Fabritech Globular® GBOP User Manual REV.1
Fabritech Globular® GBOP User Manual REV.1
Fabritech Globular® GBOP User Manual REV.1
1
Page 1 of 37
Fabritech Globular®
GBOP Bolted Cover
Summary: This manual is intended for the safe operation, maintenance and repair of the
Fabritech GBOP in all size variants.
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Table of Contents
Section B: Introduction
Features
Safety Precautions
Section D: Maintenance
Monthly Preventive Maintenance
Yearly Preventive Maintenance
Three Year Preventive Maintenance
Changing Sealing/Packing Element
Disassembly/Assembly Procedure
Replacing Seals
Replacing Wear Bands
Troubleshooting
Storage of GBOP
Storage & Inspection of Rubber Parts
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Usage Agreement
INFO:
The Info symbol above indicates that there is additional information concerning the specific
topic
CAUTION:
The caution symbol above indicates that there is a possibility of damage or injury to equipment
and or equipment. Extreme care shall be taken when performing these operations or
procedures
WARNING:
The warning symbol above indicates a high risk of damage or danger to equipment and or
personnel. Failure to follow safe work procedures could result in serious fatal injury to
personnel, as well as equipment damage.
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Depictions
Figures and graphical illustrations are provided throughout this manual as an aid
for identifying parts, and becoming familiar with the different components. The
depictions are solely for reference and are not to be considered to scale.
Safety Requirements
Proper maintenance is important for safe and reliable operation. All procedures,
notes, and precautionary advice are recommended for optimal performance.
Take precaution by observing the safety requirements set forth in this section, as well as procedures
Training of Personnel
Recommendation of Tools
Some service operations may require the use of specific tools and it is
recommended to only be used as stated. Personnel safety should be the priority.
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Replacing Components
Maintenance at Intervals
This equipment is to be used ONLY for its intended and designed purpose.
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Section B: Introduction
Bolted lid BOP models are rated for the working pressures and bore sizes on
table below.
FMS GBOP will seal on almost any shape or size tool joint, drill pipe, casing,
Kelly, drill collar, or wireline as well as an open hole (Complete Shut Off). The
sealing element maintains a seal while expanding and contracting thus allowing
tool joints to pass. Furthermore, the sealing element has the capability to strip
drill pipe under wellbore pressure.
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Features
• Simple to operate
• Wear bands prevent metal to metal contact
• Easy to service
• Compact thus saving space
• Composed of few parts
All GBOP meet or exceed all applicable API, and NACE standards for MR-0175
latest edition (Sour Gas Service).
Safety Precautions
During operation of the GBOP it is important to consider the risks and potential
hazards that may exist and or arise. It is very important to exercise and apply
standard safety precautions to avoid or mitigate any potential injuries or fatalities
that could result from error.
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All cables and hoses should be taken care of in order to prevent injury and or
damage to equipment.
• Ensure all cables and hoses are protected from cutting, scraping,
pinching, and other physical damage
• Make sure to consider routing cables and hoses outside and away
from mechanical equipment
• Make sure to comply with all recommended bend radius for cable and
hose manufacturers
Flammable materials may also include kerosene, gasoline, oxygen tanks, acetylene tanks or any
combustible gas.
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Prior to installation and or each new well, perform the following preliminary
inspections as a preventive measure
1. Clean the GBOP per table 11 on page 33
2. Inspect the GBOP components for physical damage and or abnormal
wear.
3. Perform a visual inspection on the thru bore of the upper housing
component to assess the piston and lower housing for abnormal wear.
Ensure the bore is no larger than 1/8” oversize at any point around the
bore
4. Check the sealing element through the top of the ID for discrepancies
such as cracking, chunking, and or splitting. Replace sealing element
when necessary.
Following the above preliminary inspection steps can help reduce upcoming installation time due to
unexpected errors.
Installation
The following procedures are indispensable regarding installing GBOP to
flanged, studded, or hubbed connections.
Torque data is reflected from API 5A2 recommended lubricant which should be applied to threads
and nut face.
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Studded Flanged
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Hubbed Connections
Refer to table 1
1. When assembling the clamp joint, tighten the studs alternately from one
side to the other.
2. Maintain the same distance between the two clamp halves.
3. Refer to table 1 on page 13 lists clamp sizes for bolted lid GBOP
with stud size, wrench size (across the nut flats), and recommended
torques.
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No. of Studs 12 12 16 20 20 24 28
Ring Gasket RX-45 RX-49 RX-53 RX-57 RX-74 RX-73 RX-95
*Indicated values are based on a stress equal to 50% of min. yield. Apply API 5A lubricant to face and threads of all nuts
All GBOP’s have two lifting lugs and shackles located on the top of the upper housing.
Removable lifting eyes are used to lift internal components and lower housing. Refer to the
table below.
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Table 4
Working Pressure 10,000 PSI 5,000 PSI
Piston ½”-13 NC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC
Adapter Ring ½-13 NC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC
Upper Housing * * * * * *
Lower Housing ** ** ** ** ** **
Element N/A 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC
Table 5
Working Pressure 3,000 PSI 2,000 PSI 1,000 PSI
Piston 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 1”-8 UNC
Adapter Ring 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”- UNC
Upper Housing * * * * * *
Lower Housing ** ** ** ** ** **
Element 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 5/8”-11 UNC 1”-8 UNC
GBOP weights for all available bore size, major components, and total lifting capacities of lift
shackles are in section E of this manual.
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Hydraulic Connections
GBOP’s have both OPEN & CLOSE ports that are hydraulically operated. These ports are
made up of female pipe threads. Refer to tables for thread sizes of each GBOP size
model. Make sure to keep all connections from any restrictions to prevent down time.
Hydraulic Hookup
A control system designed for Blowout Preventers is required to actuate the GBOP. The
hookup required for basic functions are illustrated below in figures. A hydraulic regulator is
indispensable in the operation of the GBOP to prevent operating pressure from exceeding the
recommended closing pressure* as well as allows application of lower operating pressures
when stripping or when closing on large diameter casing.
*Recommended closing pressure is 1,500 PSI, 3,000 PSI MAX. It can be dangerous to operate outside of recommendations.
The GBOP can be used for stripping operations in both subsea and land configurations
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Subsea Installation
When installing GBOP for subsea function, the following items are to be included in the
procedure and are indispensable to function:
Pre-charge the accumulator bottle to 500 PSI in addition to hydrostatic water depth (0.445 PSI/ft.)
Hydraulic Connections
Table 6
Working Pressure 10,000 PSI 5,000 PSI
QTY. 2 2 2 2 2 2
Table 7
Working Pressure 3,000 PSI 2,000 PSI 1,000 PSI
QTY. 2 2 2 2 2 4
Land Installations
The following procedures are to be included to all installation of GBOP for land operations:
• An accumulator surge tank in the closing line adjacent to the GBOP during stripping
• A control line to the opening port, refer to the above table
• A hydraulic regulator for the accumulator system
• Surge tank in closing line to the GBOP to prevent excess pressure surges during tool
joint stripping operations
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Accumulator bottles are only required by stripping operations on land. Accumulator bottle
requirements are identical in both land and subsea. Pre-charge accumulator bottle to 500 PSI.
Hydraulic Systems
All GBOP’s are equipped with an opening and closing hydraulic chambers/ports. The top port
is always the opening port.
Diesel, kerosene, and other flammable fluids cause elastomers to swell and deteriorate. Drilling
mud will cause pistons and cylinders to wear faster than usual.
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Under normal operating conditions, the GBOP will open and close with 1,500 PSI operating
pressure. For stripping, refer to applicable figures below.
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To close the GBOP on stationary pipe on with an OD 7” or less (including CSO), apply 1,500
PSI.
Complete Shut Off requires a minimum of 1,200 PSI operating pressure
Closing on Casing
When GBOP will be closing on casing, it is critical to adjust hydraulic operating pressure when
necessary to avoid contact of sealing element segments with the casing. Refer to the table
below for the recommended closing pressures for pipe larger than 7”. Refer to Figure
(XL) for recommended closing pressures on casing when using a 30” 1,000 PSI GBOP.
Figure 6 - Reference Closing Pressure for Casing (30” 1,000 PSI GBOP)
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Table 9
Working
GBOP Size 11-3/8” 13-3/8” 16” 18-5/8” 20”
Pressure (PSI)
20-3/4” 3,000
Sizes not listed on table above require no pressure adjustment when closing on casing
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Stripping Operations
Stripping operations will be the most severe application of GBOP. The sealing element will
encounter severe wearing conditions as drill string moves through GBOP under pressure. The
following procedures are designed to extend the life of the sealing element when stripping:
Figure 7 - Reference Closing Pressure for Stripping (4-1/16” 10,000 PSI GBOP)
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Prior to any operation of GBOP it is imperative to test for basic functionality of the following
seals:
• Seal A – Piston Inside Diameter Seal
• Seal B – Adapter Inside Diameter Seal
• Seal C – Adapter Top Seal
The wellbore pressure test is a way to test the sealing element as well as the Piston Inside
Diameter seal.
Preparation:
1. Install a test pipe or rod in the wellbore. The recommended pipe for a GBOP is 3-
1/2” OD or 5” OD
2. Anchor test pipe at the bottom of the GBOP to prevent well pressure from
causing the pipe upward
Do not use sealing element to support test pipe, as doing so will damage the bottom of the element.
Install a gauge and valve in both the opening and closing hydraulic lines.
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Testing Seal A
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b. At the bottom connection of the GBOP to the test stump and in the well
pressure piping system
If no leaks are found in these areas, seal A is leaking. To verify this leak, follow
instructions below:
• Maintain 1,500 PSI closing hydraulic pressure.
• Pump slowly to maintain rated wellbore pressure.
• Close the valve in the hydraulic closing line.
• Reduce the wellbore pressure to 0 PSI. Open the valve in the hydraulic
closing line.
• Apply hydraulic pressure to open the GBOP and bleed to 0 PSI if
disassembly required.
• Check and replace damaged seal A. Retest seal A for leakage.
Open and close the sealing element at least twice before closing element on test pipe.
Seals B and or C can only be checked with the sealing element in the open position. If
the sealing element is in the closed position, it will seal the area where both seals B & C
are located from the wellbore pressure, thus preventing a true check of the seals. If
there is a need to check these seals, proceed in accordance with the following
procedure:
1. Check the integrity of seals B and or C by flanging the GBOP through bore, while
leaving the sealing element in the open position.
2. Apply wellbore pressure
3. Check seal B by closing the valve in the opening line and observing the gage in
the opening line. This gage should read 0 PSI. If the gage does not indicate an
increase in pressure, seal B is holding. If the gage indicates a steady increase,
seal B is leaking.
4. Maintain wellbore pressure and check seal C by inspecting for external leakage.
In GBOP, hydraulic fluid will flow out between the upper and lower housing
flanges.
5. If seal C is leaking, Replace seals.
6. After GBOP is reassembled, perform testing to ensure seals are correctly
installed.
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This test procedure is a slightly modified version of the original test procedure to test the Piston
Inside Diameter upper seal A for 30” 1,000 PSI GBOP.
1. Check seal A by flanging the GBOP through bore on top and bottom, with the sealing
element in the open position.
2. Apply wellbore pressure.
3. Check seal A by closing the valve in the hydraulic closing line and observing the gage in
the closing line. This gage should read 0 PSI initially. If the gage does not indicate an
increase in pressure, seal A is holding pressure. If the gage indicates a steady increase,
then seal A is leaking. Replace seal if needed. Retest GBOP to ensure that seal A was
installed successfully.
The procedures below are indispensable to perform hydraulic pressure testing safely &
correctly.
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Equipment Hookup
1. Apply and maintain 1,500 PSI pressure to the hydraulic closing port of the GBOP. This
will move the sealing element to the closed position
2. Close the valve in the closing hydraulic line after waiting 3 minutes
Movement occurring in sealing element is common prior to stabilization, and may cause leaks until broken in. It
is important to know the difference between the rubber creeping and an actual leak.
3. Observe the gage in the closing hydraulic line. If there is no indication of pressure drop,
there is integrity in seals #1 & #2. If there is a pressure drop, seals #1, & #2 are leaking.
4. Open the valve in the closing hydraulic line to supply closing pressure to further identify
leak. Hold for up to 5 minutes.
5. Close the valve in the opening hydraulic line. The gage in the opening hydraulic line
should read 0 PSI initially. If there is a pressure increase on the gage in the opening
hydraulic line, seal #1 is leaking. If there is no pressure increase on the gage in the
opening hydraulic line, seal #2 is leaking.
6. To verify a leak in seal #2, reclose the valve in the closing hydraulic line. Apply 1,500
PSI opening pressure and inspect the lower housing bore area for the presence of
hydraulic fluid. If seals #1 and or #2 are leaking, disassemble per this manual and
replace the seals
1. Apply and maintain 1,500 PSI pressure to the hydraulic open port of the GBOP.
2. Close the valve in the opening hydraulic line.
3. Observe the opening hydraulic pressure gage. If there is no pressure drop, there is
integrity in seals #3, #4, #5. If there is a pressure drop, one or more of the three seals
are leaking.
4. Open the valve in the opening line to supply pressure to further identify the leak.
5. Check seal #5 by inspecting for external leakage. Hydraulic fluid tends to flow out
between upper and lower housing flanges.
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6. Check seal #3 by closing off the closing line and leaving the open line open to pressure.
The closing line should read 0 psi initially. If pressure increases on the gage in the
closing line, seal #3 is leaking. If there is no pressure increase in the closing line, then
seal #3 is holding pressure.
7. Check the integrity of seal #4 by visually inspecting the top of the piston for hydraulic
fluid residue.
8. Replace seals as necessary.
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Section D: Maintenance
3.1.1 Monthly
3.1.1.1 All BOP’s should be inspected for anomalies and accumulation of medium deposits on
a regular basis as per below by rig personnel.
3.1.1.1.1 Function test sealing elements in any Annular BOP daily to wipe the piston clean of
any medium.
3.1.1.1.2 Avoid cement from setting by rinsing the BOP with water and performing several
function tests. If water alone will not remove the cement, remove upper housing or
lid for cleaning.
3.1.1.1.3 Check all nuts and studs for damaged threads by visual inspection STD 53.
3.1.1.1.4 Visually inspect any readily visible BOP components for excess wear (Min. 1/8” in.
wear for bore)
3.1.1.1.5 Visually inspect the packing or sealing element for cracks, chunking, or splitting.
3.1.1.1.6 Replace sealing or packing element if required.
3.1.1.1.7 Perform every time prior to putting into operational service on the wellhead STD 53.
3.1.2 Yearly
3.1.2.1 All BOP’s should be inspected yearly in anticipation for the 3-year maintenance. The
yearly inspection goes deeper in scope than the monthly maintenance and is to be
performed by rig personnel or at
3.1.2.1.1 Clean all ring grooves and visually inspect for dings and major scratches. It is
recommended to perform a penetrant test of ring grooves. Document all findings.
3.1.2.1.2 Check all nuts and studs for damaged threads by visual inspection STD 53.
3.1.2.1.3 Remove upper housing or lid and clean all areas thoroughly with water. Emery cloth
use is recommended for cleaning light corrosion and scratches.
3.1.2.1.4 Inspect upper housing hemi sphere area for any deep scratches or dings. Inspect Lid
of other model BOPs for any deep scratches or dings, including wear plate wear.
Replace wear plate if needed. Penetrant test of hemisphere area recommended.
Document all findings.
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3.1.2.1.5 Visually inspect bore areas and all seal areas of upper housing or lid for corrosion or
pitting. Do not allow the bore to wear more than 1/8” in. oversize. Penetrant test
recommended for all seal areas. Document all findings.
3.1.2.1.6 Lubricate and remove sealing or packing element and inspect for excess wear on ID,
cracks, and or splitting. Replace if necessary.
3.1.2.1.7 Perform hydraulic pressure test and wellbore pressure test of low and high pressure
at a minimum of 5 minutes. Document findings STD 53.
3.1.3 Three Years
3.1.3.1 All annular BOP’s are to be scheduled a three-year maintenance program where
Fabritech completely disassembles the BOP, cleans, and inspects the BOP. All
elastomers/seals and sealing element/packing element are replaced, and parts are
replaced or fixed as necessary. Dimensional inspection of the entire BOP components
is performed, as well as hydraulic and wellbore pressure tests prior to factory
acceptance and certification. Studs and nuts are replaced STD 53.
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Table 10
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UPPER HOUSING
PACKING ELEMENT
ADAPTER RING
PISTON
1. Remove upper housing, packing element, and adapter ring to access the piston.
2. Vent the CLOSE port to prevent any suction while lifting. Apply very low pressure
only when needed to help take out the piston. Protect sealing areas while
handling.
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TROUBLESHOOTING
Table 11
Inspect packing
Packing element not
sealing properly. element. Replace as
needed.
Ring gasket or piping Inspect ring gasket and or
Wellbore test pressure will system. any valves for leaks.
not hold.
Check wellbore pressure
Wellbore pressure seal leak.
seals. Replace as needed.
Hydrostatic testing
apparatus pump Repair or replace pump.
malfunction
Replace worn hoses &
Hydraulic hose leak.
Hydraulic test pressure will connections.
not hold.
Hydraulic pressure seal leak. Check hydraulic seals.
Replace as needed.
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STORAGE
1. Disassemble GBOP.
2. Steam clean all parts and dry.
3. Coat all parts with grease.
4. Apply heavy grease to all OD sealing surfaces.
5. Put plugs in ports to preserve.
6. Store on high ground.
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6 7
8
9
10
12 11
13
14
15
16
17
18
19
21 20
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• Sealing Characteristics
• Fatigue Test
o The testing resulted in 50 cycles at 1,500 PSI closing pressure and 60 cycles total.
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