No.

1529

FZ68-21U Ram BOP Rev.A0

Safety guideline
The manual includes precautions that should be followed to ensure personnel safety and prevent products and
connected devices from being damaged.
For these precautions, symbols are used for alarm purpose and the following descriptions will be given depending on
severity:

Caution
It indicates that without proper preventive measures, death, serious physical injury or major property loss will
possibly occur.

Attention
Arouse your attention to important information on products and to specific parts of products or files.

Qualified personnel
Only qualified personnel are allowed to install and operate the device. Qualified personnel refer to those who,
with experience in field well-control, can install, test run and operate devices according to established safety
practices and standards.

Correct operation
Precautions:

Caution
The device and its components can only be used for description of product catalog or technical specification
and can only be connected to facilities or components recognized or recommended by Shenkai Company.
Top priority should be given to safety of well control equipment. Conduct timely replacement on quick-wear
metal parts and non-metal parts which may cause any influence on the product safety and performance in the
test, especially the ram rubber core.
The device can function correctly and safely only when transported, stored, assembled, installed correctly and
run and maintained as recommended.

Trade mark
○
R ○
R ○
R

, , are registered trade marks of Shenkai Company.

Any use of other names related to the trade marks herein by any third party for its own purpose will infringe interest of
the trade mark owner.
Copyright © 2014 Shenkai Company, All rights reserved.
Without the express written permission, it is forbidden to copy, transmit or use this manual or part of it.
Any violation of the above will be disciplined. All rights, including patent rights, utility model or appearance design
patent rights, are reserved.
Our blowout preventers comply with API 16A and GB/T20174 standard requirements, having obtaining the monogram
use permit awarded by American Petroleum Institute (API) and the production certificate issued by General
Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China(AQSIQ): 16A-0111,

, XK14-001-0002, .

Shanghai Shenkai Petroleum & Chemical Equipment Co., Ltd. hereby declares that contents of this manual are verified
and compliant with the said hardware and software. Mistakes, however, are unavoidable, so complete consistence
can’t be guaranteed. Contents of this manual are subject to periodic review and will be modified in the next version.
Your opinions on improvement are welcome.
Copyright © 2014 Shenkai Company. The information in this manual is subject to change without notice.

Shanghai Shenkai Petroleum & Chemical Equipment Co., Ltd

Technical Support Department Contract No.

Customer service hotline: +86(21)64290467 Fax: +86(21)64290467

Website: www.shenkai.com post code: 201114
 Contents
1 Overview .............................................................................................................................................. 1

2 Model Specification and Technical Parameters .................................................................................. 2

2.1 Model......................................................................................................................................... 2
2.1.1 Bore Code ....................................................................................................................... 2
2.1.2 Rated Working Pressure................................................................................................. 2
2.1.3 Temperature Rating ........................................................................................................ 2
2.2 Technical Parameters of Ram-type Blowout Preventer ............................................................ 3
3 Working Principles and Structure Characteristics ............................................................................... 5
3.1 Working Principles .................................................................................................................... 5
3.1.1 Hydraulic Control Principles ........................................................................................... 5
3.1.2 Seal Principles ................................................................................................................ 6
3.2 Structures and Features of Main Parts ..................................................................................... 6
3.2.1 Pipe Ram Assembly........................................................................................................ 7
3.2.2 Sealing Mechanism of Operating Piston Front Rod ....................................................... 8
3.2.3 Secondary Sealing Mechanism ...................................................................................... 9
3.2.4 Sealing Mechanism of Operating Piston Tail Rod .........................................................11
3.2.5 Manual Locking Mechanism of Ram ............................................................................ 12
3.3 Product Parts List .................................................................................................................... 13
4 Installation and Use ........................................................................................................................... 18
4.1 Preparation before Use ........................................................................................................... 18
4.2 Using Methods and Notes....................................................................................................... 20
5 Disassembly and Maintenance of Blowout Preventer ...................................................................... 21
5.1 Open Intermediate Flange of Blowout Preventer ................................................................... 21
5.2 Replacement of Ram and Ram’s Seal .................................................................................... 22
5.3 Repair and Replacement of Hydraulic Cylinder Assembly ..................................................... 23
5.4 Disassembly of Ram Opening and Closing Piston Rods ....................................................... 25
5.5 Installation Notes..................................................................................................................... 27
5.6 Daily Maintenance................................................................................................................... 28
5.7 Operating Period Maintenance ............................................................................................... 28
6 Preservation procedures ................................................................................................................... 30
6.1 Storing for periods greater than 30 days ................................................................................ 30
6.2 Storage of Rubber Parts ......................................................................................................... 30

7 Common Failure and Troubleshooting .............................................................................................. 31

2C24
（This manual applies to FZ68-21U Ram BOP P/N: ）
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 Manual of FZ68-21U Ram BOP Rev.A2

1 Overview
The ram BOP is an integral part of well control equipment and is mainly employed to
control wellhead pressure in the process of drilling, workover, testing etc. in order to
prevent occurrence of the well blowout and realize safety construction. Refer to Figure
1-1 for appearance of the ram BOP. It can be applied to complete the following work:
 In the case of the pipes in the well, when equipped with the corresponding pipe
ram, it can be used to seal off the annular space between the casing and the
pipes.
 In the case of no pipes in the well, when equipped with blind ram, it can be used
to seal off the wellhead completely.
 In the case of emergency, use the shear ram to shear off pipes in the well and
seal off the wellhead completely.
 While enclosing the well, mud circulating, pressure releasing, well killing and well
cleaning can be performed by means of the spool and the choke manifold
connected to the outlet at the side of BOP body.
 When ram BOP is used together with the choke manifold and kill manifold, it can
effectively control the bottom hole pressure and achieve near-balanced drilling
operation.

Figure 1-1 Appearance of U Ram BOP

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 Manual of FZ68-21U Ram BOP Rev.A2

2 Model Specification and Technical Parameters

2.1 Model

UM

Model of BOP
Rated working pressure code(Table 2-2)
Bore code: (Table 2-1)

Ram BOP code: FZ- single ram BOP; 2FZ-double ram BOP;
3FZ- triple ram BOP

2.1.1 Bore Code

Table 2-1 Bore Code

Bore Code Bore Specification （in） Bore Code Bore Specification （in）
18 7 1/16 〃 48 18 3/4〃
23 9〃 53 20 3/4〃
28 11〃 54 21 1/4〃
35 13 5/8〃 68 26 3/4〃
43 16 3/4〃 76 30〃

2.1.2 Rated Working Pressure

The rated working pressures of BOP have six levels and please refer to table 2-2.

Table 2-2 Rated Working Pressure

Rated Working Pressure

Pressure Code
MPa psi
14 13.8 2,000
21 20.7 3,000
35 34.5 5,000
70 69.0 10,000
105 103.5 15,000
140 138.0 20,000

2.1.3 Temperature Rating

The minimum temperature refers to the lowest ambient temperature that the
equipment may suffer from and the maximum temperature refers the possible highest
temperature of the fluid running through the equipment.
The metal parts of the equipment work within the temperature range as shown in
table 2-3.
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 Manual of FZ68-21U Ram BOP Rev.A2
The synthetic rubber materials of equipment contacting with the well fluid work within
the temperature rating as shown in table 2-4.

Table 2-3 Temperature Rating for Metallic Materials

Temperature Rating Code API Code Working Temperature Scope

T-75 75 -59℃~121℃(-75 ºF ~250 ºF)
T-20 20 -29℃~121℃(-20 ºF ~250 ºF)
T-0 00 -18℃~121℃(0 ºF ~250 ºF)

Table 2-4 Temperature Rating of Non-metallic Sealing Materials Contacting with the Well Fluid

Lower Limit (first letter) Upper Limit (second letter)

Code Temperature Code Temperature
A -26℃（-15℉） A 82℃（180℉）
B -18℃（0℉） B 93℃（200℉）
C -12℃（10℉） C 104℃（220℉）
D -7℃（20℉） D 121℃（250℉）
For example: AB presenting the temperature rating of -26℃~93℃ (-15℉~200℉). The specific
temperature rating is indicated on the sealing parts.

2.2 Technical Parameters of Ram-type Blowout Preventer

Table 2-5 Specification and Main Technical Parameters of Ram-type Blowout Preventer

Name Double Ram BOP Single Ram BOP

Model 2FZ68-21U FZ68-21U
Bore 679.4mm（26 3/4 in）
Rated working pressure 21MPa（3000psi）
hydrostatic test pressure 31.5MPa (4500psi)
Hydraulic-control rated
21 MPa（3000psi）
working pressure
Recommended hydraulic-control
8.4-10.5MPa(1200-1500psi)
operation pressure
Opening capacity
36L×4 36L×4
of hydraulic cylinder
Closing capacity
37L×4 37L×4
of hydraulic cylinder
Temperature rating T-20
Weight 23400kg 14100kg
Closing Ratio 12:1
Locking Screw turns (each end) 62
Statement:
a. Design and manufacturing of BOP are in compliance with API Spec 16A.
b. The anti-hydrogen sulfide stress corrosion of the BOP position contacting the well fluid meet
requirements of NACE MR-0175.
c. The weight of BOP in the connection mode of upper bolted, lower flanged and side bolted is
showed in the table (see Fig.2-1, Fig.2-2, including ram assembly). The actual weight shall change
with the change of the upper and the lower connection and the side port.

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 Manual of FZ68-21U Ram BOP Rev.A2

Figure 2-1 Overall Dimension Diagram of FZ68-21U Single Ram BOP

Figure 2-2 Overall Dimension Diagram of 2FZ68-21U Double Ram BOP

A-1 Length-Intermediate Flange closed, locking screws locked

A-2 Length-Intermediate Flange opened, locking screws unlocked
B-1 Height-flange connection
B-2 Height-upper bolted and lower flanged connection
C Width-no side outlets
Table 2-6 Overall Dimension of Ram BOP

Overall Dimension
Model
A-1 A-2 B-1 B-2 C
mm mm mm mm mm
FZ68-21U
5305 6646 1212 937 1140
Single Ram BOP
2FZ68-21U
5305 6646 1922 1647 1140
Double Ram BOP
Instructions: The actual size shall change with the change of the upper and the lower connection
and the side port.

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 Manual of FZ68-21U Ram BOP Rev.A2

3 Working Principles and Structure Characteristics

3.1 Working Principles
3.1.1 Hydraulic Control Principles

When the high pressure oil of the hydraulic control system is directed to the closing
chamber positioned in the right and left hydraulic cylinder rams, push the operating piston
and right and left ram assembly to respectively move to the center of the wellhead along
with ram chamber of the body in order to seal off the well. While the high pressure oil
enters into the opening chamber positioned in the right and left hydraulic cylinder, push
the operating piston and right and left ram assembly to respectively leave from the center
of the wellhead in order to open the wellhead. The ram switch is controlled by the
hydraulic control system reversing valve and will finish opening and closing action within
3-5 seconds.
The hydraulic control system is used for opening and closing hydraulic cylinder
assembly to facilitate ram replacement.
 Open hydraulic cylinder assembly-remove the intermediate flange bolts first. Use
the hydraulic oil to close the ram and close the pressure pushing ram and make it
move to the wellhead direction. Meanwhile, make the hydraulic cylinder assembly
to the direction of leaving from the body. When the hydraulic cylinder assembly
moved to the end, put the stroke fender on the ram closing and opening
piston to prevent the hydraulic cylinder assembly closed and use the
hydraulic oil to open the ram. Remove the ram from the body and then lift the
ram up by the lifting eye to replace the ram.
 Close hydraulic cylinder assembly-use the hydraulic oil to open the ram with the oil
causing the operating piston to move. Pull the ram assembly to its opening state
and then push the hydraulic cylinder assembly to move to the direction of the body
until close to the body. One of the significant features of the U ram BOP is that the
ram is pulled back to the opening state by the hydraulic oil before the hydraulic
cylinder assembly moves to the direction of the body, which will not cause
interference between the ram and drilling tool inside the bore when closing the
hydraulic cylinder assembly.
See figure 3-1 for the oil line diagram.
CLOSE

OPEN

Ram closed and hydraulic cylinder assembly opened

Ram opened and hydraulic cylinder assembly closed
Figure 3-1 U BOP Open and Close Hydraulics
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 Manual of FZ68-21U Ram BOP Rev.A2

3.1.2 Seal Principles

The seal of the ram BOP putting into effect of sealing the wellhead must depend on
such four seals as the seal between the top of the ram and the body, the seal between
the ram front seal and pipeline, the seal between the body and intermediate flange and
the seal between the operating piston front rod and intermediate flange.
The seal processes of the ram can be classified into two steps: first, under the effect
of the hydraulic oil, the front seal of the ram is compressed and deformed by the moving
operating piston. The top seal position is compressed by the margin between the top
rubber core and the body to form the initial seal; secondly, the front seal of the ram is
further compressed and deformed under the effect of the well pressure on the back of the
ram and meanwhile the well pressure pushes the ram upward to close to the upper seal
surface of the body so as to form the reliable seal, which can be called as well pressure
effect for packing.

3.2 Structures and Features of Main Parts

U ram BOP consists of the BOP body, intermediate flange, hydraulic cylinder
assembly, operating piston, ram change cylinder, ram opening/closing piston, locking
screw, ram assembly, sealing parts etc.
Made up of the high-strength and high-tenacity alloy steel, the pressure-bearing
parts (like BOP body, intermediate flange etc.) are formed through external refining and
proper heat treatment, preventing the harmful chemical components and nonmetallic
inclusion strictly from materials and ensuring BOP to be safe and reliable. The body ram
chamber adopts the long runway to reduce stress concentration.
Both the intermediate flange switch and ram switch are driven by the hydraulic
pressure and adopts the same one oil line. The intermediate flange employs the same
one oil line and operation to open and close the ram. Moreover, the intermediate flange
employs the same one oil line and operation to close and open the ram.

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 Manual of FZ68-21U Ram BOP Rev.A2

3.2.1 Pipe Ram Assembly

Top Seal

Ram Body

Front seal

Figure 3-2 Pipe Ram Assembly Diagram

Table 3-1 Pipe Ram Parts Table

Pipe Ram Name (quantity)
Ram Type
Ram Assembly Ram Body （2） Top Seal（2） Front seal（2）
Blind 2C24.01A.00 2C24.01A.01 2C24.01A.02.00 2C24.01A.03
5″ 2C24.01B.00 2C24.01B.01 2C24.01B.02.00 2C24.01A.03
18 5/8″ 2C24.01C.00 2C24.01C.01 2C24.01C.02.00 2C24.01A.03

The ram adopts the long runway integral type and its rubber core employs the packer
seal and top seal assembly which can be independently replaced according to their
damage conditions. They are easy to be disassembled and assembled.
Note: The sign of “HO” (Hang-Off) on the ram body indicates that drilling tools could
be hanged on. Drilling tools shall not be hanged on the ram assembly without the sign of
"HO".

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 Manual of FZ68-21U Ram BOP Rev.A2

3.2.2 Sealing Mechanism of Operating Piston Front Rod

The seal between the intermediate flange and operating piston front rod is
bidirectional, adopting the Y-type seal ring and gasket to seal the well pressure and using
the single Y-type seal ring to seal the hydraulic control pressure.

Direction of Hydraulic Control Pressure

Direction of Well Pressure

10 8 9 7 6 5 4

Figure 3-3 Sealing Mechanism of Operating Piston Front Rod

Table 3-2 Sealing Parts List of Operating Piston Front Rod

No. Name Part No. Qty（Single） Qty（Double）

8 O-ring 129.54×5.33 4 8
10 O-ring 100.97×5.33 4 8
9 Supporting gland cover C17.14 2 4
7 Gasket 102×5 SKZF101.02 2 4
6 Y-Ring of ram shaft seal SKZF101.01 4 8
5 Gasket 2C02.18 4 8
4 Retainer ring 140 2C02.17 4 8

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 Manual of FZ68-21U Ram BOP Rev.A2

3.2.3 Secondary Sealing Mechanism

The sealing mechanism between the intermediate flange and operating piston front
rod can be classified into two parts: seal for well pressure and seal for hydraulic control oil
pressure. The secondary sealing mechanism is located between the two parts. In general,
it is extremely reliable because it has multi-cultural seal rings. However, the seal rings will
be damaged due to long-term overhauling failure or other reasons, which may cause leak
at the time of sealing off well, so the secondary sealing mechanism is required to handle
the emergency this time.
Under the working conditions of well sealing off, if the fluid flows out from the
observation hole (under the intermediate flange), it shows that the seal ring has been
damaged; according to the nature of the fluid, determine whether the seal ring for well
pressure is damaged or the seal ring for oil pressure damaged. At this moment, remove
the Z1″ hexagonal plug of the upper grease hole immediately and use the socket head
wrench to rotate the screw of the hole clockwise. Inject the secondary stick sealing
grease into the annular space through the Check valve to enhance seal ring and realize
sealing remedy.

Application notice of the secondary sealing device

 In order to prevent solidification invalidation of the secondary seal grease due to

long-term non-using of BOP, BOP is not installed with the secondary seal grease
stick while ex-works. It is recommended not to install the secondary seal grease
stick while not using BOP. Only install it before BOP enters into the well and
remove it at the time of well completion and overhauling. Then clean it up.
 Prepare the special tools in advance in the case of urgent need.
 While BOP in use, have a frequent observation on the lower observation hole
(hexagon socket screw plug) to see if there is drilling fluid or oil flows out.
 After the seal ring ceases to be effective, do not inject too much secondary seal
grease. Inject it until the observation hole stops leak. Considering that the
secondary seal grease has large friction resistance and adheres to particulate
matter, it may cause greater damage to the operating piston while opening the
ram.

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 Manual of FZ68-21U Ram BOP Rev.A2

12

18

17

16
Direction of
Hydraulic Control Pressure Direction of Well Pressure

49

Figure 3-4 Structure of Secondary Sealing

Table 3-3 Secondary Sealing Mechanism Parts Table

No. Name Part No. Qty（Single） Qty（Double）

12 Z1″ Hexagonal plug 2C01.21 2 4
18 Plug cock SFZ1310-30 2 4
17 Secondary seal grease 2 4
16 Check valve SFZ1310-32.00 2 4
Z1/2″ hexagon socket
49 2C01.32 2 4
screw plug

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 Manual of FZ68-21U Ram BOP Rev.A2

3.2.4 Sealing Mechanism of Operating Piston Tail Rod

Cylinder Head Weldment

Direction of
Hydraulic Control Pressure

Operating Piston Assembly

1 2

Figure 3-5 Sealing Mechanism of Operating Piston Tail Rod

Table 3-4 Sealing Parts Table of Operating Piston Tail Rod

Qty Qty
No. Name Part No.
（Single） （Double）
1 U-Seal Φ76.2×92.08×14.27/15.72 2 4
2 O-ring 77.5×5.3 2 4

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 Manual of FZ68-21U Ram BOP Rev.A2

3.2.5 Manual Locking Mechanism of Ram

The manual locking device of ram consists of the locking screw, locking axle seat,
operating piston and manual control assembly. (The length is generally 3.38m and 3.8m,
or customized).
When needing long time to seal off the well, the manual locking device is used to
lock the ram to the closing position through rotating the hand wheel manually after the
ram is closed down by the hydraulic pressure. At this time, the hydraulic pressure can be
removed.
 Locking -- When it is locked manually, rotate the hand wheel clockwise, and drive the
lock screw for rotation by a joystick. Because the locking screw locates at the clamp
seat, rotate the locking screw to push it at the rear of main piston, forcing the main
piston moving toward the center of wellhead and locking the ram assembly.
(Generally rotating 62 turns clockwise).
 Unlocking -- The manual locking device can just locking the ram instead of opening
the ram. If to open the ram that has been locked manually, firstly reset and unlock the
locking device manually, and open the ram by hydraulic pressure. This is the only
way. The detailed operation method is:
 Firstly rotate the hand wheel to the terminal point counter-clockwise
(Generally rotating 62 turns counter-clockwise);
 And then rotate back for 1/8～1/4 turns, to prevent the lock screw from
jamming during change of temperature;
 And then the ram is opened by hydraulic pressure.

Figure 3-6 Manual Control Assembly

Figure 3-7 Locking State

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 Manual of FZ68-21U Ram BOP Rev.A2

3.3 Product Parts List

Figure 3-8 Breakdown Drawing of FZ68-21U BOP Parts

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 Manual of FZ68-21U Ram BOP Rev.A2

Table 3-5 Parts List

Quantity
No. Name Part No./Model
Single Double
1 Body -- 1 1
2 Intermediate Flange Seal 2C24.17.00 2 4
3 Ram assembly 2C24.01（）.00 2 4
4 Retainer ring 140 2C02.17 4 8
5 Gasket 2C02.18 4 8
6 Ram shaft seal Y-Ring SKZF101.01 4 8
7 Backup ring SKZF101.02 2 4
8 O-ring 129.54×5.33 4 8
9 Supporting gland cover C17.14 2 4
10 O-ring 100.97×5.33 4 8
11 Ram Guide pin 2C05.16 4 8
12 NPT1” plug screw 2C01.21 4 8
13 Nozzle flange 2C27A01.34 2 4
14 Screw 2C01.26 8 16
15 O-ring 43.7×3.55 2 4
16 Check Valve 2C01.07 2 4
17 Secondary seal grease EM-09-L/25mm 2 4
18 Plug cock 1-8UNC 2C01.20 2 4
19 Intermediate Flange bolt 2C24.09 8 16
20 Ram change cylinder 2C24.11 4 8
Backup ring
21 （Ram change cylinder / C663-22 Ф142.4×Ф151×1.7 8 16
Cylinder head）
O-ring
22 （Ram change cylinder / 142.88×5.3 8 16
Cylinder head）
23 Guide ring 2C05.18 4 8
O-ring
24 72.39×5.33 4 8
（Ram change piston / Body）
Backup ring
25 C663-22 Ф74.4×Ф83×1.7 4 8
（Ram change piston / Body）
26 Ram change piston_open 2C24.16 2 4
Backup ring
27 （Ram change piston / C663-22 Ф118.4×Ф127×1.7 8 16
Ram change cylinder）
O-ring
28 （Ram change piston / 116.84×5.33 4 8
Ram change cylinder）
29 Cylinder head 2C24.04 2 4
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 Manual of FZ68-21U Ram BOP Rev.A2
Continue Table 3-5 Parts List
Quantity
No. Name Part No./Model
Single Double
O-ring
30 161.3×5.33 4 8
（Locking Nut / Cylinder head）
Backup ring
31 C663-22 Ф 162.4×Ф 171×1.7 4 8
（Locking Nut / Cylinder head）
32 Locking Nut 2C24.10 4 8
33 Hydraulic cylinder bolt 2C24.05 16 32
34 Cap nut 2S93.03.08 32 64
Locking Screw Housing
35 2C24.01.00 2 4
assembly
36 Stud C17.03 16 32
37 Locking Screw 2C24.03 2 4
38 Screw GB/T70.1 M10×20 4 8
39 NPT 1/2" Plug 2C01.36 12 24
40 O-ring 78.74×5.33 2 4
41 U-ring H601-Ф 76.2xФ 92.08X14.27/15.72 2 4
Backup ring
42 C663-22 Ф 348.6×Ф 360×2.5 4 8
（Cylinder head / Cylinder）
O-ring
43 345.1×7 4 8
（Cylinder head / Cylinder）
44 Ram change piston_close 2C24.12 2 4
45 TPM seal TPM360 2 4
46 Operating piston assembly 2C24.08.00 2 4
47 Cylinder 2C24.06 2 4
48 Intermediate Flange 2C24.07 2 4
49 Hexagon socket screw plug 2C01.32 2 4
O-ring
50 （Intermediate Flange / Ram 88.27×5.33 4 8
change piston）
Backup ring
51 （Intermediate Flange / Ram C663-22 Ф 90×Ф 98.6×1.7 4 8
change piston）
Stroke fender 2C24.18 4 4
2C24.08.00 the operating piston assembly includes the following parts.
45-1 Piston rod 2C24.08.01 2 4
45-2 O-ring 100.97x5.33 2 4
45-3 Backup ring C664-22 102.31x111.61x1.52 4 8
45-4 Piston C16.08.02 2 4
45-5 Stop block C17.08.03 6 12
45-6 Socket head cap screw GB/T 77-2000 M12X20 6 12

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Manual of FZ68-21U Ram BOP Rev.A2

Figure 3-9 Breakdown Drawing of Spare Parts

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 Manual of FZ68-21U Ram BOP Rev.A2

Table 3-6 One-year recommended spare parts list

Quantity
No. Name Part No./Model
Single Double
2 Intermediate Flange Seal 2C24.17.00 2 4
6 Ram shaft seal Y-Ring SKZF101.01 4 8
7 Backup ring SKZF101.02 2 4
8 O-ring 129.54×5.33 4 8
10 O-ring 100.97×5.33 4 8
15 O-ring 43.7×3.55 2 4
17 Secondary seal grease EM-09-L/25mm 2 4
21 Backup ring C663-22 Ф 142.4×Ф 151×1.7 8 16
22 O-ring 142.88×5.3 8 16
23 Guide ring 2C05.18 4 8
24 O-ring 72.39×5.33 4 8
25 Backup ring C663-22 Ф 74.4×Ф 83×1.7 4 8
27 Backup ring C663-22 Ф 118.4×Ф 127×1.7 8 16
28 O-ring 116.84×5.33 4 8
30 O-ring 161.3×5.33 4 8
31 Backup ring C663-22 Ф 162.4×Ф 171×1.7 4 8
40 O-ring 78.74×5.33 2 4
H601-Ф 76.2xФ
41 U-ring 2 4
92.08X14.27/15.72
42 Backup ring C663-22 Ф 348.6×Ф 360×2.5 4 8
43 O-ring 345.1×7 4 8
45 TPM seal TPM360 2 4
50 O-ring 88.27×5.33 4 8
51 Backup ring C663-22 Ф 90×Ф 98.6×1.7 4 8
45-2 O-ring 100.97x5.33 2 4
45-3 Backup ring C664-22 102.31x111.61x1.52 4 8
45-5 Stop block C17.08.03 6 12

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 Manual of FZ68-21U Ram BOP Rev.A2

4 Installation and Use

4.1 Preparation before Use
After the ram BOP is installed in the wellhead, prior to use check the following work
and conduct the test run. Use it after determining no problems found out.
 Check if BOP is correctly installed: the hoisting bolt of the body is on the top; the
manual lock device is well installed and fixed with the hanger in the hand wheel
indicating the opening and closing cycles; the opposite angles of the attachment
bolts at all position are even and tightening.
 Check if the size of the ram rubber core is in line with that of the drilling tool in the
well.
 Check if the blowout, kill and choke manifolds are connected well.
 Use the control device to open and close all rams respectively twice by
2-3MPa(300psi~500psi) control pressure for test run.
 Remove air in the oil line.
 Check if the connection pipeline of the oil road is consistent with opening and
closing as indicated by BOP. In the case that the ram’s opening and closing
action is not consistent with that as indicated by the console handle, adjust
the connection pipeline.
 Check if the manual locking device is well connected and if the manual lever is
flexible and easy to be used for closing the ram. Record the rotating circles of the
hand wheel when the well is closed and indicate them on the hand wheel hanger.
After testing, rotate the hand wheel left to return to unlocking and open the ram
by the hydraulic pressure.
 Conduct the overall pressure test on the wellhead device according to the
relevant well control procedures and regulations. After finishing the test, screw
up all connecting bolts again and avoid tightness. Refer to table 4-1 or table 4-2
for the tightening torque of the flange bolt.
 While conducting BOP ground check test, fill BOP up by water, try to open and
close the ram to vent air in the back of the ram within the ram chamber.

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 Manual of FZ68-21U Ram BOP Rev.A2
Table 4-1 Tightening Torque Recommended Value
for Screw Stud and Bolt Connection (Metric System)

Screw Stud Tightening Screw Stud Tightening Screw Stud Tightening

and Bolt Torque and Bolt Torque and Bolt Torque
Specification N·m Specification N·m Specification N·m
M12 80 M33×3 1292 M52×3 5505
M16 153 M36×3 1737 M58×3 7892
M20 266 M39×3 2272 M64×3 10885
M22 424 M42×3 2910 M70×3 14549
M27 643 M45×3 3654 M76×3 18957
M30×3 930 M48×3 4516 M80×3 21565

Table 4-2 Tightening Torque Recommended Value

for Screw Stud and Bolt Connection (British System)

Screw Stud Tightening Screw Stud Tightening Screw Stud Tightening

and Bolt Torque and Bolt Torque and Bolt Torque
Specification ft·lb Specification ft·lb Specification ft·lb
1/2-13UNC 59 1 1/4-8UN 953 2-8UN 4060
5/8-11UNC 113 1 3/8-8UN 1281 2 1/4-8UN 5821
3/4-10UNC 196 1 1/2-8UN 1676 2 1/2-8UN 8028
7/8-9UNC 313 1 5/8-8UN 2146 2 3/4-8UN 10731
1-UN 474 1 3/4-8UN 2695 3-8UN 13982
1 1/8-UN 686 1 7/8-8UN 3331 3 1/4-8UN 17830

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 Manual of FZ68-21U Ram BOP Rev.A2

4.2 Using Methods and Notes

 Using of BOP shall be responsible by the designated personnel and the
responsibility system must be implemented. The user must (know its working
principle, performance and technical process and be capable of operation, repair,
maintenance and trouble-shooting).
 In the case of no pipes in the well, while conducting closing test on the ram, the
maximum hydraulic control pressure shall not exceed 3MPa(500psi) to avoid
damaging the rubber core. However, if there are pipes in the well, it is forbidden
to close the fully-enclosed ram.
 If needing long time to enclose the well, lock the ram by the manual locking
device and indicate it by the hanger on the console in case of mal-operation.
 After entering into the destination layer, open and close the ram once every day
to check if the opening and closing is flexible and the manual locking device is
available in good conditions. Conduct opening and closing test on the
fully-enclosed ram each time after completing the drilling. However, if there are
pipes in the well, it is forbidden to close the fully-enclosed ram.
 It is not allowed to use the ram opening method for pressure relief to prevent the
rubber core from being damaged. Before open the rams shall wait 10 minutes
after gauges indicate pressure has been bled to 0 psi or open the choke/kill
valves above and below the rams to ensure the chambers are equalized.
 Check if the manual locking device is unlocked each time before opening the ram.
After opening the ram, check if the ram is at the full open position (all returned to
the inside of the body) to prevent that the drilling tools cause damage to the ram.
 Keep the hydraulic oil clean.
 After using BOP, make the ram at the full open position for overhauling.
 Lugs on the BOP housing is used only for lifting the annular BOP body, rather
than lifting the BOP set
 Recommended Hydraulic Oil for the Hydraulic System for BOP Stacks
 ISO Brand: HM32 (used for plunger pump system with low or no Zn)
 Mobil Brand: D.T.E24 (used for plunger pump system with low or no Zn)
 Shell Brand: Tellus32 (used for plunger pump system with low or no Zn)
Note: The kinematic viscosity of hydraulic oil is 17-33 mm2/s when the temperature
is at 50℃.

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 Manual of FZ68-21U Ram BOP Rev.A2

5 Disassembly and Maintenance of Blowout Preventer

Conduct the appearance inspection and closed-preventer test prior to BOP collaring
or entering into the high pressure oil and gas layer.
After BOP serves each well, overhaul and clean it completely, replace the damaged
parts timely, grease the ram chamber of the body to prevent rust and make the
connection bolts coated with screw thread oil

5.1 Open Intermediate Flange of Blowout Preventer

5.1.1 Open the ram by the hydraulic oil and make it at the open position; (▲！Note:
the manual locking device is required to be in the unlocking state.)

Figure 5-1 Open Ram

5.1.2 Screw off the intermediate flange bolt (▲！Note: if BOP is installed in the
well, it is not allowed to screw off the intermediate flange bolt in the case of
pressure in the well.)

Figure 5-2 Screw off the Intermediate Flange Bolt

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 Manual of FZ68-21U Ram BOP Rev.A2
5.1.3 Open the intermediate flange by the hydraulic oil which is less than 10.5MPa
(1500psi) to implement ram closing action and open the intermediate flange to the limit
position. Put the stroke baffle on the ram closing and opening piston to prevent the
hydraulic cylinder assembly closed and use the hydraulic oil to open the ram, pull
the ram out of the body.

Put the stroke fender on the ram change

pistons after the cylinder assembly
opened to the limit position
Figure 5-3 Open the Intermediate Flange

The stroke fender must be put on

the ram change pistons

Figure 5-4 Open Ram

5.2 Replacement of Ram and Ram’s Seal

The seal rubber core of the ram is the key part to determine if BOP can enclose the
well or not. Once it is damaged, BOP is not able to enclose the well so it is required to
ensure it to be complete and free from damage. Once finding any damage to its seal
surface, replace it timely.
5.2.1 Remove the ram assembly upward from the tail of the ram shaft. While
removing it, the stroke fender can protect the opening and closing piston rods from knock
and scratch.

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 Manual of FZ68-21U Ram BOP Rev.A2

The stroke fender must be put on

the ram change pistons

Figure 5-5 Change Ram Assembly

5.2.2 Replace the rubber part of the ram. Pry the top seal upward, remove the front
seal forward and replace with the new rubber core.

Figure 5-6 Remove Rubber Core of Ram

5.3 Repair and Replacement of Hydraulic Cylinder Assembly

In the case of any damage to and oil leak at the operating piston’s front rod seal,
operating piston seal, operating piston’s tail rod seal and the ram opening and closing
piston seal, disassemble them for overhauling.
5.3.1 Release pressure in the hydraulic cylinder. Place a clean container under the
cylinder to prevent the hydraulic oil causing pollution to the ground in the course of
disassembly.
5.3.2 Screw off Cap Nuts

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 Manual of FZ68-21U Ram BOP Rev.A2

Figure 5-7 Screw off Cap Nuts

5.3.3 Remove Cylinder Head

Figure 5-8 Remove Cylinder Head

5.3.4 Remove Hydraulic Cylinder and Ram Change Cylinder

Figure 5-9 Remove Operating Cylinder and Ram Change Cylinder

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 Manual of FZ68-21U Ram BOP Rev.A2
5.3.5 Remove the seal ring, O-ring and backup ring of the operating piston tail rod.

Figure 5-10 Remove the Seal Ring, O-ring and Backup Ring of the Operating Piston Tail Rod

5.3.6 Pull out the operating piston

Figure 5-11 Pull out the operating piston

5.4 Disassembly of Ram Opening and Closing Piston Rods

5.4.1 Push the intermediate flange to the position close to the body until it exerts no
impact on the wrench.

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 Manual of FZ68-21U Ram BOP Rev.A2

Figure 5-12 Push the Intermediate Flange

5.4.2 Suspend the intermediate flange slightly by the crane to reduce the press of
the intermediate flange on the ram opening and closing piston rods to the smallest extent.
5.4.3 The ram opening and closing piston are connected to the body by screw
threads. There is the wrench in the upper position close to the body. Rotate the ram
opening and closing piston rods counterclockwise to unscrew those outwards. Note: in
the case of unsmooth rotation, do not apply mandatory force to disassemble the piston to
avoid causing damage to the matching surface between ram opening and closing piston
rods and the body. It is better to adjust the hanging degree of the intermediate flange and
then to try to assemble the piston.

Figure 5-13 Screw off the Ram Opening and Closing Piston

5.4.4 Remove the retainer ring, take out the operating piston’s front rod seal ring and
gasket within the intermediate flange; then take out the enhanced seal ring, locking seal
ring and O-ring.

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 Manual of FZ68-21U Ram BOP Rev.A2

Figure 5-14 Remove Sealing Parts

After assemble, the following parts should be checked:

 In-walls of the hydraulic cylinder assembly and ram change cylinder: the
inner surfaces of the hydraulic cylinder assembly and ram change cylinder have
the longitudinal strain but the strain is the slight linear friction strain or the dot
strain, which can be recovered by the extremely fine sand paper and oil stone. If
the strain is too deep and oil leak is still available regardless of having replaced
the new seal ring, recover the inner surface of the cylinder by the mechanical
processing method and meanwhile check relevant parts of the piston to find out
the strain reasons and solve them.
 The ram opening and closing piston rods and their surfaces: in the case of
the strain on the seal surface, the judging and handling method is the same with
that of the cylinder. If the solder peels off, it will cause the heavy leak. At this time,
it is required to replace with the new part or recover the damaged parts.
 Seal ring: check if there is abrasion in the lip of the sealing parts and if there is
extrusion and cut wound on the O-ring first. In case of any damage or scratch
found in the sealing parts, replace them timely.
 Piston: when the moving seal surface of the piston has over 0.2mm-depth
uneven wear, replace it. On its surface, there should be no obvious scars which
may have an impact on seal. If the solder peels off, it will cause the heavy leak.
At this time, it is required to replace with the new part or recover the damaged
parts.

5.5 Installation Notes

The installation order is contrary to that of disassembly. Note the following points:
 Check if there is the burr or sharp edge on the parts. If any, remove them to
ensure no scratch caused to the seal ring. Note to clean parts.
 Grease the seal ring while installing it. Grease the relative sealing surface to
facilitate installation.
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 Manual of FZ68-21U Ram BOP Rev.A2
 Note the direction of the lip type seal ring and ensure opening of the lip to be
opposite the direction with pressure.
 Make the seal ring to smoothly pass the guiding part of the shaft head and avoid
scratch

5.6 Daily Maintenance

When the hydraulic pressure exceeding 3.5MPa (500psi) is needed to operate the
ram assembly, check the blocking condition in the body chamber and handle the
abnormity.
Operate and test BOP once every week according to API STD 53 requirements.

▲！Note: in case of no drill columns in the well, please do not close the pipe ram or
variable bore ram to avoid causing the damage to the rubber core.

5.7 Operating Period Maintenance

For the existing BOP, besides the onsite daily maintenance, it is recommended to
have periodical examination according to requirements of SY/T 6160 Examination and
Maintenance of BOP, for the purpose of confirming the repair items. The period of
examination is divided into three-month examination, one-year examination and
three-year examination. The examination shall be done on time and may be performed in
advance according to usage condition. If one well is continuously operated over the
specified examination period, the examination shall be done according to requirements of
the next examination period after going back to the warehouse. ▲！ Caution: The
maintenance of BOP shall be subject to relevant local regulations about usage of
BOP, and the BOP shall be certified periodically by the bop original manufacturer
or a qualified third party, so as to make sure the stability and the reliability of usage
of BOP.
The three-month examination content

1、 Disassemble the BOP, carry out a visual examination of the parts;

2、 Equipment shall be tested in accordance with API 16A.

One-year examination content:

1、 Check the both side of the body, the top sealing surface inside of body, seal ring
groove, the sealing surface of intermediate flange and seal ring groove of
intermediate flange. All of them are not allowed to have any defect that affect the
sealing performance;

2、 Check the abrasion of bore of body；

3、 Check the ram packers and seals. The sealing surface shall be avoided serious
deformation, wear, cracking, ageing of rubber core and phenomena the like;

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 Manual of FZ68-21U Ram BOP Rev.A2

4、 Check the connecting channel of the ram and hook. There cannot have crack,
bending deformation; The width and height of ram are not allowed to have
serious avulsion and deformation;

5、 Check the lock shaft, cannot have cracking, bending, grooved and switch lock
shaft should be flexible;

6、 Check the thread hole, cannot have disorderly buckle, the phenomenon such as
lack of buckle;

7、 Visual check ram cavity and flange of the body, cannot have cracking.

8、 All rubber sealing parts, backing ring and O-ring that have been used over one
year or that have been damaged shall be replaced(see Table 3-6).

Three-year examination content:

1、Disassemble all of the parts and clean up. In addition to examinations according
to the requirements of the one-year check, also should deal with important size
measurement of main parts. a) If the wear extent of inner diameter of the cylinder is more
than 0.4 mm or there is obvious scars and the solder peels off, the cylinder should be
remanufacture or replacement; b) If the wear extent of piston rod is more than 0.25 mm ,it
should be remanufacture or replacement; c) If the wear ring diameter is lower than the
metal body, the wear ring should be replace; d)If cladding material of the lock shaft is
corroded and appear pits that would affect sealing, the lock shaft is overall bending or
thread damaged that would affect the lock or unlock, or the quartet at end is damaged
that will affect the connection with manual assembly, etc., the lock shaft should be
replaced.
2、Hardness testing shall be carried out on the pressure-containing parts and the
pressure-controlling parts such as body and intermediate flange. If the hardness is
abnormal（＞HRC22）, contacting manufacturer is necessary.
Repair and remanufacture parts shall be carried out according to API Spec 16A
appendix B. Replacement of parts shall be design and manufacturing by the OEM. After
checking the Bop, if the pressure-containing parts need to be welded to restore the
performance, the bop is not suitable for easy maintenance in the field, must be
remanufactured by the API Spec 16A qualified remanufacturer or authorized
remanufacturer.

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 Manual of FZ68-21U Ram BOP Rev.A2

6 Preservation procedures
Prior to shipping and storage, all equipment should avoid direct sunlight, rain and
snow shower, keep them away from acid and alkali, organic solution etc, which would
affect the quality of rubber material.

6.1 Storing for periods greater than 30 days

 All equipment shall be drained after testing and prior to storage;
 Prior to storage, parts and equipment shall have exposed metallic surfaces
protected with a rust preventative that does not become fluid and run at a
temperature of less than 50 °C (125 ℉) (Recommendation: Lithium base grease
3#) ;
 All connection faces and ring gasket grooves shall be protected with durable
covers during storage;
 The hydraulic operating system shall be flushed with a non-freezing,
corrosion-inhibiting fluid. Ports shall be plugged prior to storing
(Recommendation: Antiwear hydraulic oil 32#) .

6.2 Storage of Rubber Parts

All rubber parts shall be properly stored according to the following regulations:
 It is a must to store rubber parts in the indoor, low light and dry place with
temperature of 0-25ºC and relative humidity 50% ~ 85% and to keep them away
from the heating equipment and direct sunlight. It’s better to preserve them in the
original packaging or the packaging similar to the original packaging materials,
which has the function of shading.
 Keep rubber parts clean while in storage. Prevent them from being contaminated
by solvents, oil, grease or other semi-solid or liquid matters and from being
directly contacted with sulphur, manganese, copper, copper alloy (including
bronze), polyvinyl chloride (PVC), timber containing wood preservative oil and
other rubber products including different rubber constituents.
 Keep rubber parts away from ozone-generating equipment( e.g.: mercury vapor
lamp, high-voltage electrical equipment, electric motor or any electrical devices
which can generate electric arc; avoid being directly exposed under the sunlight
or the light (e.g.: the fluorescent lamp) containing plenty of ultraviolet.
 Store the rubber parts which are under the slack state and have no bending,
extrusion and hanging. It is not allowed to tie the tag on the rubber parts by the
string, metal wire or adhesive tape in order to prevent causing deformation to the
sealing surface.
 Check the rubber parts frequently. In the case that they have clamminess,
softening, hardening, aging, embrittlement, cracking, bending, flaw etc, it is not
 Generally, the storage period of rubber parts is 2 years.
30

7 Common Failure and Troubleshooting
No, Failure
The medium in the well flows
out from the connection
1 b.The sealing surface
between the body and
intermediate flange.
The moving direction of the
ram is not consistent with that
2 between the control device
as indicated on the nameplate
of BOP control device.
The hydraulic control system
3 is normal but the ram can not
be fully closed.
The medium in the well flows
into the Operating Cylinder to
4 front rod and repair the
cause the oil to be contained
with water and air.
BOP’s hydraulic parts can not
make pressure stable and the
5 opening and closing of the
intermediate flange is not
flexible.
After close the ram, pressure
6
can not be sealed off.
The control oil line is normal
but the ram or intermediate
7 Eliminate the sediment.
flange can not be opened by
the hydraulic pressure.
Manual of FZ68-21U Ram BOP Rev.A2
Possible Causes Troubleshooting
a.The seal ring of BOP
intermediate flange is a.Replace the damaged
damaged. flange seal assembly.
b.Clean the sealing surface
between BOP body and and restore the damaged
intermediate flange has position.
been stained or damaged.
The connecting pipeline
Replace the pipeline position
of BOP's oil line interface.
and BOP is wrongly linked
The contact end of the ram
has other materials or Clean the ram and
deposit of sand and intermediate flange.
slurry.
The seal ring of the
Replace the damaged seal
operating piston front rod
ring of the operating piston
is damaged or the
operating piston front rod
damaged operating piston
shaft is deformed or has
front rod position.
strain.
The seal rings and sealing
surfaces of BOP’s
Replace all seal rings, repair
Operating Cylinder,
the sealing surface or replace
operating piston and ram
with new parts.
opening and closing piston
are damaged.
The seal rubber core of Replace the seal rubber core
the ram and upper sealing of the ram and repair the
surface of the body ram sealing surface of the body
chamber are damaged. ram chamber.
The ram gets stuck by the
sediment.
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Manual of FZ68-21U Ram BOP Rev.A2

Design by:

（Technical engineer）

Audited by:

（Chief engineer）

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Rev：A0