No.1525
FZ54-14U Ram BOP
Rev.A0
Security Guide
The manual covers matters needing attention for ensuring personal safety as well as protecting product and connected
equipment from damage.
All matters needing attention are given with symbols for clear warning and are also respectively described with the
following characters upon on the severity:
Notice
Ignoring proper prevention measures may cause injuries, deaths, serious personal injury or large property loss.
Notice
Catch your attention on important information of the product or specific part during handling with the product or files.
Competent person
No one but the competent person is authorized to assemble and operate the equipment. The competent person shall be
the person with certain experience on on-site well control and be able to assemble, perform test run and operate the
equipment according to specified safety practices and standards.
Correct way to use
Pay attention to the following:
Notice
The equipment and assemblies thereof shall be applied only to description in product catalogue or technical manual, and
shall be connected only with devices or assemblies that are approved by Shenkai or other recommended manufacturers.
Safety first shall be complied for well control equipment. Any quick-wear metal and non-metal part, in particular the
rubber core that influences the product safety and performance in test shall be replaced timely.
The product can work correctly and safely on the premise of correct transportation, storage, assembling, installing, and
being operated and maintained by the recommended mode.
Trademarks
R
○
R
○
、
、
R
○
are the registered trademark of Shenkai.
Any third party using other names related to the trademarks in this manual for its own purpose (s) shall be treated as infringing the
rights and interests of the proprietor of the trademarks.
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd. holds the copyright○c 2014. All rights reserved.
None of the manual or contents may be reproduced, transmitted or used without clear written authorization.
Rights reserved. All rights reserved, including patent right, utility model or appearance design exclusive right.
The BOP meets the requirements of standards API 16A and GB/ T20174 and gained logo usage license issued
by API and production license issued by State Administration for Quality Supervision and Inspection and
Quarantine: 16A-0111,
, XK14-001-0002 and
.
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd. hereby declares that by check the contents of the manual are
consistent with the product and cannot in the nature of things be free from error, the consistency is maximized. The contents of the
manual will be reviewed at fixed period and modified in the next version. Suggestions for improvements are highly welcomed.
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd. holds the copyright○c 2014. No inform will be made for any
change.
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd.
After-sale Service Department
Customer Hotline: +86(21)64290467
Fax:+86(21)64290467
Website:www.shenkai.com
Postal Code: 201114
Catalogue
1 Overview .............................................................................................................................................. 1
2 Model & Specification and Technical Parameters ............................................................................... 2
2.1 Model......................................................................................................................................... 2
2.1.1 Bore Code ....................................................................................................................... 2
2.1.2 Rated working pressure .................................................................................................. 2
2.1.3 Temperature grade ......................................................................................................... 2
2.2 Technical Parameters of ram BOP ........................................................................................... 4
3 Working Principles and Structure Characteristics ............................................................................... 6
3.1 Working principle....................................................................................................................... 6
3.1.1 Hydraulic control principle .............................................................................................. 6
3.1.2 Sealing principle ............................................................................................................. 7
3.2 Structural features of main parts ............................................................................................... 7
3.2.1 Pipe ram assembly ......................................................................................................... 8
3.2.2 Sealing part for front rod of main piston ......................................................................... 9
3.2.3 Secondary seal ............................................................................................................. 10
3.2.4 Sealing part for tail rod of main piston .......................................................................... 12
3.2.5 Manual locking mechanism of ram ............................................................................... 13
3.2.8 The sealing way of Intermediate Flange ...................................................................... 14
3.3 Parts list................................................................................................................................... 15
4 Installation and Use ........................................................................................................................... 20
4.1 Preparation for use.................................................................................................................. 20
4.2 Usage and matters needing attention ..................................................................................... 22
5 Dismounting and Maintenance of BOP ............................................................................................. 23
5.1 Opening Intermediate Flange of BOP..................................................................................... 23
5.2 Replacement of ram and its sealing rubber core .................................................................... 24
5.3 Replacement of Seal Ring between Intermediate Flange and Body ..................................... 25
5.4 Repair and replacement of cylinder assembly........................................................................ 25
5.5 Disassembly of ram opening and closing piston rod .............................................................. 27
5.6 Matters needing attention for assembly .................................................................................. 29
5.7 Daily maintenance................................................................................................................... 29
5.8 Operating Period Maintenance ............................................................................................... 30
6 Preservation procedures ................................................................................................................... 32
6.1 Storing for periods greater than 30 days ................................................................................ 32
6.2 Storage of Rubber Parts ......................................................................................................... 32
7 Common Troubles and Troubleshooting ........................................................................................... 33
(The Manual applies to FZ54-14U Ram BOP P/N:
C25
2C25
)
FZ54-14U Ram BOP User Manual
Rev.A0
1 Overview
Ram BOP is the key part of well control device and its main purpose is to control
wellhead pressure to effectively prevent blowout accident and realize safe construction
during drilling, well repair, well test and other processes. Its appearance sees Fig.1-1.
The following operations can be finished with it:
 Sealing the annular space between the sleeve and the pipe column by
corresponding pipe ram when there is a pipe column in the well;
 Sealing the whole wellhead by full ram when there is no pipe column;
 Sealing the whole wellhead in case of emergency by cutting off the pipe column
with a shear ram;
 Realizing slurry circulation, choke and blowout controller, well control, well
flushing and the like special operations via the well controller and choke manifold
connected to the stone and the side outlet of body, when the well is sealed;
 Controlling the pressure at the bottom of well and realizing the near balance by
cooperating with choke and well control manifold.
Fig.1-1 Appearance of 2FZ54-14U Double-ram BOP
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FZ54-14U Ram BOP User Manual
Rev.A0
2 Model & Specification and Technical Parameters
2.1 Model
U
Model of BOP
Rated working pressure code(Table 2-2)
Bore code: (Table 2-1)
Ram BOP code: FZ- single ram BOP; 2FZ-double ram BOP;
3FZ- triple ram BOP
2.1.1 Bore Code
Table 2-1 Bore Coder
Bore Code
18
Bore Specification （in）
7 1/16 〃
Bore Code
48
Bore Specification （in）
18 3/4〃
23
9〃
53
20 3/4〃
28
35
11〃
54
68
21 1/4〃
13 5/8〃
16 3/4〃
43
26 3/4〃
30〃
76
2.1.2 Rated working pressure
The BOP has rated working pressure at six grades, as shown in Table 2-2.
Table 2-2 Rated working pressure
Pressure code
Rated working pressure
MPa
psi
14
13.8
2,000
21
20.7
3,000
35
34.5
5,000
70
69.0
10,000
105
103.5
15,000
140
138.0
20,000
2.1.3 Temperature grade
Minimum temperature is namely the minimum environmental temperature that might
be suffered from, and maximum temperature is namely the maximum temperature of the
liquid flowing through the equipment.
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FZ54-14U Ram BOP User Manual
Rev.A0
Metal parts of the equipment work within the temperature range as shown in Table
2-3.
Synthetic rubber materials in the equipment, contacting with the liquid in the well,
work at the temperature grade as shown in Table 2-4.
Table 2-3 Temperature grade of metal material
Temperature Rating Code
API Code
Working Temperature Scope
T-75
75
-59℃~121℃(-75 ºF ~250 ºF)
T-20
20
-29℃~121℃(-20 ºF ~250 ºF)
T-0
00
-18℃~121℃(0 ºF ~250 ºF)
Table 2-4 Temperature grade of nonmetal sealing material in contact with liquid in well
Lower Limit (first letter)
Upper Limit (second letter)
Code
Temperature
Code
Temperature
A
-26℃（-15℉）
A
82℃（180℉）
B
-18℃（0℉）
B
93℃（200℉）
C
-12℃（10℉）
C
104℃（220℉）
D
-7℃（20℉）
D
121℃（250℉）
For example: AB presenting the temperature rating of -26℃~93℃ (-15℉~200℉). The specific
temperature rating is indicated on the sealing parts.
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FZ54-14U Ram BOP User Manual
Rev.A0
2.2 Technical Parameters of ram BOP
Table 2-5 Specification and main technical parameters of ram BOP
Description
Double-ram BOP
Model
2FZ54-14U
Drift diameter
Rated working
pressure
Hydrostatic test
pressure
Hydraulic control
rated working
pressure
Recommended
hydraulic control
operation pressure
Starting capacity of
hydraulic cylinder
Closing capacity of
hydraulic cylinder
Closing Ratio
Locking Screw turns
(each end)
Temperature grade
c
Weight
Single-ram BOP
FZ54-14U
1
539.8mm（21 /4 in）
14MPa(2000Psi)
21MPa (3000Psi)
21 MPa（3000Psi）
8.4-10 .5MPa(1200-1500Psi)
16.7L×4
16.7L×4
17.7L×4
17.7L×4
7.0:1
50圈
T-20
14500kg
14500kg
Instructions:
a. The BOP is designed and manufactured according to specifications API Spec 16A.
b. The part in the BOP, in contact with liquid in well is resistant to hydrogen sulfide stress corrosion,
and the requirements of NACE MR-0175 are met.
c. The weight of BOP in the connection mode of flanged is showed in the table (see Fig.2-1,
Fig.2-2, including ram assembly). The actual weight shall change with the change of the upper and
the lower connection and the side port.
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FZ54-14U Ram BOP User Manual
Rev.A0
Fig.2-1 Size diagram of appearance of FZ54-14U single-ram BOP
Fig.2-2 Size diagram of appearance of 2FZ54-14U double-ram BOP
A-1
Length-intermediate flange is closed, and the end of clamp axis is unlocked
A-2
Length-intermediate flange is opened, and the end of clamp axis is unlocked
B-1
Height-flange connection
B-2
Height-upper bolted and lower flanged connection
C
Width-not including side port
Table 2-6 Size of appearance of ram BOP
Overall dimension
Model
A-1
mm
A-2
mm
B-1
mm
B-2
Mm
C
mm
FZ54-14U
Single Ram BOP
4120
5800
944
765
1000
2FZ54-14U
Double Ram BOP
4120
5800
1638
1638
1000
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FZ54-14U Ram BOP User Manual
Rev.A0
3 Working Principles and Structure Characteristics
3.1 Working principle
3.1.1 Hydraulic control principle
When the high pressure oil of hydraulic control system enters the closed chamber of
left and right cylinder rams, it will push the main piston, and the left and right ram
assembly will move toward the center of wellhead along the ram chambers of the body,
enabling the sealing of the wellhead. When the high pressure oil enters the opened
chamber of left and right cylinder rams, it will push the main piston and the left and right
ram assembly will move far away from the center of well head, enabling the opening of
wellhead. The ram switch is controlled by the selector valve of hydraulic control system.
Generally the opening and the closing can be finished within 3～5 seconds.
The hydraulic control system can be used to open and close the cylinder assembly,
so as to replace the ram.
 Open the cylinder assembly -- after unscrewing cylinder bolts, close the ram by the
hydraulic oil, and the pressure for closing the ram will push the ram toward the
wellhead, while pushing the cylinder assembly far from the body, and the ram will
move out of the body. And then lift the ram to replace it by hoist screws.
 Close the cylinder assembly -- Open the ram by hydraulic oil that will push the main
piston, and pull back the ram assembly to the opening status, and then push the
hydraulic cylinder assembly toward the body until being fitting with the body. One of
important features of UM ram BOP is that: Before the cylinder assembly moves
toward the body, the ram will firstly be pulled back to the opening status by the
hydraulic oil. So when the cylinder assembly is closed, the ram will not be interfered
with the drilling tool in the through-hole.
Diagram of oil circuit is showed in Fig.3-1.
CLOSE
OPEN
The ram is closed, and the cylinder assembly is opened
The ram is opened, and the cylinder assembly is closed
Fig.3-1 Diagram of hydraulic circuit of ram switch and cylinder assembly switch
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FZ54-14U Ram BOP User Manual
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3.1.2 Sealing principle
The ram BOP shall ensure four available sealing places at least to maintain effective
sealing of well head. They are respectively the sealing between the top ram sealing and
the body; the sealing between the front ram sealing and the pipe column, and that
between the body and the front sealing; the sealing between the body and the
intermediate flange; the sealing between the front bar of main piston and the intermediate
flange.
The sealing of ram is finished by two steps: the first step is that under the effect of
hydraulic oil the main piston pushes the rubber core of the front ram sealing to make the
front part of seal squeezed and deformed, and also pushes the top of interference and
compression seal between the rubber core and the body of sealing, which form the initial
sealing; the second step is that when there is pressure in the well, the well pressure will
push the front ram seal from the rear part of ram for further squeeze and deformation.
Meanwhile the well pressure will push the ram from the bottom to lift it to fit on the sealing
surface of body, namely, the effect of assisting sealing with the well pressure is realized.
3.2 Structural features of main parts
The U-type ram BOP is comprised of body, intermediate flange, cylinder assembly,
main piston, cylinder for replacing the ram, ram ON/OFF piston, lock screw, ram
assembly and sealing parts and the like main parts.
The body, the intermediate flange and the like pressure-bearing parts are made of
high strength and high tenacity alloy steel, strictly controlling the harmful chemical
components and non-metal substances of materials, making the secondary refining,
forging and molding, so as to ensure safe and reliable usage of BOP after proper heat
treatment. The ram chamber of body is in a shape of long runway so as to reduce stress
concentration.
Both the intermediate flange switch and the ram switch are driven hydraulically from
the same oil circuit. The open-close ram for intermediate flange are from the same oil
circuit under the same operation; it is the same with the close-open ram for Intermediate
flange.
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FZ54-14U Ram BOP User Manual
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3.2.1 Pipe ram assembly
Top rubber core
Ram body
Front rubber core
Fig.3-2 Diagram of pipe ram assembly
Table 3-1 Parts of pipe ram
Description (quantity) of pipe ram assembly
Ram Type
Ram assembly
Ram body (2)
Front rubber core
(2)
Top rubber core
(2)
Blind
2C25.08A.00
2C25.08A.01
2C05.01A.03
2C05.08A.02
5″
2C25.08B.00
2C25.08B.01
2C05.01B.02
2C05.08A.02
13 3/8"
2C25.08C.00
2C25.08C.01
2C05.01C.02
2C05.08A.02
Note: The number in the bracket means the quantity of rams in a pair of pipes
The ram is an integrated long runway style. Its sealing rubber core adopts the
assembly structure of front sealing and top sealing. The front seal and the top seal can be
replaced independently according to the damage condition. The assembly and the
disassembly are simple and labor saving.
Note: The sign of “HO” (Hang-Off) on the ram body indicates that drilling tools could
be hanged on. Drilling tools shall not be hanged on the ram assembly without the sign of
"HO".
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FZ54-14U Ram BOP User Manual
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3.2.2 Sealing part for front rod of main piston
Two-way seal is adopted between the Intermediate flange and the front rod of main
piston. The wellhead can be sealed by Y-seal and gaskets. The hydraulic control
pressure can be sealed by O-ring.
11
10
9
8
7
6
5
Direction of hydraulic
Direction of well
control pressure
pressure
Fig.3-3 Structure of sealing part for front rod of main piston
Table 3-2 List of sealing parts for front rod of main piston
Qty
Qty
（Single）
（Double）
2C25.18
2
4
Fastened sealing ring
2C02.25
2
4
Reinforced sealing ring
2C02.26
2
4
2C02.27
2
4
No.
Description
P/N
11
O-ring
10
9
8
Sealing ring of front rod of
main piston
7
gasket
2C02.28
2
4
6
gasket
2C02.18
2
4
5
Retainer ring 140
2C02.17
2
4
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FZ54-14U Ram BOP User Manual
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3.2.3 Secondary seal
The sealing part between the Intermediate flange and the front rod of main piston is
comprised of two parts. The first one is the sealing wellhead. And the other one is the oil
pressure for sealing the hydraulic control. The secondary seal is at the middle of the two
parts. Generally, the sealing is highly reliable by the sealing ring of several structures. But
the sealing ring may be damaged due to not being maintained for a long term or other
reasons, leakage may happen during well sealing. The secondary seal will be needed for
emergency handling.
At the condition of well sealing, if any fluid flows from the access hole (at the bottom
of the Intermediate flange), the sealing ring shall have been damaged. Whether the
sealing ring for well sealing pressure or that for the oil sealing pressure is damaged can
be damaged according to the property of fluid. Now remove the Z1″ external hex blocking
for greasing hole at the top immediately. Rotate the hole screws clockwise by a socket
head wrench. Eject the secondary sealing grease in bar shape to the annular space via a
one-way valve, so as to reinforce the sealing ring and make sealing compensation.
Precautions during usage of secondary sealing device:
 To prevent the secondary sealing grease from being solidified and invalid when
the BOP is not used for a long term, the secondary sealing grease bar shall not
be mounted when the BOP leaves out of factory, and our company also doesn't
recommend to install the secondary sealing grease bar when the BOP is not
used. It shall not be mounted before being inserted to the well, and removed
after well completion and maintenance. It shall be washed to keep clean.
 Special tools shall be prepared in advance for urgent need.
 Observe frequently from the access hole (internal hexagonal plug screws with
hole) at the bottom whether drilling fluid or oil fluid flows during usage of BOP.
 After the sealing ring becomes invalid, the secondary sealing grease shall not be
ejected excessively, which shall be subject to the standard that the observation
hole would not be leaked. Because the friction resistance of secondary sealing
grease is high and particles are adhered, a major damage may happen to the
main piston.
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FZ54-14U Ram BOP User Manual
Rev.A0
18
19
17
16
Direction of hydraulic control
Direction of well pressure
pressure
44
Fig.3-4 Structure of secondary seal
Table 3-3 Parts list of secondary sealing device
Qty
Qty
（Single）
（Double）
2C01.21
2
4
Cock 1-8UNC
2C01.20
2
4
17
Secondary sealing grease
EM-09-1/L25mm
2
4
16
Check valve
2C01.07
2
4
2C01.32
2
4
No.
Description
P/N
18
Z1″ External hexagonal blocking
19
44
Z1/2″ hexagon socket screw
plug
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FZ54-14U Ram BOP User Manual
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3.2.4 Sealing part for tail rod of main piston
Main cylinder
Direction of hydraulic
control pressure
Main piston
24
25
Fig.3-5 Sealing part for tail rod of main piston
Table 3-4 List of sealing parts for tail rod of main piston
Qty
Qty
（Single）
（Double）
2C01.49
2
4
77.5×5.3
2
4
No.
Description
P/N
1
Sealing ring of tail rod of main piston
2
O-ring
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FZ54-14U Ram BOP User Manual
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3.2.5 Manual locking mechanism of ram
The manual locking mechanism of ram is comprised of locking screw, locking axle
seat, main piston and manual control assembly. (The length is generally 3.8m and 3.38m,
or customized).
The effect of manual locking mechanism is when it takes a long time to have well
sealing, and after the ram is closed hydraulically, rotate the hand wheel by manual force,
and lock the ram at the closed position. At this time, the hydraulic pressure may be
released.
 Locking -- When it is locked manually, rotate the hand wheel clockwise, and drive
the lock screw for rotation by a joystick. Because the locking screw locates at the
clamp seat, rotate the locking screw to push it at the rear of main piston, forcing
the main piston moving toward the center of wellhead and locking the ram
assembly (Generally rotating 50 turns clockwise).
 Unlocking -- The manual locking device can just close the ram instead of opening
the ram. If to open the ram that has been locked manually, firstly reset and
unlock the locking device manually, and open the ram by hydraulic pressure.
This is the only way. The detailed operation method is:
 Firstly rotate the hand wheel to the terminal point counter-clockwise
(Generally rotating 50 turns counter-clockwise);
 And then rotate back for 1/8～1/4 turns, to prevent the clamp axle from
jamming during change of temperature;
 And then the ram is opened by hydraulic pressure.
Fig.3-6 Manual control assembly
Fig.3-7 Locking status
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FZ54-14U Ram BOP User Manual
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3.2.8 The sealing way of Intermediate Flange
The sealing between the intermediate flange and the body for ram BOP adopts the
O-ring, showed in the following figure;
O-ring
Fig.3-8 Seal (side door sealing ring) of Intermediate Flange and installation
Table 3-7 Parts list of seal (side door sealing ring) assembly of middle flang
No.
Description
P/N
2
O-ring
2C25.16
14
Qty
Qty
（Single）
（Double）
2
4
FZ54-14U Ram BOP User Manual
3.3 Parts list
Figure 3-9 Breakdown Drawing of BOP Parts
15
Rev.A0
FZ54-14U Ram BOP User Manual
Rev.A0
Table 3-6 BOP Parts List
No.
Description
Part No/Model
1
Body
2
Qty
（Single）
（Double）
--
1
1
O-ring
2C25.16
2
4
3
Ram assembly
2C25.08 ( ) .00
1
2
4
Guide pin
2C05.16
4
8
5
Retainer ring 140
2C02.17
2
4
6
gasket
2C02.18
2
4
7
Sealing ring of front rod of
main piston
2C02.27
2
4
8
gasket
2C02.28
2
4
9
Reinforced sealing ring
2C02.26
2
4
10
Fastened sealing ring
2C02.25
2
4
11
O-ring
2C25.18
2
4
12
O-ring
41.2X3.55
2
4
13
Nozzle Flange
2C25.09
2
4
14
Stud M12X35
GB70-85
8
16
15
Intermediate Flange Screw
2C25.10
24
48
16
Check value
2C01.07
2
4
17
Secondary sealing grease
EM-09-L/25mm
2
4
18
NPT1” External hexagonal
blocking
2C01.21
4
8
19
Cock 1-8UNC
2C01.20
2
4
20
O-ring
345X7
2
4
21
Operating Piston Assembly
2C25.06.00
2
4
22
Lip ring of piston
2C01.08
4
8
24
Seal ring of Tail Rod
2C01.49
2
4
25
O-ring
77.5X5.3
2
4
26
Bonnet Screw
2C25.11
8
16
27
Bonnet
2C25.03.00
2
4
28
Seal Gland
2C05.05
2
4
29
Seal Plug
2C05.04
2
4
30
NPT1” Plug
2C01.34
4
8
31
Locking screw
2C25.02
2
4
32
Locking Screw Housing
2C25.01.00
2
4
33
Bolt M36（L=110）
GB70-85
12
24
34
NPT1/2”Hexagon Socket
Plug Head
2C01.36
8
16
35
Ram closing piston
2C25.15
2
4
16
FZ54-14U Ram BOP User Manual
Rev.A0
Continued Table 3-6 Parts list
No.
Description
Part No/Model
36
O-ring
37
Qty
（Single）
（Single）
112X7
4
8
Ram opening piston
2C25.14
2
4
38
Ram change cylinder
2C25.13
4
8
39
O-ring
165X7
4
8
40
O-ring
73X5.3
4
8
41
Guide ring
2C05.18
4
8
42
O-ring
150X7
4
8
43
O-ring
90X5.3
4
8
44
NPT1/2” Hexagon Socket
Plug Socket Head
2C01.32
2
4
45
Intermediate Flange
2C25.12
2
4
2C25.06.00 Operating Piston Assembly contain Following Parts
21-1
Hook（一）
2C05.06.02
2
4
21-2
Stop block
2C02.11A-04
4
8
21-3
Piston Rod
2C25.06.01
2
4
21-4
O-ring
100.97x5.33
2
4
21-5
Backup ring
C664-22 102.31x111.61x1.52
4
8
21-6
Piston
2C25.06.02
2
4
21-7
Stop block
C17.08.03
6
12
21-8
Screw M12X20
GB/T 77-2000
6
12
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FZ54-14U Ram BOP User Manual
Rev.A0
Figure 3-10 Breakdown Drawing of Spare Parts
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FZ54-14U Ram BOP User Manual
Rev.A0
Table 3-7 Spare parts list for one year
Qty
Qty
（Single）
（Double）
2C25.16
2
4
Sealing ring of front rod of main
piston
2C02.28
4
8
8
gasket
2C02.27
2
4
9
Reinforced sealing ring
2C02.26
2
4
10
Fastened sealing ring
2C02.25
2
4
11
O-ring
2C25.18
2
4
12
O-ring
41.2×3.55
2
4
17
Secondary sealing grease
EM-09-L/25
2
4
20
O-ring
345×7
2
4
21-2
Stop
2C02.11A-04
1
2
21-7
Stop
C17.08.03
6
12
22
Lip ring of piston
2C01.08
4
8
24
Seal ring of Tail Rod
2C01.49
2
4
25
O-ring
77.5×5.3
2
4
36
O-ring
112×7
4
8
39
O-ring
165×7
4
8
40
O-ring
73×5.3
4
8
41
导向环
2C05.18
4
8
42
O-ring
150X7
4
8
43
O-ring
90X5.3
4
8
No.
Description
Part No/Model
2
O-ring
7
19
FZ54-14U Ram BOP User Manual
Rev.A0
4 Installation and Use
4.1 Preparation for use
After the ram BOP is installed at the wellhead, check the following operations before
use, and it shall be used when it is thought no problem by the test running.
 Check if BOP is correctly installed: the hoisting bolt of the body is on the top; the
manual lock device is well installed and fixed with the hanger in the hand wheel
indicating the opening and closing cycles; the opposite angles of the attachment
bolts at all position are even and tightening.
 Check whether the size of mounted ram rubber cores and the size of drilling tools
under the well;
 Check whether the blowout control, the well control, and the choke manifold are
well connected;
 Use the control device to open and close all rams respectively twice by
2-3MPa(300psi~500psi) control pressure for test run.
 Remove air in the oil line.
 Check if the connection pipeline of the oil road is consistent with opening and
closing as indicated by BOP. In the case that the ram’s opening and closing
action is not consistent with that as indicated by the console handle, adjust
the connection pipeline.
 Check whether the manual locking device is well connected, and whether it is
flexible to open and close the ram by manual lever, and record the rotating turns
of hand wheel during the well shut-in, and hang a sign on the hand wheel. After
the trial run, rotate the hand wheel leftward to return and unlock. Open the ram
by the hydraulic pressure;
 Have complete pressure test to the wellhead device, and the pressure test
standard shall be executed according to the well control regulations. After the
pressure test, tighten again the connection bolt, to prevent the loosening or
uneven. The tightening torque of flange bolt is showed at Table 4-1 or Table 4-2;
 When the BOP is performed with ground inspection and test, the BOP shall be
filled with water, and then open and close the ram for once to release the air in
the rear of ram chamber.
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FZ54-14U Ram BOP User Manual
Rev.A0
Table 4-1 Recommended value (Metric system) of connecting and tightening torque of stud and screw
Tightening
torque
Tightening
torque
Tightening
torque
N·
m
ft·
lb
Specifications
of stud and
screw
M33×3
1292
952
M52×3
5505
4060
113
M36×3
1737
1280
M58×3
7892
5821
266
196
M39×3
2272
1674
M64×3
10885
8028
M22
424
313
M42×3
2910
2145
M70×3
14549
10731
M27
643
474
M45×3
3654
2693
M76×3
18957
13982
M30×3
930
686
M48×3
4516
3328
M80×3
21565
15906
Specifications of
stud and screw
N·
m
ft·
lb
M12
80
59
M16
153
M20
Specifications of
stud and screw
N·
m
ft·
lb
Table 4-2 Recommended value (British system) of connecting and tightening torque of stud and screw
Specifications of
stud and screw
1
/2-13UNC
5
/8-11UNC
3
/4-10UNC
7
/8-9UNC
1-8UN
1
1 /8-8UN
Tightening
torque
N·
m
80
153
266
424
643
930
ft·
lb
59
113
196
313
474
686
Specifications of
stud and screw
1
1 /4-8UN
3
1 /8-8UN
Tightening
torque
N·
m
ft·
lb
1292
953
2-8UN
5505
4060
1
7892
5821
1
10885
8028
3
1737
1
1 /2-8UN
Tightening
torque
Specifications
of stud and
screw
2272
1281
1676
2 /4-8UN
2 /2-8UN
N·
m
ft·
lb
5
2910
2146
2 /4-8UN
14549
10731
3
3654
2695
3-8UN
18957
13982
3331
1
24174
17830
1 /8-8UN
1 /4-8UN
7
1 /8-8UN
4516
21
3 /4-8UN
FZ54-14U Ram BOP User Manual
Rev.A0
4.2 Usage and matters needing attention
 The usage of BOP shall be responsible by specially-assigned person. Relevant
responsibilities are carried out. User shall know the working principles, the
performance and the technological process; and be able to operate, maintain,
care and have troubleshooting;
 When there is no pipe column in the well, if to make a test on closing the pipe ram,
the maximum hydraulic control pressure shall not exceed 3MPa so as to avoid of
damage to rubber core. When there is a pipe column in the well, it is forbidden to
close the full ram;
 When it takes a long time to have well sealing, lock the ram by a manual lock
device, and hang an instruction on the control console, so as to avoid of faulty
operation;
 After entering the destination layer, the ram shall be opened and closed once
everyday. Check if the closing and opening are flexible and if the manual clamp
device is under good condition. Every time after pulling out of the hole, the test
on opening and closing of full ram shall be done, and it is forbidden to close the
full ram when there is a pipe column in the well;
 It is forbidden to release the pressure by opening the ram, which may damage
the rubber core. Before open the rams shall wait 10 minutes after gauges
indicate pressure has been bled to 0 psi or open the choke/kill valves above and
below the rams to ensure the chambers are equalized.
 Every time before opening the ram, check whether the manual locking device has
been unlocked. After opening, check if the ram is at the fully-opened position
(completely returning into the body), to protect the ram from being damaged by
the drilling tool;
 The hydraulic oil shall be kept clean;
 After using the BOP, keep the ram at the fully-opened position for the purpose of
maintenance.
 Lugs on the BOP body is used only for lifting the BOP body, rather than lifting the
BOP set
 Recommended Hydraulic Oil for the Hydraulic System for BOP Stacks
 ISO Brand: HM32 (used for plunger pump system with low or no Zn)
 Mobil Brand: D.T.E24 (used for plunger pump system with low or no Zn)
 Shell Brand: Tellus32 (used for plunger pump system with low or no Zn)
Note: The kinematic viscosity of hydraulic oil is 17-33 mm2/s when the temperature
is at 50℃.
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FZ54-14U Ram BOP User Manual
Rev.A0
5 Dismounting and Maintenance of BOP
The BOP shall be subjected to appearance examination and seal test before starting
drilling each time or entering high-pressure hydrocarbon reservoir.
BOP shall be comprehensively disassembled for examination and cleaning after
serving a well each time, and any damaged parts shall be replaced timely. Oil shall be
coated on the ram chamber of the body to avoid rusting, and the screw thread oil shall be
coated on the connecting thread part.
5.1 Opening Intermediate Flange of BOP
5.1.1 Open the ram by hydraulic oil to keep the ram at the opening position; (▲！
Caution: The manual lock device shall be under unlocking status. )
Fig.5-1 Opening the ram
5.1.2 Loosening the cylinder bolt (▲！ Caution: If the BOP is mounted on the
well, the cylinder bolt shall not be uninstalled if any pressure in the well);
Fig.5-2 Loosening the cylinder bolt
5.1.3 The hydraulic oil less than 10.5MPa shall be used to open the intermediate
flange, namely making the action of closing the ram, to open the intermediate flange to
the limit position. To prevent the intermediate flange from closing, in case necessary two
wooden beams at the same size shall be put between the intermediate flange and the
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FZ54-14U Ram BOP User Manual
Rev.A0
shell, or the control pipe line shall be disassembled;
Fig.5-3 Opening the intermediate flange
5.2 Replacement of ram and its sealing rubber core
The ram rubber core is the key part deciding whether the BOP has the effect of well
sealing. Once being damaged, the BOP will lose its effect. So it must be ensured
complete and not damaged. Once any damage at the sealing surface is found, it must be
replaced timely.
5.2.1 Ram assembly is lift to the top from the rear part of ram axle. When the ram
assembly is taken out, protect the opening and closing piston rod, to prevent hit and
scratch;
Fig.5-4 Removal of ram assembly
5.2.2 To replace the ram rubber part, firstly pry out the top sealing and the remove
24
FZ54-14U Ram BOP User Manual
Rev.A0
the front seal and replace with new rubber core.
Fig.5-5 Disassembly of ram rubber core
5.3 Replacement of Seal Ring between Intermediate Flange
and Body
When the sealing ring for the intermediate flange is damaged, it has to remove the
sealing ring of the intermediate flange:
5.3.1 Pry the sealing ring by tools;
Fig.5-6 Pry out the sealing ring of Intermediate Flange
5.3.2 When replacing a seal, pay attention on the position of sealing ring that shall be
applied with lubricating oil during installation of sealing part.
5.4 Repair and replacement of cylinder assembly
If any damage or oil leakage is found at the front rod seal of main piston, seal of main
piston, tail rod seal of main piston, or the closing and opening piston seal of ram, they
shall be disassembled for maintenance immediately
5.4.1 Release the pressure in the cylinder. Put a clean vessel under the cylinder to
prevent the pollution by the hydraulic oil.
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FZ54-14U Ram BOP User Manual
Rev.A0
5.4.2 Remove bolts of the Locking Screw Housing, nuts, Locking Screw Housing and
Locking Screw.
Fig.5-7 Remove bolts of the Locking Screw Housing, nuts, Locking Screw Housing and
Locking Screw
5.4.3 Remove screws of cylinder head and screws of intermediate flange;
Fig.5-8 Remove screws of cylinder head and screws of Intermediate Flange
5.4.4 Remove cylinder and ram replacement cylinder;
Fig.5-9 Remove cylinder and ram replacement cylinder
5.4.5 Remove the tail sealing ring of main piston and O-ring;
26
FZ54-14U Ram BOP User Manual
Rev.A0
Fig.5-10 Remove the tail sealing ring of main piston and O-ring
5.4.6 Take out the main piston;
Fig.5-11 Take out the main piston
5.5 Disassembly of ram opening and closing piston rod
5.5.1 Push the intermediate flange to the position near to the body, so as not to affect
the operation by a wrench;
Fig.5-12 Push the Intermediate Flange
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FZ54-14U Ram BOP User Manual
Rev.A0
5.5.2 Hang up the intermediate flange by a crane gently, so as to minimize the lower
pressure that the intermediate flange may apply to the opening and closing piston rod of
ram;
5.5.3 The opening and closing piston of ram is threaded with the body. Its position
near to the body has a flat face for usage of wrench. Rotate the ram opening and closing
piston rod counter-clockwise, and rotate it outward. Caution: If the rotation is not smooth,
the disassembly shall not be done forcefully, so as to protect the fitting surface between
the ram opening and closing piston rod and the body. At this time, the hanging degree of
intermediate flange shall be adjusted and the trial disassembly can be done;
Fig.5-13 Removal of ram opening and closing piston
5.5.4 Remove the retainer ring. Take out the sealing ring of front rod of main piston
and washer, and then take out the reinforced sealing ring, the fastened sealing ring and
O-ring;
Fig.5-14 Removal of sealing part
Part examination after disassembling is as follows:
 Inner wall of cylinder assembly, and inner wall of ram replacement cylinder:
Examine the longitudinal damage of the cylinder assembly and the internal
surface of ram replacement cylinder. If the damage is caused by shallow linear
friction or dotted mark, fine abrasive paper or oilstone can be used for repairing.
In case of serious pulling scar, when the oil leakage can't be stopped by
replacing new sealing ring, the mechanical processing method shall be taken for
repairing the inner surface of cylinder. Meanwhile check relevant parts of piston
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FZ54-14U Ram BOP User Manual
Rev.A0
to find out causes and give solution.
 Ram opening and closing piston rod and its surface: When there is a pulling
scar at the sealing surface, the judgment and treatment method are the same
with that of cylinder. If the clad layer is peeled off, serious leakage may happen.
In this case, new parts must be replaced or the damaged parts must be repaired.
 Sealing ring: Whether the lip side of the sealing part is damaged, or whether the
O-ring is squeezed out or cut. Any damaged sealing part shall be replaced.
 Piston: If the uneven wear depth on the movable sealing surface of piston
exceeds 0.2mm, it shall be replaced, and other surfaces shall not have obvious
scar that affects the sealing. If the clad layer is peeled off, serious leakage may
happen. In this case, new parts must be replaced or the damaged parts must be
repaired.
5.6 Matters needing attention for assembly
The assembly is in sequence opposite to disassembly and needs attention on the
following points:
 Examine whether there is burr or sharp corner in the part, if any, remove them, so
as to prevent the sealing ring from being scratched. Please keep clean;
 Coat lubricating oil on surface of sealing ring when the sealing ring is assembled,
coat oil on the corresponding surface of the matched sealing ring, in order to
assemble conveniently;
 Pay attention to the direction of the lip-type sealing ring, and make sure that the
opening of the lip side faces the pressure direction.
 Make sure that the sealing ring can pass through the guide part of axle head
smoothly without scratching.
5.7 Daily maintenance
When the ram assembly operated by hydraulic pressure higher than 3.5MPa (500psi)
is needed, check the jamming condition of body chamber and solve abnormal conditions.
It is required to operate and test the BOP for one time every week according to
requirements of API STD 53.
▲！ Caution: When there is no drill stem in the well, to protect the rubber core from damage,
do not close the pipe ram or the variable diameter ram
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FZ54-14U Ram BOP User Manual
Rev.A0
5.8 Operating Period Maintenance
For the existing BOP, besides the onsite daily maintenance, it is recommended to
have periodical examination according to requirements of SY/T 6160 Examination and
Maintenance of BOP, for the purpose of confirming the repair items. The period of
examination is divided into three-month examination, one-year examination and
three-year examination. The examination shall be done on time and may be performed in
advance according to usage condition. If one well is continuously operated over the
specified examination period, the examination shall be done according to requirements of
the next examination period after going back to the warehouse. ▲！ Caution: The
maintenance of BOP shall be subject to relevant local regulations about usage of
BOP, and the BOP shall be certified periodically by the bop original manufacturer
or a qualified third party, so as to make sure the stability and the reliability of usage
of BOP.
The three-month examination content
1、 Disassemble the BOP, carry out a visual examination of the parts;
2、 Equipment shall be tested in accordance with API 16A.
One-year examination content:
1、 Check the both side of the body, the top sealing surface inside of body, seal ring
groove, the sealing surface of bonnet and seal ring groove of bonnet. All of them
are not allowed to have any defect that affect the sealing performance;
2、 Check the abrasion of bore of body；
3、 Check the ram packers and seals. The sealing surface shall be avoided serious
deformation, wear, cracking, ageing of rubber core and phenomena the like;
4、 Check the connecting channel of the ram and hook. There cannot have crack,
bending deformation; The width and height of ram are not allowed to have
serious avulsion and deformation;
5、 Check the lock shaft, cannot have cracking, bending, grooved and switch lock
shaft should be flexible;
6、 Check the thread hole, cannot have disorderly buckle, the phenomenon such as
lack of buckle;
7、 Visual check ram cavity and flange of the body, cannot have cracking.
8、 All rubber sealing parts, backing ring and O-ring that have been used over one
year or that have been damaged shall be replaced(see Table 3-7).
Three-year examination content:
30
FZ54-14U Ram BOP User Manual
Rev.A0
1、Disassemble all of the parts and clean up. In addition to examinations according
to the requirements of the one-year check, also should deal with important size
measurement of main parts. a) If the wear extent of inner diameter of the cylinder is more
than 0.4 mm or there is obvious scars and the solder peels off, the cylinder should be
remanufacture or replacement; b) If the wear extent of piston rod is more than 0.25 mm ,it
should be remanufacture or replacement; c) If the wear ring diameter is lower than the
metal body, the wear ring should be replace; d)If cladding material of the lock shaft is
corroded and appear pits that would affect sealing, the lock shaft is overall bending or
thread damaged that would affect the lock or unlock, or the quartet at end is damaged
that will affect the connection with manual assembly, etc., the lock shaft should be
replaced.
2、Hardness testing shall be carried out on the pressure-containing parts and the
pressure-controlling parts such as body and bonnet. If the hardness is abnormal（＞
HRC22）, contacting manufacturer is necessary.
Repair and remanufacture parts shall be carried out according to API Spec 16A
appendix B. Replacement of parts shall be design and manufacturing by the OEM. After
checking the Bop, if the pressure-containing parts need to be welded to restore the
performance, the bop is not suitable for easy maintenance in the field, must be
remanufactured by the API Spec 16A qualified remanufacturer or authorized
remanufacturer.
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FZ54-14U Ram BOP User Manual
Rev.A0
6 Preservation procedures
Prior to shipping and storage, all equipment should avoid direct sunlight, rain and
snow shower, keep them away from acid and alkali, organic solution etc, which would
affect the quality of rubber material.
6.1 Storing for periods greater than 30 days
 All equipment shall be drained after testing and prior to storage;
 Prior to storage, parts and equipment shall have exposed metallic surfaces
protected with a rust preventative that does not become fluid and run at a
temperature of less than 50 °C (125 ℉) (Recommendation: Lithium base grease
3#) ;
 All connection faces and ring gasket grooves shall be protected with durable
covers during storage;
 The hydraulic operating system shall be flushed with a non-freezing,
corrosion-inhibiting fluid. Ports shall be plugged prior to storing
(Recommendation: Antiwear hydraulic oil 32#) .
6.2 Storage of Rubber Parts
All rubber parts shall be properly stored according to the following regulations:
 It is a must to store rubber parts in the indoor, low light and dry place with
temperature of 0-25ºC and relative humidity 50% ~ 85% and to keep them away
from the heating equipment and direct sunlight. It’s better to preserve them in the
original packaging or the packaging similar to the original packaging materials,
which has the function of shading.
 Keep rubber parts clean while in storage. Prevent them from being contaminated
by solvents, oil, grease or other semi-solid or liquid matters and from being
directly contacted with sulphur, manganese, copper, copper alloy (including
bronze), polyvinyl chloride (PVC), timber containing wood preservative oil and
other rubber products including different rubber constituents.
 Keep rubber parts away from ozone-generating equipment( e.g.: mercury vapor
lamp, high-voltage electrical equipment, electric motor or any electrical devices
which can generate electric arc; avoid being directly exposed under the sunlight
or the light (e.g.: the fluorescent lamp) containing plenty of ultraviolet.
 Store the rubber parts which are under the slack state and have no bending,
extrusion and hanging. It is not allowed to tie the tag on the rubber parts by the
string, metal wire or adhesive tape in order to prevent causing deformation to the
sealing surface.
 Check the rubber parts frequently. In the case that they have clamminess,
softening, hardening, aging, embrittlement, cracking, bending, flaw etc, it is not
 Generally, the storage period of rubber parts is 2 years.
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FZ54-14U Ram BOP User Manual
Rev.A0
7 Common Troubles and Troubleshooting
No.
1
Failure
Causes
The medium in the well flows
out of the connection part of the
body and the intermediate flange.
a. The sealing ring for
intermediate flange of BOP
is damaged;
b. The sealing face of the
BOP
body
and
the
intermediate flange have
bribes
or
have
been
damaged.
2
The moving direction of ram is
inconsistent with the nameplate
for control device of BOP
The connecting pipes of
control device and the
connection pipe of BOP are
wrongly connected.
3
The hydraulic system works
normally, but the ram is not
closed properly.
The contact port of ram has
other substances or deposit
of sands and slurry.
If the medium in the well goes
into the cylinder, the oil may
contain moisture.
If the sealing ring of front
rod of main piston is
damaged, the front rod axis
may be deformed of main
piston or the surface may be
pulled.
4
5
6
The hydraulic portion of BOP
can not maintain the pressure,
and the opening and closing of
intermediate
flange
are
inflexible.
If any damage is found at the
cylinder assembly of BOP,
main piston and the sealing
ring for opening and closing
of ram.
After the ram is closed, the
pressure can't be sealed.
The rubber core of ram seal
may be damaged, or the top
sealing surface for ram
chamber on the shell is
damaged.
a. Replace damaged assembly
of flange sealing;
b. Clean out the foreign matters
on the sealing face and restore
the damaged parts.
Replace the pipe position at the
oil circuit port of BOP.
Replace
the
ram
and
the
intermediate flange.
Replace the damaged sealing
ring for the front rod of main
piston, and repair the front rod
portion of main piston.
Replace each sealing ring, and
repair the sealing surface or
replace with new parts.
Replace the rubber core of ram
sealing, and repair the sealing
surface of ram chamber of
body.
a.
7
Though the control oil circuit is
normal, the ram or the side door
can't be opened by hydraulic
force.
The ram is jammed by
muddy sands;
b. The oil circuit of BOP is
jammed;
c. The connecting pipes of
control device and the
connection pipe of BOP
are blocked.
Troubleshooting
33
a.
Clean up the muddy sand;
b. Clean up the oil circuit;
c.
Clean
or
replace
connection pipes.
the
Design by:
（Technical engineer）
Audited by:
（Chief engineer）
FZ54-14U Ram BOP User Manual
Rev.A0
Rev. A0
35