Operations Manual

13-5/8" 10K GK Annular BOP

BOP PRODUCTS, LLC

www.BOP-Products.com

9118 Sweetbush
Houston, TX 77064
281-955-6321
 TABLE OF CONTENTS
1.0 SCOPE
2.0 APPLICABLE SPECIFICATIONS
3.0 GENERAL INFORMATION
4.0 INSTALLATION
5.0 OPERATION
5.1 HYDRAULIC OPERATING FLUIDS
5.2 HYDRAULIC SYSTEM OPERATION
5.3 PACKING ELEMENT TESTING
5.4 SURFACE STRIPPING OPERATIONS
6.0 PACKING ELEMENT REPLACEMENT
7.0 MAINTENANCE
7.1 MAINTENANCE SCHEDULE
7.2 DISASSEMBLY
7.3 CLEANING AND LUBRICATION
7.4 INSPECTION
7.5 ASSEMBLY
7.6 TROUBLESHOOTING
7.6.1 GENERAL TROUBLESHOOTING
7.6.2 ISOLATION OF SEAL LEAKAGE
8.0 STORAGE
9.0 ASSEMBLY DRAWING AND BILL OF MATERIALS

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1.0 SCOPE

This document describes the installation, operation, and maintenance for Type GK Blowout
Preventer assemblies.

2.0 APPLICABLE SPECIFICATIONS

rd
2.1 API Specification 16A (ISO 13533:2001): Specification For Drill Through Equipment, 3 Edition
th
2.2 API Specification 6A (ISO 10423:2003): Specification For Wellhead and Christmas Tree Equipment, 19
Edition
2.3 BOP-P Specification TP138 REV2: Hydrostatic Testing of Annular Blowout Preventers to API Spec 16A
2.4 NACE Specification MR0175, Sulfide Stress Cracking Resistant Metallic Materials For Oilfield
Equipment, (Latest Edition)

3.0 GENERAL INFORMATION

The Type GK Annular Blowout Preventer is designed for safe well pressure control during drilling and
workover operations. The simple design has been proven and accepted for reliable operation in all oil and gas
areas in the world. Four main components: body, piston, head, and packing element allow for easy maintenance
and reliability. The packing element can close on all pipe, casing, wireline, coiled tubing, and other objects to its full
working pressure. Stripping of pipe, tubing, and wireline through the packing element can also be accomplished
at lower pressures. The GK Blowout Preventer can also perform open hole closure per the requirements of ISO
13533 (16A).

The normal configuration of the GK Blowout Preventer is of a flanged bottom (or clamp hub) connection and
a studded top flange connection. Hydraulic operation is performed by connection to open and close (NPT) ports
located on the body, which are connected to the control system. A tapered, steel reinforced rubber-packing element
is forced inward by an upward movement of the piston. Steel inserts prevent extrusion of the rubber and feed inward to
close on any pipe or tubular in the well bore. A replaceable wear plate underneath the head limits wears from the
inserts as they move radially inward during operation.

Replacement of the packing element is performed by unscrewing the head and lifting the element out of the
piston bowl. A new element is then lowered into the piston bowl. Latched heads are also available.

All materials used in the construction of the Type GK Annular Blowout Preventer are rated by NACE MR-0175 and
ISO 13533 for use in hydrogen sulfide environments.

Special features of the Type GK Annular Blowout Preventer:

• Designed and manufactured to ISO 13533 and API Specification 16A for Drill Through Equipment
• Available in all standard bore and pressure ratings
• Special rubber materials available for non standard environments
• Standard operation pressure of 1500-psi (10,34 MPa)
• Forged materials rated for H2S service

4.0 INSTALLATION

4.1 Check correct installation and hook-up of the blowout preventer (BOP) Control System in accordance
with the operation manual recommendations. The operating fluid should be 10 wt. Hydraulic oil or oil
having a viscosity between 200 and 300 SSU at 100F. Check that the hydraulic operating fluid is
filtered, clean and free of debris.
4.2 Remove any flange protectors and clean all ring groove seal areas. Remove all plugs from open and
close operating ports (1” NPT).
4.3 Perform basic visual inspection (see section 7.4.1).
4.4 Lifting lugs are provided on the body (Item 5). Coat all ring groove seal surfaces with a thin coat of grease
(no. 2).
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 4.5 Install proper ring gaskets into mating or BOP gasket areas. Carefully align and lower BOP to interfacing
equipment onto mating flange connections.
4.6 Install flange bolting or clamps onto flange connections using a diagonal make-up pattern per the
requirements of API specification 6A. Use only new ring gaskets when making up API flanged
connections.
4.7 Torque flange bolting to API Spec. 6A (re. 2.1 ANNEX D) or vendor recommended torque for clamps.
4.8 Connect hydraulic operating hoses to the open and close ports (1” NPT).
4.9 For stripping operations, connect an accumulator bottle to the closing line adjacent to the BOP. The
bottle precharge should be 50% of the normal closing pressure for maintenance of a seal for a given well
pressure (see table 5.2B).

5.0 OPERATION

5.1 HYDRAULIC OPERATING FLUIDS

5.1.1 The proper selection and use of the hydraulic operating fluid will have a great impact on the
service life and operation of the BOP.
5.1.2 The operating environment is also important in selection of the operating fluid. In ambient low
temperature conditions hydraulic oil or ethylene glycol added to water based operating fluids
may be required to prevent freezing.
5.1.3 Hydraulic oils with a viscosity between 200 and 300 SSU at 100F. (38C) should be used.
5.1.4 Water-soluble oil mixtures with ethylene glycol and biocide additives may also be used.
5.1.5 The operating fluids must also be compatible with the BOP control system.
5.1.6 A clean filtered operating fluid will extend the service life of the BOP and ensure reliable
operation of the BOP when required.

5.2 HYDRAULIC SYSTEM OPERATION

The Type GK BOP is designed to seal and hold pressure up to its rated working pressure. The
packing element will seal around tool joints, drill pipe, casing, tubing, and wireline, as well as sealing over an
open well bore.
The maximum operating pressure for the Type GK BOP is 1500 psi, but the BOP is designed to seal
at much lower operating pressures in most cases. The general rule is that the Type GK BOP should be
operated at a pressure just high enough to establish a seal between the packing element and the item in the
well bore. Table 5.2A gives the recommended operating pressures to establish an initial seal for different
pipe sizes.
TABLE 5.2A
RECOMMENDED PRESSURE TO INITIATE SEAL

Pipe O.D. Sealing Pressure (psi)

(Inches) 7-1/16” 11” 13-5/8”
5M 5M 5M
9.625 - - 600
8.625 - 350 600
7.625 - 350 600
7 - 350 600
6.625 - 350 600
5 400 450 650
4.5 400 450 650
3.5 450 825 700
2.875 450 800 750
2.375 500 900 950
1.90 600 - 1000
1.66 700 - 1000
CSO 1000 1150 1150
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 Once a seal has been established, operating pressure should be reduced to the minimum required to
maintain a seal. Table 5.2B gives the recommended closing pressures to maintain a seal. If leakage occurs
at a given pressure, increase operating pressure until a seal is maintained.

TABLE 5.2B
RECOMMENDED PRESSURE TO MAINTAIN SEAL

Pipe Operating Pressure Required to Maintain Seal (psi)

O.D. 7-1/16” 5M 11” 5M 13-5/8” 5M
(Inches) Well Pressure (psi) Well Pressure (psi) Well Pressure (psi)
500 1500 2500 3500 5000 500 1500 2500 3500 5000 500 1500 2500 3500 5000
9.625 - - - - - - - - - - 400 50 50 50 50
8.625 - - - - - 275 125 50 50 50 400 50 50 50 50
7.625 - - - - - 275 125 50 50 50 400 50 50 50 50
7 - - - - - 275 125 50 50 50 400 50 50 50 50
6.625 - - - - - 275 125 50 50 50 400 50 50 50 50
5 175 50 50 50 50 375 225 100 50 50 500 150 50 50 50
4.5 175 50 50 50 50 375 225 100 50 50 500 150 50 50 50
3.5 325 50 50 50 50 450 275 100 50 50 550 300 50 50 50
2.875 325 50 50 50 50 725 550 375 200 50 650 400 150 50 50
2.375 425 275 125 50 50 825 650 475 300 50 850 600 350 100 50
CSO 1000 1000 1000 1000 1000 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150

5.2.1 To adjust operating pressure, adjust the bleed pressure of the annular pressure regulator on
the driller’s air remote control panel or on the accumulator unit. See the operating manual for
the particular type of control system in question for details.
5.2.2 To close the packing element, apply closing pressure (see Table 5.2A & B) to the close port
of the BOP.
5.2.3 Check for leakage past the packing element. If leakage is present, increase closing pressure
gradually until leakages ceases, up to a maximum operating pressure of 1500 psi.
5.2.4 To open the packing element, apply opening pressure to the open port of the BOP.

5.3 PACKING ELEMENT TESTING

5.3.1 SEAL ON DRILL PIPE

5.3.1.1 Position stationary drill pipe into the center of the BOP vertical bore.
5.3.1.2 Apply closing pressure (see Table 5.2A) to the close port of the BOP.
5.3.1.3 Apply BOP test pressure up to the rated working pressure of the BOP.
5.3.1.4 Check for visual leakage or pressure drop on monitoring pressure gauge.
5.3.1.5 If leakage past the packing element occurs, gradually increase opening pressure
until the packing element seals. Do not exceed 1500 psi.
5.3.1.6 Check for any pressure increase in the open chamber of the BOP. Leakage of well
bore pressure into the open chamber is a result of seal failure of items 8 or 9.
Disassembly of the BOP and replacement of the seals is required.
5.3.1.7 After successful pressure testing, bleed off all bore pressure beneath the packing
element.
5.3.1.8 Apply opening pressure to the open port of the BOP.
5.3.1.9 Ensure full opening of the packing element.

5.3.2 SEAL ON CASING

5.3.2.1 Special care must be taken when testing the packing element on casing or tubing.
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 Casing or tubing may have collapse pressures less than the working pressure of the
BOP.
5.3.2.2 The metal reinforcing segments of the packing element may directly contact the
casing and cause excessive stresses to the casing.
5.3.2.3 Apply closing pressure (see Table 5.2A) to the close port of the BOP. Note that
closing pressures are lower for larger pipe sizes.
5.3.2.4 Apply BOP test pressure.
5.3.2.5 Check for visual leakage or pressure drop on monitoring pressure gauge.
5.3.2.6 If leakage past the packing element occurs, gradually increase opening pressure
until the packing element seals. Do not exceed 1500 psi.
5.3.2.7 Check for any pressure increase in the open chamber of the BOP. Leakage of well
bore pressure into the open chamber is a result of seal failure of items 8 or 9.
Disassembly of the BOP and replacement of the seals is required.
5.3.2.8 After successful pressure testing, bleed off all bore pressure beneath the packing
element.
5.3.2.9 Apply opening pressure to the open port of the BOP.
5.3.2.10Ensure full opening of the packing element.

5.3.3 SEAL OVER OPEN HOLE

5.3.3.1 Closure on an open hole is the most demanding requirement of the packing element
in an annular BOP.
5.3.3.2 The maximum pressure, which can be held beneath a closed packing element, is
50% of the rated working pressure of the BOP.
5.3.3.3 Open hole closure of the packing element will reduce the service life of the element
and should only be used in emergency situations.
5.3.3.4 Open hole closure should not be used in the normal pressure testing operations of
the BOP stack.
5.3.3.5 Apply 1500-psi operating pressure to the close port of the BOP.
5.3.3.6 Apply BOP test pressure up to 50% of rated working pressure of the BOP.
5.3.3.7 Check for visual leakage or pressure drop on monitoring pressure gauge.
5.3.3.8 Check for any pressure increase in the open chamber of the BOP. Leakage of well
bore pressure into the open chamber is a result of seal failure of items 8 or 9.
Disassembly of the BOP and replacement of the seals is required.
5.3.3.9 After successful pressure testing, bleed off all bore pressure beneath the packing
element.
5.3.3.10Apply opening pressure to the open port of the BOP.
5.3.3.11Ensure full opening of the packing element.
5.3.3.12If possible, visually inspect the packing element for excessive rubber loss or metal
intrusion into the well bore of the BOP.

5.4 SURFACE STRIPPING OPERATIONS

Drill pipe can be rotated and tool joints stripped through a closed Type GK packing element while
maintaining a full seal against the pipe. These operations introduce significantly more wear to the packing
element than sealing around a static drill pipe. Using proper procedure during stripping operations can
minimize this wear.
When the tool joint passes through the packing element, a method of absorbing pressure surges in
the operating system must be available. Pressure surges significantly increase packer wear and can
potentially cause damage to the BOP if they occur when operating pressure is near maximum. The
recommended system modification to stabilize pressure surges is the addition of an accumulator bottle in
the close line of the operating system. The accumulator bottle should have a gas precharge of 50% of the
normal closing pressure for maintenance of a seal for a given well pressure (see table 5.2B). The hose
between the BOP close port and the accumulator bottle should be as short as possible.
An alternative to the addition of an accumulator bottle is to set the annular pressure regulator to the
desired pressure and allow the regulator to bleed off surges in the operating system. The responsiveness
of the regulator may come into question using this method, so the accumulator bottle hookup is preferred.

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 If conditions allow, stripping should be performed with a slight leak at the packer-to-pipe seal to
provide lubrication and prevent excessive temperature buildup in the element. As the sealing element
wears, the closing pressure will need to be incrementally increased to prevent excessive leakage.
If conditions do not allow for leakage during stripping, the closing pressure should be adjusted to a
value just sufficient to maintain a seal.
The recommended procedures follow:

5.4.1 Ensure that one of the two methods of absorbing pressure surges discussed above is in
place.
5.4.2 Close the BOP with initial closing pressure per table 5.2A.
5.4.3 Just prior to commencing stripping operations, reduce closing pressure to a value
sufficient to allow a slight leak (150-250 psi below minimum sealing pressure given by
table 5.2A).
5.4.4 As required closing pressures approach 1500-psi, give consideration to switching to
another BOP to complete stripping operations.

6.0 PACKING ELEMENT REPLACEMENT

6.1 REPLACEMENT OF ELEMENT AFTER REMOVING DRILL PIPE

6.1.1 Remove head lock screw (Item 19).

6.1.2 Install two lifting eyes 180 deg. in head (Item 1) stud holes.
6.1.3 Apply torque counterclockwise to head using a long (10’-12’ long, 3” dia.) pipe anchored
against the lifting eyes in the head. If a crane is available, it is recommended that it be
used to lift up slightly on the head using the lifting eyes to reduce torque required to turn
head.
6.1.4 Using the lifting eyes attached to the head, lift the head from the BOP.
6.1.5 Screw lifting eyes into the packing element (Item 2) and lift out.
6.1.6 Grease new packing element including bottom of element and the metal segments in
areas that make contact with head.
6.1.7 Install new packing element (Item 2) on top of piston.
6.1.8 Ensure eyebolts have been removed from element.
6.1.9 Install head (Item 1). Screw head into body using method similar to removal (see 7.2.3,
7.2.4), applying opposite torque. Head is made up when shoulder is flush with body and
head lock screw hole lines up with hole in body.
6.1.10 Install head lock screw (Item 19) and tighten to 100 ft-lb torque (13.8 kg-m).
6.2 REPLACEMENT OF ELEMENT WITH DRILL PIPE PRESENT (SPLITTING)

It is possible to replace a packing element while drill pipe is present in the bore of the BOP. This
operation is potentially hazardous and should not be used except as a last resort. BOP Products, LLC.
assumes no responsibility for the safety of the replacement operation, the safety of a BOP that contains
a packing element prepared in this manner, or the seal integrity of a BOP containing an element
prepared in this manner.

Remove head and old packing element (see 7.2.1 through 7.2.3). With the drill pipe
6.2.1
present in the bore, the head and element must be suspended above the BOP until the
element has been successfully replaced.
6.2.2 Cut old packing element to free it from the drill pipe.
6.2.3 While prying two adjacent metal segments apart, cut new packing element completely
through the rubber between the segments.
6.2.4 Pry cut ends of new packing element apart.
6.2.5 Lubricate the ends of the cut with soap and water or grease.
6.2.6 Pass the new sealing element around the drill pipe.
6.2.7 Install head (Item 1). Screw head into body using method similar to removal, applying
opposite torque. Head is made up when shoulder is flush with body and head lock screw
hole lines up with hole in body.
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 6.2.8 Install head lock screw (Item 19) and tighten to 100 ft-lbs torque (13.8 kg-m).

7.0 MAINTENANCE

7.1 MAINTENANCE SCHEDULE

Early detection and repair of irregularities in a BOP prevent failure during a drilling emergency. A
preventative maintenance program provides testing and inspection guidelines to ensure safe rig operation.
Table 7.1 gives the recommended maintenance schedule for Type GK BOPs.

TABLE 7.1
PREVENTATIVE MAINTENANCE PROGRAM FOR BOPS
(Does not supersede other tests required by certifying agencies).

Interval Performed Procedure

Where By

Monthly / After Thoroughly clean the BOP and inspect for

Rig Rig Personnel
each Well damage. Well bore pressure test.

Rig
Remove head and sealing element. Inspect
Personnel /
Yearly Rig visually. Hydraulic pressure test and well
BOP-P
bore pressure test.
Serviceman
BOP-P
BOP-P or Completely disassemble. Inspect parts and
Personnel or
Every 3 Years Adequate repair / replace as needed. Replace all seals.
Under BOP-P
Facility Hydraulic pressure test and well bore test.
Supervision

7.2 DISASSEMBLY

7.2.1 Visually inspect body (Item 5) lifting lugs for cracks or damage. Damaged or cracked lifting
lugs should not be used for lifting.
7.2.2 Remove head lock screw (Item 19).
7.2.3 Install two lifting eyes 180 deg. in head (Item 1) stud holes.
7.2.4 Apply torque counterclockwise to head using a long (10’-12’, 3” dia.) pipe anchored
against the lifting eyes in the head. If a crane is available, it is recommended that it be
used to lift up slightly on the head using the lifting eyes to reduce torque required to turn
head.
7.2.5 Using the lifting eyes attached to the head, lift the head from the BOP.
7.2.6 Remove pipe plug (Item 17) from head.
7.2.7 Set head upside down on flat surface.
7.2.8 Carefully remove head seals (Items 6 and 8) using a dull screwdriver. Beware of scratching
metal seal areas and stretching seals more than the minimum amount necessary to remove
them.
7.2.9 Remove 6 cap screws (Item 30) from wear plate (Item 29).
7.2.10 Remove wear plate.
7.2.11 Visually inspect packing element (Item 2) lifting eye holes for corrosion or damage. Lifting
eye holes with cracks, extensive corrosion, missing threads, or bent threads should not be
used for lifting.
7.2.12 Attach lifting eyebolts (2 places) into the packing element.
7.2.13 Remove the packing element from the BOP.
7.2.14 Visually inspect piston (Item 3) lifting eye holes for corrosion or damage. Lifting eye holes
with cracks, extensive corrosion, missing threads, or bent threads should not be used for
lifting.
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 7.2.15 Attach lifting eyebolts (2 places) into the piston.
7.2.16 Remove the piston from the BOP.
7.2.17 Carefully remove piston seals (Items 9 and 10) using a dull screwdriver. Beware of
scratching metal seal areas and stretching seals more than the minimum amount necessary
to remove them.
7.2.18 Remove 12 cap screws (Item 18) from bolted cage (Item 4) installed in body.
7.2.19 Thread a sling through bolted cage slots and lift out of body.
7.2.20 Thoroughly clean all parts with a cleaning solvent as shown in section 7.3.
7.2.21 Perform a visual inspection as shown in section 7.4.

7.3 CLEANING AND LUBRICATING

TABLE 7.3
CLEANING INSTRUCTIONS FOR TYPE GK
BOP
Area Process Lubricant
Steam, High
BOP Exterior N/A
Pressure Water
Bore Areas (Head, Steam, High
Hydraulic Oil
Piston, Body) Pressure Water

Studs/Nuts Water, Wirebrush Grease specified in API 5A2

Ring Groove Emery Cloth Grease

Steam High
Head Grease
Pressure Water
Sand Paper, Emery
BOP Surface of Head Grease
Cloth

Lifting Eye Threads Water, Wirebrush Pack heavily with grease to prevent corrosion

Sealing Areas Emery Cloth Hydraulic Oil

Seals Damp Cloth Hydraulic Oil

High Pressure Grease exterior, including bottom and tips of

Element
Water metal segments
Sand Paper, Emery
Piston Hydraulic Oil (do not use grease)
Cloth
Sand Paper, Emery
Body Grease
Cloth

Wear Band Grooves Cleaning Solvent Hydraulic Oil

7.4 INSPECTION

7.4.1 BASIC VISUAL INSPECTION OF ASSEMBLED BOP

7.4.1.1 A visual inspection of the BOP should be made prior to installation.
7.4.1.2 Thoroughly clean BOP exterior, ring grooves, stud holes, and bolt holes (see section
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 7.3).
7.4.1.3 Using high-pressure water, clean the interior area and well bore of the BOP.
7.4.1.4 Inspect ring groove seal areas for damage or corrosion. Remove rust with fine
grade sandpaper (320 grit or higher). Pay particular attention to wear, nicks, and
vertical lines on the outmost surface of the ring groove. Ring groove sealing areas
are critical to the operation of the BOP and must be repaired if damaged.
7.4.1.5 Inspect body (Item 5) lifting lugs for damage, cracks, or wear. Shackles or lugs that
are damaged or cracked should not be used for lifting.
7.4.1.6 Inspect stud holes for corrosion or damage. Stud holes with cracks, extensive
corrosion, missing threads or bent threads must be repaired.
7.4.1.7 Inspect flange bolt holes for damage. Flange bolt holes with cracks or large gouges
must be repaired.
7.4.1.8 Inspect operating port threads for damage. Operating port threads with cracks,
extensive corrosion, missing threads, or bent threads must be repaired. Operating
port threads are a sealing area, and damage can cause leakage.
7.4.1.9 Inspect vertical bore of the BOP for damage for Kelly (drill pipe) wear, and for any
bore obstructions such as hanging rubber or metal inserts protruding into the bore.
Cracks, dents, large gouges in the bore may hinder passage of equipment through
the BOP and may require repair.
7.4.1.10Protruding rubber or metal inserts may require repair or replacement of the packing
element.
7.4.1.11If protrusions are found, ensure that the BOP is fully open. Trim away hanging
rubber with sharp knife or hand saw. Redress protruding metal segments by
grinding.
7.4.1.12If damage to element is too severe to be corrected by light repairs such as trimming,
grinding, and polishing, finish visual inspection and proceed with inspection of
packing element per 7.4.2.
7.4.1.13For BX ring grooved flanges, the raised face must be inspected for damage that
would impair face-to-face contact of the flange with a mating flange.

7.4.2 VISUAL INSPECTION OF PACKING ELEMENT

7.4.2.1 Perform basic visual inspection as in section 7.4.1.

7.4.2.2 Remove head (see section 6.1).
7.4.2.3 Inspect packing element lifting eye holes for corrosion or damage. Lifting eye holes
with cracks, extensive corrosion, missing threads, or bent threads should not be
used for lifting.
7.4.2.4 Remove packing element (see section 6.1).
7.4.2.5 Inspect element for damage to metal reinforcement inserts.
7.4.2.6 Grind all sharp edges or damaged areas of metal inserts.
7.4.2.7 Inspect exterior of rubber for tearing or peeling.
7.4.2.8 Cut away torn or peeled rubber using sharp knife or hand saw.
7.4.2.9 Ensure element bore is free of hanging or loose rubber.
7.4.2.10Visually inspect piston without removing from BOP.
7.4.2.10.1 Inspect piston lifting eye holes for corrosion or damage. Lifting eye
holes with cracks, extensive corrosion, missing threads, or bent threads
should not be used for lifting.
7.4.2.10.2 Inspect element contact area on piston and piston bore for damage and
wear.
7.4.2.10.3 Check bore for pits and vertical scores and the contact area for pits and
gouges.
7.4.2.10.4 Minor pits and scores on the walls can be removed in the field by
grinding and/or polishing. Sharp or rolled edges should be removed
with emery cloth or by grinding.
7.4.2.10.5 Repaired surface should be coated with grease.
7.4.2.10.6 Severe pits and scores may require machining and/or welding, which
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 should be performed in a BOP-P approved facility.

7.4.2.11 Visually inspect underside of head

7.4.2.11.1 Inspect wear plate (Item 29) on underside of head for heavy scoring,
pitting, corrosion, or gouging.
7.4.2.11.2 Check for rolled metal in the bore and dress up if necessary. If wearing
is uneven, or scoring or cuts more than .06” deep are present, replace
wear plate.
7.4.2.11.3 Inspect head to body threads for damage.
7.4.2.11.4 Minor damage can be removed in the field by grinding and/or polishing.
7.4.2.11.5 Repaired surface should be coated with grease.

7.4.2.12After inspection is completed along with any necessary repairs, reassemble BOP
(see section 6.1).

7.4.3 VISUAL INSPECTION OF BOP COMPONENTS

7.4.3.1 Perform basic visual inspection as in section 7.4.1.

7.4.3.2 Completely disassemble BOP per section 7.2.
7.4.3.3 Clean all parts thoroughly per section 7.3.
7.4.3.4 Body
7.4.3.4.1 Inspect bolt holes for bolted cage for heavy corrosion and bent or
missing threads.
7.4.3.4.2 Inspect upper I.D. seal area for pitting, scratching, or scoring.
7.4.3.4.3 Inspect middle I.D. seal area for pitting, scratching, or scoring.
7.4.3.4.4 Inspect lower I.D. seal area for pitting, scratching, or scoring.
7.4.3.5 Head
7.4.3.5.1 Inspect body to head seal area for pitting, scratching, or scoring.
7.4.3.5.2 Inspect head to body threads for damage.
7.4.3.5.3 Inspect head to piston seal grooves for pitting, scratching, or scoring.
7.4.3.5.4 Inspect wear plate area for heavy wear, scoring, or corrosion.
7.4.3.5.5 Inspect wear plate bolt holes for heavy corrosion and bent or missing
threads.
7.4.3.5.6 Inspect stud bolt holes for cracks or excessive wear.
7.4.3.5.7 Inspect pipe plug threads for heavy corrosion and bent or missing
threads.
7.4.3.6 Piston
7.4.3.6.1 Inspect element contact area for wear, scoring, and corrosion.
7.4.3.6.2 Inspect piston bore for scoring or Kelly wear.
7.4.3.6.3 Inspect upper sealing area for pitting, scratching, or scoring.
7.4.3.6.4 Inspect middle seal grooves for pitting or scratching.
7.4.3.6.5 Inspect lower seal grooves for pitting, scratching, or scoring.
7.4.3.7 Wear plate
7.4.3.7.1 Inspect for heavy wear, scoring or corrosion.
7.4.3.7.2 Check for rolled metal in the bore and dress up if necessary. If wearing
is uneven, or scoring or cuts more than .06” deep are present, replace
wear plate.
7.4.3.8 Bolted Cage
7.4.3.8.1 Inspect for Kelly wear, damage, or excessive corrosion.
7.4.3.8.2 If bolted cage shows excessive wear or gouges, replace.
7.4.3.9 Any type of damage to a seal area (pitting, scratches, etc.) that is more than .010”
(0,25 mm) deep that cannot be removed through polishing may require repair at a
BOP-P approved facility.
7.4.3.10After inspection is completed along with any necessary repairs, reassemble BOP
(see section 6.1).

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 7.5 ASSEMBLY

7.5.1 Install seals (Items 6, 8, 9, 10), replacing as required. Ensure correct lip seal orientation when
installing seals (see assembly detail).
7.5.2 Install bolted cage (Item 4) in body.
7.5.3 Bolt cage into place with 12 cap screws (Item 18). Tighten bolts to 55-75 ft-lbs torque (7.6-
10.4 kg-m).
7.5.4 Oil coat cylinder area in body (Item 5) and oil I.D and O.D. of piston (Item 3). Do not use
grease. Grease sometimes produces a thick film, which prevents the piston from dropping in
place easily.
7.5.5 Install piston in body.
7.5.6 Grease packing element (Item 2) including bottom of element and the metal segments in
areas that make contact with head.
7.5.7 Install packing element on top of piston.
7.5.8 Attach wear plate (Item 18) to head using 6 cap screws (Item 30). Tighten cap screw to 70 ft-
lbs torque (9.6 kg-m).
7.5.9 Ensure eyebolts have been removed from element.
7.5.10 Install head (Item 1). Screw head into body using method similar to removal (see 7.2.3,
7.2.4), applying opposite torque. Head is made up when shoulder is flush with body and
head lock screw hole lines up with hole in body.
7.5.11 Install head lock screw (Item 19) and tighten to 100 ft-lbs torque (13.8 kg-m).
7.5.12 Install pipe plug (Item 17) and tighten to 50 ft-lbs torque (6.9 kg-m).

7.6 TROUBLESHOOTING

7.6.1 GENERAL TROUBLESHOOTING

TABLE 7.6.1
SOLUTIONS TO COMMON PROBLEMS

Problem Possible Cause Remedy

Will not hold well Element not sealing Check packing element for wear on top. Replace if
bore pressure necessary.
Piping system leaking Check fittings and/or valves for leakage in piping
system.
Well bore pressure seal leaking Check well bore pressure seal. Replace if damage is
evident.
Pump malfunction Repair or replace pump.
Will not hold Leaking hydraulic hoses Replace hoses or connections.
hydraulic pressure Hydraulic pressure seals leaking Check hydraulic seals. Replace if damage is evident.
Existing element Buildup of mud or dried cement A. For dried cement, remove the element and
will not seal between the element segments clean thoroughly.
B. For dried mud, flush out thoroughly and flew
the element.
Inadequate hydraulic pressure Apply recommended operating pressure for stationary
applied pipe.
Hydraulic pressure seals leaking Check hydraulic seals. Replace if damage is evident.
New element will Inadequate hydraulic pressure Apply recommended operating pressure for stationary
not seal applied pipe.
Hydraulic pressure seals leaking Check hydraulic seals. Replace if damage is evident.

7.6.2 ISOLATION OF SEAL LEAKAGE

7.6.2.1 SEAL TEST OF SEALS 9 AND 10

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 7.6.2.1.1 Ensure that open port is vented to atmosphere.
7.6.2.1.2 Apply closing pressure to close port. If packing element is installed, use
required initial closing pressure to close on recommended test mandrel.
If no packing element is present, apply 1500-psi to close port.
7.6.2.1.3 If leakage occurs inside bore, seal 10 is leaking.
7.6.2.1.4 If leakage occurs from open port, seal 9 is leaking.

7.6.2.2 SEAL TEST OF SEALS 6, 8, AND 9

7.6.2.2.1 Ensure that close port is vented to atmosphere.

7.6.2.2.2 Apply 1500-psi to open port.
7.6.2.2.3 If leakage occurs from close port, seal 9 is leaking.
7.6.2.2.4 If leakage occurs inside bore, seal 8 is leaking.
7.6.2.2.5 If leakage occurs between head and body, seal 6 is leaking.

7.6.2.3 SEAL TEST OF SEALS 8 AND 10

7.6.2.3.1 Make up blind flanges on top and bottom connections.

7.6.2.3.2 Ensure close port is vented to atmosphere.
7.6.2.3.3 Ensure open port is vented to atmosphere.
7.6.2.3.4 Apply working pressure to the well bore.
7.6.2.3.5 If leakage occurs from close port, seal 10 is leaking.
7.6.2.3.6 If leakage occurs from open port, seal 8 is leaking.

8.0 STORAGE

8.1 STORAGE OF TYPE GK BOP

8.1.1 SHORT TERM STORAGE

In the case that a Type GK BOP is scheduled to be stored for a period of 6 months or less, use
the following procedure for storage:

8.1.1.1 Remove packing element (see sections 7.2.1 through 7.2.3).

8.1.1.2 Clean the BOP and element (see section 7.3) and grease.
8.1.1.3 Store the packing element according to section 8.2.
8.1.1.4 Coat internal surfaces with hydraulic oil or equivalent.
8.1.1.5 Reassemble BOP (see section 7.5) without packing element.
8.1.1.6 Pack API ring grooves with heavy grease and cover connections with wooden or
plastic protectors.
8.1.1.7 Ensure the operating piston is in the fully open position.
8.1.1.8 Completely fill operating system with petroleum based hydraulic fluid and plug ports.
8.1.1.9 Store BOP elevated in a dry room with connections covered.

8.1.2 LONG TERM STORAGE

In the case that a Type GK BOP is scheduled to be stored for a period of greater than 6
months, use the following procedure for storage:

8.1.2.1 Completely disassemble the BOP (see section 7.2).

8.1.2.2 Steam clean all parts and allow them to dry.
8.1.2.3 Coat all parts with heavy grease.
8.1.2.4 Wrap all O.D. sealing surfaces with wax cloth, if possible.
8.1.2.5 Plug all hydraulic ports with pipe plugs.
8.1.2.6 Store BOP elevated in a dry room with connections covered.

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8.2 STORAGE AND INSPECTION OF RUBBER GOODS

Aging of rubber parts is based on several factors such as exposure to light, storage atmosphere, storage
temperature, and size of the rubber part.

8.2.1 STORAGE

8.2.1.1 Store rubber in a cool, dark area. Light that contains ultraviolet rays (such as
sunlight) is very harmful to elastomers, and exposure during storage must be
avoided. Hot storage conditions cause aging to accelerate.
8.2.1.2 Store rubber in an environment free of ozone. Rubber parts tend to react with ozone
and deteriorate more rapidly in ozone rich environments. Electrical equipment such
as generators, electrical sparking equipment, or electric motors, produces ozone and
should not be stored near rubber goods. Deterioration due to oxidization (caused by
exposure to atmospheric oxygen or ozone) is characterized by the development of a
hard skin that eventually crazes in small cracks and may turn chalky and assume a
bark like appearance.
8.2.1.3 Store rubber in an unstressed condition. Stretching or bending will accelerate aging
and cracking. Do not hang rubber goods from pegs or fold for compact storage. If it
is necessary to store rubber goods in a deformed position, periodically inspect them
for signs of aging.
8.2.1.4 Store rubber in a dry area away from oil, grease, and other foreign fluids, which can
cause swelling, shrinkage, and deterioration.

8.2.2 INSPECTION

Rubber should be inspected when it is to be taken out of storage and put into service. Always
obey a first-in first-out policy with regard to the use of stored rubber goods.

8.2.2.1 Examine surface of rubber part for cracking, skin hardening, chalkiness, or bark like
appearance.
8.2.2.2 Bend, stretch, and compress part and look for signs of minute cracks.

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9.0 ASSEMBLY DRAWING AND BILL OF MATERIALS

GK

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 PN
PN
PN
PN
PN
PN SN
SN
SN
SN
SN
SN
PN SN
DESC.
DESC.
DESC.
DESC.
DESC.
DESC.
DESC.
SIZE
SIZE
SIZE
SIZE
SIZE
SIZE API
API
API
API
API
API WP
WP
WP
WP
WP
WP
SIZE API WP
BORE
BORE
BORE
BORE
BORE
BORE TEMP.
TEMP.
TEMP.
TEMP.
TEMP.
TEMP.
BORE TEMP.
PDC
PDC
PDC
PDC
PDC
PDC DATE
DATE
DATE
DATE
DATE
DATE
PDC DATE

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