the chain sling.
7. Tighten the head clockwise (right hand) as shown
in Figure 5-2, using the pipe or rod from Step C of
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Operator's Manual
Pipe Plug (17)
Head Lock Screw (19)
BOP Head – Screwed (1)
Head Gasket (6)
Wear Plate (29)
Wiper Ring (15)
Wear Band (13)
Head to Piston
Double U-Seal (11 and 12)
Packing Unit (2)
Piston (3)
Middle Piston Seals (9)
Body (5)
Inner Sleeve (4)
Wear Band (14)
Lower Piston
Double U-Seal (33 and 34)
Figure 5-8
Cutaway of Screwed Head GK® 11 5000 PSI
BOP with Wear Bands, Showing Position
of Parts.
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5.5 Disassembly - Latched Head

Without Wear Bands
bers in figure correspond to item numbers in procedure.
17 32
LOWED DURING LIFTING OPERATIONS. BE SURE
AND CAPABLE OF HANDLING THE LOAD.

NOTE: Except for the tools listed below, disassembly of 7
the GK® annular BOP can be performed with standard
tools. 6
1. Three piston lift assemblies, Hydril Part No. 3105638-
6 8
2. Three eyebolts (1-1/4"-7UNC x 1 3/4’ Lg.), Hydril Part 29
No. 3112077 (for lifting head)
30
TION: This chain sling is for disassembly and assem-
bly purposes only. Do not use to lift the annular BOP 2
assembly.)
No.1900077-08 (for lifting packing unit).
B. Vent Pressure from Annular BOP Assembly.

1. Vent the closing and opening chambers, ensuring
3
that no trapped pressure exists in the BOP which will
cause injury to personnel and/or damage the equip-
ment. 9
2. Open the valves in the control system to exhaust the
pressure and/or loosen the hydraulic connections to 10
allow the pressure to bleed off.
WARNING: STAND CLEAR OF ESCAPING PRESSURE 18

TO AVOID INJURY.
4
C. Remove Head. 23
1. Release the annular head (Item 1) by backing off the 22
jaws (Item 21). Unscrew the clamping screws (Item
22) by rotating them counterclockwise four turns or
until the jaws shoulder against the body (Item 5). 25
CAUTION: Take care not to continue turning the
24
screws after the jaws have shouldered. Excessive 26 21
torque at shouldering may cause thread damage.
NOTE: If a jaw does not retract as described due to
the lack of engagement with spacer sleeve screw 27 5
(Item 23), tighten the shoulder screw to approxi-
mately 50 lb-ft (68 N•m).
2. Remove the four head clamp screws and head clamps
(Items 31 and 32) from the annular head. NOTE:
Alternately loosen the screws on opposite sides to
unload the head evenly.
Figure 5-9:
Latched Head GK 11"-5000 PSI Without Wear Bands-
head.
Disassembly
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Operator's Manual
4. Using Hydril chain sling , lift the head out of the body. G. Remove Jaws.
Remove sling and eyebolts. Perform the following procedure for each jaw (Item 19).
5. Remove the six cap screws (Item 30) and the wear 1. Remove pipe plug (Item 25).
plate (Item 29). 2. Hold clamping screw (Item 22) and remove spacer
6. Remove the head dirt seal (Item 7), Head gasket sleeve screw (Item 23) from the clamping screw.
(Item 6), and upper U-seals (Items 8). 3. Remove the clamping screw and spacer sleeve (Item
24) from the body (Item 5). Remove spacer sleeve
D. Remove Packing Unit. from the clamping screw. Remove the jaw (21) from
1. Install two eyebolts (5/8"-11UNC x 1 3/4” Lg.) into the inside of the body. NOTE: Keep the jaws in
packing unit (Item 2). sequence so that they can be returned to their original
2. Using Hydril chain sling, lift the packing unit out of the position.
piston (Item 3).
E. Remove Piston.
1. Install three piston lifting devices onto the piston
(Item 3) as follows and as shown in Figure 5-6:
a. Position each lift device over the top edge of the
piston above the eyebolt holes in the piston
shoulder, taking care not to damage the sealing
surface on the outside diameter.
b. Tighten the eyebolts until the lift devices are
snug against the piston shoulder.
lifting.
2. Using Hydril chain sling 1900179-0354, gently lift
piston out of the preventer body. If a vertical lift is not
possible or the piston does not lift out freely, slowly
apply low (50 PSI) hydraulic pressure to the closing
chamber.
3. Remove the lift devices from the piston, taking care

not to damage the sealing surface on the outside
diameter.
4. Remove the middle U-seals (Items 9) and the lower
U-seals (Items 10).

inner sleeve (Item 4).
2. Using Hydril chain sling 1900178-0354, attach the
hooks (equally spaced) into the slots in the sleeve
and lift the inner sleeve out of the annular BOP.
3. Remove sling.
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5.6 Assembly - Latched Head

Without Wear Bands
dure. Numbers in figures correspond to item numbers
procedure. 17 32
31
WARNING: THIS IS VERY HEAVY EQUIPMENT,
AND EXTREME SAFETY PROCEDURES MUST
BE FOLLOWED DURING LIFTING OPERATIONS.
BE SURE THAT LIFTING EQUIPMENT IS IN GOOD
CONDITION AND CAPABLE OF HANDLING THE 1
LOAD. 7

NOTE: Except for the tools listed below, assembly of
8
the GK® annular BOP can be performed with stan- 29
dard tools.
30
1. Three piston lift assemblies, Hydril Part No.
3105638-6
2. Three eyebolts (1-1/4"-7UNC x 1 3/4” Lg.), Hydril 2
TION: This chain sling is for disassembly and
assembly purposes only. Do not use to lift the
4. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg.), Hydril 3
Part No. 1900077-08 (for lifting packing unit)
5. Castor oil 9
18
"Parts and Storage."
B. Clean, Inspect BOP, and Lubricate. 4

23
3. Ensure that working surfaces are free of burrs, 25
rough edges, or other defects. 24
4. Inspect all seals installed in the head and piston. 26 21
Replace any damaged seals in use over one
year. (NOTE: Hydril recommends that all seals
be replaced whenever a BOP is disassembled 27 5
and assembled.) Seals and must be installed as
shown in Figures 5-10 and 5-11. Coat packing
unit, seals, and non-extrusion rings with castor oil
before installation. CAUTION: Use of petroleum
base oil or grease will reduce seal life. Figure 5-10:
5. Lubricate all threads of fasteners with Moly Paste Latched Head GK 11"-5000 PSI Without Wear Bands-
503 thread lubricant except where noted in this Assembly
procedure.
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PAGE
Operator's Manual
6. Coat interior surfaces with castor oil. careful not to damage the sealing surfaces on the
inside diameter of the body and the seals on the
C. Install Jaws. outside diameter of the piston during assembly.
1. Install the jaws (Item 21) into the annular body 4. Remove the sling and lift devices from the piston,
with the short side of the teeth down and in the taking care not to damage the sealing surface on
same sequence as disassembled. NOTE: If a the outside diameter.
new jaw is installed within a set of well worn jaws,
polish the new jaw to match existing jaws to F. Install Packing Unit.
ensure equal load sharing. 1. Lubricate the bowl of the piston (Item 3) and pack-
2. Install the O-ring (Item 26) in the external groove ing unit (Item 2) with castor oil. Install two eyebolts
of each clamping screw (Item 22). (5/8"-11UNC x 1 3/4” Lg.) into packing unit. Using
3. Install the clamping screws and screw them all- Hydril chain sling 1900179-0354, lift the packing
the-way in hand tight. CAUTION: Be careful not unit and set it into the bowl of the piston.
to overtighten the clamping screws, or the jaw will 2. Remove the sling and eyebolts from the packing
extend beyond the sides of the body. unit.
4. Insert the spacer sleeve (Item 24) and spacer
sleeve screw (Item 23) through each clamping G. Install Head.
screw. Turn the screws into the jaws (Item 21) 1. Unscrew the clamping screws (Item 22) by rotating
until tight (approximately 50 lb-ft/68 N•m). IM- them counterclockwise four turns or until the jaws
PORTANT: Do not lubricate the threads of the shoulder against the body (Item 5). CAUTION:
spacer sleeve screws. Take care not to continue turning the screws after
5. Install pipe plugs (Item 25) into clamping screws. the jaws have shouldered. Excessive torque at
6. Ensure that all of the jaws are retracted fully by shouldering may cause thread damage. NOTE: If
turning the clamping screws counterclockwise a jaw does not retract as described due to the lack
until the jaws are shouldered against the body. of engagement with spacer sleeve screw (Item 23),
tighten the spacer sleeve screw counterclockwise
D. Install Inner Sleeve. (left hand thread) to approximately 150 lb-ft (203
1. Using Hydril chain sling 1900179-0354, attach N•m).
the three hooks (evenly spaced) into the slots in 2. Install the wear plate (Item 29) on the inner face of
the sleeve and install the inner sleeve (Item 4) the annular head (1) and install the capscrews
into the body. (Item 30). Torque the capscrews to 50 lb-ft (68
2. Install the capscrews (Item 18) and torque to 150 N•m).
lb-ft (203 N•m). 3. Install the head dirt seal (Item 7), head gasket (6),
3. Remove chain sling. and upper U-seals (Items 8) onto the head.
4. Install three eyebolts (1-1/4"-7UNC x 1 3/4” Lg.)
E. Install Piston. into head.
1. Install thelower U-seals (Item 10) on the lower 5. Using Hydril chain sling 1900179-0354, lift and
segment of the piston (Item 3). install the head into the annular body (Item 5).
2. Install the middle U-seals (Item 9) onto the upper Remove the sling and eyebolts.
segment of the piston. Orient the seal lips as 8. Install four head clamps (item 31) and screws (Item
shown in Figure 5-9 and/or 5-10. 32) to secure the head fully into place. Tighten the
3. Install the piston into the body using the piston lift head clamp screws until tight.
devices. Install each device onto the piston as 9. Turn the clamping screws (Item 22) clockwise to
shown in Figure 5-6, taking care not to damage engage the jaws (Item 21) fully into the locking rings
the sealing surface on the outside diameter. of the preventer head and apply 350 lb-ft (475 N•m)
Lubricate all mating surfaces with castor oil be- of torque. CAUTION: To prevent unequal clear-
fore lowering the piston over the inner sleeve. ance between the head and the body, tighten the
Ensure that the piston is aligned vertically with jaws/latches alternately on opposite sides or in a
the inner sleeve prior to lowering. Vent the Close crisscross pattern.
ports to atmosphere. With proper vertical align-
ment, the piston will slide its normal full stroke to
the bottom of the preventer body. CAUTION: Be
R

Pipe Plug (17)
Head Clamp Screw (31)

Head Clamp (30)
Head Dirt Seal (7)
BOP Head – Latched (1)
Jaw Mechanism
(21,22,23,24,25,26)
Wear Plate (29)

Head Gasket (6)
U-Seal, Upper (8)

Packing Unit (2)
Piston (3)
U-Seal, Middle (9)
Body (5)
Inner Sleeve (4)
U-Seal, Lower (10)
Figure 5-11
Cutaway of GK® 11-5000 PSI
Latched Head BOP Without
Wear Bands, Showing Position
of Parts.
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PAGE
Operator's Manual
5.7 Disassembly - Latched Head

With Wear Bands 17 32
bers in figure correspond to item numbers in procedure. 31

EXTREME SAFETY PROCEDURES MUST BE FOL-
15
NOTE: Except for the tools listed below, disassembly of 13
the GK® annular BOP can be performed with standard
tools. 12 11 29
1. Three piston lift assemblies, Hydril Part No. 3105638- 30
6
2. Three eyebolts (1-1/4"-7UNC x 1 3/4’ Lg.), Hydril Part
No. 3112077 (for lifting head) 2
TION: This chain sling is for disassembly and assem-
bly purposes only. Do not use to lift the annular BOP
assembly.)
No. 1900077-08 (for lifting packing unit). 3
B. Vent Pressure from Annular BOP Assembly.

1. Vent the closing and opening chambers, ensuring 9
that no trapped pressure exists in the BOP which will 14
cause injury to personnel and/or damage the equip-
ment. 34 33
2. Open the valves in the control system to exhaust the
pressure and/or loosen the hydraulic connections to 18
allow the pressure to bleed off.
4
WARNING: STAND CLEAR OF ESCAPING PRESSURE 23
TO AVOID INJURY. 22
C. Remove Head.
1. Release the annular head (Item 1) by backing off the 25
jaws (Item 21). Unscrew the clamping screws (Item 24
22) by rotating them counterclockwise four turns or 26 21
until the jaws shoulder against the body (Item 5).
CAUTION: Take care not to continue turning the
screws after the jaws have shouldered. Excessive 27 5
torque at shouldering may cause thread damage.
NOTE: If a jaw does not retract as described due to
the lack of engagement with spacer sleeve screw
(Item 23), tighten the shoulder screw to approxi-
mately 50 lb-ft (68 N•m).
2. Remove the four head clamp nuts and head clamps
(Items 31 and 32) from the annular head. NOTE: Figure 5-12:
Alternately loosen the nuts on opposite sides to Latched Head GK 11"-5000 PSI With Wear Bands-
unload the head evenly. Disassembly
head.
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4. Using Hydril chain sling , lift the head out of the body. sleeve screw (Item 23) from the clamping screw.
Remove sling and eyebolts. 3. Remove the O-ring (Item 26) from the clamping screw.
5. Remove the head dirt seal (Item 7), wiper ring (Item 4. Remove the clamping screw and spacer sleeve (Item
15), head gasket (Item 6), head to piston double U- 24) from the body (Item 5). Remove spacer sleeve from
seal (Items 11 and 12), and the wear band (Item 13) the clamping screw. Remove the jaws (Item 21) from
from the head. the inside of the body. NOTE: Keep the jaws in
6. Remove the six cap screws (Item 30) and the wear sequence so that they can be returned to their original
plate (Item 29). position.
D. Remove Packing Unit.

2. Using Hydril chain sling, lift the packing unit out of the
piston (Item 3).
E. Remove Piston.
1. Install three piston lifting devices onto the piston (Item
3) as follows and as shown in Figure 5-6:
a. Position each lift device over the top edge of the
piston above the eyebolt holes in the piston
shoulder, taking care not to damage the sealing
surface on the outside diameter.
b. Tighten the eyebolts until the lift devices are
snug against the piston shoulder.
lifting.
2. Using Hydril chain sling 1900179-0354, gently lift
piston out of the preventer body. If a vertical lift is not
possible or the piston does not lift out freely, slowly
apply low (50 PSI) hydraulic pressure to the closing
chamber.
3. Remove the middle U-seals (Item 9), lower piston

double U-seal (Items 33 and 34), and the wear band
(Item 14) from the piston.
4. Remove the lift devices from the piston, taking care
not to damage the sealing surface on the outside
diameter.

inner sleeve (Item 4).
2. Using Hydril chain sling 1900178-0354, attach the
hooks (equally spaced) into the slots in the sleeve
and lift the inner sleeve out of the annular BOP.
3. Remove sling.
G. Remove Radial Latches.

Perform the following procedure for each radial latch (Item
19).
1. Remove pipe plug (Item 25).
2. Hold clamping screw (Item 22) and remove spacer
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PAGE
Operator's Manual
5.8 Assembly - Latched Head

With Wear Bands 17 32
dure. Numbers in figures correspond to item numbers in 31
procedure.
WARNING: THIS IS VERY HEAVY EQUIPMENT,

AND EXTREME SAFETY PROCEDURES MUST 1
BE FOLLOWED DURING LIFTING OPERATIONS.
7
BE SURE THAT LIFTING EQUIPMENT IS IN GOOD
15
CONDITION AND CAPABLE OF HANDLING THE 6
LOAD.
13
A. Gather Tools and Materials. 12 11 28

NOTE: Except for the tools listed below, assembly 29
of the GK® annular BOP can be performed with
standard tools.
2
1. Three piston lift assemblies, Hydril Part No.
3105638-6
2. Three eyebolts (1-1/4"-7UNC x 1 3/4” Lg.), Hydril
TION: This chain sling is for disassembly and 3
assembly purposes only. Do not use to lift the
4. Two eyebolts (5/8"-11 UNC x 1 3/4” Lg. ), Hydril 9
Part No. 1900077-08 (for lifting packing unit) 14
5. Castor oil
34 33
8. Spare parts including seal kit. Refer to Section 4
6, "Parts and Storage." 23
22
B. Clean, Inspect BOP, and Lubricate.
2. Perform the inspection procedures that are ap-
plicable in Section 4, "Maintenance and Test- 24
26 21
ing".
3. Ensure that working surfaces are free of burrs,
rough edges, or other defects. 27 5
4. Inspect all seals and wear bands installed on the
head and piston. Replace any damaged seals
and wear bands in use over one year. (NOTE:
Hydril recommends that all seals and wear bands
be replaced whenever a BOP is disassembled
and assembled.) Seals and must be installed as
Figure 5-13:
shown in Figures 5-13 and 5-14. Coat packing
Latched Head GK 11"-5000 PSI With Wear Bands-
unit, seals, and non-extrusion rings with castor Assembly
oil before installation. CAUTION: Use of petro-
leum base oil or grease will reduce seal life.
R

5. Lubricate all threads of fasteners with Moly Paste ports to atmosphere. With proper vertical align-
503 thread lubricant except where noted in this ment, the piston will slide its normal full stroke to the
procedure. bottom of the preventer body. CAUTION: Be
6. Coat interior surfaces with castor oil. careful not to damage the sealing surfaces on the
inside diameter of the body and the seals on the
C. Install Jaws. outside diameter of the piston during assembly.
1. Install the jaws (Item 21) into the annular body 4. Remove the sling and lift devices from the piston,
with the short side of the teeth down and in the taking care not to damage the sealing surface on
same sequence as disassembled. NOTE: If a the outside diameter.
new jaw is installed within a set of well worn
latches, polish the new jaw to match existing F. Install Packing Unit.
jaws to ensure equal load sharing. 1. Lubricate the bowl of the piston (Item 3) and pack-
2. Install the O-ring (Item 26) in the external groove ing unit (Item 2) with castor oil. Install two eyebolts
of each clamping screw (Item 22). (5/8"-11UNC x 1 3/4” Lg.) into packing unit. Using
3. Install the clamping screws and screw them all- Hydril chain sling 1900179-0354, lift the packing
the-way in hand tight. CAUTION: Be careful not unit and set it into the bowl of the piston.
to overtighten the clamping screws, or the jaw 2. Remove sling and eyebolts from packing unit.
will extend beyond the sides of the body.
4. Insert the spacer sleeve (Item 24) and spacer G. Install Head.
sleeve screw (Item 23) through each clamping 1. Unscrew clamping screws (Item 22) by rotating
screw. Turn the screws into the jaws (Item 21) them counterclockwise four turns or until the jaws
until tight (approximately 50 lb-ft/68 N•m). IM- shoulder against body (Item 5). CAUTION: Take
PORTANT: Do not lubricate the threads of the care not to continue turning screws after the jaws
spacer sleeve screws. have shouldered. Excessive torque at shouldering
5. Install pipe plugs (Item 25) into clamping screws. may cause thread damage. NOTE: If a jaw does
6. Ensure that all of the jaws are retracted fully by not retract as described due to the lack of engage-
turning the clamping screws counterclockwise ment with spacer sleeve screw (Item 23), tighten
until the jaws are shouldered against the body. the spacer sleeve screw counterclockwise (left
hand thread) to approximately 150 lb-ft (203 N•m).
D. Install Inner Sleeve. 2. Install the wear plate (Item 28) on the inner face of
1. Using Hydril chain sling 1900179-0354, attach the annular head (1) and install the capscrews
the three hooks (evenly spaced) into the slots in (Item 29). Torque capscrews to 50 lb-ft (68 N•m).
the sleeve and install the inner sleeve (Item 4) 3. Install the head gasket (6) and head dirt seal (Item
into the body. 7) on the lower outside diameter of the head. Install
2. Install the capscrews (Item 18) and torque to 150 the head to piston double U-seal (Items 11 and 12),
lb-ft (203 N•m). wiper ring (Item 15), and wear band (Item 13) onto
3. Remove chain sling. the lower inside diameter of the head. Refer to
Figures 5-13 and 5-14 for seal orientation.
E. Install Piston. 4. Install three eyebolts (1-1/4"-7UNC x 1 3/4” Lg.)
1. Install the lower piston double U-seal (Items 33 into head.
and 34) and wear band (Item 14) on lower 5. Using Hydril chain sling 1900179-0354, lift and
segment of the piston (Item 3). install the head into the annular body (Item 5).
2. Install the middle U-seals (Item 9) onto the middle Remove the sling and eyebolts.
segment of the piston. Orient the seal lips as 6. Install four head clamps (item 31) and screws (Item
shown in Figures 5-13 and 5-14. 32) to secure the head fully into place. Tighten the
3. Install the piston into the body using the piston lift screws until tight.
devices. Install each device onto the piston as 7 Turn clamping screws (Item 22) clockwise to en-
shown in Figure 5-6, taking care not to damage gage jaws (Item 21) fully into locking rings of
the sealing surface on the outside diameter. preventer head and apply 350 lb-ft (475 N•m) of
Lubricate all mating surfaces with castor oil be- torque. CAUTION: To prevent unequal clearance
fore lowering the piston over the inner sleeve. between head and the body, tighten the jaws alter-
Ensure that the piston is aligned vertically with nately on opposite sides or in a crisscross pattern.
the inner sleeve prior to lowering. Vent the Close
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PAGE
Operator's Manual
Pipe Plug (17)

Head Clamp Screw (31)
Head Clamp (30)
Head Seal (7)

BOP Head – Latched (1)
Wear Plate (29)
Jaw Mechanism
(21,22,23,24,25,26)
Wiper Ring (15)
Head Gasket (6)
Wear Band (14)

Head to Piston
Double U-Seal (11, 12)
Packing Unit (2)
Piston (3)
U-Seal, Middle (9)
Body (5)
Inner Sleeve (4)
Wear Band (13)
Lower Piston Double U-Seal (33, 34)
Figure 5-14
Cutaway of Latched Head GK® 11-5000 PSI
BOP with Wear Bands, Showing Position
of Parts.
R

6.0 PARTS AND STORAGE
6.1 Parts List — Screwed Head Without Wear Bands

Approx.
Item No. Net Wt. Part
17
No. Part Name Req. (Lb) Number 19
BOP Assembly 1 8,200 1002140

1 BOP Head - 1
Screwed 1 1,880 1002143 6
2▲ Packing Unit-
Natural (NR) 1 305 1003260-01 8
Nitrile (NBR) 1 311 1003260-02
29
3 Piston 1 1,380 1002145-1
4** Inner Sleeve 1 ... 1004201
5 Body 1 4,645 1002141 30
6 Head Gasket 1 2 31402 2
8 U-Seal, Upper 2 2.13 31403
9 U-Seal, Middle 2 2 30736
10 U-Seal, Lower 2 1.75 32599
17 Pipe Plug, Piston 1900065- 1
Indicator 1 ... 05
3
18** Inner Sleeve Screw 1920026-
12 ... 12012
19 Head Lock Screw 1 1.19 1002149
9
29* Wear Plate 1 24.15 1004203
30* Wear Plate 1920026-
10
Capscrew 6 0.13 08007
• Field Replacement
Sleeve Kit 1 ... 1006100 4
▲ Seal Kit- Complete 1 14.41 1002150
18
ACCESSORIES
Chain Sling Assy 1 45 33565-M

Eyebolt, Piston 3 1.94 30952
Eyebolt, Head, 1 1/4”-7NC 2 4.25 32006 5
Protector Plate 1 66 31406
Protector Plate Screw 4 0.13 1900043
08010
▲ Recommended spares for one year service.
• For converting welded sleeve on some model BOPs to bolted
sleeve only. Sleeve does not interchange with Item 4.
* Requires head conversion to accept wear plate; some models of
this BOP do not have the wear plate.
** Some BOPs are equipped with Sleeve P/N 1004075 and
Capscrew 1920026-12016. Check P/N stamped on bottom of Figure 6-1:
sleeve for replacement. Screwed Head GK® 11"-5000 PSI without Wear Bands
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PAGE
Operator's Manual
6-2
6.2A Parts List — Screwed Head With Wear Band Modificationa

Approx.
19
a
BOP Assembly 1 8,200 1002140-WB
1 Head - Screwed 1 1,880 3136824
1
2▲ Packing Unit- 6
Natural (NR) 1 305 1003260-01 15
Nitrile (NBR) 1 311 1003260-02 13
3 Piston 1 1,380 3136680
4** Inner Sleeve 1 ... 1004201 12 11
5 Body 1 4,645 1002141
29
6 Head Gasket 1 2 31402 30
9 U-Seal, Middle Piston 1 ... 30736
2
11 Double U-Seal, Head 1 2.13 1002921
12 Non Extrusion Ring 2 ... 1002922
13 Wear Band, Head 1 ... 1931099-05
14 Wear Band, Piston 1 ... 1931099-04
15 Wiper Ring 1 ... 3136747
3
17 Pipe Plug, Piston
Indicator 1 ... 1900065-05
18** Inner Sleeve Screw 1 1004201
9
19 Head Lock Screw 1 1.19 1002149 14
29* Wear Plate 1 24.15 1004203
34
30* Wear Plate 1920026-
Capscrew 6 0.13 08007 33
33 Double U-Seal, Piston 1 ... 3136746 4
• Field Replacement 18
Sleeve Kit 1 ... 1006100
ACCESSORIES
Chain Sling Assy 1 45 33565-M
5
Eyebolt, Piston 5/8”-11UNC 2 1.94 30952
Eyebolt, Head, 1 1/4”-7UNC 2 4.25 32006
Protector Plate Screw 4 0.13 1900043
08010
• For converting welded sleeve on some model BOPs to bolted
sleeve only. Sleeve does not interchange with Item 4.
* Requires head conversion to accept wear plate; some models of
this BOP do not have the wear plate.
** Some BOPs are equipped with Sleeve P/N 1004075 and Figure 6-2:
Capscrew 1920026-12016. Check P/N stamped on bottom of Screwed Head GK® 11"-5000 PSI with Wear Band
sleeve for replacement. Modification
a
Wear band modification at Hydril Authorized Repair Facility (ARF).
The abbreviation “WB” will be stamped on the name plate after the modification. See Parts List 6.2B (PNI04-007-02 Rev A1)
BOP assembly number (XXXXXXX-WB) to indicate wear band for modification kit parts.
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6.2B Parts List — Screwed Head Wear Band Modification Kit

PNI04-007-02 Rev A1
Approx.
No.a Part Name Req. (Lb) Number
1 Head - Screwed 1 1,880 3136824

3 Piston 1 1,380 3136680
13 Wear Band, Head 1 ... 1931099-05
14 Wear Band, Piston 1 ... 1931099-04
... Seal Kit- Complete 1 14.41 3137431
a
Item number refers to Parts List 6-2A and Figure 6-2.
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PAGE
Operator's Manual
6-4
6.3 Parts List — Screwed Head With Wear Bands At Manufacturea

Approx.
No. Part Name Req. Number* 17
(Lb) 19
BOP Assembly 1 8,200 *
1 Head - Screwed 1 1,880 *
1
2▲ Packing Unit-
6
Natural (NR) 1 305 1003260-01 15
Nitrile (NBR) 1 311 1003260-02 13
3 Piston 1 1,380 *
4 Inner Sleeve 1 ... 1004201 12 11
5 Body 1 4,645 *
29
6 Head Gasket 1 2.0 31402 30
2
11 Double U-Seal, Head 1 2.13 1002921
13 Wear Band, Head 1 ... 1931099-05
14 Wear Band, Piston 1 ... 1931099-04
15 Wiper Ring 1 ... 3136747
3
17 Pipe Plug, Piston
Indicator 1 ... 1900065-05
18 Inner Sleeve Screw 6 0.13 1920026-
9
12012 14
19 Head Lock Screw 1 1.19 1002149
29 Wear Plate 1 24.15 3123805 34
30 Wear Plate 1920026- 33
Capscrew 6 0.13 08007 4
33 Double U-Seal, Piston 1 ... 3136746
34 Non Extrusion Ring 2 ... 3136745 18

ACCESSORIES
Chain Sling Assembly 1900179-
1 ... 0354
5
Eyebolt, Head, 1 1/4-7UNC 3 4.25 3112077
Protector Plate 2 66 3113411-37
Piston Lift Device 3 ... 3105638-6

a
Wear bands are installed at manufacture.
* This parts list is generic in construction and part numbers are listed
for all components that are standard except for non-standard compo-
nents or those that require regulatory certification, which may change
from one assembly to another. These parts are specific to the
assembly part number stamped on the BOP name plate. If you want
a complete parts list specific to your equipment, contact Hydril.
Include the assembly part number and/or serial number from the Figure 6-3:
name plate. If name plate is missing or damaged, the serial number Screwed Head GK® 11"-5000 PSI with Wear Bands
is stamped on the body.
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6.4 Parts List — Latched Head Without Wear Bands

Approx. 32
Item No. Net Wt. Part 17
BOP Assembly 1 8,200 1004060

1 BOP Head-Latched 1 1900 1002223
2▲ Packing Unit
Natural Rubber (NR) 1 305 1003260-01 1
Nitrile (NBR) 1 311 1003260-02
7
3 Piston 1 1380 1002145
4 Inner Sleeve 1 ... 1004201 6
5 Body 1 4645 1004061-02
6 Head Gasket 1 2.44 31402 8
7 Head Dirt Seal 1 ... 51189 29
8 U-Seal ,Upper 2 2.13 31403 30
9 U-Seal, Middle 2 2 30736
10 U-Seal, Lower 2 1.75 32599
17 Pipe Plug, Piston Indicator 1 ... 1900065-05 2
18 Inner Sleeve Screw 1920026-
12 ... 12012
21 Jaw 16 ... 1004065
22 Jaw Clamping Screw 16 3.75 1004067
23 Spacer Sleeve Screw 1900184-
16 ... 10024 3
24 Spacer Sleeve 16 ... 1004068
25 Pipe Plug 16 ... 1900065-08
26 Jaw Clamping Screw 1900001- 9
O-Ring 16 0.02 329
27 Relief Fitting 1 0.03 1900086-03 10
29 Wear Plate 1 ... 1004203
30 Wear Plate Capscrew 1920026-
18
6 0.09 08007
31 Head Clamp 4 0.85 1002351
32 Head Clamp Screw 1900049- 4
4 0.67 14024 23
▲ Seal Kit- Complete ... 18 1004074 22
ACCESSORIES
25
Chain Sling Assembly 1 ... 1900179-
0354 24
26 21
Eyebolt, Head, 1 1/4”-7UNC 2 4.25 3112077
Protector Plate 1 66 31406 5
Protector Plate Screw 4 0.13 1900043- 27
08010
Figure 6-4:
Latched Head GK 11"-5000 PSI Without
Wear Bands
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PAGE
Operator's Manual
6-6
6.5A Parts List — Latched Head With Wear Band Modification*

Approx.
No. Part Name Req. (Lb) Number 17 32
31
BOP Assembly 1 8,200 1004060-WB*
1 BOP Head-Latched 1 1900 3136678
2▲ Packing Unit
Natural Rubber (NR) 1 305 1003260-01
Nitrile (NBR) 1 311 1003260-02 1
3 Piston 1 1380 3136680
4 Inner Sleeve 1 ... 1004201 7
5 Body 1 4645 1004061-02 15
6 Head Gasket 1 2.44 31402 6
7 Head Dirt Seal 1 ... 51189 13
12 11 29
11 Double U-Seal, Head 1 ... 1002921
13 Wear Band, Head 1 ... 1931099-05
14 Wear Band, Piston 1 1931099-04
2
15 Wiper Ring 1 ... 3136747
17 Pipe Plug, Piston Indicator 1 ... 1900065-05
12 ... 12012
21 Jaw 16 ... 1004065
23 Spacer Sleeve Screw 1900184- 3
16 ... 10024
24 Spacer Sleeve 16 ... 1004068
9
25 Pipe Plug 16 ... 1900065-08
O-Ring 16 0.02 329
27 Relief Fitting 1 0.03 1900086-03 34 33
29 Wear Plate 1 ... 1004203 18
6 0.09 08007
31 Head Clamp 4 0.85 1002351 4
23
4 0.67 14024
▲ Seal Kit- Complete ... 18 3137417
24
26 21
ACCESSORIES
0354 27 5
Eyebolt, Head, 1 1/4”-7UNC 2 4.25 3112077
Protector Plate Screw 4 0.13 1900043-
08010
▲ Recommended spares for one year service. Figure 6-5:
* Wear band modification at Hydril Authorized Repair Facility (ARF). Latched Head GK 11"-5000 PSI With
The abbreviation “WB” will be stamped on the name plate after the Wear Band Modification
BOP assembly number (XXXXXXX-WB) to indicate modification.
See parts list 6.5B (PNI04-007-03 Rev A1) for modification kit parts.
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6.5B Parts List — Latched Head Wear Band Modification Kit

PNI04-007-03 Rev A1
Approx.
No.a Part Name Req. (Lb) Number
1 Head - Screwed 1 1,880 3136678

3 Piston 1 1,380 3136680
13 Wear Band, Head 1 ... 1931099-05
14 Wear Band, Piston 1 ... 1931099-04
... Seal Kit- Complete 1 14.41 3137417
a
Item number refers to Parts List 6-5A and Figure 6-5.
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PAGE
Operator's Manual
6-8
6.6 Parts List — Latched Head With Wear Bands At Manufacturea

Approx.
No. Part Name Req. (Lb) Number 17 32
BOP Assembly 1 8,200 * 31

1 BOP Head-Latched 1 1900 *
2▲ Packing Unit
Natural Rubber (NR) 1 305 1003260-01
Nitrile (NBR) 1 311 1003260-02 1
3 Piston 1 1380 *
4 Inner Body Sleeve 1 ... 1004201 7
5 Body 1 4645 * 15
6 Head Gasket 1 2.44 31402 6
7 Head Dirt Seal 1 ... 51189 13
12 11 29
11 Double U-Seal ,Head 1 ... 1002921
13 Wear Band, Head 1 ... 1931099-05
14 Wear Band, Piston 1 1931099-04
2
15 Wiper Ring 1 ... 3136747
17 Pipe Plug, Piston Indicator 1 ... 1900065-05
12 ... 12012
21 Jaw 16 ... 3136678
23 Spacer Sleeve Screw 1900184- 3
16 ... 10024
24 Spacer Sleeve 16 ... 1004068
9
25 Pipe Plug 16 ... 1900065-08
O-Ring 16 0.02 329
27 Relief Fitting 1 0.03 1900086-03 34 33
29 Wear Plate 1 ... 1004203 18
6 0.09 08007
31 Head Clamp 4 0.85 1002351 4
23
4 0.67 14024
▲ Seal Kit- Complete ... 18 3137417
ACCESSORIES 24
26 21
0354
Piston Lift Device 3 ... 3105638-6 27 5
Eyebolt, Head 2 4.25 3112077
Protector Plate Screw 4 0.13 1900043-
08010
a
Wear bands are installed at manufacture. Figure 6-6:
* This parts list is generic in construction and part numbers are listed Latched Head GK 11"-5000 PSI With
for all components that are standard except for non-standard Wear Bands
components or those that require regulatory certification, which may
change from one assembly to another. These parts are specific to Include the assembly part number and/or serial number from
the assembly part number stamped on the BOP name plate. If you the name plate. If name plate is missing or damaged, the
want a complete parts list specific to your equipment, contact Hydril. serial number is stamped on the body.
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6.7 Preventer Storage

The following preservation procedure protects the Hydril® "Maintenance and Testing" for testing procedures.
11 5/8"-5000 PSI annular BOP for up to two years of NOTE: For additional discussion on operating fluid
storage. The protection period is dependent primarily upon and specific fluid recommendations, refer to Hydril
the sealing integrity of the end connections and sealing of Engineering Bulletin EB9909A on Hydril Website
other pressure boundary penetrations. www.hydril.com.
3. Drain the bore and rinse thoroughly behind the pack-
6.7.1 Preservation Procedure ing unit and inner sleeve with water displacement oil.
4. Drain the operating fluid and flush out the operating
A. Materials Required fluid paths and chambers (Open and Close) with water
1. Cortec VCI 369 grease (for unpainted machined face displacing oil.
surfaces) 5. Allow the bore, operating fluid paths and chambers
2. Cortec VCI 609 vapor phase corrosion inhibitor, 10 (Open and Close) to dry.
ounce (for bore and exposed interior surfaces) 6. Install pipe plugs into Open and Close ports.
3. Two protective covers for the end connections. 7. Apply Cortec VCI 369 grease to bottom connection
4. Water displacement oil such as Hougton Rust Veto mating surface .
4221 or Stack Guard 180; Witco Macco 1961; or any 8. Install a protective cover on the bottom connection.
AW Hydraulic Oil 46 (required for removal of water Ensure that a tight seal exists between the BOP and
after hydrostatic testing) the cover. Use silicone cauk if necessary.
5. One tube of silicone caulk (additional sealing for 9. Drop 10 ounces of Cortec VCI 609 vapor phase
protective covers) corrosion inhibitor into the bore of the BOP.
10. Apply Cortec VCI 369 grease to the top connection
B. Procedure mating surface.
1. Disassemble, clean, inspect, lubricate, and assemble 11. Install a protective cover on the top connection. En-
the annular BOP. Refer to the maintenance procedure sure that a tight seal exists between the BOP and the
in Section 4, "Maintenance and Testing" and Section cover. Use silicone cauk if necessary.
5, "Disassembly and Assembly." Replacement of 12. Touch up paint where necessary. Contact Hydril for
worn packing units, seals, and other parts can be paint specifications.
made conveniently at this time. Hydril recommends 13. Coat unpainted exterior surfaces with Cortec VCI 369
the replacement of all seals when the annular BOP is grease.
disassembled.
2. Test the packing unit and seals, using a 50/50 mix of 6.7.2 Depreservation Procedure and Return to Service
fresh water (DO NOT USE SEA WATER OR BRINE) Remove the end connection covers and blow or rinse out
and glycol mixed with corrosion inhibitor or BOP hy- the vapor phase corrosion inhibitor.
draulic fluid as an operating fluid. Refer to Section 4,
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PAGE
Operator's Manual
6-10
6.8 Rubber Goods Storage

The term rubber goods includes synthetic compounds (motors, switch gear, or any high voltage equipment produc-
such as Nitrile Copolymers and Neoprene, as well as ing corona and ozone). Avoid locations susceptible to drafts
natural rubber parts. The ideal storage situation for that will carry the atmosphere from electrical machinery to
rubber goods would be in air tight containers maintained the rubber goods storage area.
in a cool, dry, dark storage area. 4. The practice of first-in, first-out is essential with rubber
The following recommendations will allow vendors goods.
and users of oil field equipment to maximize normally5. Store rubber goods in a relaxed position in their normal
available storage facilities for rubber goods: shape. For example, do not hang O-rings on nails. Do not
1. Keep the rubber storage area as dark as possible — keep assemblies in stretched attitudes, e.g., O-rings on
preferably indoors, not outdoors, and away from glands, BOP testers, and operator parts.
direct sunlight, skylights, windows, and direct artifi-6. Rubber goods storage areas should be kept as dry as
cial lighting. possible. Remove oil, grease or other foreign materials from
2. Select a cool location (approximately 65oF) that is the storage area to preclude spillage on rubber goods.
away from heaters, stoves, and direct blasts of7. If storage for extended periods is anticipated, sealed con-
space heaters. tainers are recommended. Impervious surface coverings
3. Keep rubber goods away from electrical machinery such as waxing will increase shelf life.
OPERATOR'S MANUAL
Pressure Control Equipment

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Manual 6609E

Pressure Control Equipment

Hydril Company LP/ P.O. Box 60458 / Houston, Texas 77205

Operator's Manual PAGE

OPERATOR QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

SECTION 1.0 – INSTALLATION AND OPERATION

SECTION 2.0 – PHYSICAL DATA

SECTION 3.0 – PACKING UNITS AND SEALS

SECTION 4.0 – MAINTENANCE AND TESTING

SECTION 5.0 – DISASSEMBLY AND ASSEMBLY

SECTION 5.0 – DISSASSEMBLY AND ASSEMBLY (CONTINUED)

SECTION 6.0 – PARTS AND STORAGE

Operator's Manual 1-vii

OPERATOR QUICK REFERENCE

2 3/8” 900 825 650 475 300 50

2 7/8" 800 725 550 375 200 50

3 1/2" 825 450 275 100 50 50

4 1/2"-5 " 450 375 225 100 50 50

5 1/2"-8 5/8" 350 275 125 50 50 50

ANNULAR BOP TESTING AND OPERATION

Opening Chamber 8.08 30.6

Full Piston Stroke 7 1/8 in. 181 mm

Distance From Top of Head To Top of Piston

Maximum — Piston Full

Minimum — Piston at Full

Operator's Manual PAGE

1.0 INSTALLATION AND OPERATION

Operator's Manual PAGE

1.2.4 Principle of Operation

Operator's Manual PAGE

Figure 1-4 Figure 1-5

Figure 1-6 Figure 1-7

1.2.5 Surface Operation and Hookup

The surface hookup of the GK® shown in Figure 1-8

Operator's Manual PAGE

1.2.6 Surface Stripping Operations

Closing Pressure Closing Pressure

Opening Pressure Opening Pressure

Operator's Manual PAGE

2.0 PHYSICAL DATA

2.1 Engineering Data

2.2 Bolt and Wrench Data

Ref. Description Thread Wrench Recommended Torque

17 Pipe Plug—Piston Indicator 1/2" NPT 3/8" Hex Key 50 69

LATCHED HEAD ONLY

2.3 Lubricant List

2.4 Dimensions - Screwed Head

N AS CAST Figure 2-1

Nominal Dimensions — Inches

▲5M ▲10M ▲5M ▲10M ▲5M ▲10M

47.75 48.50 44.88 ... 39.63 40.25 19.06 5.69 13 3/16

11.81 44.25 37.50 35.75 ... 2.00 32.00 36.75

▲ Lower Connector Pressure Rating

Operator's Manual PAGE

2.5 Dimensions - Latched Head

M AS CAST Figure 2-2

*1” NPT, 1 set of ports, 18” from lifting lug.

Nominal Dimensions — Inches

▲5M ▲10M ▲5M ▲10M ▲5M ▲10M

48.25 49.00 45.31 ... 40.06 40.69 19.88 4.00 14.19

11.25 44.25 42.25 36.38 2.00 32.00 36.75

▲ Lower Connector Pressure Rating

2.6 API Ring Joint Flange Connections