shaffer lxt 7-5m-user manual

8/18/2019 Shaffer LXT 7-5M-User Manual

1/75

www.nov.com

Customer Name

Rig Name

Sales Order Number

Reference Reference Description

Shaffer 71 / 16"–5,000 psi LXT Ram BOPThis document contains proprietary and confidential information whichbelongs to National Oilwell Varco; it is loaned for limited purposes onlyand remains the property of National Oilwell Varco. Reproduction, inwhole or in part; or use of this design or distribution of this information toothers is not permitted without the express written consent of NationalOilwell Varco. This document is to be returned to National Oilwell Varcoupon request and in any event upon completion of the use for which itwas loaned.

© National Oilwell Varco

National Oilwell Varco

12950 West Little York

Houston, TX 77041

Phone: 713-937-5000

Fax: 713-856-4138

Document Number Rev.

29100155 D

User’s Manual

Shaffer ® 71 / 16"–5,000 psi

LXT Ram Blowout Preventer


2/75

Revision History

D 12-16-2009 Update graphics and technical corrections SF

C 01-09-2009 Update Chapter 3 and 4 BB

B 23-04-2009 Update graphics SF RH RH

A 09-02-2006 Issued for implementation CAN

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Change Description

Revision Change Description

A First issue

B Updated various graphics using Pro-E models and made minor corrections to parts tables for single BOP.

C Update lock bar maintenance procedures.

D Updated various graphics using Pro-E models and made few corrections to chapters.


3/75

Table of Contents


Revision D

Page iii of iv

iii

www.nov.com

Chapter 1: General InformationConventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Equipment Repairs or Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Welding and Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2: IntroductionGeneral Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1BOP Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Door Locking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Hydraulic Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Chapter 3: Installation and OperationPreinstallation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Condition of BOP is Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2BOP Maintained on Scheduled Maintenance Program . . . . . . . . . . . . . . . . . . . . 3-2

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Hydraulic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Closing and Opening the Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Manual Locking the Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Unlocking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Opening Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Closing Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Chapter 4: MaintenancePreventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1When to Call a Service Representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Monthly Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Three-Month Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Yearly Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Three-Year to Five-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8


4/75www.nov.com

Table of Contents


Revision D

Page iv of iv

iv

Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Field Wellbore Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Door Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Emergency Ram Shaft Packing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Ram Assembly Removal and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Changing Pipe and Blind Ram Rubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24Offset Rams for Dual Completions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24Aluminum Drill Pipe Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Storing the LXT BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25LXT BOP Data Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25Cleaning and Storage of the LXT BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Chapter 5: Specifications and Parts ListsCustomer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Exploded Views and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Handwheel Assembly (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12


5/75www.nov.com

1-1


Revision D

Page 1-1 of 4

General Information

Conventions

This manual is intended for use by field engineering, installation, operation, and repairpersonnel. Every effort has been made to ensure the accuracy of the information

contained herein. National Oilwell Varco (NOV), will not be held liable for errors in thismaterial, or for consequences arising from misuse of this material.

Notes, Cautions, and Warnings

Notes, cautions, and warnings provide readers with additional information, and to advisethe reader to take specific action to protect personnel from potential injury or lethalconditions. They may also inform the reader of actions necessary to prevent equipment

damage. Please pay close attention to these advisories.

Note:

Caution:

Warning:

ii

The note symbol indicates that additional information is

provided about the current topic.

The caution symbol indicates that potential damage toequipment, or injury to personnel exists. Followinstructions explicitly. Extreme care should be taken when

performing operations or procedures preceded by thiscaution symbol.

W a r n i n g

r

n

i

n

The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure tofollow safe work procedures could result in serious or

fatal injury to personnel, significant equipmentdamage, or extended rig down time.


6/75

General Information1LXT Ram Blowout Preventer

Revision D

Page 1-2 of 4

www.nov.com

1-2

Illustrations

Illustrations (figures) provide a typical and graphical representation of equipment, it’scomponents or screen snapshots for use in identifying parts, establishing nomenclature or

calling out notes and procedures. Illustrations may or may not show all current aspects ofthe equipment nor be drawn to scale. Illustrations will not reflect any changes made afterpublication.

For component information specific to the product purchased, see the technical drawingsincluded with your National Oilwell Varco documentation.

Safety Requirements

The National Oilwell Varco equipment is installed and operated in a controlled drilling rigenvironment involving hazardous situations. Proper maintenance is important for safe andreliable operation. Procedures outlined in the equipment manuals are the recommended

methods of performing operations and maintenance.

Personnel Training

All personnel performing installation, operations, repair, or maintenance procedures on the

equipment, or those in the vicinity of the equipment, should be trained on rig safety, tooloperation, and maintenance to ensure their safety.

Contact the National Oilwell Varco training department for more information about

equipment operation and maintenance training.

Recommended Tools

Service operations may require the use of tools designed specifically for the purpose

described. The equipment manufacturer recommends that only those tools specified beused when stated. Ensure that personnel and equipment safety are not jeopardized when

following service procedures and that personnel are not using tools that were notspecifically recommended by the manufacturer.

To avoid injury to personnel or equipment damage,carefully observe requirements outlined in this section.

Personnel should wear protective gear during installation,maintenance, and certain operations.


7/75

1-3

www.nov.com

LXT Ram Blowout PreventerRevision DPage 1-3 of 4

General Information 1

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities suchas electrical, hydraulic, pneumatic, or cooling water.

Isolate energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.

Wear proper protective equipment during equipment installation, maintenance, orrepair.

Replacing Components

Verify that all components (such as cables, hoses, etc.) are tagged and labeledduring assembly and disassembly of equipment to ensure correct installment.

Replace failed or damaged components with original equipment manufacturercertified parts. Failure to do so could result in equipment damage or injury topersonnel.

Routine Maintenance

Equipment must be maintained on a routine basis. See product-specific service manuals

for maintenance recommendations.

Proper Use of Equipment

National Oilwell Varco equipment is designed for specific functions and applications, and

should be used only for its intended purpose.

Read and follow the guidelines below before installing

equipment or performing maintenance to avoidendangering exposed persons or damaging equipment.

Failure to conduct routine maintenance could result inequipment damage or injury to personnel.


8/75

General Information1LXT Ram Blowout Preventer

Revision D

Page 1-4 of 4

www.nov.com

1-4

Safety Precautions

Exposure to the daily hazards of drilling can lead rig crews and service personnel to

disregard or overlook hidden hazards. The safety precautions listed below should beobserved at all times.

Equipment Repairs or AdjustmentsTurn off the system power and bleed all pressure prior to making any repairs or

adjustments that do not require system power.

Hydraulic Lines

Hydraulic lines carrying fluids at high pressures can inflict potentially fatal injuries if thepressure escapes. Protect hydraulic lines from cutting, scraping, pinching, or other

physical damage. Always wear hard hats and safety glasses when working aroundhydraulic lines. Bleed the pressure from any hydraulic line prior to disconnecting any

fittings. Respect the prescribed ASME code minimum bend radius for hydraulic lines.

Bending around too short a radius can rupture the line.

Welding and Cutting

Do not weld or operate acetylene-cutting torches near unprotected electrical cable, flexiblehose, or hose bundles. Weld spatter can seriously damage the hose or cable. Ensure no

slag or spatter enters the hydraulic system.

Replacement Parts

Many of the BOP components, though apparently similar to commercial hardware, aremanufactured to system design specifications. To avoid possible hazardous failures, use

only exact NOV replacement parts or assemblies (see Chapter 5, titled "Specifications andParts Lists”).


9/75www.nov.com

2-1


Revision D

Page 2-1 of 6

Introduction

General Description

National Oilwell Varco (NOV) manufactures Shaffer® 7 1/16" LXT blowout preventers with5,000 psi working pressure and 3,000 psi working pressure. Both preventers are identical

in operation. The difference between the two preventers is the API end connections, whichlimit the working pressure of the preventer.

The Shaffer® hydraulic operated model LXT ram blowout preventer (LXT BOP) with

manual locking operators provides a rugged, reliable preventer that is easily serviced inthe field. The manual lock LXT BOP is available in single and double models (see Figure

2-1). Contact NOV sales for special configurations.

Figure 2-1. LXT Single and Double Preventers

NOV manufactures manual lock LXT BOPs in the sizes shown in the table titled “LXT BOP

Available Sizes and Working Pressures”.

LXT BOP Available Sizes and Working Pressures

Working Pressure Bore

5,000 psi (345 bar) 7-1 / 16” (180 mm)

3,000 psi (207 bar) 7-1 / 16" (180 mm)


10/75

Introduction2LXT Ram Blowout Preventer

Revision D

Page 2-2 of 6

www.nov.com

2-2

Special features include:

Patented “Boltless Door” design for fast and simple ram changes.

Radial door seals between door and body.

Standard internal H2S trim.

One piece ram assemblies.

Wear rings between the piston and cylinder to increase seal life.

Polyurethane lip-type piston seals with lifetime lubrication.

Lip-type ram shaft seals to hold the wellbore pressure and the opening hydraulicpressure.

Secondary ram shaft packing seals.

Slider Bar, Protective Cover (Optional).

Figure 2-2. LXT BOP Protective Cover (P/N 20039943)

Slider Bar Cover


11/75

2-3

www.nov.com


Introduction 2

The LXT preventer is designed for drilling and workover service. The LXT preventers arehydraulically operated and can be manually locked by turning a handle or (optional)

handwheel (see Figure 3-5 on page 3-8) . The standard trim unit is suitable for internalH2S environments. Units can be manufactured for Arctic to -75 ºF (-59 ºC) and full H2S

environmental services. Standard units can be retrofitted for full environmental H2S

service. NOV preventers are manufactured in accordance with the American PetroleumInstitute (API) specification 16A and the National Association of Corrosion Engineers

(NACE) document NACE Standard MR 0175 (current revision).

This manual provides the installation, operation, and maintenance procedures forstandard manual lock LXT BOP models with manual lock operators. The manual lock

operators are used to close the ram assemblies on the drill pipe and close off the wellbore. The manual lock operators require a hydraulic closing pressure of 1,500 psi (103

bar) to accomplish sealing the well bore pressure to the rated working pressure of thepreventer. Maximum working pressure for the hydraulic operators is 3,000 psi (207 bar).

When the rams are hydraulically closed, the manual lock acme thread locking bolts arerotated clockwise to manually lock the rams in the closed position (see Figure 2-3).

Figure 2-3. LXT Blowout Preventer

Acme Thread

Lock BoltHydraulic

Operator

Hydaulic Operator

(3,000 psi WP)

Side Outlets Boltless Door Assemblies

Secondary Seal Assemblies

Locking Bars(Manually removed and

inserted)


12/75


Revision D

Page 2-4 of 6

www.nov.com

2-4

BOP Functional Overview

A ram BOP is a safety tool used during the drilling or workover operation to control well

bore pressure. The BOP achieves this pressure control by closing its rams to seal arounddrilling tubulars, an open hole or to shear drilling tubulars under various drilling conditions.

Under normal drilling the BOP has little or no internal pressure. However, if the drill bitpenetrates a high-pressure oil or gas pocket in the well, the BOP rams can be closed so

that the high-pressure returning well fluid (whose pressure has overcome the weight of thedrilling mud) will not blow out of the well. The BOP is normally composed of a pressurecontaining body with a vertical through bore with doors (including door operators) on either

side, which hold the BOP rams and their hydraulic operating mechanisms. Flanged orstudded API connections are configured on either end of the body at the vertical bore to

facilitate connecting the LXT preventer to a BOP Stack or other well control components.The body is generally configured with two outlets (one on each side) under each ramcavity located 90º to the doors, which are routed laterally through the body to the vertical

bore forming a well bore fluid outlet path. The side outlets are used in conjunction with thechoke and kill valves, choke manifold and other well control equipment to bring the high

well bore pressure under control using a variety of well control techniques available to thewell operator. (See Figure 2-3 on page 2-3 for BOP general features.)

The LXT Ram BOPs are functioned hydraulically by the rig operator using the BOPControl System. BOP controls are generally located on the Drillers and/or Toolpushers

Control Panels and at the Hydraulic Power Unit (HPU).

Door Locking System

The LXT BOP door locking system provides simple and fast opening and closing of BOP

doors, representing a major step toward easy servicing. Several operational benefits areavailable from this system.

The LXT BOP door locking system departs from the conventional bolting method. The

entire door attachment method can be accomplished by a single individual opening andclosing the doors.

The LXT BOP door locking system replaces axially-loaded threaded members (bolts) withtransaxially-loaded bearing members. The bearing members act as locking pins, taking

the separation load (generated by well bore pressure) in bearing and shear only, not in

tension. The bearing members (locking bars) are contained between the body and door onthe BOP, providing a pressure containing lock. The number of locking members (lockingbars) is reduced to two, running across the top and bottom of the door (see Figure 2-3 on

page 2-3). This replaces the threaded member system of four to ten bolts per door.Actuation or engagement of the two locking members is fast and easy, dramatically

reducing the opening and closing time compared to the threaded member system whichrequires that each bolt be made up separately.

The LXT BOP door locking system utilizes a set of lateral grooves located in both the door

and BOP body running perpendicular to the ram cavity. These grooves, when aligned,allow load bearing (locking) bars to lock the door and body together. The round lock barsare inserted into or pulled from the grooves to accomplish the manual lock and unlock

process. Groove pairs and locking bars are located both above and below the ram cavityspanning the interface between the door and body. (See Figure 2-4 on page 2-5.)


13/75

2-5

www.nov.com


Introduction 2

Figure 2-4. Lockbar Grooves

Once the lock bars are removed, the door assembly is pulled away from the BOP bodysliding along two support rods allowing access to the ram assembly. The LXT door

assembly does not hinge on a bracket, thus providing a manual process that is simple, fastand reliable. For more detail about the door locking system, see the section titled "OpeningDoors" on page 3-12 and the section titled "Closing Doors" on page 3-14).

Hydraulic Operators

The LXT BOP is equipped with manual lock hydraulic operators. The manual lockhydraulic operators are located either side of the LXT body (see Figure 2-4).

The LXT BOP manual lock hydraulic operators are closed with 1,500 psi (103 bar). This

pressure squeezes the ram assembly rubber around the pipe and between the ramassemblies and the upper seat of the ram cavity to seal-off the well bore pressure. Eachoperator is manually locked in the close position by the clockwise rotation of the acme

thread locking bolt (see Figure 2-4). The locking bolts prevent the rams from being openedby the well bore pressure, even when closing hydraulic pressure is removed. The hydraulic

operators do not require adjustment for changes in ram types or to compensate for ram

wear over time.

Acme Thread

Locking BoltHydraulic

Operator

Hydraulic

Operator

Support Rods

Door LockbarGrooves

Support Rods

Lockbar (2 per door)

BOP BodyLockbarGrooves


14/75


Revision D

Page 2-6 of 6

www.nov.com

2-6

This page intentionally left blank.


15/75


16/75

Installation and Operation3LXT Ram Blowout Preventer

Revision D

Page 3-2 of 14

www.nov.com

3-2

Condition of BOP is Unknown

If the condition of the BOP is unknown (e.g., stored for some length of time, has not beenmaintained on a scheduled maintenance program, etc.), perform a three-month

maintenance check, as described in the section titled "Three-Month PreventiveMaintenance" on page 4-4. The three-month maintenance check includes:

Visual inspection and thorough greasing the inside of the BOP; Performing a field wellbore pressure test (see the section titled "Field Wellbore

Pressure Test" on page 4-9);

Performing an hydraulic pressure test (see the section titled "Hydraulic PressureTest" on page 4-11);

Operate the manual locks (see the section titled "Manual Locking the Rams" onpage 3-12).

BOP Maintained on Scheduled Maintenance

Program

If the BOP has been properly maintained (scheduled maintenance program), a monthlymaintenance check is all that is required. (See the section titled "Monthly Preventive

Maintenance" on page 4-3.)

The monthly maintenance check includes:

Performing a field wellbore pressure test (see the section titled "Field Wellbore

Pressure Test" on page 4-9);

o Checking for external hydraulic leaks while pressure testing.

Verify that door lock bars are propperly lubricated. Failureto heed this caution may cause difficulty manually rotatingthe lock bar.

ii

Cleaning, inspection and testing of the LXT BOP

immediately after completion of drilling operations reducesinstallation time on the next well (see the section titled "Cleaning and Storage of the LXT BOP" on page 4-25).


17/75

3-3

www.nov.com


Installation and Operation 3

Installation Instructions

1. Install BOP right-side-up. The LXT models have lifting lugs labeled ‘TOP’, which are

above and to the right of the side outlets (see Figure 3-1).

On all LXT models:

Externally, the side outlets for the choke and kill lines are below the rams;

Internally, the skids in the ram compartments are below the rams, and ramsealing areas are located in the top of the ram cavity.

Figure 3-1. Lifting LXT BOP

W a r n i n g

r

n

i

n

If the BOP is installed upside-down, it will not contain

wellbore pressure.

Side Outlet


18/75


Revision D

Page 3-4 of 14

www.nov.com

3-4

2. Lift the LXT manual lock BOP. On models with lifting lugs cast into the body, theBOP is lifted by wrapping a chain or lifting strap of sufficient strength around the lug

(see Figure 3-1 on page 3-3).

3. Make flanged and studded connections:

(See Figure 3-2.)

a. Install the ring gasket dry. See the table titled "API Ring Gaskets" on page 5-15,

for the proper part number.

b. Install the BOP on the mating flange.

c. Lubricate the stud threads and nut faces with Moly Paste Lube 503 (P/N

7403582) or grease specified in API BUL 5A2: Thread Compounds.

Figure 3-2. End Connections

Do not lift the BOP by the hydraulic operators. This willdamage the operator cylinder, piston assembly and/or the

ram shaft and prevent the BOP from working correctly.

Do not lift the BOP with the slider bars.This will damage

the slider bars and prevent the BOP from working correctly.

ii

For BOP weight information, see the table titled "BOP

Characteristics" on page 5-2. Use a chain or cable capableof lifting the weight given.

Flange Connection Studded Connection


19/75

3-5

www.nov.com



d. Install the studs and/or nuts. See the table titled "API Nuts" on page 5-13 andthe table titled "Tap End Studs for API Flanges" on page 5-14 for the proper part

number.

e. Tighten all nuts uniformly in a diametrically staggered pattern, as shown in

Figure 3-3. See the table titled "Recommended Flange Bolt Torque" on page 3-6 for proper torque specifications.

Figure 3-3. Flange Bolting Sequence

Use extreme care during removal and installation of studsand nuts. Inspect the threads of the studs and stud hole fordamage such as deformation, stripping, or burns. Do not

over-torque studs when installing in studded flange.

Use specified lubricants. Do not use Loctite ™ or similar

compounds.

1

2

3

4

5

6

7

8

9

10

11

12


20/75


Revision D

Page 3-6 of 14

www.nov.com

3-6

* Torque values are satisfactory for both standard and H 2 S studs. Reference API specification 6A. The abovetable shows torque values arrived at by using new commercial stud bolts and nuts, well-lubricated threads, and

nut faces with API thread compound (API Bul. 5A2: Thread Compounds). This produces a stress of 52,500 psi

(362.0 MPa) in the bolting.

Recommended Flange Bolt Torque

Torque*(using API thread compound)

Torque* (using MolyPaste 503—P/N 7403582)

Bolt Size ft-lb. Nm ft-lb. Nm

¾"-10 UNC 200 271.2 114 154

7 / 8"-9 UNC 325 440.6 181 245

1"-8 UNC 475 644.0 269 365

1 1 / 8"-8 UNC 600 813.5 386 523

1 ¼"-8 UNC 900 1,220.2 533 723

1 3 / 8"-8 UNC 1,200 1,627.0 712 965

1 ½"-8 UNC 1,400 1,898.2 926 1,255

1 5 / 8"-8 UNC 1,700 2,304.9 1,180 1,600

1 ¾"-8 UNC 2,040 2,765.9 1,476 2,001

1 7 / 8"-8 UNC 3,220 4,365.7 1,818 2,465

2"-8 UNC 3,850 5,219.9 2,209 2,995

2 ¼"-8 UNC 5,250 7,130.0 3,149 4,269

2 ½"-8 UNC 7,250 9,860.0 4,324 5,862


21/75

3-7

www.nov.com



4. Repeat step 3 to connect the side flanges.

5. Connect hydraulic lines from BOP closing unit to the 'Open' and 'Close' ports of theBOP. Make sure all connections are clean and tight. Each set of rams requires one

opening and one closing line.

Figure 3-4. Open and Close Hydraulic Ports

ii

Opening and closing hydraulic ports are clearly marked onthe front and back side of the BOP (see Figure 3-4).

A gauge and valve can be included in the opening andclosing hydraulic lines to the BOP. This will facilitate testing

procedures (see Figure 4-10 on page 4-14).

T

OP

Open Ports(1 per cavity)

(close ports on back side)


22/75


Revision D

Page 3-8 of 14

www.nov.com

3-8

6. Install handwheel (see section titled "Handwheel Assembly" located in theSpecifications and Parts Lists of this user's manual).

A universal joint and handwheel are optional (P/N 185599) for each locking shaft.

Handwheel extensions are cut from 2 inch (50.80mm) schedule 40 pipe furnished by thecustomer. Perform the following:

a. Fabricate a handwheel extension for each locking shaft.

b. Attach a handwheel to one end of each extension.

c. Attach a universal joint to the other end of each handwheel extension (see

Figure 3-5).

Figure 3-5. Manual Lock Handwheel Assembly (Optional)

7. Perform a Field Wellbore Pressure Test. (See the section titled "Field WellborePressure Test" on page 4-9.)

ii

Two handwheel assemblies are required on a single LXTpreventer and four handwheel assemblies are required on

a double LXT preventer.

2” Schedule 40 Pipe(Customer Supplied)

Universal Joint

Handwheel

Assembly


23/75

3-9

www.nov.com



Operation

Hydraulic Operation

The rams can be hydraulically closed and manually locked. Under normal operatingconditions, 1,500 psi (103 bar) hydraulic pressure is recommended. This operatingpressure will close any model LXT BOP and contain its rated wellbore pressure. Hydraulic

operating pressure may be increased to 3,000 psi (207 bar) on any LXT BOP, if desired.

Hydraulic Fluid

Hydraulic fluid under pressure drives the pistons, which then close and opens the rams.

The hydraulic fluid used should have the following characteristics:

Non-freezing in cold climates

Lubricity to reduce wear

Chemical compatibility with the elastomer seals

Corrosion inhibitors for metal surface protection.

Recommended Hydraulic Fluid

Hydraulic oil with viscosity between 200 and 300 SSU at 100 ºF (38 ºC). In the LXT

closed hydraulic system, there is no waste of oil and fluid costs are negligible.

Where pollution due to accidental spillage of hydraulic fluid is a problem, use a

water soluble oil or premix control fluid. To prevent freezing at lower temperatures,adding ethylene glycol without any additives is recommended. Do not usecommercial antifreeze mixes.

Emergency Fluid Recommendations

In an emergency, where hydraulic fluid is lost and the BOP must be operated, the fluidslisted below can be substituted:

1. When using hydraulic oil:

Add motor oil (SAE 10W is recommended but heavier oils can be used)

Add water if motor oil is not available, but after the emergency, the hydraulicsystem must be flushed and refilled with hydraulic oil

2. When using a water soluble mixture or premix fluid, add more water.

LXT Fluid Volume Requirements

Working

Pressure

Bore

Size

Piston

Size

Closing

Ratio

Gallons to

Open

Gallons to

Close

5,000 psi 7" 5" 8.45 .32 .39

3,000 psi 7" 5" 8.45 .32 .39


24/75


25/75

3-11

www.nov.com



Figure 3-6. Manual Lock Rams

O p e r a t o r i n C L O S E D

a n d L O C K E D

p o s i t i o n

O p e r a t o r i n O P E N p

o s i t i o n

a n d C L O S E D

D o o r

M a

n u a l L o c k i n g

S h a f t

P i s t o n T a i l R o d

O p e r a t o r i n O P E N

p o s i t i o n

a n d O P E N

D o o r

H a n d l e f o r 7 ” - 5 M

L o c k i n g

S h a f t M a n u a l O p e r a t i o n

O p e r a t o r i n C L O S E D

a n d U N L O C K E D

p o s i t i o n


26/75


Revision D

Page 3-12 of 14

www.nov.com

3-12

Manual Locking the Rams

1. Apply 1,500 psi (103 bar) closing hydraulic pressure.

2. Using the handle (see Figure 3-6 on page 3-11) or handwheel, carefully rotate each

locking shaft clockwise until it locks; each locking shaft will move inward until it stops

against ram shaft tailrod.

Control system hydraulic pressure may now be removed.

Unlocking Operation

1. Apply 1,500 psi (103 bar) hydraulic closing pressure.

2. Rotate the locking shaft counterclockwise until it stops.

3. Rotate 1 / 8 of a turn clockwise to prevent temperature changes from jamming the

locking shaft in the unlocked position.

4. See the section titled "Opening the Rams" on page 3-10.

Opening Doors

The LXT is designed for easy door opening. (See Figure 3-9 on page 3-14).

Do not over tighten. If over tightened, the locking shaft canbe damaged.

Do not apply opening hydraulic pressure while the BOP is

manually locked. This may damage the locking shaftthreads.

W a r n i n g

r

n

i

n

Prior to opening door, ensure that support bars areinstalled and end caps are installed and secured with

end cap retaining bolt. If end caps are not installed, thedoor can slide off end of support bars (see Figure 3-8

on page 3-13). Failure to heed this warning can causeinjury to personnel and damage to equipment.


27/75

3-13

www.nov.com



1. Disconnect any external handwheel assemblies.

2. Using dead-blow sledgehammer, strike lock bar retainer cap to break lock bar loose(see Figure 3-9 on page 3-14, item 1).

3. Unscrew and remove hand knobs from the both ends of LXT lock bar(see Figure 3-7).

Figure 3-7. LXT Lock Bars

4. Install slide hammer (see Figure 3-9 on page 3-14, item 3). Remove both lock barsfrom the door to be opened. Use care not to damage lock bar surfaces. Store bars

in safe location.

5. To open the door, grip door assembly by cylinder head and pull door away from BOPbody (See Figure 3-8).

Figure 3-8. Opening LXT Door

Hand Knobs

End Cap StopsSupport Bars


28/75


Revision D

Page 3-14 of 14

www.nov.com

3-14

Closing Doors

1. Prior to closing door, carefully clean and lubricate support rods, lock bars, lock bar

grooves on door, and body with standard grease.

2. Push door assembly in against body

3. Install the lock bars into grooves and install retaining caps..

4. See the section titled "Ram Assembly Removal and Inspection" on page 4-19 foradditional information.

Figure 3-9. Door Opening

ii

Do Not Use grease on door seal area of door and body.

Lubricate door seal area and body with SAE 10W oil.

W a r n i n g

r

n

i

n

Ensure that lock bar retaining caps are installed prior

to operating BOP.

Lockbar

Retaining Caps

Slide Hammer Assembly

1. Strike retainer caps withdead-blow sledgehammer..

3. Attach slide hammerto pull rods.

2. Unscrew retaining caps.


29/75www.nov.com

4-1


Revision D

Page 4-1 of 28

Maintenance

Preventive Maintenance

Maintenance Schedule

The purpose of the maintenance schedule is to detect wear in a NOV Shaffer ® manuallock model LXT BOP so that it can be repaired before a failure occurs in a drilling

emergency. The inspection sequence avoids repetition of work so that minimum time isrequired for a thorough maintenance program. (See the table titled "MaintenanceSchedule, Manual Lock Ram BOP1" on page 4-2.)

Additional information is available in the following publications:

API Spec. 6A, 16A

API RP53

NOV Brochures

When to Call a Service Representative

Repairs are performed by either the rig personnel or a NOV service representative. Thefollowing identifies the repairs normally performed by the rig personnel and provides

guidelines to determine when a service representative should be called.

Rig personnel normally perform the following:

Changing rams to different pipe sizes

Running wellbore pressure tests and hydraulic pressure tests

Replacing worn ram rubbers and door seals

Buffing out minor scratches on the ram sealing area and door sealing area of the

body.

iiThere are two lower and two upper door assemblies

installed on a double LXT Ram BOP. Due to the slider barconfiguration and the QD male hydraulic coupler (item 8)

on the door, to the QD female hydraulic coupler (item 25)on the body (see the table titled "BOP and Door Components" on page 5-4 and Figure 5-2 on page 5-5 for

illustration). To avoid confusion while installing the doorsonto the body, it is recommended to remove only one door

assembly at a time from the BOP body. In this manner, thedoor to body QD hydraulic connections and slider bars will

properly align with each other.


30/75

Maintenance4LXT Ram Blowout Preventer

Revision D

Page 4-2 of 28

www.nov.com

4-2

A NOV service representative normally will be called to make any repairs that require thehydraulic system to be opened, including the following:

Replacing piston seals

Replacing cylinder seals

Replacing manifold pipe seals

Re-packing the ram shaft tail rod

Re-packing the ram shaft seal assembly

Run yearly inspections to determine if the BOP needs to be sent to a repair facilityfor major rework.

1. Specific data is required for ordering parts. See the section titled "Ordering Replacement

Parts" on page 5-1.

2. These intervals are typical and serve as convenient designations to separate the simpler from

the more complex inspections.

3. Some operators use the yearly maintenance inspection as a rig acceptance test.

4. Three-year to five-year maintenance will be performed only after a yearly inspection indicates

the need for it.

ii

The annual inspection includes wellbore pressure tests,hydraulic pressure tests, inspection and measurement of

the ram cavities.

Maintenance Schedule, Manual Lock Ram BOP1

Performed

Interval2 At By Summary

Daily Rig Rig PersonnelOperate all rams. Look for external hydraulic leaks (see

"Daily Maintenance”).

Monthly Rig Rig Personnel

Clean, inspect, and lubricate door lock bars. Run a field

wellbore pressure test. Look for external hydraulic leaks

(see the section titled "Monthly Preventive Maintenance"

on page 4-3).

Three Months Rig Rig Personnel

Open doors and inspect visually. Run a field wellborepressure test and an internal hydraulic pressure test.

Operate manual locks (see the section titled "Three-

Month Preventive Maintenance" on page 4-4).

Yearly3 RigNOV Service

Representative

Open doors. Measure rams and ram cavity. Do field

repairs as needed. Run a field wellbore pressure test and

an internal hydraulic pressure test. Operate manual locks

(see the section titled "Yearly Preventive Maintenance"

on page 4-8).

Three-Five

Years4Service/ Repair

Facility

NOV Service

Personnel

Completely disassemble. Repair or replace all parts as

required. Replace all seals. Run a field wellbore pressure

test and an internal hydraulic pressure test. Operate

manual locks (see the section titled "Three-Year to Five-

Year Maintenance" on page 4-8).


31/75

4-3

www.nov.com


Maintenance 4

Daily Maintenance

The procedures described below should be performed daily:

1. All rams should be functioned to verify that they operate properly. If possible, watchthe rams move by using a mirror to obtain a reflected image of the rams. If this is not

possible, observe the movement of the tail rod.

2. Check the tail rod shaft seal areas, cylinder head o-ring areas, manifold pipe seals,door seal areas, weep holes, hydraulic connections, and all pipe plugs for possible

leakage of hydraulic fluids (see Figure 4-1 on page 4-4).

3. Check areas for possible leakage of well fluid and/or hydraulic fluid (see Figure 4-1on page 4-4).

Monthly Preventive Maintenance

Run this test series before starting a new well and at least monthly while drilling.

1. Ensure all lock hand knobs are in place and tight.

2. Clean, inspect, and lubricate door lock bars.

3. Run a field wellbore pressure test as described in the section titled "Field WellborePressure Test" on page 4-9.

4. While running the field wellbore pressure test, look for external hydraulic leaks (see

Figure 4-1 on page 4-4).

5. If universal joints are installed, check them to ensure they are tight on the locking

shaft.

ii

Pipe rams should be closed on pipe. Blind rams should beclosed and opened when the pipe is out of the hole.

iiTo observe if the ram shaft packings are leaking, the

weep hole plugs must be removed on each door (seeFigure 4-12 on page 4-18).

Verify that door lock bars are properly lubricated. Failure toheed this caution can cause removal of bars to become

difficult.


32/75


Revision D

Page 4-4 of 28

www.nov.com

4-4


Figure 4-1. Possible Leak Areas

Three-Month Preventive Maintenance

1. Before opening the doors, run a field wellbore pressure test as described in thesection titled "Field Wellbore Pressure Test" on page 4-9 and a hydraulic pressuretest as described in the section titled "Hydraulic Pressure Test" on page 4-11. This

information will be very helpful in the following inspections. Also, a NOV servicerepresentative can be called at this time if hydraulic system repairs are required.

2. While the rams are closed, turn the locking shaft approximately two turns clockwiseand then turn them back to the fully unlocked position. This will verify that the

manual locks function satisfactorily.

3. Remove the handle or universal joints from the locking shafts.

4. Open the rams with 1,500 psi (103 bar).

5. Bleed all hydraulic pressure.6. Open the doors and remove the rams (see the section titled "Ram Assembly

Removal and Inspection" on page 4-19).

7. Clean and inspect rams (see the section titled "Ram Assembly Removal andInspection" on page 4-19).

8. Wash out the inside of the BOP so that it can be inspected.

9. Remove minor pits and scratches from the ram rubber sealing surface with emery

cloth.

Cylinder HeadO-Rings

All Hydraulic Path

Plugs

ManifoldSeals

Tail RodSeal Assemblies

Ram Shaft Weep

Holes (1 per Cyl.)Door Seals

Hydraulic

Connections

API Connections


33/75

4-5

www.nov.com


Maintenance 4

10. Check the bore for accidental damage (See Figure 4-2). Smooth as required.Occasionally the drill pipe will rotate against the bore and cause excessive wear.

Measure the maximum bore diameter and estimate the maximum wear on any side.

If any radius is more than 1 / 8" (3.18 mm) oversize, send the BOP to a NOV repair

facility for a complete rework.

Figure 4-2. LXT Bore Cavity

11. Check the door sealing area on the BOP body for pits and scratches. Remove pitsand scratches with emery cloth.

12. Close door assemblies and install lock rods and retaining caps.

13. Inspect the ram shafts as follows:

a. Apply reduced closing hydraulic pressure to fully extend both ram shafts for

inspection.b. Reduce closing hydraulic pressure to 0 psi (0 bar).

c. Open the doors. (See the section titled "Opening Doors" on page 3-12.)

d. Visually check the Outside Diameter of each ram shaft for pits and scratches.The ram shafts should be replaced by a NOV service representative if pits or

scratches are visible.

e. Visually check the end of each ram shaft for cracks in the neck between the endand the shaft. The ram shafts should be replaced by a NOV service

representative if cracks are visible.

f. Close the door assembly, install lock rods and retaining caps.

g. Apply reduced opening pressure to retract rams.14. Inspect the tail rod end of the ram shaft.

a. Apply opening hydraulic pressure to extend the ram shaft.

b. If a tail rod is bent or cracked, the ram shaft should be replaced. If replacement

is necessary, call a NOV service representative.


34/75


Revision D

Page 4-6 of 28

www.nov.com

4-6

15. Inspect the locking shaft.

a. Apply closing pressure.

b. Screw in clockwise.

c. Back out counter clockwise.

d. Check for freedom of movement.

16. Inspect the door sealing surfaces.

a. Open Doors (See the section titled "Opening Doors" on page 3-12.

b. Remove the door seals (see Figure 4-3).

Figure 4-3. Remove Door Seal

ii

Anytime door assembly is open, bleed pressure to 0 psi (0

bar).


35/75

4-7

www.nov.com


Maintenance 4

c. Inspect the door seal area. Smooth minor pits with emery cloth.

Figure 4-4. Inspecting Door Seal Area

d. Clean and oil the door sealing surface on the body with SAE 10W oil.

e. Oil the door seal seat and face with SAE 10W oil.

f. Clean QDs in door and body.

g. Replace the door seals (see Figure 4-5) if extruded, brittle, cut, or nicked. (See

the section titled "Door Seal Replacement" on page 4-16 and the section titled

"Troubleshooting" on page 4-15.)

Figure 4-5. Replacing Door Seal


36/75


Revision D

Page 4-8 of 28

www.nov.com

4-8

17. Reinstall the rams (see the section titled "Installation of Rams" on page 4-22).

18. Close doors.

19. Clean and grease support bars.

20. Clean and grease lockbar grooves on door and body.

21. Run a final field wellbore pressure test (see the section titled "Field Wellbore

Pressure Test" on page 4-9) before the BOP is returned to service.

Yearly Preventive Maintenance

Yearly maintenance is performed by a NOV service representative. The purpose of the

yearly maintenance operation is to evaluate wear in the BOP so that a major overhaul(three-year maintenance) can be scheduled at a convenient time, but before a failureoccurs.

The yearly maintenance includes:

Wellbore pressure test

Hydraulic pressure test

Inspection and measurement of cavity for wear and damage

A complete review of BOP performance to determine if the BOP should be sent to a

NOV repair facility for a major overhaul.

Three-Year to Five-Year Maintenance

Three-five year maintenance is performed in a NOV repair facility after a yearlymaintenance check determines it is necessary. The BOP is completely disassembled,

cleaned, and inspected. All elastomer seals are replaced and all parts are repaired orreplaced as required. Hydraulic and wellbore pressure tests are run and the BOP is

returned to service.

ii

All elastomer seals should be replaced during the three-

five year inspection regardless of condition.


37/75

4-9

www.nov.com


Maintenance 4

Pressure Testing

Field Wellbore Pressure Test

The final details of the test sequence will be established by the operator and contractor;therefore, modifications to this procedure may be required. See API Spec. 16A and APIRP53, paragraph 7.A.2 for additional information.

Equipment Required

Connect the listed equipment as shown in Figure 4-6:

Two pressure gauges

Four valves

A test pump

Figure 4-6. Recommended Field Wellbore Pressure Test Equipment Set-up

Test Locations

The BOP can be tested in any of the following locations:

In a wellhead mounted stack

On a test stump

On a blind flange

BOP

Gauge 1 Gauge 2

Valve 1A

Valve 1B

Bleeder Valve

Valve 2

TEST PUMP


38/75


39/75

4-11

www.nov.com


Maintenance 4

Leak Repair

To repair leaks, perform the following:

1. Reduce all hydraulic pressure and wellbore pressure to 0 psi (0 bar).

2. API connection—tighten bolts or replace ring gasket as required (see step 3 of thesection titled "Installation Instructions" on page 3-3).

3. Door Seal—replace door seal (see the section titled "Door Seal Replacement" onpage 4-16).

4. Ram Shaft Weep Hole—call a NOV service representative. For an emergencyrepair, see the section titled "Emergency Ram Shaft Packing Repair" on page 4-17.As soon as possible after the emergency, call a NOV service representative to

replace the ram shaft packing.

5. Ram—replace the ram rubbers (see the section titled "Changing Pipe and BlindRam Rubbers" on page 4-24).

Hydraulic Pressure Test

The final details of the test sequence will be established by the operator and contractor;therefore, modifications to this procedure may be required. See API Spec. 16A and API

RP53, paragraph 7.A.2 for additional information.

ii

If the hydraulic system was opened before this test, close

and open the rams three times to purge air from thesystem.

Pipe rams should always be closed on pipe to avoidexcessive ram rubber wear. Closure on a tool joint willdamage the block.

Blind rams should only be closed on an open hole. Closing

on pipe will damage the rubber and possibly the block.


40/75


Revision D

Page 4-12 of 28

www.nov.com

4-12

Opening Hydraulic Pressure Test

The opening hydraulic pressure test is performed according to the steps listed below:

1. Vent hydraulic closing pressure to zero psi (zero bar).

2. Apply 1,500 psi (103 bar) or 3,000 psi (55 bar), optional opening pressure.

3. Close the valve in the opening hydraulic line (see Figure 4-7).

Figure 4-7. Recommended Hydraulic Line Hookup

4. Observe the gauge between the valve and the BOP.

5. If there is no pressure drop, end the test.

6. If there is a pressure drop, perform the steps listed below:

a. Check for external leaks at the following locations (see Figure 4-8 on page 4-

13):

Weep holes for ram shaft seal leaks—if leaking call a NOV service

representative

Cylinder seal leaks—if leaking call a NOV service representative

Door seal leaks—if leaking see the section titled "Door Seal Replacement" onpage 4-16.

Gauge

Valve

ClosingHydraulic

Line

OpeningHydraulicLine


41/75

4-13

www.nov.com


Maintenance 4

Figure 4-8. Possible External Leaks

b. Check for internal leaks past the pistons in the following manner:

Disconnect the closing hydraulic line. A small amount of fluid will flow out of theBOP initially and stop. If fluid continues to flow out of the BOP, it is leaking past

the piston and repairs are required.

Reinstall the closing hydraulic line.

Call a NOV service representative to repair the leak.

Cylinder HeadO-Rings

All Hydraulic Path

Plugs

ManifoldSeals

Tail RodSeal Assemblies

Ram Shaft Weep

Holes (1 per Cyl.)Door Seals

Hydraulic

Connections

API Connections


42/75


Revision D

Page 4-14 of 28

www.nov.com

4-14

Closing Hydraulic Pressure Test

The closing hydraulic pressure test is performed according to the steps listed below:

1. Vent hydraulic opening pressure to zero psi (zero bar).

2. Apply 1,500 psi (103 bar) or (optional) 3,000 psi (207 bar) closing pressure.

3. Close the valve on the closing hydraulic line (see Figure 4-10).

Figure 4-9.

Figure 4-10. Ram Hydraulic Test Hook-up

4. Observe the gauge between the valve and the BOP.

5. If there is no pressure drop, end the test.

6. If there is a pressure drop, perform the steps listed below:

a. Check for external leaks at the following locations (see Figure 4-1 on page 4-4):

Cylinder head seals-if leaking, call a NOV service representative

Locking shaft seals-if leaking, call a NOV service representative

Manifold pipe seals-if leaking, call a NOV service representative

b. Check for internal leaks past the pistons in the following manner:

Disconnect the opening hydraulic line. A small amount of fluid will flow out of

the BOP initially and stop. If fluid continues to flow out of the BOP, it isleaking past the piston and repairs are required.

Reinstall the opening hydraulic line.

Call a NOV service representative to repair the leak.

Gauge

Valve

ClosingHydraulicLine

OpeningHydraulicLine


43/75

4-15

www.nov.com


Maintenance 4

Troubleshooting

For a list of common problems likely to be encountered during operation, including

possible causes and corrective action, see "Troubleshooting-LXT Manual Lock BOP" tablebelow:

Troubleshooting-LXT Manual Lock BOP

Problem Possible Cause Correction

Will not hold well

pressure

BOP is upside-down. When BOP is right side up, the side outlets are below the skids.

Inside the BOP, the side outlets are below the rams (see the

section titled "Installation Instructions" on page 3-3).

Bad ram rubbers Check ram rubbers and replace if necessary (see the section

titled "Ram Assembly Removal and Inspection" on page 4-19.

Damaged seat Check seat sealing area for cuts and sealing surface scratches.

Smooth minor damage with emery cloth (see the section titled

"Three-Month Preventive Maintenance" on page 4-4).

Leaking ram shaft seal Check the weep holes in the doors for leakage. Replace the ram

shaft seal if necessary. A temporary repair can be made byenergizing the plastic packing, but the seal should be replaced

as soon as possible (see the section titled "Emergency Ram

Shaft Packing Repair" on page 4-17, Figure 4-1 on page 4-4).

Leaking door seal Check for leaks between the doors and the body. Replace the

door seals as required (see the section titled "Monthly

Preventive Maintenance" on page 4-3 and the section titled

"Door Seal Replacement" on page 4-16).

Pump leaking in the test

unit

Install isolation valve in the pump line close to the BOP. Install a

pressure gauge between the isolation valve and the BOP. No

indication of pressure drop indicates a leak in the test unit.

Rams will not

close

Hydraulic fluid not reaching

the BOP

Remove the closing line from BOP and pump a small amount of

hydraulic fluid through it. If no fluid appears, the line is plugged.Clear the closing line.

Opening hydraulic line

plugged or piston seal

damaged

Remove opening line from the BOP and apply closing hydraulic

pressure.

1. If hydraulic fluid spurts out of BOP briefly and stops and rams

close, the opening hydraulic line is plugged. Call a NOV

service representative.

2. If hydraulic fluid spurts out of BOP continuously, the piston

seal is damaged. The rams would also move, but there would

be no pressure buildup. Call a NOV service representative.

Foreign substance in the

wellbore area

Open the door(s) and inspect for cement, metal fragments, etc.

Clean the ram cavity.

Lock bars are hardto remove

Corrosion or material buildup

Thoroughly clean bars and grooves then re-lubricate. A newapplication of Perma-Silk G (solid film lubricant) maybe needed.

One (or both)

rams will open

partly, but will not

move out of the

wellbore

Manual lock(s) rams partly

locked

Unlock rams. Check for damage to the locking shafts, threads, or

bent shaft (see the section titled "Three-Month Preventive

Maintenance" on page 4-4).


44/75


Revision D

Page 4-16 of 28

www.nov.com

4-16

Corrective Maintenance

Door Seal Replacement

The door seal is replaced by performing the steps listed below:

1. Disconnect the universal joints from the locking shafts.

2. Open the doors (see the section titled "Ram Assembly Removal and Inspection" on

page 4-19).

3. Remove the door seal from its seat (see Figure 4-11).

Figure 4-11. Replacing the Door Seal

4. Clean the door seal seat and face.

5. Inspect the door seal seat for damage. Remove minor pits and scratches with emerycloth. If the seat is badly damaged, call a NOV service representative.

6. Clean and oil the door sealing surface on the body with SAE 10W oil.

7. Oil the door seal seat and face with SAE 10W oil.

Door assemblies

are hard to slide

Bent or dirty slide rods Check the straightness of the rods. Replace if necessary. Clean

and lubricate.

Worn DU Bearings Replace the door DU bearings for the slide rods. See the table

titled "BOP and Door Components" on page 5-4.

Troubleshooting-LXT Manual Lock BOP (Continued)

Problem Possible Cause Correction


45/75

4-17

www.nov.com


Maintenance 4

8. Install a new door seal.

9. Close the door.

Emergency Ram Shaft Packing Repair

An emergency repair can be made by reducing the hydraulic pressure to 0 psi (0 bar) and

activating the secondary ram shaft seal on the BOP (see Figure 4-12 on page 4-18). Assoon as possible after the emergency, call a NOV service representative to repack the ram

shaft.1. Remove the pipe plug from the port on the door.

2. With the pipe plug removed, a second socket head screw plug is exposed. Tighten

this clockwise to inject the secondary ram shaft seal.

3. Replace the socket head pipe plug removed in step 1.

4. Call a NOV service representative to repack the ram shaft.

Do not substitute an O-ring for the door seal. Use correctNOV replacement parts only. Failure to heed this caution

may result in malfunction of the BOP.

ii

On the LXT, the secondary seal port is located betweenthe lock bar gooves on the side of the door.

ii

Additional packing may be injected until the leak stops.Remove the packing plug, add packing and re-tighten the

packing plug.

W a r n i n g

r

n

i

n

It is imperative to replace ram shaft seal assemblies assoon as possible. Continued use with emergency

packing can damage BOP components.


46/75


Revision D

Page 4-18 of 28

www.nov.com

4-18

Figure 4-12. LXT Secondary Seal Assembly

Secondary SealPort Location

Weep Hole

Port Plug (P/N 066504)

Packing Plug (P/N 207077)

Check Valve(P/N 20023094)

Ram Shaft SealAssembly (P/N 185174)

Secondary Packing (P/N 050000)

Door


47/75

4-19

www.nov.com


Maintenance 4

Ram Assembly Removal and Inspection

Procedures for removal and installation of pipe, blind and shear rams in the LXT BOP arethe same.

Removal of Rams

Remove the rams according to the steps listed below:

1. Open the rams with 1,500 psi hydraulic pressure.

2. Bleed hydraulic pressure to 0 psi (0 bar) so that the door will open easily and to

prevent possible damage. (See Figure 4-13.)

Figure 4-13. LXT Ram BOP

W a r n i n g

r

n

i

n

Support rods must be installed with end caps before

starting this operation.


48/75


Revision D

Page 4-20 of 28

www.nov.com

4-20

3. Remove two of the retaining caps on both bars. Remove the two door lock bars.(See Figure 4-14 and Figure 4-15.) Store lock bars in safe area.

Figure 4-14. Pulling the Lower Lock Bar

Figure 4-15. Pulling the Upper Lock Bar

ii

If the bar cannot be removed by hand. The supplied ‘slidehammer’ can be used (see Figure 3-9 on page 3-14).


49/75

4-21

www.nov.com


Maintenance 4

4. By hand, pull the door assembly back along the support bars until it stops. SeeFigure 4-16.

Figure 4-16. Pull Door Assembly Open

5. Slide ram out and lift. See Figure 4-17 and Figure 4-18 on page 4-22.

Figure 4-17. Slide The Ram Assembly Out

If the BOP is not flanged to a wellhead or securely

fastened, open only one door at a time. The weight of twoopen doors may tip the BOP over.


50/75


Revision D

Page 4-22 of 28

www.nov.com

4-22

Figure 4-18. Removing/Installing The Ram Assembly

Cleaning and Inspection of Rams

1. Clean the rams.2. Inspect the ram rubbers for damage such as cracking, gouging, chunking, or

splitting. Replace the rubbers if damaged (see the section titled "Changing Pipe andBlind Ram Rubbers" on page 4-24).

Installation of Rams

1. Thoroughly grease all ram exterior surfaces and the ram shaft-mounting slot.

2. Grease the inside of the BOP body at the following locations:

Ram shaft foot.

Side pads in the body cavity.

Skids in the bottom of the body cavity.

Ram sealing seat in the top of the body cavity.

3. Clean and oil the door face with SAE 10W oil; replace the door seal if damaged (see

the section titled "Door Seal Replacement" on page 4-16).

4. Clean and oil the door sealing surface on the body with SAE 10W oil.

Do not use grease on door faces or sealing surfaces.


51/75

4-23

www.nov.com


Maintenance 4

5. Lift the ram assembly into position, then slide the assembly horizontally onto theram shaft foot (see Figure 4-18 on page 4-22).

6. Manually close the door of the preventer and replace the lock bars and retaining

caps. See Figure 4-19.

Figure 4-19. Closing the Door Assembly

ii

Grease the support rods before and after opening andclosing the door assembly. Clean and grease all the lockbars and grooves before closing the doors.


52/75


Revision D

Page 4-24 of 28

www.nov.com

4-24

Changing Pipe and Blind Ram Rubbers

New One-piece Design

1. Clean the ram.

2. Insert a screwdriver or small pry bar under the end of the top seal and pry up and

out of the ram block. (See Figure 4-20.)

Figure 4-20. Remove Top Seal and Face Seal

3. Remove the top seal until the pins are out of the face seal.

4. Remove the face seal.

5. Clean and lubricate the seal areas of the ram block with SAE 10W oil.

6. Install the new face seal.

7. Install the new top seal. Align the seal pins with the holes in the face seal. Tap thenew seal into the block seal area.

Offset Rams for Dual CompletionsSingle offset rams have only one bore, which is offset to API centerline standards. This

allows complete control of a dual completion when the second tubing string is to be runlater.

Dual offset rams are furnished to API centerline standards for complete control of a dual

completion when both tubing strings are run together.

Contact your local Shaffer sales representative for delivery dates. Be sure to specify thefollowing when ordering:

BOP size and working pressure.

If single or dual offset rams are required.

Tubing OD and type of coupling so the coupling OD can be determined.

Casing size and weight so that the casing ID can be determined.

Tubing hanger centerline dimensions.

Pry up on each endto remove from face seal

and ram block.


53/75

4-25

www.nov.com


Maintenance 4

Aluminum Drill Pipe Rams

Since aluminum drill pipe has an oversize OD, these rams must have oversize bores inboth the ram blocks and in the ram rubber extrusion plates. Contact your local NOV sales

representative for part numbers and the following:

BOP size and working pressure.

Aluminum drill pipe OD.

Storing the LXT BOP

LXT BOP Data Location

For the location of BOP data, see Figure 4-21 on page 4-26.

Operation information is contained on plates mounted on the cylinder heads.

The body part number is located on the body.

Most components of the LXT BOP are stamped with their part numbers and othermanufacturing data.

Cleaning and Storage of the LXT BOP

A BOP should be cleaned immediately after it is taken out of service. Proper cleaning of aBOP before it is stored will increase its life significantly. If a BOP is in an active drilling

program, this cleaning should be done approximately every three months or when the rigis between wells see the table titled "LXT Ram BOP Cleaning and LubricatingInstructions" on page 4-27.

1. Open the doors and remove the rams (see the section titled "Removal of Rams" on

page 4-19).

Store rubber parts in their natural shape. Do not hang o-rings on nails or hooks.

Storage areas should be kept as dry as possible. Oil, grease or other fluidsshould be stored elsewhere to avoid spillage.

If storage is for a long duration, it is recommended that rubber parts be placed insealed containers or be given a protective surface covering impervious totemperature or light, This will extend the shelf life.

ii

Always give the serial number or assembly part numbersand size of the LXT BOP when ordering parts.

If the BOP is not flanged to a wellhead or securely

fastened, open only one door at a time. The weight of twoopen doors may tip the BOP over.


54/75


Revision D

Page 4-26 of 28

www.nov.com

4-26

Rubber parts should be used on a first in, first out basis.

2. Inspect rubber parts according to the instructions listed below:

Each rubber part must be inspected before it is put into service.

Bend, stretch, or compress each part and look for cracks.

Observe if the rubber part has a hard skin or small cracks which may become

chalky or bark like in appearance.

Figure 4-21. Data Information

ii

Some cracks are not obvious, but when the rubber part isbent, stretched or compressed, very minute cracks will

become apparent.

Most components of the LXThave their part numbers stampedon them.

i

ASSY. NO.

DATE OF MFR.

ASSY. WT.

API PDC

SERIAL NO.

TRIM/TEMP. CLASS

OTLT. RG. GSKT.

OTLT. SIZE

BTM. RG. GSKT.

BTM. CONN.

TOP RG. GSKT.

TOP CONN.

WKG. PRESS.

BORE SIZE

PREVENTER

BLOWOUT

PSI

IN

HYD. OPER. SYSTEM PRESS:

RATED WKG.

RECMD. OPER.

PSI

PSI

132894

FOR CORRECT DOOR CLOSURE

ATTENTION

SLIDE DOOR COMPLETELY CLOSED,

PULL DOWN SLIGHTLY ON CYLINDER

HEAD TO ALLOW EASE OF

INSTALLING LOWER LOCK BAR FIRST

THEN LIFT SLIGHTLY ON CYLINDER

HEAD TO INSTALL UPPER

LOCK BAR

2 2 6 7


55/75

4-27

www.nov.com


Maintenance 4

* Do not use a wire brush to clean the ring groove. Install new ring gaskets dry.

NOTE: The lock bars and grooves may require a field application of the solid film lubricant Perma-

Silk® G. This lubricant is an air drying, MoS2 based solid film lubricant with an epoxy binder system.

The coating provides a low coefficient of friction with good corrosion resistance and is ideal for

higher load carrying applications. (Technical data available on request)

LXT Ram BOP Cleaning and Lubricating Instructions

Part How to Clean Lubricants

1. LXT exterior

Steam or high pressure water

WARNING

Diesel fuel is a Flammable liquid. It will

cause rubber goods to swell and

deteriorate.

N/A

2. LXT interior Steam, high pressure water SAE-10W hydraulic oil or equivalent.

3. Studs/nuts Water, wire brushGrease specified in API 5A2.

Moly Paste 503 (P/N 7403582)

4. Ring groove* Emery Cloth(Grease if not immediately in

service).

5. Ram assemblySteam, high pressure water (See Warning)

Grease

6. Lifting eye threads Water, wire brushPack heavy grease to prevent

corrosion.

7. Seat sealing

surfacesEmery cloth SAE-10W oil or equivalent.

8. Bore Steam, high pressure water Grease

9. Skids and side pads Steam, high pressure water, emery cloth Grease

10. Sealing areas

(door face, doorsealing surface)

Emery Cloth SAE-10W oil or equivalent.

11. Seals Wipe with damp cloth SAE-10W oil or equivalent.

12. Door seal grooves Emery cloth SAE-10W oil or equivalent.

13. Door slide rod Steam, high pressure water Grease

14. Lock bars and

groovesSteam, high pressure water

Grease, SAE-10W oil or equivalent.

See Note.


56/75


Revision D

Page 4-28 of 28

www.nov.com

4-28



57/75www.nov.com

5-1


Revision D

Page 5-1 of 18

Specifications and Parts Lists

Customer Service

Direct all correspondence to one of the addresses provided below:

Mailing Address

National Oilwell Varco (NOV)

P.O. Box 1473

Houston, Texas 77251, U.S.A.

Shipping Address

12950 West Little York Houston, Texas 77041

Phone: (713) 937-5000

Fax: (713) 937-5779

Repair Center

5100 N. Sam Houston Parkway West Houston, Texas 77086

Phone: (281) 569-3000

Parts Lists

Parts IdentificationAll parts required for maintenance or repair are available from NOV. Figures correspond to

the parts list, which identifies each part by number. Using this part number and part namewill ensure procurement of the proper part when ordering parts.

Ordering Replacement Parts

When ordering replacement parts, please specify the following information:

Part name – list part name as called out on the applicable drawing

Part number – list part number as called out on the applicable drawing

Quantity – list the quantity needed Serial number – list the serial number (if applicable) as shown on the nameplate

Recommended Spare Parts

The the table titled "Model LXT Manual Lock Spare Parts Kit (P/N 20024693)" on page 5-

11 provides recommended spare par ts coverage for the LXT preventer.


58/75

Specifications and Parts Lists5LXT Ram Blowout Preventer

Revision D

Page 5-2 of 18

www.nov.com

5-2

Exploded Views and Parts Lists

Figure 5-1 on page 5-3 shows a cutaway view of the LXT Manual-Lock Door. The parts listis contained in the table titled "BOP and Door Components" on page 5-4 lists the parts.

BOP Characteristics

WELLBORE CHARACTERISTICS

Working Pressure5,000 psi (3,000 psi optional.

See note below)

Max. Ram Size 5-1 / 2”

OPERATOR CHARACTERISTICS

Working Pressure 1500 psi (3,000 psi max.)

Volume to Open 0.32 Gallons per cylinder

Volume to Close 0.39 Gallons per cylinder

Closing Ratio 8.45:1

Piston Stroke 4.19 inches

Ram Shaft 1-5 / 8” Diam.

ESTIMATED WEIGHTS

Single, S X S, 2” flg outlets

with rams1,360 lbs.

Single, S X F, 2” flg outlets

with rams 1,460 lbs.

Double, S x S, with rams 2,420 lbs.

Ram Assembly 30 to 42 lbs. per set

ii

NOV manufactures 5,000 psi 7 1/16" LXT blowout

preventers and 3,000 psi working pressure 7 1/16" LXTblowout preventers. Both preventers are identical in

operation. The difference between the two preventers isthe API end connections, which limit the working pressure

of the preventer to 3,000 psi.


59/75

5-3

www.nov.com


Specifications and Parts Lists 5

Figure 5-1. LXT Door Assembly Components

Locking Shaft

Cylinder Head

Manifold

Cylinder

Nut w /Washer

Stud

Q/D Nipple (x2)

O-Ring

Door Seal

Piston Shaft

Plug (x2)

O-Ring (x4) Pipe Plug

Piston Seal

Screww /Washer (x2)

Ram ShaftSeal Assembly

O-Ringw /Backup (x2)

Piston ShaftSeal

Door


60/75


Revision D

Page 5-4 of 18

www.nov.com

5-4

BOP and Door Components

Item

No.

P/N Description Qty

1 — DOOR, 7-5M LXT, W/ PLASTIC INJECTION 1

2 20022087 CYL, 7-5M LXT 1

3 20022086 SHAFT, PSTN, 7-5M LXT 1

4 20022088 SHAFT, LKG, 7-5M, LXT 1

5 20022653 MNFD, 7-5M LXT 1

6 20022084 CYL, HD, FM, 7-5M LXT 1

7 20022103 SEAL, DOOR, 7-5M, LXT 1

8 1500390 NIPPLE, Q/D, 3/8”, CHECK VLV TYPE, SAE MALE 2

9 5019416 O-RING 2

10 030928 O-RING, SPG 2

11 032008 RG, BACKUP 2

12 20022403 SEAL, POLYPAK, 2-1/16” OD X 1-11/16” ID”, .375 DEEP 1

13 032006 SEAL, PSTN, 4-5/8”ID X 5”OD X 3/16”CS 1

14 185174 RSSA, 1-5/8” SHAFT 1

15 030653 O-RING 4

16 20022704 DU BRG #16DU24 2

17 020009 NUT, HX, HVY, 7/8"- 9UNC, A194Gr2H, BLK FINISH 4

18 20022090 STUD, 7-5 LXT 4

19 065008 PLUG, SKT HD, HX, 1/4" NPT 1

20 20020275 PLUG, PIPE, SKT HD, 1/4"- 18NPT x 1/16" DIA 1

21 066502 PLUG, SKT HD, HX, 1/2" NPT, ALLOY STL, CAD PLTD 2

22 8010201 SCREW, HHC, 1/2"- 13UNC x 3/4" LG, SS 2

NS 20025967 PLUG, PIPE, SKT HD,1/4"-18NPT x 1/32”DIA 1

23 20001174 WSHR, FL, 1/2", 316 SS 2

24 025046 WSHR,LK, SPLIT, 7/8"DIA, CAD PLTD, CARBON STL 4

25 1500389 CPLR, Q/D, 3/8”, CHECK VLV TYPE, SAE FEMALE 2

26 20022085 BAR, SLIDER 2

27 20022650 CAP END, SLIDER BAR 2

28 8002856 SCREW, SHC, 3/8” UNC X 3/4” LG 2


61/75

5-5

www.nov.com



Note: Quantity shown is for one (1) set of door components.

Figure 5-2. LXT BOP and Door Components

29 20022089 LOCK, BAR 2

30 20021470 KNOB, HAND 4

31 066504 PLUG, PORT 1

31A 2007077 PLUG, PACKING

32 050000 PKG, STICK, INJECTION, PLASTIC 1

33 20023094 VLV ASSY, CHECK, 3/4-10 UNC-2A 1

NS 8130121 SCREW, DRV, #6 x 1/4” LG, .120” HOLE SIZE, SS, RD HD 4

NS 185181 HANDLE, F/7-5M MANUALLY OPERATED BOP 1

NS 20020261 HAMMER, SLIDE, 24” LG X 5/8” - 1/8” THREAD END 1

NS 050193 RG GSKT, R-24, CAD PLTD, OVAL 4

NS 050202 RG GSKT, R-46, CAD PLTD, OVAL 2

NS 064036 PROTECTOR, FLG, STDD, 2-5M 4

NS 064078 PROTECTOR, STDD, 7-5M (PLASTIC) 2

NS 20024128 BORE AND GROOVE PROTECTOR 2

See foldout.


62/75

14

www.nov.com

LXT Ram BOP

RevisionD

6

18

2

1011

16

7

26

12

19

9

25

22

2

30

29

27

28

BOP Body

Figure 5-2. LXT BOP and Door Components

24

31

32

33


63/75


Revision D

Page 5-6 of 18

www.nov.com

5-6

* Quantity shown is for 1 assembly. Note that a single model requires 2 assemblies, a double model

requires 4 assemblies. Increase quantities as required.

Figure 5-3. LXT Ram Shaft Seal Assembly

Model LXT Ram Shaft Seal Assemblies

Item No. Description Qty. Part Number

— Ram Shaft — 1-5 / 8”

— Assembly Number — 185174

1 Retainer, Ring 1 141365

2 Holder, Ring, Wiper 1 185172

3 Scraper, Ring 1 032005

4 Seal, Polypak 1 032004

5 Adapter, Packing 1 185173

6 Seal, Polypak, Deep 1 032009

OPERATOR

BOP BODY

Plastic Injection Hole

1

2

3

4

5

6


64/75

5-7

www.nov.com



* Quantity shown is for 1 assembly. Note that a single model requires 2 assemblies, a double model requires 4

assemblies. Increase quantities as required.

Figure 5-4. LXT Piston Shaft Seal Assembly

Model LXT Cylinder Head/Piston Shaft Seal Assembly

Item No. Description Qty. Part Number

3 Piston Shaft — 1-5 / 8”

12Cylinder Head/Piston

Shaft Seal1 20022403

Piston Shaft

Cylinder Head

PistonShaft Seal


65/75


Revision D

Page 5-8 of 18

www.nov.com

5-8

Figure 5-5. LXT Pipe Ram Assembly

Rams for Model LXT Blowout Preventers

BOP Ram (Type or Model)

Working Pressure Bore Assembly Current

Components

Regular

Duty

Support

Drill Type

Rubber Block

3,000/5,000 psi LXT 7" LXT LXT LXT LXT

Ram Block

Top Seal

Face Seal


66/75

5-9

www.nov.com



* 3,000/5,000 LXT BOP uses Chasovoy™ Ram assemblies.

3,000/5,000 psi 7-1/16 LXT Pipe Ram Assembly *

Pipe OD Complete

Assembly

Ram Block Face Seal

Assembly

Top Seal

Assembly

7

1

/ 16", 3,000/5,000 psi, (18

0 mm)

CSO 722224 722156 722183 722181

11 / 4", 32 mm 722259 722285 722286 722181

1.315", 33 mm 722225 722157 722184 722181

1.660", 42 mm 722226 722158 722185 722181

1.900", 48 mm 722227 722159 722186 722181

2 1 / 16", 52 mm 722228 722160 722187 722181

2 3 / 8", 60 mm 722229 722161 722188 722181

2 7 / 8", 73 mm 722230 722162 722189 722181

3 1 / 2", 89 mm 722231 722163 722190 722181

4", 102 mm 722232 722164 722191 722181

4 1 / 2", 114 mm 722233 722165 722192 722181

5", 127 mm 722234 722166 7221

shaffer lxt 7-5m-user manual

Documents