Operation and Maintenance Manual

TL Blowout Preventer
18-3/4” 15,000 psi WP
with Manual Locking Screw

TC9113
 All the information contained in this manual is the exclusive property of Cameron Interna-
tional Corporation (“Cameron”). Any reproduction or use of the calculations, drawings, pho-
tographs, procedures or instructions, either expressed or implied, is forbidden without the
written permission of Cameron or its authorized agent.

Initial Release 01
(SD-010387-10-01)
August 2009

Revision 02
January 2010

Copyright © 2010 all rights reserved

by
Cameron International Corporation (“Cameron”)

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PREFACE

The procedures included in this book are to be performed in conjunction with the requirements
and recommendations outlined in API Specifications. Any repairs to the equipment covered by
this book should be done by an authorized Cameron service representative. Cameron will not
be responsible for loss or expense resulting from any failure of equipment or any damage to any
property or death or injury to any person resulting in whole or in part from repairs performed by
other than authorized Cameron personnel. Such unauthorized repairs shall also serve to termi-
nate any contractual or other warranty, if any, on the equipment and may also result in equip-
ment no longer meeting applicable requirements.

File copies of this manual are maintained. Revisions and/or additions will be made as deemed nec-
essary by Cameron. The drawings in this book are not drawn to scale, but the dimensions shown
are accurate.

This book covers Cameron products, which are products of

Cameron International Corporation (“Cameron”).

Cameron
P.O. Box 1212
Houston, Texas 77251-1212
713-939-2211
http://www.c-a-m.com

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Notes:

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Table of Contents

TL BOP, 18-3/4” 15,000 psi WP - Assembly Components...................................................6

(Illustration and Parts List)

TL BOP, Bonnet Manual Locking Screw - Components.....................................................9

(Illustration and Parts List)

TL BOP, Bonnet Manual Locking Screw With Tandem Booster........................................13

(Illustration and Parts List)

18-3/4”15,000 psi WP TL BOP - Pipe Rams Components...................................................19

(Illustration and Parts List)

18-3/4”15,000 psi WP TL BOP - Flex Packer Rams Components........................................20

(Illustration and Parts List)

18-3/4”15,000 psi WP TL BOP - Variable Bore Rams Components....................................21

(Illustration and Parts List)

18-3/4”15,000 psi WP TL BOP - Double V Shear Rams Components................................22

(Illustration and Parts List)

18-3/4” 15,000 psi WP TL BOP With Manual Locking Screws..........................................23

Operation and Maintenance

I. Physical Data...........................................................................................................23
II. Applicable Operating Characteristics...................................................................25
III. Disassembly Procedure — Standard Bonnets.....................................................26
IV. Disassembly Procedure — Tandem Booster Bonnets.........................................30
V. Assembly Procedure — Standard Bonnets..........................................................32
VI. Assembly Procedure — Tandem Booster Bonnets.............................................35
VII. Operation And Installation................................................................................40
VIII. Maintenance......................................................................................................40
IX. Testing..................................................................................................................41
X. Storage..................................................................................................................42

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 9 3 1

47.2

4 5

10 71 72

34

163.26 ( Bonnets Closed ) 228.50 ( Bonnets Open )

20 21

58 59 57 56 55 50

51
26.15
40.80

11.5

97.96 34.06
34.00

6 8 7

49
48

212.14 ( Bonnets Closed ) 278.38 ( Bonnets Open )

TL Double BOP, 18 3/4” 15,000 psi WP

P/N 2113797-21
SK-013970-26 SD 042552

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TL BOP, 18-3/4” 15,000 psi WP - Assembly Components
Qty Qty
Item Description Spare
Single Double
1 1 1 Body
3 8 16 Stud Bonnet - Standard Bonnet
4*** 8 8 Stud Bonnet - Tandem Booster Bonnet
5*** 8 8 Wear ring - Tandem Booster Bonnet
6*** 4 4 Set Screw - Tandem Booster Bonnet – Upper Bolt
7*** 4 4 Bearing - Bonnet Stud- Tandem Booster Bonnet
8*** 4 4 Retainer Bearing - Tandem Booster Bonnet
9 8 16 Cap Nut Bonnet
10 2 4 Ram Guide Pin
20 2 4 Bonnet Seal Carrier
21* 4 8 Bonnet Seal Y
34* 4 8 Seal Ring Y
48 1 2 Bonnet, Subassembly, Right Hand - Tandem Booster
49 1 2 Bonnet, Subassembly, Left Hand - Tandem Booster
50 1 2 Bonnet, Subassembly, Right Hand
51 1 2 Bonnet, Subassembly, Left Hand
55 1 1 Name Plate, Patent
56 1 1 Name Plate, Ram Type Bop, API 16A
57 1 1 Name Plate, “Top”, Ram Type Bop
58** 20 20 Stud, Double Ended (Top Studded Connection)
59** 20 20 Nut, Heavy Hex (Top Studded Connection)
71** 16 32 Stud Double Ended (Side Outlet Studded Connection)
72** 16 32 Nut, Heavy Hex (Side Outlet Studded Connection)
Accessory Components
- 1 1 Removal Tool, Seal Carrier
- 2 2 Ram Tray Assembly
- 4 8 Bonnet Extension Rod
- 2 4 Hand Wheel Kit
- 1 1 Screw Hexagonal Head Cap for Removal Tool, Seal Carrier
237022-02 1 1 Hytorc Hydraulic Wrench Reaction Tool - Standard Bonnet
237022-04 1 1 Hytorc Hydraulic Wrench Reaction Tool- Tandem Booster Bonnet
Expendable Items
** 2 4 Ring Gasket – Side Outlets
** 2 2 Ring Gasket – Top Connection
- 1 1 Paste #503 Molybdenum Disulfide
- 1 1 Ram Lube Chemola

* Included in seal kit

** Part and quantity depend on bore size and working pressure
*** Quantity for one cavity tandem booster

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Notes:

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TC9113 10
TL BOP, Manual Locking Screw Bonnet - Components
Item Qty Description Spare
2 1 Bonnet
3 1 Operating Piston
4 1 Ram Change Piston (Open)
5 1 Ram Change Piston (Close)
6 2 Ram Change Cylinder
7 2 Ram Change Access Cap
11 1 Retaining Ring, Spirolox, Connecting Rod Y
12 1 Retainer Ring, Primary Connecting Rod Y
13 1 Back-Up Ring, Connecting Rod Y
14 1 Seal Ring, Primary Connecting Rod Seal Y
15 1 Ring, Spacer - Connecting Rod Y
16 2 Seal Ring, Secondary Connecting Rod Seal Y
17 2 Ring, Back-Up , Connecting Rod Y
18 1 Ring, Retainer - Primary, Connecting Rod Y
19 1 Retaining Ring, Spirolox-Int Y
20 1 Wear Ring Y
23 1 Operating Cylinder
24 1 Finish Cylinder Head
25 8 Double Ended Stud,, 2.750-8UN-2A X 26.00” Lg
26 8 Nut, Heavy Hex 2.750-8
27 1 Seal Ring, Tail Rod Seal Y
28 1 Ring, Back-Up - Tail Rod Y
29 1 Retaining Ring, Spirolox- Tail Rod Y
30 2 Seal Ring, Operating Piston Y
31 1 O Ring- Operating Cylinder Y
32 1 Wear Ring-Operating Piston Y
33 2 Wear Ring- Ram Change Piston, Y
35 4 O Ring- Ram Change Cylinder Y
36 2 Seal Ring- Ram Change Piston Y
37 2 Seal Ring- Ram Change Piston Y
38 2 O Ring - Ram Change Access Cap Y
39 2 Lifting Eye
40 2 Tubing Gland
41 2 Blind Plug
42 1 Back Up Ring Y
43 1 Housing Locking Screw
44 1 Locking Screw
45 1 O Ring Y
46 6 Screw, 12 Pt Cap
51 1 O-Ring Y
52 1 Back Up/Spacer Ring - Operating Cylinder Y
62 2 Pipe Plug
63 2 Bearing Bonnet Flange
64 1 C.O.G Adjusting Plate Assembly

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Notes:

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TC9113 15
Notes:

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TL BOP, Manual Locking Screw Bonnet with Tandem Booster
Item Qty Description Spare
2 1 Bonnet
3 1 Intermediate Flange
4 1 Finish Cylinder Head
6 1 Ram Change Piston (Open)
7 1 Ram Change Piston (Close)
8 2 Ram Change Cylinder
9 2 Ram Change Access Cap
10 8 O-Ring - Sub Y
11 1 Retaining Ring, Spirolox, Connecting Rod Y
12 1 Retainer Ring, Primary Connecting Rod Y
13 1 Back-Up Ring, Connecting Rod Y
14 1 Seal Ring, Primary Connecting Rod Seal Y
15 1 Ring, Spacer - Connecting Rod Y
16 2 Seal Ring, Secondary Connecting Rod Seal Y
17 2 Ring, Back-Up , Connecting Rod Y
18 1 Ring, Retainer - Primary, Connecting Rod Y
19 1 Retaining Ring, Spirolox-Int Y
20 1 Wear Ring Y
21 1 Operating Cylinder - Outer
22 1 Stop Ring
23 1 Operating Cylinder- Inner
24 1 Sub – Inner
25 1 Sub – Outer
26 8 Nut, Heavy Hex 2.750-8
27 3 Seal Ring, Tail Rod Seal Y
28 3 Back-Up Ring - Tail Rod Y
29 3 Retaining Ring, Spirolox- Tail Rod Y
30 2 Seal Ring Y
31 4 O-Ring Y
32 2 Ring, Wear - Od 18.023” X, 17.787” X 1.420” Wide Y
33 2 Wear Ring, Ram Change Piston, Y
34 1 Tail Rod – Operating Piston
35 4 O-Ring- Ram Change Cylinder Y
36 2 Seal Ring- Ram Change Piston Y
37 2 Seal Ring- Ram Change Piston Y
38 2 O-Ring - Ram Change Access Cap Y
39 3 Lifting Eye
40 4 Tubing Gland
41 4 Blind Plug
42 3 Back Up Ring Y
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 Item Qty Description Spare
43 8 Double Ended Stud
44 1 Locking Screw
45 1 Check Valve
47 1 Adapter Outside Tail Rod
48 1 Adapter Inside Tail Rod
50 4 Sleeve for Stud, Tandem Booster
52 1 Operating Piston
53 4 Screw Socket Head Cap
54 10 Screw Socket Head Cap Y
58 2 Grease Fitting
59 1 Button – Operating Piston
60 1 Piston Outer Operating Piston
64 1 C.O.G Adjusting Plate Assembly
65 1 Housing Locking Screw
66 6 Screw 12 Pt Cap
67 1 O-Ring Y
68 2 Bearing Bonnet Flange Y
100 1 Name Plate – Hydraulic Operating Pressure
101 1 Blank Plate

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18-3/4” 15,000 psi WP TL BOP - Pipe Ram Components
Item Qty Description
1 1 Body
2 1 Packer
3 1 Top Seal, Camram
4 1 Ram Wear Pad Right
5 1 Ram Wear Pad Left
6 2 Screw, Ram Wear Pads

Quantity for one ram assembly

All Packers and Seals

4 Listed are Hi-Temp

Est Wt 700 lb (318 kg) Pipe or Casing Ram Subassembly

P/N 2163090-( )-( )
SD 016632

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18-3/4” 15,000 psi WP TL BOP - Flex Packer Ram Components
Item Qty Description
1 1 Body, Hang Off Ram
2 1 Flexpacker NR
3 1 Top Seal, Camram
4 1 Ram Wear Pad, Right
5 1 Ram Wear Pad, Left
6 2 Screw, Ram Wear Pads

Quantity for one ram assembly

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18-3/4” 15,000 psi WP TL BOP - Variable Bore Ram Components
Item Qty Description
1 1 Body, VBR
2 1 Packer, VBR
3 1 Seal, “Top”
4 1 Wear Pad, Right
5 1 Wear Pad, Left
6 2 Screw, Wear Pads

Quantity for one ram assembly

5
6
Est Wt 630 lb (286 kg)

Variable Bore Ram Subassembly

SD 011530

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18-3/4” 15,000 psi WP TL BOP - Double V Shear Ram Components
Item Qty Description
Upper DVS Subassembly
1 1 Ram Body, Upper Double V-Shear
2 1 Side Packer, Right,
3 1 Side Packer, Left
4 1 Seal, “Top”, Camram (TM)
5 1 Pad, Right Ram Wear
6 1 Pad, Left Ram Wear
7 2 Screw, Ram Wear Pads
8 1 Blade Packer, DVS Ram
Lower DVS Subassembly
9 1 Ram Body, Lower Double V-Shear
10 1 Side Packer, Right
11 1 Side Packer, Left
12 1 Seal, “Top”, Camram (TM),
13 1 Pad, Right Ram Wear
14 1 Pad, Left Ram Wear

Quantity for one set

Lower DVS Shear RAM Subassembly Upper DVS Shear RAM Subassembly

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18-3/4” 15,000 psi WP TL BOP With Manual Locking Screws
Operation And Maintenance

I. Physical Data

A. Lubricants

1. Ram lubricant: Cameron Ram lube (P/N 713878) or a water resistant non petroleum
base grease.
2. Thread lubricant: API-5A-Lub, or (MoS2) molybdenum Disulfide grease SLECT-A-
TORQ Paste #503 (4 lb can P/N 705444).
3. Multi-purpose lubricant or grease: JET MARINE 2571 (P/N 2728484-01)
4. Corrosion resistant grease for environmental surface protection : CORROLESS CCI
350 (P/N 2728450-01)
5. Seals and sealing surfaces: SAE-30 Weight Oil .Ref EQUIVIS ZS 32 (P/N 619011-75)

B. Dimensional Data

A-1 Length - Standard bonnets closed, with locking screws locked

A-2 Length - Standard bonnets opened, with locking screws unlocked
A-3 Length - Tandem booster bonnets closed, with locking screws locked
A-4 Length - Tandem booster bonnets opened, with locking screws unlocked
B-1 Height - studded x flanged
B-2 Height - flanged x flanged
B-3 Height - studded x studded
C Width - studded outlets
Centerline of preventer to outlet flange or hub face. This distance is variable and must
D
be determined per individual specifications.
E-1 Top of preventer to centerline of outlet -flanged
E-2 Top of preventer to centerline of outlet -studded
F-1 Top of upper ram to top flange face
F-2 Top of upper ram to top studded face
G Height of ram
Centerline of upper outlet to centerline of lower outlet & centerline of upper cavity to
H
centerline of lower cavity

TC9113 23
 Style A-1 A-2 A-3 A-4 B-1 B-2 B-3
49.13 in
163.26 in 228.50 in 212.14 in 278.38 in 64.38 in 57.50 in
Single [1247.90]
[4146.8] [5804.0] [5388.4] [7070.9] [1635.2] [1460.4]

163.26 in 228.50 in 212.14 in 278.38 in 83.18 in 98.43 in 67.93 in

Double
[4146.8] [5804.0] [5388.4] [7070.9] [2112.8] [2500.2] [1725.4]
163.26 in 228.50 in 212.14 in 278.38 in 117.2 in 101.98 in
Triple --
[4146.8] [5804.0] [5388.4] [7070.9] [2977.8] [2590.4]

Style C E-1 E-2 F-1 F-2 G H

46.81 in 40.69 in 25.437 in 31.962 in 11.175 in 11.53 in 34.06 in
Single
[1189] [1033.5] [646.1] [811.84] [283.85] [292.86] [865.0]
46.81 in 40.69 in 25.437 in 31.962 in 11.175 in 11.53 in 34.06 in
Double
[1189] [1033.5] [646.1] [811.84] [283.85] [292.86] [865.0]
46.81 in 40.69 in 25.437 in 31.962 in 11.175 in 11.53 in 34.06 in
Triple
[1189] [1033.5] [646.1] [811.84] [283.85] [292.86] [865.0]

C. Weights Data

Style End Connections Lock Screws Tandem Booster

Flg x Flg - -
Single
Flg x Std 15000 Kg 18650 kg
Flg x Flg 29000 Kg -
Double
Flg x Std 28300 Kg 29900 kg*
Triple Flg x Std - -
*one cavity with tandem booster

1. Standard Bonnet locking screw assembly 18-3/4” 15,000 psi WP: 2700 kg.
2. Tandem booster Bonnet assembly 18-3/4” 15,000 psi WP: 4500 kg.
3. Average rams assembly 318 kg/700 lb each.

D. Lifting and Handling

1. Lift BOP assemblies only with slings appropriately rated for the maximum weight of
the BOP.
2. Lift ram assemblies by installing a lifting eye in the threaded preparation in the
ram.(Use washers if necessary to ensure eye bolt shoulder is bottoming out on top
of ram block).
3. Handle all other subassemblies using appropriately and certificated rated slings.

E. External Thread Connections

Description Size Location

Open Port 1.25” SAE BOP Body, Front
Close Port 1.25” SAE BOP Body, Back

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 F. Hydraulic Operating System Requirements

1. Hydraulic operating system:

a. Storage – Cameron recommends using preservation fluid : OCEANIC EPF (P/N
718100) or Houghton Stackguard (P/N 2711391-04) which offer both a liquid and
vapor phase protection
b. Standard operation – Use a fresh water lubricant that form a true solution
rather than an emulsion when mixed with water and/or antifreeze. Cameron
recommends using Houghton Stackmagic 200F (P/N 2711391-02-02) or ERIFON
HD603N (P/N 619011-91)
2. Fluid Requirement:

Rams (One Set) Rams

Open Close
Closing Ratio Opening Ratio
Gallons Litres Gallons Litres
Standard Bonnets
22.4 84.8 24.6 92.5 6.7:1 3.1:1
Tandem Booster Bonnets
43.1 163.15 45.1 171.8 14.3:1 6.9:1

G. API 16A Drift Diameter

API drift for 18-3/4” is 18.720” (475 mm)

H. Temperature Rating:

There is no industry accepted method of establishing BOP temperature ratings at this

time. These are estimates based on lab testing and field performance. Temperature rat-
ings for rubber components must take into account the environmental exposure history,
the chemical environment while at temperature, and other factors. Therefore, a single
number rating can be misleading if all conditions are not understood. (SEE EB 833 D)

II. Applicable Operating Characteristics

A. Subassemblies

1. Pipe rams/ casing rams

a. Seals around pipe or casing of specified size
b. Pipe rams support 600,000 lb [272,727 kg] and seal both low or high pressure
2. Flexpackers Rams
a. Seals around 5” and 5-1/2” drill pipe
b. Seals around 5” and 6-5/8” drill pipe
3. VBR (Variable Bore Rams)
a. Seals around 5” to 3-1/2” drill pipe
b. Seals around 5-1/2” to 3-1/2” drill pipe
c. Seals around 5-7/8” to 3-1/2” drill pipe
TC9113 25
 d. Seals around 6-5/8” to 3-1/2” drill pipe
e. Seals around 7-5/8” to 3-1/2” drill pipe

Note: It is not recommended to hang off on the VBR packer. Refer to the latest revision of
EB-859D

4. Shear Rams – Refer to the lasted revision of EB702D for capability

III. Disassembly Procedure - Standard bonnets

Note: The work area should be clean and well lighted.

Note: The operation of Cameron ram type BOPs is as follows: When pressure is applied to the
OPEN port, the rams will open or retract within the bonnet AND the bonnets will close
if they are in the open position. Conversely, when pressure is applied to the CLOSE port,
the rams will close in on the well-bore AND the bonnets will open if the cap nuts are
not installed. All personnel should be clear of the bonnets when operational pressure is
applied during the following steps.

A. Ram Removal (Standard bonnets)

1. Connect the OPEN and CLOSE ports of the BOP to the hydraulic power supply.
2. Apply 1500 psi (104 Bars) opening pressure to the BOP and remove the bonnet cap
nuts (9).
3. Install an extension rods on each upper bonnet studs.
4. Apply 200-300 psi (14-20 Bars) closing pressure to the BOP to open the bonnets.
5. Install the ram trays across the lower bonnet studs and secure with stud hook or
sleeve if so equipped. (See TL BOP ram removal illustration)
6. Apply 500 psi (34.4 Bars) opening pressure to clamp the tray between the body and
bonnet and to move the rams to the open position.
7. Install a lifting eye in the side of the rams and use a pry bar in the ram tray slots to
move the ram to the side of the preventer.
8. Install a lifting eye in the top of the rams and remove from the ram tray.
9. Apply 500 psi (34.4 Bars) closing pressure to the preventer long enough to unclamp
the ram trays from their position between the body and the bonnet.
10. Remove the ram tray.
11. Apply 200-300 psi (14-20 Bars) opening pressure to move the bonnet assembly to
the closed position. Take care of O-Rings during closing on seal carrier.
12. Remove extension rod from bonnets studs
13. Vent opening pressure and disconnect the hydraulic supply lines from the pre-
venter.

B. Bonnet removal (Standard bonnets)

1. Install lifting eyes in the bonnet and cylinder head of one bonnet assembly or in
COG Adjusting plate (64).

TC9113 26
 2. Use a chain sling to pick up on these two points enough to take the bonnet weight
off the ram change pistons
3. Remove the ram change access caps (7) and remove the O-rings (38) from the ac-
cess caps
4. Back out the ram change pistons (4 and 5) it might be necessary to adjust the ten-
sion in the chain sling to achieve the proper lift to take the load off the ram change
pistons and allow them to turn freely

Caution: It is essential to alternate between pistons when backing out to ensure even load
distribution.

5. Remove the ram change pistons from the bonnet.

6. Remove the bonnet from the body.
7. Remove the bonnet seal (21).
8. Remove the bonnet seal carrier (20) and bonnet seal (21), using the seal carrier
removal tool P/N 2010064-05, which slots into the bonnet side seal carrier groove.
Seal carrier is removed by turning on the screws set against the body.
9. Take the bonnet assembly down and place it in the bonnet assembly stands with
the locking screw side up.

Caution: Take care not to damage the connecting rod (3).

10. Remove each polypak (34) from the ram change piston bores.

C. Bonnet disassembly (Standard bonnets)

Bonnet disassembly should be performed with the body-side of the bonnet standing on
blocks or a stand to allow the connecting rod/button to protrude below without any
weight on it.
1. Remove the six screws (46) and housing (43).
2. Remove the cylinder head screws (26) from the bonnet assembly and use a sling to
lift the cylinder head assembly from the bonnet.
3. Install a C clamp on the tail rod of the operating piston (3) and remove the oper-
ating piston from the bonnet. The operating cylinder (23) may come out with the
operating piston. If so, use a rubber hammer to drive the operating cylinder off the
operating piston.
4. Remove the wear ring (32) and seal (30) from the operating piston.
5. Use two .250”-20 eye bolts to remove the operating cylinder (23) from the bonnet.
6. Remove the O-rings (31), (51) and back-up ring (52) from the operating cylinder.
7. Remove the ram change cylinders (6) from the bonnet.
8. Remove the O-rings (35) from the ram change cylinders.
9. Remove the following items from the bonnet:
a. Studs (25)
b. Spirolox Ring (19)
c. Retainer Ring (18)
d. Seal Ring (16)
TC9113 27
 e. Back-Up Ring (17)
10. Turn the bonnet over (body side up) and remove the following items:
a. Spirolox Ring (11)
b. Retainer Ring (12)
c. Seal Ring (14)
d. Back-Up Ring (13)
e. Spacer Ring (15) and wear ring (20)
f. Seal Ring (16)
g. Back-Up Ring (17)
h. Seals (36) and Bearings (63)
11. While the cylinder head is lying on its side, remove the following items:
a. Spirolox Ring (29)
b. Back-Up Ring (28)
c. Seal ring (27)
d. Back up ring (42)
e. Seal ring (45)

TC9113 28
TC9113 29
 IV. Disassembly Procedure - Tandem Booster Bonnets

A. Ram Removal (Tandem Booster bonnets)

This procedure should be followed in removing the tandem booster bonnets from the
BOP. Since the bonnets are mounted with very large torque applied to the nuts, care
should be taken in establishing suitable reaction surfaces while loosening these cap nuts.
Attention should be given to the span necessary to remove these bonnets. Bonnet remov-
al will require a minimum total of 400” (33.3 feet) (10.16 meters) of clearance across the
bonnets.
1. Connect the OPEN and CLOSE ports of the BOP to the hydraulic power supply.
2. Apply 1500 psi (103 Bars) opening pressure to the BOP.
3. Remove the eight bonnet cap nuts (9) that hold the bonnets to the BOP.
4. Apply 500 psi (34 Bars) closing pressure to the bonnets and gradually increase if
necessary up to 1500 psi (103 Bars). This will open the bonnets.
5. Install ram trays across the bottom bonnet studs.
6. Apply 500 psi (34 Bars) opening pressure to the BOP. This will close the bonnets,
clamping them to the trays. It will also retract the rams where they can be removed.
7. Remove the rams.
8. Apply 500 psi (34 Bars) closing pressure to the BOP, which will unclamp the trays so
they can be removed, and remove the trays.
9. Vent opening pressure and disconnect the hydraulic supply lines from the pre-
venter.

B. Bonnet removal (Tandem Booster bonnets)

1. Back-out the two set screws (6) that occur in each of the two bearing retainers (8).
These bearing retainers exist at the top two bonnet studs.
2. Unscrew each bearing retainer (8) from their preparation in the bonnet.
3. Install lifting eyes in the bonnet and cylinder head of one bonnet assembly or in
COG Adjusting plate (64).
4. Use a chain sling to pick up on these two points enough to take the bonnet weight
off the ram change pistons
5. Remove each split ring bearing (7) from the bonnet. They are half-moon shaped
bearing rings. The weight of the bonnet may have to be shifted to allow removal of
these rings.
6. Remove the ram change access caps (9) and remove the O-rings (38) from the ac-
cess caps
7. Back out the ram change pistons (4 and 5) it might be necessary to adjust the ten-
sion in the chain sling to achieve the proper lift to take the load off the ram change
pistons and allow them to turn freely

Caution: It is essential to alternate between pistons when backing out to ensure even load
distribution.

8. Properly sling the bonnet assembly and slide it off the bonnet studs.

TC9113 30
 9. Remove the bonnet from the body.
10. Remove the bonnet seal (21).
11. Remove the bonnet seal carrier (20) and bonnet seal (21), using the seal carrier
removal tool P/N 2010064-05, which slots into the bonnet side seal carrier groove.
Seal carrier is removed by turning on the screws set against the body.
12. Take the bonnet assembly down and place it in the bonnet assembly stand with the
locking screw side up.

Caution: Take care not to damage the connecting rod (3).

13. Remove each polypak (34) from the ram change piston bores.

C. Bonnet disassembly (Tandem Booster bonnets)

Bonnet disassembly should be performed with the body-side of the bonnet standing on
blocks or a stand to allow the connecting rod/button to protrude below without any
weight on it.

Caution: Care should be taken so that the assembly does not tip over during disassembly.

1. Remove the eight nuts (26) from the studs.

2. Use a sling to lift the cylinder head assembly from the bonnet. The outside cylinder
(21) may lift with the head. If it does, care must be taken so that it does not release
from its gland during lifting.

Caution: Nothing other than O-ring friction holds the outside cylinder to the cylinder head. It
could release at any time during lifting.

3. Lift the cylinder head to clear the end of the tail-rod and lower it to within a few
inches of the deck. Bang alternate sides of the cylinder with a rubber sledge ham-
mer to disengage it from its gland in the head. If the cylinder (21) does not lift with
the head, it must be removed from the assembly. To do this, install lifting eyes in
the preparations on its end and lift it from the assembly.
4. Remove the O-rings (31) from the cylinder.
5. Remove lock and backup rings (29) (28) (27) (42) and (67) from the cylinder head
and set it aside for locking screw disassembly
6. Remove the six screws (66) and housing (65).
7. Remove the hydraulic subs (25) from it preparation. Remove the O-ring (10) from
the sub.
8. Install lifting eyes in the outer piston (60) and lift it from the assembly.
9. Remove polypak (30) and wear ring (32) from the piston, along with lock and
backup rings (29) (28) (27) and (42).
10. Sling the tail-rod to support it. Loosen the two set screws (54) that occur in the side
of the outside tail-rod adapter (47) and unscrew the outside tail-rod adapter from
the inside tail-rod adapter.

Caution: Loosening this piece will disengage the tail-rod section from the assembly. Make sure
it does not topple over during this step.

TC9113 31
 11. Remove the tail-rod (34) from the assembly.
12. Loosen the eight set screws (54) that occur in the top of the inside tail-rod adapter
(48) and unscrew the inside tail-rod adapter from the piston (52).
13. Install lifting eyes in the intermediate flange (3) and lift it from the assembly. The
inner cylinder (23) may come out with the intermediate flange. If it does, care must
taken so that it does not release from its gland during lifting.

Caution: Nothing other than O-ring friction holds the inside cylinder to the intermediate
flange. It could release at any time during lifting.

14. Lift the flange to clear the end of the main piston and lower it to within a few
inches of the deck. Bang alternate sides of the cylinder with a rubber sledge ham-
mer to disengage it from its gland. If the cylinder (23) does not come off with the
flange it must be removed from the bonnet. Install lifting eyes in the preparations
in the end and lift it from its gland.

Caution: The intermediate flange captures and holds each of four stud sleeves (50). Removing
it will leave each sleeve standing free on the bonnet. Be careful not to tip them over
during removal.

15. Remove O-rings (31) from the cylinder.

16. Remove each stud sleeve (50).
17. Lift each ram change cylinder (8) and their contents, ram change pistons (6) and
(7), from the bonnet.
18. Remove O-rings and wear bands (35) (37) (33) and (36) from each ram change sub-
assembly.
19. Remove hydraulic subs (24) from the bonnet.
20. Remove O-rings (10) from the sub.
21. Install lifting eyes in the operating piston (52) and lift it from the bonnet
22. Remove rings (30) and (32) from the piston.
23. Remove rings (19) (18) (17) and (16) from the connecting rod bore in the bonnet.
24. Turn the bonnet over and remove rings (11) (12) (14) (13) (20) (15) (16) and (17)
from the connecting rod bore on this side.

V. Assembly Procedure - Standard Bonnets

A. Part Preparation Prior to Assembly

The work area should be clean and well lighted.

1. Remove all dirt, grit, oil, and contaminants from the ram bore, ram change piston
holes, bonnet stud holes, all fluid passageways in the body and bonnet. Clean de-
tergent and fresh water should be used for cleaning. High pressure air may also be
used if it is dry air.
2. Clean all internal surfaces of the bonnets using clean detergent and fresh water.
Lubricate internal sealing surfaces.
3. Clean pistons and cylinders, using clean detergent and fresh water. Lubricate areas
that will come in contact with other parts.
TC9113 32
 4. Sealed elastomer containers should not be opened until they are required for as-
sembly. This is to prevent contamination and damage to the seal.

Caution: Never lay the operating piston down so that the seal surface on the connecting rod,
tail rod or OD of the piston can be damaged.

B. Bonnet Assembly (Standard bonnets)

1. Place each bonnet (2) on stands or pallets with the body side up.

Caution: Take care to ensure that the bonnet does not roll over.

2. Install the following parts in the connecting rod bore:

a. Back-Up Ring (17)
b. Seal Ring (16)
c. Spacer Ring (15)
d. Wear ring (20)
e. Back-Up Ring (13)
f. Seal Ring (14)
g. Retainer Ring (12)
h. Spirolox Ring (11)
3. Install seals (36) and bearings (63) in the ram change piston bores.
4. Turn the bonnet over. Set the bonnet on a raised surface which will allow the op-
erating piston connecting rod to be installed through the bonnet past the bonnet
face. Install the following items:
a. Back-Up Ring (17)
b. Seal Ring (16)
c. Retainer Ring (18)
d. Spirolox Ring (19)
5. Remove any excess lubricant to prevent it from holding debris.
6. Lubricate the ram change piston bores, connecting piston bore, ram change cylin-
der, and operating piston cylinder preparations.
7. Install the O-rings (31), (51) and back-up ring (52) onto the operating cylinder (23)
and install the operating cylinder on the bonnet. The end with the back-up ring
goes into the bonnet.
8. Install the O-rings (35) on the ram change cylinders (6) and install the ram change
cylinders on the bonnet.
9. Install the seal rings (30) and wear ring (32) on the operating piston (3) and install
on the bonnet.

Caution: Take care to protect the connecting rod and tail portions of the operating piston dur-
ing assembly. These two surfaces are coated with an abrasion resistant coating that is
brittle. The operating piston may be lifted by a C clamp around the tail rod.

10. Prepare the ram change pistons (4 and 5) for installation by installing the seal and
bearing (33 and 37).
TC9113 33
 Caution: Take care to protect the piston rod portions of the ram change pistons.

11. Review the appropriate documentation to determine if a left or right hand bonnet
is required and refer to the assembly drawing for the proper location of the open
and close ram change pistons.

Caution: Take care to ensure that the ends of the ram change pistons are not damaged during
this operation.

12. Lower the ram change pistons (4 and 5) into the appropriate ram change piston
preparations.
13. Coat the shorter threaded end of the studs (25) with thread lubricant. Install the
coated ends in the bonnet. Torque until the last of the thread is flush with the sur-
face of the bonnet
14. Install the O-ring (45), back-up ring (42), seal ring (27), back up ring (28) and spiro-
lox ring (29) in the cylinder head (24).

Note: If C.O.G ADJUSTING PLATE ASSEMBLY (65) is part of the assembly, mount it before in-
stalling screws (26).

15. Install the cylinder head (24)

16. Coat the threaded end of the screws (25) with thread lubricant and tighten the 8
nuts (26) uniformly. (See torque chart).
17. Install O-rings (38) on the ram change access caps (7) and install them.

Note: There is no torque for these caps. They bottom out in the head.

18. Install the locking housing (43) with six housing screws (46), lubricated with thread
lube. (See torque chart)

Note: If C.O.G ADJUSTING PLATE ASSEMBLY (65) is part of the assembly, mount it before in-
stalling screws (26).

19. Install O-rings (21) on the seal carrier (20) and lubricate well.
20. Install O-ring (22) on the bonnet and lubricate well.
21. Install seal carrier (20) onto the bonnet by pressing one end in first.
Then (using the connecting rod button for leverage) pry the opposite end in while
maintaining uniform pressure on the installed end.

C. BOP assembly (Standard bonnets)

1. Install the extension rods (2163165-01) on each of the two top bonnet studs on
each side of the BOP.
2. Install lifting eyes in the bonnet and cylinder head of one bonnet assembly. Use
these lifting points or the COG adjusting plate to bring the bonnet to the BOP
straight and level and guide it over the extension rods.
3. Align the ram change pistons (4 and 5) to their respective preparations and thread
them in the body.

TC9113 34
 Note: The ram change pistons have different thread sizes. The ‘OPEN’ piston has a thread size
of 3 1/8”. The ‘CLOSE’ piston has a thread size of 3”. They should make up and tighten
freely, without difficulty. Make sure the proper piston is installed to line up with the
proper preparation on the body. The bonnet level may have to be adjusted to allow
easy tightening of these pistons.

4. Rest the bonnet on the extensions and remove the lifting slings.
5. Repeat steps 1 thru 4 for the bonnet on the other side of the BOP.
6. Connect the OPEN and CLOSE ports of the BOP to the hydraulic power supply.

Note: The operation of Cameron ram type BOPs is as follows: When pressure is applied to the
‘OPEN’ port, the rams will open or retract within the bonnet AND the bonnets will close
if they are in the open position. Conversely, when pressure is applied to the ‘CLOSE’
port, the rams will close in on the well-bore AND the bonnets will open if the cap nuts
are not installed. All personnel should be clear of the bonnets when operational pres-
sure is applied during the following steps.

7. Apply 500 psi (34 Bars) closing pressure to the BOP and gradually increase pressure
if necessary up to 1500 psi (103 Bars), which opens the bonnets completely, and
install the ram trays.
8. Apply 500 psi opening pressure to the BOP to clamp the trays between the body
and bonnet. This application will also retract the con-rods into the bonnets.
9. Install the rams by sliding them onto the buttons.
10. Apply 500 psi closing pressure to unclamp the trays. This application will also close
the rams. Remove the ram trays.
11. Apply 1500 psi opening pressure to the BOP (which
closes the bonnets).
12. Remove the extension rods
13. Install bonnet cap nuts (9) and tighten them uniformly.
(See torque chart) using reaction tool provided and
hydraulic wrench as shown in Fig. 1.

Torque Chart
Moly #503 API 5A
Item Name Size
Ft-lb N•m Ft-lb N•m
46 Cap Screw 2-1/2’’-8UN 4325 5862 6295 8535
26 Nut 2-3/4’’-8UN 3500 4745 5096 6909
9 Bonnet Cap Nut 5’’-4 ACME 2000 2711 2912 3948

VI. Assembly Procedure - Tandem Booster Bonnets

A. Bonnet Preparation

1. Place the bonnet (2) upright on a work surface.

Caution: Care should be taken to ensure that the bonnet does not fall over.

2. Lubricate the connecting rod seal gland and install (11) through (20) as shown in
TC9113 35
 the Bonnet Subassembly drawing. Remove any excess lubricant to prevent it from
holding debris. Check that the snap rings are properly installed.
3. Lubricate the seal groove in the ram change piston bores and install a seal ring (36)
on each. Remove any excess lubricant to prevent it from holding debris.
4. Install 3/8” AE high pressure plug and gland, (40) and (41) (1 place). See Torque
Table.

B. Intermediate Flange Preparation

The assembly operations required for this portion of the assembly procedure can be ac-
complished with the intermediate flange (3) placed with the piston seal gland facing up.
1. Lubricate the tail rod seal gland and install (42) (27) (28) and (29). Remove any ex-
cess lubricant to prevent it from holding debris. Check that the snap ring, item 29, is
properly installed.
2. Install 3/8” AE high pressure plug and gland, (40) and (41) (2 places).
See Torque Table.

C. Cylinder Head Preparation

The assembly operations required for this portion of the assembly procedure can be ac-
complished with the cylinder head (4) placed in any position other than piston side down.
1. Lubricate the tail rod seal gland and install (42) (27) (28) and (29). Remove any ex-
cess lubricant to prevent it from holding debris. Check that the snap ring, item (29),
is properly installed.
2. Install 3/8” AE high pressure plug and gland, (40) and (41) (1 place).
See Torque Table.

D. Locking Assembly Installation

This portion of the assembly process is best accomplished if the cylinder head is placed,
piston side down, on a clean, level surface. Steps should be taken to ensure that there is
not any coating build-up on the mating surfaces of the cylinder head or the locking as-
sembly.

E. Outer Operating Piston Preparation

This portion of the assembly process is best accomplished if the outer operating piston
(item 60) is placed, seal gland side up, on a clean, level surface.
1. Lubricate the tail rod seal gland and install (42) (27) (28) and (29). Remove any
excess lubricant to prevent it from holding debris. Check that the snap ring (29) is
properly installed.
2. This portion of the assembly process is best accomplished if the outer operating
piston is placed, seal gland side down, on a clean, level surface.
3. Install the Stop Ring (22) using the 4 screws (53). See Torque Table.

F. Bonnet Assembly

1. Place the prepped bonnet in an assembly stand with the operating system side fac-
ing up.
2. Lubricate the ram change piston bores, operating piston bore, and operating piston
cylinder seal preparations.
TC9113 36
 3. Lower the operating piston into place. Care must be taken to protect the connect-
ing rod and tail rod portions of the operating piston during assembly. These two
surfaces are coated with an abrasion resistant coating that is brittle. Care must also
be taken not to damage the tail rod threads.
4. Install the seal and bearing (30) and (32) onto the operating piston (52).
5. Prepare the cylinder (23) by installing seals (31) into their grooves.
6. Lubricate the seals and lower the cylinder into place. If necessary, a clean soft mal-
let can be used to engage the seals into their bores.
7. Install eight studs (43) into the bonnet. Coat the shorter of the threaded end
threads with thread lubricant and screw the coated thread into the bonnet. Torque
the studs until the last scratch of the thread is flush with the surface of the bonnet.
8. Prepare the ram change pistons (6) and (7) for installation by installing the seal and
bearing (33) and (37). Care must be taken to protect the piston rod portions of the
ram change pistons.
9. Lower the ram change pistons into the appropriate ram change piston prepara-
tions.

Note: Review the appropriate documentation to determine if a left or right hand bonnet is
required and refers to the assembly drawing for the proper location of the open and
close ram change pistons. Care must be taken to ensure that the ends of the ram change
pistons are not damaged during this operation.

10. Prepare the ram change cylinders (8) for installation by installing seals (35) into
their grooves.
11. Lubricate the seal and bearing on the ram change piston head and lower the ram
change cylinders into place. If necessary, a clean soft mallet can be used to engage
the seals into their bores.
12. Prepare the inner seal sub (24) by installing seals (10) into their grooves.
13. Lubricate the seals on the inner seal sub and position the seal sub into their bores in
the bonnet.
14. Place the four stud sleeves (50) on the bonnet, centered over each stud hole in the
bonnet.

G. Intermediate Flange Assembly

1. Lubricate the ram change cylinder bores, operating piston tail rod bore, and outer
operating piston cylinder seal preparations.
2. Carefully lower the intermediate flange. If necessary, a clean soft mallet can be
used to engage the seals into their bores.
3. Install seals (38) in the ram change access cap (9).
4. Lubricate the ram change access cap threads and the seal bore and install the ram
change access caps. There is not any torque requirement for the ram access port, it
makes up solidly against the ram change cylinder.
5. Install the inside tail rod adapter (48). Thread the adapter onto the tail rod until it
has bottomed out. Strike the adapter repeatedly with a heavy hammer to ‘set’ it.

Note: Clean each set screw (54) with Loctite solvent and treat the threads with Loctite #567.

TC9113 37
 6. Install each of the eight set screws (54) hand tight.
7. Strike, with a hammer the adapter-local to each set screw to ‘set’ them.
8. Tighten each set screw. (See Torque Table).
9. Install the tail rod (34) by lowering it onto the inside tail rod adapter.

Note: Care must be taken to protect the tail rod during assembly. This surface is coated with
an abrasion resistant coating that is brittle.

10. Slide the outside adapter (47) over the end of the tail rod and thread it onto the
inside tail rod adapter until it has bottomed out.
11. Clean, apply Loctite and install each of the set screws (54). (See Torque Table).
12. Lower the outside operating piston in place, with stop ring facing toward the bon-
net.
13. Install the seal and bearing (30) and (32) onto the outside operating piston.
14. Prepare the outside operating piston cylinder (21) by installing seals into their
grooves.
15. Lower the outside operating cylinder in place.
16. Prepare the outside seal sub (25) by installing seals (10) into their grooves.
17. Lubricate the seals on the outside seal subs and position the seal subs into their
bores in the intermediate flange.

H. Installation of the cylinder head and manual Lock

1. Lubricate the seal sub preps, operating piston cylinder prep, and the tail rod with
lubricant and lower the cylinder head into position
2. Coat the threads and flanks of the nuts (26). Install the nuts on the studs. See
Torque Table.
3. Install the locking housing (65) with six housing screws (66), lubricated with thread
lube. (See torque chart)

I. BOP Assembly - Tandem Booster Bonnets

1. Install bonnet seal carrier (20) fitted with O-rings (21).

2. Slide each of the two bearing retainers (8) over the top bonnet studs (4) with the
threaded end facing the bonnet.
3. Install lifting eyes in the bonnet and cylinder head of one bonnet assembly. Use
these lifting points to bring the bonnet to the BOP straight and level and guide it
over the bonnet studs.
4. Align the ram change pistons (4 and 5) to their respective preparations and thread
them in the body.

Note: The ram change pistons have different thread sizes. The ‘OPEN’ piston has a thread size
of 3-1/8”. The ‘CLOSE’ piston has a thread size of 3”. They Should make up and tighten
freely, without difficulty. Make sure proper piston is installed to line up with the proper
preparation on the body. The bonnet level may have to be adjusted to allow easy tight-
ening of these pistons.

TC9113 38
 5. Install each of the four split bearings (7) into the counter bore of the top two bon-
net stud holes in the bonnet.

Note: The weight of the bonnet may have to be shifted to allow installation.

6. Slide each retainer toward bonnet and thread them into the preparations on the
bonnet.
7. Tighten each of the four set screws (6) into the retainers. See Torque Table.
8. Repeat steps 1 thru 7 for the bonnet on the other side of the BOP.
9. Connect the ‘OPEN’ and ‘CLOSE’ ports of the BOP to the hydraulic power supply.

Note: The operation of Cameron ram type BOPs is as follows: When pressure is applied to the
‘OPEN’ port, the rams will open or retract within the bonnet and the bonnets will close
if they are in the open position. Conversely, when pressure is applied to the ‘CLOSE’
port, the rams will close in on the well-bore and the bonnets will open if the cap nuts
are not installed.

Caution: All personnel should be clear of the bonnets when operational pressure is applied
during the following steps.

10. Apply 1500 psi (103 Bars) closing pressure to the BOP (which opens the bonnets
completely) and install the ram trays.
11. Apply 500 psi (34 Bars) opening pressure to the BOP to clamp the trays between
the body and bonnet. This application will also retract the connecting rods into the
bonnets.
12. Install the rams by sliding them onto the buttons.
13. Apply 500 psi (34 Bars) closing pressure to unclamp the trays. This application will
also close the rams. Remove the ram trays.
14. Apply 1500 psi (103 Bars) opening pressure to the BOP
(which closes the bonnets).
15. Install the bonnet cap nuts (9) and tighten them uni-
formly (see torque table) using reaction tool provided
and hydraulic wrench as shown on Fig. 2.
16. Bleed off all pressure to the BOP.

Torque Chart
Moly #503 API 5A Adhesive
Item Name Size
Ft-lb N•m Ft-lb N•m Ft-lb N•m
41 Plug 3/8” 30 41 44 59 - -
66 Cap Screws 2-1/2”-8UN 4324 5862 5096 8535 - -
53 Cap Screws 5/8”-11UN 64 87 96 130 - -
26 Cap Nut 2-3/4”-8UN 5000 6778 8370 11,387 - -
54 Set Screw 1/4”-20UN Use Thread Sealant 3.3 5
BOP Assembly
6 Set Screw Use Thread Sealant 40 54
9 Bonnet Cap Nuts 5-1/4”-Acme 20,000 27,114 29,120 39,479 - -
TC9113 39
 VII. Operation and Installation

A. Preparation

Prior to the installation of the preventer, ensure that the following requirements are met:
1. The capacity and the pressure rating of the accumulators and the pressure pumps
must comply with the API RP 53 recommendations or appropriate regulatory agen-
cy requirements.
2. Ensure that the ring gaskets are correct for the preventer flange, the hub size, and
the pressure rating.

B. Installation

1. Install the preventer, ensuring that the preventer is right-side-up (outlets are below
the center of the preventer).
2. Inspect the preventer, the ram subassemblies, and all rubber parts during installa-
tion.
3. Remove the external mechanical protectors.
4. Lift the BOP with slings installed around the body of the BOP.
5. Install the BOP on a test stump/fixture.
6. Drain the fluid from the operating system.
7. Remove the 1” ball valves or pipe plugs from the inlet and outlet connections.
8. Connect the hydraulic control lines, and flush the operating system with clean fluid.
9. Test for leaks in the operating system (refer to Part IX-1.c).
10. Install rams in accordance with assembly procedure described in Part V&VI.
11. While installing the rams, inspect the ram bore and bonnet.
a. Inspect the vertical bore for key seating.
b. Inspect the intersection between the vertical bore and the ram bore. Grind out
any raised metal surfaces. Do not remove any metal below the original surface.

VIII. Maintenance

A. Routine Maintenance

1. If more than 500 psi (34.4 Bars) hydraulic pressure is required to operate the ram
subassemblies when there is no pressure in the well bore, determine the cause and
correct any irregularities.

Caution: To avoid damage to the packers, close pipe and flexpacker rams only when pipe is in
the preventer.

2. Pressure test and operate the preventer once a week per API RP 53
3. Once a month inspect the tail rod of the operating piston. The surfaces in contact
between tail rod and manual locking screw must always be lubricated. Lubricate if
necessary.
4. “Periodic Field Testing” or appropriate regulatory agency requirement.
TC9113 40
 B. Periodic Maintenance

1. Once a year, or every six months in cold weather conditions, completely disassemble
the preventer.

Note: For a detailed description of disassembly, see Part III& IV, DISASSEMBLY PROCEDURE.

a. Clean all parts. Do not use a wire brush on sealing areas.

b. Replace all rubber seals, gaskets, and O-rings.
c. Replace ram packing according to condition.
d. Repair or replace damaged metal parts.
2. Reassemble the preventer.

Note: For a detailed description of assembly, see Part V&VI, ASSEMBLY PROCEDURE.

After reassembling the preventer, test the rams and operating system. Refer to
Part IX, TESTING for the correct procedure.

IX. Testing

A. Hydraulic Operating System

1. Test the hydraulic operating system after installation.

a. Flush the hydraulic operating system with clean operating fluid.
b. Test for proper stroking of the rams and operating system.
1.) Apply a maximum of 300 psi (20 Bars) hydraulic pressure to the OPEN port.
2.) Ensure that the rams open.
3.) Reduce hydraulic pressure to zero psi.
4.) Apply a maximum of 300 psi (20 Bars) hydraulic pressure to the CLOSE port.
5.) Ensure that the rams close.
6.) Reduce hydraulic pressure to zero psi.
c. Test for leaks in the operating system.
1.) Remove the hydraulic line from the OPEN port.

Note: If testing pipe, casing, or flexpacker rams, be sure that an appropriate size test mandrel
is installed into the preventer. DO NOT close the rams on an open hole unless closing
pressure is less that 300 psi. Flexpackers should be tested with the largest pipe size for
that packer.

2.) Apply
300 psi (20 Bars) hydraulic pressure to the CLOSE port, and observe the
OPEN port for leaks.
3.) Increase the pressure to 3000 psi (200 Bars), and observe the OPEN port for
leaks.
4.) Inspect
for leaks between the bonnet and the BOP body. Bleed all pressure
from the BOP closing line.
5.) Replace the hydraulic line to the OPEN port.

TC9113 41
 6.) Remove the hydraulic line from the CLOSE port.
7.) Apply
300 psi (20 Bars) hydraulic pressure to the OPEN port, and observe the
CLOSE port for leaks.
8.) Increase the pressure to 3000 psi (200 Bars), and observe the CLOSE port for
leaks.
9.) Inspect
for leaks between the body and the bonnet. Bleed all pressure from
the BOP opening line.
10.) Replace the hydraulic line to the CLOSE port.
11.) Replace the seals if leaks were observed and repeat the test with new seals.
12.) Repeat the procedure for each preventer.

B. Ram Test
(After installation and as required by API RP53 or appropriate regulatory agency.)

Hydraulically test ram packers with water using the following procedure:
1. Install the BOP stack on a prepared test stump or install a test plug below the BOP
if on the wellhead.
2. Inspect for ram packer leaks at low pressure by closing rams on an appropriate size
test mandrel (none if blinds or shears are used) with 1500 psi (103 Bars) operating
pressure, and apply 200 psi (14 Bars) pressure under the rams. Hold pressure for 3
minutes. Maximum pressure drop is 10 psi (.69 Bars) in 3 minutes.
3. Increase pressure slowly to the rated working pressure of the preventer. Hold pres-
sure for 3 minutes. Maximum pressure drop is 100 psi (7 Bars) in 3 minutes.
4. If rams leak at low pressure or at working pressure, inspect for worn ram packers
and replace if necessary.
5. Repeat the above procedure for each set of casing, pipe, shear, and flexpacker
rams.

X. Storage

A. Blowout Preventer

1. Open the bonnets and remove the ram subassemblies.

2. Remove the top seals and packers, then wash the ram subassemblies.
3. Lubricate the ram bodies, covering them with a heavy grease.

Caution: DO NOT lubricate the top seals or packers.

4. Do not store the ram subassemblies inside the preventer.

Note: Rubber products that have been put into service and that are subsequently stored, will
have an unpredictable shelf-life. This is attributable to their varied physical condition
when returned to storage, due to the inability to completely remove elastomeric sol-
vents (hydrocarbon contaminates, etc.) and storage in a container filled with air (chemi-
cally active gases).

5. Clean the inside and outside machined surfaces of the preventer.

TC9113 42
 6. Dry with an air blaster until no moisture is left inside or outside the preventer.
7. Inspect the ram bores and the vertical bores for burrs.
8. Remove burrs by touching the surface lightly with a grinder using 36 to 60 grit
paper.
9. Lubricate the ram bore with CORROLESS CCI 350 (P/N 2728450-01).
10. Lubricate the end and outlet connection faces with CORROLESS CCI 350 (P/N
2728450-01) and cover them with flange protectors.
11. Flush the operating system using clean operating fluid.
12. Fill the operating system with preservation fluid.
13. Install pipe plugs into the OPEN and CLOSE connections.

Caution: DO NOT use the bonnet lifting eyes to lift a preventer.

14. To lift the preventer, use ropes or slings around the ends of the body.

B. Elastomers

1. Store rubber products inside a cool dark, dry storage area.

a. The preferred storage temperature range for rubber goods is from 40°F (5°C) to
80°F (25°C).
b. Rubber goods should be wrapped or otherwise protected from direct exposure
to sunlight or artificial light with a high ultraviolet content (such as fluorescent
lighting). Do not store in direct sunlight even if wrapped, as overheating will
result.
c. Store rubber parts in a relaxed position. Do not stretch or hang O-rings and
seals. Labels should not be attached to seals with string, wire, or tape, as these
items may deform the sealing surface.
2. Use airtight containers when possible to protect against circulating air.
3. Ozone is extremely harmful to rubber. Ensure that there is no equipment in the
storage area which may generate ozone, such as mercury vapor lams, high-voltage
electrical equipment, electric motors, or any electric apparatus which produces arc-
ing.
4. Keep the rubber products clean and free of solvents, oil, greases, or any other
semisolid or liquid materials during storage. Rubber goods should specifically be
protected against direct contact with: manganese, copper, copper alloys (including
brass), polyvinyl chloride (PVC), creosote-impregnated timber, other rubber goods
of different rubber compounds, sulfur, and copper napthenate.
5. When cleaning is necessary, rubber goods may be cleaned with either soap and
water or methyl alcohol. After cleaning, the rubber goods should be dried at room
temperature.
6. Examine the part before installation.

Important: Rubber goods taken from storage must ALWAYS be inspected before installation.
Rubber goods should not be flexed at temperatures below 40°F (5°C). Rubber
goods in storage should be inspected every 12 months to ensure that they are still
serviceable.

TC9113 43
 a. Ensure that the part does not have a tacky surface or noticeable softening or
hardening of the surface.
b. Flex the part and inspect with a magnifying glass to ensure that there are no
cracks.
c. Replace items which show any of the aging signs mentioned above.

TC9113 44