QUICK REF.

OPERATOR’S MANUAL 1-1

R

GK® 11”-5000 psi

Annular Blowout Preventer

OPERATOR’S MANUAL
R
GK® 11”-5000 psi
Annular Blowout Preventer
4.1 Maintenance
Prior to placing the GK® blowout preventer into service, the
following visual inspections should be performed:
1. Inspect upper and lower connections for pitting, wear,
and damage—especially in ring grooves and stud bolt
holes. Worn or damaged ring grooves must be welded,
machined, and stress relieved. Worn or damaged stud bolt
holes can be drilled and tapped to the next larger size and
fitted with step-studs.
NOTE: The Hydril® GK® blowout preventer is a pri-
mary pressure vessel. The blowout preventer sur-
faces exposed to wellbore fluids will meet NACE
Standard MR-01-75. Proper handling and repair are
required to maintain any original integrity. Field
welding is not recommended as it induces undesir-
able stresses which must be relieved by proper heat
treating procedure or controlled by special welding
procedures.
2. Check the body for wear and damage—especially in the
internal cylinder walls for pits and vertical scores. Minor pits
and scores can be removed in the field with emery cloth.
Repaired surface should be coated with silicon grease or
castor oil. Severe pits and scores may require machining
and/or welding which should be performed in a machine
shop. Cracks must be corrected.
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 sleeve for cuttings which may
restrict piston movement. Some model BOPs have a welded
body sleeve and may be field repaired by conversion to a
bolted sleeve (see Section 4.4).
1 6
8
8
1
Figure 4-1
PAGE
4-1
M
ay
20
01
5. Check for piston damage and wear—especially the
inner and outer walls for pits and vertical scores and the
tapered bowl for pits and gouges.
Minor pits and scores on the walls can be removed in the
field with emery cloth. Repaired surface should be coated
with silicon grease or castor oil. Severe pits and scores may
require machining and/or welding which should be per-
formed in a machine shop.
Pits and gouges in the tapered bowl should be filled with
a permanent type adhesive, such as epoxy. Sharp or rolled
edges should be removed with emery cloth or a grinder.
Repair will be satisfactory when a relatively smooth surface
is achieved.
6. Check the wear plate in the inner bottom face of the
head for wear. In addition to the aging process of time and
use, wear of this metal surface is produced by the combi-
nation of vertical (upward thrust) and lateral forces. These
forces are generated each time the packing unit is closed.
Severe wear is exhibited in the form of grooves or channels
shaped by the steel segments of the packing unit.
The inner bottom face of the head serves as a wall to
prevent upward movement of the packing unit. Friction
between these metal surfaces is controlled at a level which
does not impair lateral movement of the packing unit.
Repair of this surface is accomplished by replacing the
wear plate. Some models of this BOP do not have the wear
plate, but may be converted.
7. Inspect the packing unit for wear, cracking, hardness,
and correct elastomer composition. See Section 3 for
packing unit information and Section 4.3 for packing unit
testing.
8. Check seal ring for nicks, cuts, fraying of lips, and
abrasion. Worn or damaged seal rings should be replaced.
See Section 4.2 for pressure testing of seals.
7
5
2
4
 PAGE

OPERATOR’S MANUAL 4-2

R

GK® 11”-5000 psi

M
ay
Annular Blowout Preventer

20
01
4.2 Seal Testing
When it is known or suspected that a seal within the GK
blowout preventer is leaking, it is recommended that all 6
seals be replaced. However, if only the seal in question is
to be replaced, it must first be determined which seal is
leaking. The following procedure is provided:
1. Test seals 9 (lower) and 10 (upper).
a. Pressurize closing chamber. The test pressure to 8 UPPER
be used in the closing chamber should be the
initial closing pressure required using the recom-
mended test mandrel if a packing unit is installed
(1500 psi if no packing unit is installed).
b. Open opening chamber to atmosphere.
8 LOWER
IF: Closing fluid is seen at opening chamber—seal 9
(lower) is leaking.
IF: Closing chamber pressure gauge is dropping and
no fluid is seen at opening chamber—seal 10
(upper) is leaking.
2. Test seals 8 (lower), 9 (upper), and 6.
a. Pressurize opening chamber (1500 psi).
b. Open closing chamber to atmosphere. 9 UPPER
IF: Fluid is seen coming from area between body and
head—seal 6 is leaking.
9 LOWER
IF: Fluid is seen coming into the wellbore—seal 8
(lower) is leaking.
IF: Fluid is seen at closing chamber—seal 9 (upper) 10 UPPER
is leaking.
3. Test seals 8 (upper) and 10 (lower). 10 LOWER
a. Open closing chamber to atmosphere.
b. Open opening chamber to atmosphere.
c. Pressurize wellbore (5000 psi maximum). (Re-
quires blind flange on top, as packing unit is
open.)
IF: Fluid is seen coming from the opening chamber—
seal 8 (upper) is leaking.
IF: Fluid is seen coming from the closing chamber—
seal 10 (lower) is leaking.
4. For packing unit testing, see Section 4.3. Figure 4-2
 PAGE

OPERATOR’S MANUAL 4-3

R

GK® 11”-5000 psi

M
ay
Annular Blowout Preventer

4.3 Packing Unit Testing
Proper procedure for pressure testing any annular blowout
preventer ensures subsequent seal off and maximum
packing unit life. Reliable pressure seal off tests are made
by closing the packing unit with prescribed closing cham-
ber pressure on recommended size test pipe and by
20
01
determining the remaining piston travel after seal off is
achieved. Optimum packing unit life is obtained by
testing at low rubber stress levels. Minimum packing
unit stress is achieved by use of the minimum closing
chamber pressure that will initiate and maintain a seal
off on the recommended size test pipe.

4.3.1 Packing Unit Testing—Surface

The GK® blowout preventer is designed to be well pressure
assisted in maintaining packing unit seal off once initial seal
off has been effected. Initial seal off is effected by applying
pressure to the closing chamber. As well pressure or test
pressure increases, the closing force on the packing unit
also increases.
As well pressure exceeds the required level, the packing TAPE MEASURE 5/16" ROD
unit is maintained closed on pipe by well pressure alone.
During routine BOP testing, once initial seal off is achieved,
closing pressure should be proportionally reduced as well
pressure is increased (see the Control Pressure Graph,
Figure 1-8).
Closing pressure required to effect initial seal off may
vary between packing units. Begin the test with the rec-
ommended initial closing pressure shown in Figure 1-8,
depending on the style packing unit installed.
Piston Stroke can be measured on GK® blowout pre-
venters through a vertical passage in the top of the BOP
head. The maximum and minimum distances from the top
of the head to the top of the piston are stamped on the BOP
head and are also listed in the table below. Piston stroke
remaining at seal off is a direct indicator of remaining
packing unit life. Record the piston stroke and the closing
pressure at initial seal off for each test. Compare with
previous results and with maximum piston stroke for the
BOP to ensure subsequent seal offs. A valid test on any
annular BOP is only achieved when the remaining piston
stroke is measured at test seal off.

Distance From Top of Head to Top of Piston

Maximum (piston in full down position) 11-1/8"

Minimum (piston at full stroke) 4"

Figure 4-3: Piston Stroke Measurement

Older model BOPs may not have the Piston Indicator Hole
as shown in Figure 4-3 above. See Section 4.4 for
modilcation.
 PAGE

OPERATOR’S MANUAL 4-4

R

GK® 11”-5000 psi

M
ay
Annular Blowout Preventer

20
01
4.4 BOP Modifications

4.4.1 Piston Indicator Hole Modification

Older Model BOPs without piston indicator holes may be
modified as shown in Figure 4-4 below.

R – 11.968"

.719 DRILL
1/2"-14NPT TAP CL PISTON INDICATOR BOP CL

.339" DIA.
DRILL THROUGH

Figure 4-4: Field modification for addition of Piston

Indicator Hole to older model BOPs.

The procedure* for adding the piston indicator hole is as
follows:
1. Drill one .339" diameter hole through the BOP head at a
point located on R=11.968" radius from the centerline
( CL) of the BOP Head.
2. Counterbore with .719 " diameter drill. x 1 3/8" deep.
3. Tap the .719" diameter hole with a 1/2"-14 NPT tap.
4. Insert a 1/2"-14NPT pipe plug and torque to 50 lb-ft.
* A drill press should be used.
 PAGE

OPERATOR’S MANUAL 4-5

R

GK® 11”-5000 psi

M
ay
Annular Blowout Preventer

4.4.2. Bolted Body Sleeve Modification
To maintain original integrity without welding, older model
BOPs having a welded body sleeve may be repaired
through conversion to a bolted sleeve. This conversion is
accomplished by using the Field Replacement Sleeve Kit,
part number 1006100.
The Field Replacement Sleeve Kit contains the follow-
ing:
1. 1—Drill Template
2. 1—27/64" Dia. Pilot Drill
3. 1—19/32" Dia. Counterbore Drill
4 1—1/2"-13UNC Tap
5. 1—Bolted Body Sleeve
6. 12—1/2"-13UNC X 1 1/4" Lg. Hex Head Cap Screws
The procedure for converting the BOP from a slotted
body sleeve to a bolted sleeve is as follows:
1. Remove old body sleeve.
2. Grind out all weld from the counterbore and the 20o
Grind All Weld From
o
Counterbore And 20 Bevel
20
01
bevel that would interfere with the new sleeve (see
Figure 4-5).
3. Insert drill template as shown in Figure 4-6.
4. Drill one 27/64" diameter hole, 1 1/4" deep, through one
of the 27/64" diameter holes in the template.
NOTE: Template has eleven 27/64" diameter holes
and one 9/16" diameter hole.
5. Remove the template and counterbore hole with 19/32"
diameter drill (see Figure 4-7).
6. Tap the hole with 1/2"-13UNC tap, 1" deep.
7. Re-insert the template and bolt to the BOP through the
9/16" hole in the template.
8. Drill a 27/64" diameter hole, 1 1/4" deep, in the 11
remaining places.
9. Remove the template and counterbore 19/32" diameter
in 11 places.
10. Tap 11 holes with 1/2"-13UNC tap.
11. Install new sleeve and bolt down tight (see Figure 4-8).
27/64" Dia. Drill Drill Template

Figure 4-5 Figure 4-6

19/32" Dia. Counterbore Drill 13 1/8 +/– 1/16" To Top Of Body

With 27/64" Dia. Pilot
Bolted
Body Sleeve

Figure 4-7 9/16" Hole

19/32" Counterbore
1/2"-13UNC Thread
27/64" Dia.

Figure 4-8