T3 Annulars BOP Operators Manual 7022

Operator’s Manual: 11” - 5K MODEL 7022 ANNULAR BOP, SCREWED HEAD

OPERATOR’S MANUAL

P/N 640020495-01 Rev. A

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OPERATOR’S MANUAL

HEAD

WEAR PLATE

PACKING UNIT

PISTON

INNER SLEEVE

BODY

11” - 5K MODEL 7022 ANNULAR BOP – SCREWED HEAD

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Table of Content

1.0 Installation & Operation ................................................................................................................... 3 1.1 Principle of Operation ...................................................................................................................... 3 1.2 Operation ......................................................................................................................................... 6

1.2.1 Surface Installation ................................................................................................................... 6 1.2.2 Surface Stripping Operations .................................................................................................... 9

2.0 Physical Data ................................................................................................................................. 11 2.1 Engineering Data ............................................................................................................................ 11 2.2 Bolt Data ........................................................................................................................................ 12 2.3 Inside Dimensions .......................................................................................................................... 13 2.4 Outside Dimensions ....................................................................................................................... 14 3.0 Maintenance and Testing ................................................................................................................ 15 3.1 Maintenance Procedure .................................................................................................................. 15 3.2 Seal Testing.................................................................................................................................... 17 4.0 Disassembly and Assembly ............................................................................................................ 19 4.1 Disassembly ................................................................................................................................... 19 4.2 Assembly ....................................................................................................................................... 22 5.0 Parts & Storage .............................................................................................................................. 24 5.1 Parts List ........................................................................................................................................ 26 5.2 Diverter storage .............................................................................................................................. 26 5.3 Rubber Goods Storage .................................................................................................................... 26

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1.0 Installation & Operation

1.1 Principle of Operation

The 11” - 5K Model 7022 Blowout Preventer is an annular type BOP which seals off reliably on

almost any shape or size – drill pipe, drill collars, casing, tool joints in the well bore or completely seal off (CSO) of the open bore. The 11” – 5K annular BOP has been designed for use on surface installations

Closing action begins when hydraulic fluid is pumped into the closing chamber of the annular BOP

below the piston and raises the piston pushing the element up; the element’s spherical shape causes it to close in at the top as it moves upward. Because the well bore pressure below the sealed off packing unit tends to push the piston down and decreases the closing force; therefore, closing pressure must be maintained during well control operations. During well control operations, drill pipe can be rotated and tool joints stripped through a closed packing unit while maintaining a full seal on the pipe. The annular BOP can be operated with any normal close and open units having a separate pressure regulator valve for the annular blowout preventer and sufficient accumulator volume. (See Section 2.1 of this manual for close and open chamber volume). The hydraulic operating fluid should be clean, light petroleum hydraulic oil, or water with a water-soluble oil added. In cold climates, anti-freeze should be added to prevent freezing.

Figure 1.1 Cross section of Diverter / BOP with Packing Unit fully Open

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The closing time of the diverter is determined by the rate at which the hydraulic fluid can be delivered to the closing chamber. Using short, large diameter control lines, large bore control valves, and a large accumulator volume can reduce closing time. An excessively high setting on the pressure regulator valve will have little effect on the diverter closing time.

Figure 1.2 The piston squeezes packing unit rubber inward to close the opening by upward force

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Figure 1.3 The annular BOP opens to full bore to allow passage of large diameter tools through open bore

Figure 1.4 The annular BOP with packing unit seals off on drill pipe

Figure 1.5 The annular BOP diverter with packing unit seals off on square or hexagonal kellys

Figure 1.6 The annular BOP diverter with packing unit closed on open hole

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1.2 Operation

1.2.1 Surface Installation

Operation for 11” – 5K annular BOP requires opening and closing pressure. Figure 1.7 shows the surface installation of the annular BOP with hydraulic operating pressure line connecting to the closing chamber and opening chamber of the diverter. Pressure applied to the closing chamber raises the piston and pushes the packing unit up; the element’s spherical shape causes it to close in at the top as it moves upward. Well pressure or test pressure acts on the piston below the sealed off packing unit and tends to increase the closing force acting on the packing unit. Figure 1.8, Control Pressure graph shows the relationship of closing pressure and well pressure required to effect optimum seal off for the 11” – 5K annular BOP. During normal drilling operations, it is recommended that the pressure regulator valve for the annular BOP be set at the initial closing pressure shown for the size pipe being used. This pressure will ensure that initial seal off is achieved should a “kick” be encountered. During diverter testing operations, once initial seal off is achieved, closing pressure should be maintained as well pressure is increased.

OPENINGCHAMBER

LINE

CLOSINGCHAMBER

LINE

Figure 1.7

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0

500

1000

1500

0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

WELL/TEST PRESSURE (PSI)

CL

OS

ING

PR

ES

SU

RE

(P

SI)

5-1/2" through 8-5/8" pipe 4-1/2" through 5" pipe 3-1/2" pipe 2-7/8" pipe 2-3/8" pipe CSO

Figure 1.8 Closing pressure Vs well / test pressure for different drilling pipes

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CONTROLSYSTEM

HYDROSTATICHEAD

CAUTION : The 11“ – 5K annular BOP is sensitive to its position relative to the control system. If the control system is located at a level higher than the closing chamber of the diverter, the hydrostatic head of the operating fluid may be sufficient to prevent the piston from coming completely down. This will prevent the packing unit from opening to full bore. For these situations, the installation of a spring-activated normally closed 2-way valve rated for 3000 psi in the closing line to drain the fluid head is recommended (refer to Figure 1.9). Be sure to drain the fluid into a container.

Figure 1.9

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1.2.2 Surface Stripping Operations

OPENINGCHAMBER

LINE

CLOSINGCHAMBER

LINE

During well control operations, drill pipe can be rotated and tool joints stripped through a closed packing unit while maintaining a full seal off on the pipe. Rotation or stripping through a closed and sealed packing unit will shorten its life. Longest life for the packing unit is obtained by adjusting the closing forces low enough to maintain a seal on the drill pipe with a slight amount of drilling fluid leakage as the tool joint passes through the packing unit. Slow tool joint stripping speeds reduce surge pressures, prolonging packing unit life. The pressure regulator valve should be set to provide and maintain the proper control pressure. If the pressure regulator valve does not respond fast enough for effective diverter control, a surge absorber (accumulator) should be installed in the closing chamber control line adjacent to the diverter (Figure 1.11). Pre-charge the accumulator to one-half of the closing pressure required to affect a seal off at the existing well pressure for the pipe size in use. CAUTION : Rotation of drill pipe in one position generates heat that is detrimental to the packing unit if

continued for a long period of time.

Figure 1.10 Surface Hookup

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OPENINGCHAMBER

LINE

CLOSINGCHAMBER

LINE

Figure 1.11 Surface Hookup with surge absorber

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2.0 Physical Data 2.1 Engineering Data

English Metric

Bore 11 in 279.4 mm

Working Pressure 5000 psi 351.54 kg/cm2

Shell Test Pressure (Factory Test Only) 10000 psi 703.1 kg/cm2

Closing Chamber Test Pressure (Factory Test Only) 4500 psi 316.4 kg/cm2

Opening Chamber Test Pressure (Factory Test Only) 4500 psi 316.4 kg/cm2

Volume – Closing Chamber 10.40 gallons 39.37 liters

Volume – Opening Chamber 8.62 gallons 32.63 liters

Piston Stroke 7.125 inches 180.98 mm

Port Size 1.00” – 11 ½ NPT -

Weight 8,225 lb 3731 kg

Shackle Swivel Safe Working Load (Each) 8,000 4 Ton

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2.2 Bolt Data

Ref. No. Description Thread Recommended Torque

Ft-Lbs Meter-Kg

6 Cap Screw – Inner Body Sleeve

3/4” – 10 UNC 152 21

7 Cap Screw - Wear Plate 1/2” – 13 UNC 45 6.2

13 Head Lock Screw 1.00” – 8 UNC 360.8 49.7

14 Pipe Plug – Piston Indicator 1/2” NPT 50 6.9

16 Connecting Stud 1 7/8” – 8 UN 2533 350

17 Connecting Nut 1 7/8” – 8UN 2533 350

- Eyebolt - Piston 5/8” – 11 UNC Snug Snug

- Eyebolt - Head 1 ¼” – 7 UNC Snug Snug

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2.3 Inside Dimensions

L

A

D

BF

CJ EH

G

K

Figure 2-1 NOMINAL

DIMENSION A B C D E F

Bore Major O.D.

Piston Upper I.D

Body Minor O.D.

Piston

Top of Body to Top of Sleeve

Lower I.D Body

INCHES 11.015 30.726 30.754 23.233 13.125 23.254

NOMINAL DIMENSION G H J K L

Piston Height Top of Sleeve to Bottom of Wear

Plate

Packing Unit Height

Stroke Head Height

INCHES 23.282 12.187 12.187 7.125 14.455

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2.4 Outside Dimensions

D

A

F

H

C

B

G

E

Figure 2-2

NOMINAL DIMENSIONS - INCHES

A B C D E F G H

52.41 33.75 13.46 48.583 9.69 25.75 32.00 37.50

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3.0 Maintenance and Testing 3.1 Maintenance Procedure

Prior to placing the T3 annular BOP into service, the following visual inspections (as noted in Figure 3.1) should be performed.

1

1

2

3

3

2

4

5

6

7

7

1. Inspect the upper and lower connections for pitting, wear, and damage – especially in ring grooves and stud bolt holes. Worn or damaged ring grooves must be repaired in a T3 Energy Services Inc. authorized machine shop.

NOTE: The T3 annular BOP is a primary pressure vessel. As supplied, the diverter surfaces exposed

to well bore fluids meet the requirements for H2S service. Proper handling and repair are required to maintain the original integrity. Field welding is not recommended as it induces undesirable stresses that must be relieved by proper heat-treating procedures or controlled by special welding procedures.

Figure 3-1 Areas and Parts Requiring Maintenance

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2. Check the body for wear and damage – especially in the internal cylinder walls for pits and

vertical scores. Check the wear plate for damage to the surface that contacts the packing unit. Remove minor pits and scores with emery cloth. Coat the repaired surface with silicon grease or castor oil. Severe pits and scores that require machining and/or welding must be repaired in a T3 Energy Services Inc. authorized machine shop.

3. Inspect the vertical bore for wear and damage from drill string and drill tools – especially in

the area of the ring grooves. If wear is excessive, the area must be repaired.

4. Check the inner body sleeve for wear, damage, and looseness. Check slots in inner body sleeve for cuttings that may restrict piston movement.

5. Check the piston for damage and wear – especially the seal surfaces for pits and vertical

scores and the tapered bowl for pits and gouges Remove minor pits and scores on the walls with emery cloth. Coat the required surface with silicon grease or castor oil. Severe pits and scores that require machining and/or welding must be repaired in a T3 Energy Services Inc. authorized machine shop. Remove sharp or rolled edges with emery cloth or a grinder. The repair is satisfactory when the surface is relatively smooth.

6. Inspect the packing unit for wear, cracking, hardness, and correct elastomer composition.

7. Check the seal rings for nicks, cuts, fraying of lips, and abrasion. Replace worn or damaged seal rings.

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3.2 Seal Testing

Head Gasket (8)

U-Seal (10)

U-Seal (9)

U-Seal (11)

a) Test seals 9 and 10. • Pressurize closing chamber with pressure referenced in Figure 1.8. Apply

1500 psi if no packing unit is installed. Use the recommended test mandrel if a packing unit is installed.

• Open opening port to atmosphere IF: Closing fluid is visible at opening port – seal 10 is leaking

IF: Closing chamber pressure gauge is dropping and no fluid is detected at bottom flange - seal 9 is leaking

Figure 3-2 Seals

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b) Test seals 8, 10 and 11.

• Pressurize opening chamber (1500 psi) • Open closing port to atmosphere.

IF: Fluid is detected coming from area between body and head – seal 8 is leaking IF: Fluid is seen coming into the wellbore – seal 11 is leaking IF: Fluid is visible at closing port – seal 10 is leaking. c) Test seals 9 and 11.

• Open closing port to atmosphere. • Open opening port to atmosphere. • Install blind flange on top of preventer. Pressurize wellbore (5000 psi

maximum) IF: Fluid is detected coming from the opening port – seal 11 is leaking. IF: Fluid is detected coming from the closing port – seal 9 is leaking.

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4.0 Disassembly and Assembly 4.1 Disassembly

Refer to figures 4-1 and 4-2 while following this procedure

DETAIL J

DETAIL H

Wear Plate Cap Screw (7)

Wear Plate (5)

Head (4)Plug (14)

Body (1)

Inner Body Sleeve (2)

Piston (3)

Inner Body Sleeve Cap Screw (6)

Packing Unit (12)

DETAIL G

Figure 4-1

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Head Cap Screw (13)

U-Seal (11)

U-Seal (10)

U-Seal (9)

4.1.1 Vent all Pressure

Vent the closing chamber to atmosphere ensuring that no trapped pressure exists, which will cause injury to personnel, and/or damage to equipment. Open the valves in the control system to exhaust the pressure and/or loosen the hydraulic connections to allow the pressure to leak out.

WARNING: STAND CLEAR OF ESCAPING PRESSURE TO AVOID I NJURY

Figure 4-2

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4.1.2 Head Removal (item 4)

• Remove head lock screw (item 13) • Unscrew blowout preventer head (item 4) in counter-clockwise direction as

shown on figure 4-3 • Lift off blowout preventer head with two 1 ¼” 7UNC eyebolts installed in top

of head.

NOTE: Do not attempt to loosen the blowout preventer head by applying heat.

Figure 4-3

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4.1.3 Packing Unit Removal (Item 12)

Install two eyebolts into packing unit. Lift packing unit of piston. Use a sling of adequate length to prevent side loading of eyebolts.

4.1.4 Piston Removal (Item 3)

Install two 5/8” – 11UNC eyebolts in top of piston. Slowly lift piston vertically to free from preventer body. If a vertical lift is unfeasible of if the piston does not freely lift out, slowly apply low (50 psi) hydraulic pressure to the closing chamber. DO NOT USE AIR OR GAS!

4.1.5 Inner Body Sleeve Removal (Item 2)

• Remove 6 inner body sleeve cap screws (item 9) from around the body sleeve. • Lift out the inner body sleeve with a sling and hooks under the slots.

4.2 Assembly Refer to Figure 4-1 and Figure 4-2 while following this procedure. 4.2.1 Clean and Inspect All Parts Before Assembly

• Ensure that working surfaces are free of burrs, rough edges, or other defects. • Inspect all seals and replace any damaged seals or seals in use over one year. • Coat all seals and non-extrusion rings with silicon grease or castor oil before

installation.

CAUTION: Use of petroleum base oil or grease will reduce seal life

4.2.2 Inner Body Sleeve Installation (item 2) • Install inner body sleeve (item 2) into inside bottom of blowout preventer

body. • Install 6 inner body sleeve cap screws ( item 6) and torque torque to 152 ft-

lbs. 4.2.3 Piston Installation (item 3)

• Lubricate and install the lower U-seals (Item 9) on the lower segment of the piston

• Lubricate and install the upper U-seals (Item 10) on the upper segment of the piston

• Install two (5/8” - 11UNC) eyebolts on top of piston. Lubricate all mating surfaces before lowering the piston into the body. Ensure that the piston is

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aligned vertically with the body prior to lowering. With proper vertical alignment, the piston will slide its normal stroke to the bottom of the preventer body.

CAUTION : Be careful not to damage the seals during assembly

• Remove eyebolts 4.2.4 Install the Packing Unit (Item 12)

• Lubricate the piston bowl with silicon grease or castor oil. • Lift the packing unit with two eyebolts and set it into the piston bowl which is

already installed inside of the preventer..

4.2.5 Install the Head (Item 4) • Lubricate and install the head gasket (Item 8) in the seal groove on outside of

the preventer head. • Lubricate and install U-seals (item 11) in seal grooves on inside of the head. • Clean threads of foreign matter and check threads for burrs or rough edges.

Lubricate locking threads of the head with anti-seize compound. • Install two 1 ¼” 7UNC eyebolts installed in top of head. • Lift head and install wear plate (item 5) with cap screws (item 7). Torque the

screws to 45 ft-lbs. • Lower and align the lead thread of the head with the lead thread of the body • Screw head clockwise (right hand) into body until it shoulders against top of

body • Line up lock screw hole in head with hole in body and install head cap screw

(item 13). Torque the screw to 360 ft-lbs • Remove eyebolts from head. Preventer is ready for use/testing.

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5.0 Parts & Storage

DETAIL J

DETAIL H

Wear Plate Cap Screw (7)

Wear Plate (5)

Head (4)Plug (14)

Body (1)

Inner Body Sleeve (2)

Piston (3)

Inner Body Sleeve Cap Screw (6)

Packing Unit (12)

DETAIL G

Figure 5-1

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Head Cap Screw (13)

U-Seal (11)

U-Seal (10)

U-Seal (9)

Studs (16)

Nuts (17)

Shackle (15)

Figure 5-2

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5.1 Parts List Refer Fig 5.1 & 5.2

Item Part Name Qty Part Number Assembly SN067020386-01 1 Body 1 SN280020375-01 2 Sleeve, Inner Body 1 SN880020385-01 3 Piston 1 SN725020379-01 4 Head 1 SN575020380-01 5 Wear Plate 1 SN73A020381-01 6 Cap Screw, Socket Head 6 UB100029-01 7 Cap Screw, Socket Head 6 UB100141 8 Head Gasket 1 SN520CS0007 9 U-Seal 2 SN840CS0010 10 U-Seal 2 SN840CS0009 11 U-Seal 2 SN840CS0008 12 Packing Unit 1 SN473CS0005 13 Cap Screw, Socket Head 1 SN830CS0011 14 Plug, Pipe 1 UB100050 15 Shackle, Swivel 4 UB100157 16 Stud 16 UN9300187080950 17 Nut 16 UN6700187

5.2 Diverter storage

At the conclusion of each well or prior to placing the annular BOP in storage for even a brief period, it is recommended that the preventer be disassembled, cleaned, inspected, lubricated thoroughly with non-petroleum base oil such as cast oil or rapeseed oil, and reassembled. Replacement of worn packing units, or packers, seat rings, and other parts can be made conveniently at this time Flange or hub faces and ring grooves should be protected with covers, and ports should be plugged.

5.3 Rubber Goods Storage

The term rubber goods include synthetic compounds such as Nitrile Copolymers and Neoprene, as well as natural rubber parts. The ideal storage situation for rubber goods would be in vacuum-sealed containers maintained in a cool, dry, dark storage area. The following recommendations will allow vendors and users of oil field equipment to maximize normally available storage facilities for rubber goods.

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1. Keep the rubber storage area as dark as possible – preferably indoors, not outdoors, and away from direct sunlight, skylights, windows, and direct artificial lighting.

2. Select a cool location (approximately 650 F) that is away from heaters, stoves, and direct blasts of space heaters.

3. Keep rubber goods away from electrical machinery (motors, switch gear, or any high voltage equipment producing corona). Avoid locations susceptible to drafts that will carry the atmosphere from electrical machinery to the rubber good storage area.

4. The practice of first-in, first out is essential with rubber goods. 5. Store rubber goods in a relaxed position in their normal shape. For example, do not hang o-rings

on nails. Do not keep assemblies in stretched attitudes, e.g., o-rings on glands, BOP testers, and operators parts.

6. Rubber goods storage areas should be kept as dry as possible. Remove oil, grease or other foreign materials from storage area to preclude spillage on rubber goods.

7. If storage for extended periods is anticipated, sealed containers are recommended. Impervious surface coverings such as waxing will increase shelf life.

Factors that accelerate the deterioration of rubber goods are atmosphere, light and heat. The term “aging” means cumulative effects of all three attacking agents over a period of time. Other factors that will affect rubber goods include stretching or bending from normal shape, extreme cold, chemical reactions with solvents and petroleum products. Exposure to the atmosphere allows oxygen to react with the rubber goods. Ozone (O3), a very active form of oxygen, is especially detrimental to rubber goods. The principal sources of ozone contributing to rubber goods deterioration are: (1) atmospheric ozone, and (2) ozone created by electrical discharges such as lighting, high voltage corona, or electrical machinery. Points of strain in rubber goods attacked first by ozone and will be characterized by deep cracks. Ozone and normal oxygen (O2) will attack rubber goods much as steel rusts. Oxidation is characterized by a hard skin, which eventually crazes in small cracks and may turn chalky or assume a bark-like appearance. Strong, direct light, especially sunlight, has a harmful effect on rubber goods. The ultraviolet content of the light spectrum accelerates cracking. Light, especially sunlight, is undesirable and should be avoided at all times. Heat, whether the result of sunlight, artificial or accidental heating, will also have harmful effects upon rubber goods. Heat results in a gradual hardening of the rubber goods. The process is greatly accelerated when ozone or oxygen is present. In extremely cold climates, some rubber goods will become so brittle that they will shatter when dropped or handled roughly. Any stretching or bending of rubber goods in storage from a relaxed, normal shape will result in accelerated aging or cracking. Rubber goods, both natural and synthetic, possess some degree of susceptibility to deterioration from various solvents, especially oil field liquid hydrocarbons. These materials cause swelling/shrinkage of the rubber goods with which they are in contact.

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T3 Annulars BOP Operators Manual 7022

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