Operation & Maintenance Manual

T3 Model 6012 Ram BOP

© T3 Energy Services All Rights Reserved

T3-1251035 REV C
 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

TABLE OF CONTENTS

1.0 PRODUCT DESCRIPTION .......................................................................................................................................2

2.0 CLOSURE BOLTING TORQUE REQUIREMENTS .............................................................................................2
3.0 HYDRAULIC OPERATING DATA...........................................................................................................................5
4.0 OPERATION AND INSTALLATION PROCEDURES ..........................................................................................8
4.1 PREPARATION......................................................................................................................................................8
4.2 INSTALLATION......................................................................................................................................................8
5.0 ASSEMBLY PROCEDURE ......................................................................................................................................9
5.1 PREPARATION PRIOR TO ASSEMBLY ...........................................................................................................9
5.2 BONNET ASSEMBLY ...........................................................................................................................................9
6.0 DISASSEMBLY PROCEDURE..............................................................................................................................11
6.1 BOP DISASSEMBLY...........................................................................................................................................11
6.2 BONNET DISASSEMBLY...................................................................................................................................12
7.0 MOVING AND STORAGE ......................................................................................................................................12
8.0 TROUBLESHOOTING ............................................................................................................................................18
8.1 GENERAL INFORMATION ................................................................................................................................18
8.2 COMMON PROBLEMS.......................................................................................................................................18

Page 1 of 20 T3-1251035 REV C

 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

1.0 PRODUCT DESCRIPTION

The T3 Model 6012 Ram Type Blowout Preventer (BOP) is used to contain wellbore pressure in land and platform
drilling operations. The rams in T3 Model 6012 BOP are hydraulically operated and pressure energized.
Wellbore pressure acts on the rams to increase sealing force and maintain the wellbore seal in the event of
hydraulic pressure loss. As the wellbore pressure increases, seal integrity is improved.

The T3 Model 6012 BOP is designed to use hydraulic pressure to open and close the rams. The same hydraulic
system is used to access the rams for a quick ram change operation. The pressure applied via the CLOSE port
to close the rams also opens the bonnet when the bonnet bolts are removed (Figure 2). When the bonnet is
opened to the fully extended position, the ram is clear of the body and is accessible for removal. In the same
manner, the pressure applied via the OPEN port to open the rams closes the bonnet when it is extended (Figure
3). During this operation, the rams are moved away from the body faces before the bonnet begins to move
toward the body faces. This insures that the rams do not obstruct the bore or interfere with pipe in the wellbore.

2.0 CLOSURE BOLTING TORQUE REQUIREMENTS

The T3 Model 6012 BOP requires that the bonnet bolts are torqued to specific specifications to insure that the
bonnet gasket will perform as designed. The torque values shown in Table 1 are dependant upon the type of
lubricant used on the bolt threads. T3 recommneds a molylube, which is a petroleum based lubricant containing
70% or more Molybdenum Disulfied. An API 5A type lube can also be used, but the torque requirements are
greater. The bonnet bolts shall be torqued in the pattern shown in Figure 1.

Torque requirements for the intermediate flange to bonnet cap screws are shown in Table 2. These fasteners
shall be torqued in an alternating pattern to insure even tightening.

All values listed in Tables 1 & 2 are ±10%.

1 4

3 2

Figure 1 Bonnet Bolt Torquing Sequence

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
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TABLE 1

BONNET BOLT TORQUE REQUIREMENTS

MOLY LUBE API 5A LUBE
WORKING HEX
BORE SIZE THREAD SIZE TORQUE TORQUE
PRESSURE SIZE
inches inches (µ = .07) (µ = .13)
psi inches
ft-lbs ft-lbs
7.06 3000 1.750-8UN 2-3/8" 1475 - 1625 2590 - 2850
7.06 5000 2.000-8UN 2-3/8" 2125 - 2340 3765 - 4140
7.06 10000 2.500-8UN 2-3/4" 3550 - 3900 6320 - 6950
7.06 15000 2.875-8UN 2-3/4" 5715 - 6285 10,240 – 11,265

11.00 3000 2.250-8UN 2-3/4" 3505 - 3860 6230 - 6850

11.00 5000 2.500-8UN 2-3/4" 4540 - 4995 8090 - 8900
11.00 10000 3.125-8UN 2-3/4" 7705 - 8475 13,830 – 15,210
11.00 15000 3.750-8UN 3-1/2" 15,705 – 17,275 28,370 – 31,205

13.62 3000 2.750-8UN 2-3/4" 5275 - 5800 9440 – 10,385

13.62 5000 2.875-8UN 2-3/4" 6630 - 7295 11,880 – 13,070
13.62 10000 3.750-8UN 3-1/2" 12,350 – 13,580 22,300 – 24,530
13.62 15000 4.500-8UN 4-5/8" 21,730 – 23,900 39,440 – 43,385

16.75 3000 2.875-8UN 3-1/2" 6895 - 7585 12,315 – 13,550

16.75 5000 3.500-8UN 3-1/2" 11,895 – 13,085 21,480 – 23,625
16.75 10000 4.500-8UN 4-5/8" 21,915 – 24,105 39,775 – 43,750

18.75 10000 4.750-8UN 4-5/8" 29,905 – 32,895 54,325 – 59,760

20.75 3000 2.500-8UN 2-3/8" 5640 - 6200 10,050 – 11,055

21.25 2000 2.250-8UN 2-3/4" 4460 - 4905 7920 - 8715

21.25 5000 4.750-8UN 4-5/8" 19,650 – 21,610 35,690 – 39,260
21.25 10000 5.000-8UN 4-5/8" 40,375 – 44,410 73,395 – 80,735

26.75 2000 2.500-8UN 2-3/8" 3395 - 3735 6050 - 6655

26.75 3000 3.750-8UN 3-1/2" 7095 - 7805 12,815 – 14,095

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

TABLE 2

INTERMEDIATE FLANGE TO BONNET FASTENER

TORQUE REQUIREMENTS
MOLY LUBE API 5A LUBE
WORKING
BORE SIZE THREAD SIZE TORQUE TORQUE
PRESSURE
inches inches (µ = .07) (µ = .13)
psi
ft-lbs ft-lbs
7.06 3000 - 15000 1.125-8UN 400 685

11.00 3000 - 10000 1.125-8UN 400 685

11.00 15000 1.250-8UN 555 955

13.62 3000 - 10000 1.250-8UN 555 955

13.62 15000 1.500-8UN 960 1675

16.75 3000 - 10000 1.500-8UN 960 1675

18.75 10000 2.000-8UN 2300 4060

20.75 3000 1.375-8UN 740 1280

21.25 2000 1.375-8UN 740 1280

21.25 5000 - 10000 2.000-8UN 2300 4060

26.75 2000 - 3000 1.500-8UN 960 1675

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

3.0 HYDRAULIC OPERATING DATA

TABLE 3

PIPE BONNET
WORKING GALLONS GALLONS
BORE SIZE CLOSING
PRESSURE TO OPEN TO CLOSE
inches RATIO
psi (ONE SET) (ONE SET)
7.06 3000 - 15000 1.3 1.3 6.9:1

11.00 3000 -10000 3.4 3.5 7.3:1

11.00 15000 5.7 5.8 9.8:1

13.62 3000 - 10000 5.5 5.8 7.0:1

13.62 15000 10.4 10.6 10.6:1

16.75 3000 - 5000 9.8 10.6 6.8:1

16.75 10000 11.6 12.5 6.8:1

18.75 10000 21.3 23.1 7.4:1

20.75 3000 8.1 8.7 7.0:1

21.25 2000 8.1 8.7 7.0:1

21.25 5000 27.3 30.0 7.2:1
21.25 10000 24.5 26.9 7.2:1

26.75 2000 - 3000 10.1 10.8 7.0:1

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

TABLE 4

LARGE BORE SHEAR BONNET

WORKING GALLONS GALLONS
BORE SIZE CLOSING
PRESSURE TO OPEN TO CLOSE
inches RATIO
Psi (ONE SET) (ONE SET)
7.06 3000 – 15000 1.3 1.3 6.9:1

11.00 3000 -10000 6.8 7.9 12.0:1

11.00 15000 8.9 9.0 15.2:1

13.62 3000 – 10000 10.5 10.9 10.8:1

13.62 15000 16.0 16.2 16.2:1

16.75 3000 - 10000 18.4 19.0 10.4:1

20.75 3000 14.3 14.9 10.8:1

21.25 2000 14.3 14.9 10.8:1

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
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"CLOSE" PORT
HYDRAULIC CLOSE LINE

Figure 2 Hydraulic pressure path - rams closed and bonnets open

"OPEN" PORT

HYDRAULIC "OPEN" LINE

Figure 3 Hydraulic pressure path - rams open and bonnets closed

Page 7 of 20 T3-1251035 REV C

 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

4.0 OPERATION AND INSTALLATION PROCEDURES

4.1 PREPARATION

Prior to the installation of the BOP, insure that the capacity and the pressure rating of the accumulators
and the pressure pumps comply with API RP53 recommendations or appropriate regulatory agency
requirements and that the ring gaskets are correct for the BOP flanges and the pressure rating.

4.2 INSTALLATION

4.2.1 Mounting Unit

a) Remove all flange protective covers. Clean the ring groove, flange face and bore. Position
the BOP assembly so the “OPEN” & “CLOSE” port labels are right-side up.

b) Inspect the BOP, the ram subassemblies, and all rubber parts during installation

4.2.2 Hydraulic Connection

Connect the hydraulic supply lines to OPEN and CLOSE ports on the BOP body.

4.2.3 Mechanical Lock Test

Use a hand wheel or other suitable device to turn the locking screws clockwise until they
stop, locking the rams. Turn the locking screws counter-clockwise until they stop. This
permits the hydraulic system to open the rams and confirms successful operation of the
ram locking device.

4.2.4 Pre-Operational Tests

a) Test system operation by applying 500 PSI maximum hydraulic pressure to close the rams.
After verifying the rams are closed, apply pressure to OPEN port to open the rams.

CAUTION: DO NOT EXCEED A SYSTEM OPERATING PRESSURE OF 3000 PSI OR

DAMAGE TO THE UNIT MAY RESULT.

b) Close the appropriate pipe rams on the drill pipe in order to perform the low pressure test.
Closing pressure shall be equal to or less than the rated working pressure of the system.
While closed, apply 200-300 PSI pressure below the ram and hold for a minimum of ten (10)
minutes. Pressure loss should not exceed 5 PSI. Refer to Troubleshooting Section if
pressure loss exceeds acceptable limit.

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
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NOTE: CLOSING PIPE RAMS WITHOUT A MANDREL IN THE BORE WILL

SIGNIFICANTLY DECREASE RAM PACKER USEFUL LIFE IF MORE THAN 200
PSI OF HYDRAULIC OPERATING PRESSURE IS USED.

c) While the rams are closed, also perform the high pressure test. Apply the maximum working
pressure of the system below the ram and hold for a minimum of ten (10) minutes. The
pressure loss should not exceed 100 PSI. Refer to Troubleshooting Section if the pressure
loss exceeds the acceptable limit.

NOTE: IF THE PREVENTER AND WELL CASING HAVE DIFFERENT MAXIMUM

RATINGS, USE THE LOWER OF THE TWO.

d) Blind ram testing shall be executed without drill pipe by performing steps a) through c) above.

5.0 ASSEMBLY PROCEDURE

5.1 PREPARATION PRIOR TO ASSEMBLY

5.1.1 The work area should be clean and well lit.

5.1.2 Remove all dirt, grit, oil, and contaminates from the ram bore, ram change piston holes, bonnet
stud holes, all fluid passageways in the body, and intermediate flange. Clean water and detergent
should be used for cleaning. High pressure air may also be used if it is dry air
5.1.3 Clean all internal surfaces of bonnets using clean water and detergent. Lubricate internal sealing
surfaces.
5.1.4 Clean pistons, cylinders, and intermediate flanges, using clean water and detergent. Lubricate
areas that will come in contact with other parts with light oil.
5.1.5 Lubricate sealing surfaces behind the threads in the bonnet stud holes in the BOP body with light
oil after cleaning this area.
5.1.6 Elastomer seal containers should not be opened until they are required for assembly to prevent
contamination and damage to the seal.

5.2 BONNET ASSEMBLY

5.2.1 Refer to figures 5, 6 and 7.

5.2.2 Place bonnet (2) on stands or pallets with the bore side up.
5.2.3 Install the tail rod lip seal (17) and the wiping O-ring (18) into the bonnet (2).
5.2.4 Place the opening cylinder O-rings (14) on the operating cylinder (4).
5.2.5 Insert the operating cylinder (4) into the bonnet (2).
5.2.6 Install the ram change cylinders (8) into the bonnet (2).
5.2.7 Place ram change piston O-rings (23) and the ram change piston to body O-rings (19) on both
ram change pistons (6) and (7)
5.2.8 Insert the assembled ram change pistons (6) and (7) into the bonnet so that the piston with cross-
drilled holes is on the OPEN side and the piston with thru hole is on the CLOSE side.

CAUTION: KEEP THE THREADED END OF THE RAM CHANGE PISTON CLEAN.

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T3 Model 6012 Ram BOP
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5.2.9 Place the operating piston wear ring (35) and the seal ring (16) onto the operating piston (3).
5.2.10 Position the assembled operating piston (3), (35) and (16) into the bonnet (2)
5.2.11 Place the intermediate flange (1) on the assembly table with the threaded holes for the guide pins
(38) in the bottom position.
5.2.12 Place the operating piston rod O-ring (15) in the central bore (see Figure 7).
5.2.13 Install the plastic packing ring (28) and energizing ring (29). (see Figure 7)
5.2.14 Install the connecting rod lip seal (30), lip seal retainer (33), and retainer ring (34). (see Figure 7)
5.2.15 Install the O-rings (20) onto the intermediate flange (1). (see Figure 7)
5.2.16 Install the cylinder O-rings (21) and (22) onto the ram change cylinders (8).
5.2.17 Apply a light coat of light oil to the O-rings and inside the corresponding seal bores in the bonnet
(2) and the intermediate flange (1).
5.2.18 Install the assembled intermediate flange onto the assembled bonnet.
5.2.19 Install the cap screws (9) from the bottom side of the intermediate flange and tighten them
securely. Be sure that the plastic packing port on the intermediate flange is on the same side of
the assembly as the lifting eye hole on the bonnet.
5.2.20 Tighten the cap screws in a crisscross pattern so that the intermediate flange pulls down straight
and level with respect to the face of the bonnet. Torque the cap screws per the Table 2 in
Section 2.
5.2.21 Screw the ram guide pins (38) into the intermediate flange. Tighten the guide pins with a pipe
wrench to a maximum torque of 500 ft-lb.
5.2.22 Install the lifting eye into the bonnet.
5.2.23 Position the bonnet assembly next to the body. After verifying that the bonnet assembly is level,
screw the ram change pistons onto the body and tighten the ram change pistons securely against
the body using a wrench on the flats provided.

CAUTION: MAKE SURE THAT THE OPEN AND CLOSE PISTONS ARE IN THE
APPROPRIATE LOCATION WITH RESPECT TO THE BODY.

5.2.24 Insert the bonnet bolts (10) through the bonnet and intermediate flange.
5.2.25 Push the bonnet bolt O-rings (24) over the bonnet bolt threads onto the undercut.
5.2.26 Screw the plastic packing check valve (25) all the way into the preparation in the intermediate
flange.
5.2.27 Insert one stick of plastic packing (36) above the check valve (25) and install the plastic packing
screw (26). Do not apply any torque to the plastic packing screw.
5.2.28 Install a 1” NPT pipe plug (27) to close the hole.
5.2.29 Install the bleeder gland (32) with the plug (31) into the bonnet.
5.2.30 Install the tap end locking screw studs (11) into the bonnet. The short threaded ends screw into
the bonnet. These studs can be tightened with a small pipe wrench.
5.2.31 Install the locking screw (13) into the locking screw housing (5).
5.2.32 Install the locking screw housing over the studs with the flats on the housing flange vertical. Install
and tighten the locking screw housing nuts (12).

NOTE: ALL HYDRAULIC LINES MUST BE IN PLACE. INSTALL THE BONNET SEAL
BEFORE THE RAMS ARE INSTALLED.

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T3 Model 6012 Ram BOP
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5.2.33 Lubricate the seal bores for the bonnet seal in both the BOP body and the intermediate flange.
5.2.34 Install the bonnet seal (37) that will reside in the seal bore of the intermediate flange.
5.2.35 Lubricate the seal with light oil.
5.2.36 Once the bonnet seals are securely installed, connect the hydraulic lines to the OPEN and
CLOSE ports on the sides of the BOP body.
5.2.37 With the bleed gland (32) loose, on the top of bonnets, apply 200-300 PSI OPEN and CLOSE
operating pressure alternately to expel air from the operating system.
5.2.38 After the air is bled from the system, tighten the bleed plugs (31).
5.2.39 Install the appropriate ram assemblies onto the operating piston.
5.2.40 After assembling both bonnets, apply 1500 PSI hydraulic pressure to the OPEN ports to close the
bonnets.
5.2.41 Apply thread lubricant to the threads and below the head of the bonnet bolts (10)
5.2.42 Screw and torque the bonnet bolts as shown in Figure 1 per the Table 1 in Section 2.

6.0 DISASSEMBLY PROCEDURE

6.1 BOP DISASSEMBLY

6.1.1 Refer to figures 8, 9, 5, 6 and 7.

6.1.2 Use an air wrench to break and unscrew the bonnet bolts (10) on both sides of the BOP.
6.1.3 Apply hydraulic pressure to the CLOSE port of the BOP body to open the bonnet assembly.
6.1.4 Screw the lifting eye into the top of the ram.
6.1.5 Lift and remove the ram from the operating piston.
6.1.6 Remove bonnet seal (37) that resides in the seal bore of the BOP body.
6.1.7 Break loose the locking screw housing nuts (12) with a spanner and a hammer wrench.
6.1.8 Remove the nuts (12), the locking screw housing (5) and the locking screw (13).
6.1.9 Remove the locking screw housing studs (11) with a small pipe ranch.
6.1.10 On the top of the bonnet assembly, remove:
a) The bleeder gland (32) and the bleeder plug (31).
b) The pipe plug (27).
c) The plastic packing screw (26), the plastic packing (36).
6.1.11 Unscrew the plastic packing check valve (25).
6.1.12 Remove the O-ring (24) from each bonnet bolt and remove the bolts from the bonnet assembly.
6.1.13 Insert the lifting eye into the intermediate flange or into the bonnet.
6.1.14 Attach a hoisting cable to the lifting eye and apply tension to the cable to hold up the bonnet
assembly. Verify that the bonnet assembly is level.
6.1.15 Loosen the ram change pistons (6) and (7) using a wrench on the flats provided.
6.1.16 Once the ram change pistons are completely loose and removed from the body, move the bonnet
assembly away from the BOP body.

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T3 Model 6012 Ram BOP
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6.2 BONNET DISASSEMBLY

6.2.1 Remove the ram guide pins (38) from the intermediate flange (1).
6.2.2 Remove the cap screws (9) to separate the intermediate flange (1) from the bonnet (2).
6.2.3 Remove the ram change cylinder O-rings (21) and (22) from the ram change cylinders (8), and
remove the cylinders from the bonnet.
6.2.4 Remove the operating cylinder O-rings (14) from the operating cylinder (4), and remove the
cylinder from the bonnet.
6.2.5 Remove the operating piston seal ring (16) and the operating piston wear ring (35) from the
operating piston, and remove the piston from the bonnet.
6.2.6 Remove the remaining seals in the bonnet bore, including the wiping O-ring (18) and the lip seal
(17)
6.2.7 Remove the following seals from the intermediate flange (1):
a) Retainer ring (34)
b) Washer (33)
c) Lip seal (30)
d) Plastic packing ring (28) and Plastic energizing ring (29)
e) O-ring (15)

7.0 MOVING AND STORAGE

If the BOP must be taken out of service, proper preparation must be taken to protect the unit during
inactivity. The following steps must be performed to assure proper operation when the unit is returned to
service:

a) Drain all fluid from the system operating lines. Install a mixture of ethylene glycol and water in
the unit to protect all seals and assure their flexibility. (Pure ethylene glycol in the unit will
damage all seals. The mixture ratio of water to ethylene glycol is a function of the
temperature and the brand of ethylene glycol being used). Place plugs in the ports to retain
fluid and keep foreign matter out of the unit.
b) Brush rust preventive material on all bores and ring groove surfaces.
c) Place flange covers over all flanges and secure in place with plastic plugs originally provided
with the unit. If not available, use any suitable fastener.

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BONNET ASSEMBLY
OPEN RIGHT

BODY

BONNET ASSEMBLY
OPEN LEFT

BONNET ASSEMBLY
OPEN RIGHT

BODY

BONNET ASSEMBLY
OPEN LEFT

Figure 4
Blowout Preventer Assembly

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Figure 5
Bonnet Assembly Detail 1

Figure 6
Bonnet Assembly Detail 2

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T3 Model 6012 Ram BOP
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Figure 7
Bonnet Assembly Detail 3

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OPEN RIGHT BONNET ASSEMBLY (Figures 5, 6 & 7)

ITEM NO. QTY. DESCRIPTION
1 1 INTEMEDIATE FLANGE
2 1 BONNET
3 1 PISTON, OPERATING
4 1 CYLINDER, OPERATING
5 1 HOUSING, LOCKING SCREW
6 1 PISTON, RAM CHANGE CLOSE
7 1 PISTON, RAM CHANGE OPEN
8 2 CYLINDER, RAM CHANGE
9 12 SCREW, SOCKET HEAD CAP
10 4 BOLT, BONNET
11 8 STUD, LOCKING SCREW HOUSING
12 8 NUT, LOCKING SCREW HOUSING
13 1 LOCKING SCREW
14 2 O-RING, OPERATING CYLINDER
15 1 O-RING, OPERATING PISTON ROD TO INT FLANGE
16 1 LIP SEAL, OPERATING PISTON
17 1 SEAL RING, TAIL ROD
18 1 O-RING, WIPING
19 2 O-RING, RAM CHANGE PISTON TO BODY
20 2 O-RING, RAM CHANGE PISTON ROD TO INT FLANGE
21 2 O-RING, RAM CHANGE CYLINDER TO INT FLANGE
22 2 O-RING, RAM CHANGE CYLINDER TO BONNET
23 2 O-RING, RAM CHANGE PISTON
24 4 O-RING, BONNET BOLT RETAINER
25 1 CHECK VALVE, PLASTIC PACKING
26 1 SCREW, PLASTIC PACKING
27 1 PIPE PLUG, PLASTIC PACKING
28 1 RING, PLASTIC PACKING
29 1 RING, PLASTIC ENERGIZING
30 1 SEAL RING, CONNECTING ROD
31 1 PLUG, BLEEDER
32 1 GLAND, BLEEDER
33 1 WASHER
34 1 RING, RETAINER
35 1 WEAR RING, OPERATING PISTON
36 1 PACKING, PLASTIC
37 1 SEAL, BONNET
38 2 PIN, RAM GUIDE
39 2 PIPE PLUG

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OPEN LEFT BONNET ASSEMBLY (Figures 5, 6 & 7)

ITEM NO. QTY. DESCRIPTION
1 1 INTEMEDIATE FLANGE
2 1 BONNET
3 1 PISTON, OPERATING
4 1 CYLINDER, OPERATING
5 1 HOUSING, LOCKING SCREW
6 1 PISTON, RAM CHANGE OPEN
7 1 PISTON, RAM CHANGE CLOSE
8 2 CYLINDER, RAM CHANGE
9 12 SCREW, SOCKET HEAD CAP
10 4 BOLT, BONNET
11 8 STUD, LOCKING SCREW HOUSING
12 8 NUT, LOCKING SCREW HOUSING
13 1 LOCKING SCREW
14 2 O-RING, OPERATING CYLINDER
15 1 O-RING, OPERATING PISTON ROD TO INT FLG.
16 1 LIP SEAL, OPERATING PISTON
17 1 SEAL RING, TAIL ROD
18 1 O-RING, WIPING
19 2 O-RING, RAM CHANGE PISTON TO BODY
20 2 O-RING, RAM CHANGE PISTON ROD TO INT FLANGE
21 2 O-RING, RAM CHANGE CYLINDER TO INT FLG.
22 2 O-RING, RAM CHANGE CYLINDER TO BONNET
23 2 O-RING, RAM CHANGE PISTON
24 4 O-RING, BONNET BOLT RETAINER
25 1 CHECK VALVE, PLASTIC PACKING
26 1 SCREW, PLASTIC PACKING
27 1 PIPE PLUG, PLASTIC PACKING
28 1 RING, PLASTIC PACKING
29 1 RING, PLASTIC ENERGIZING
30 1 SEAL RING, CONNECTING ROD
31 1 PLUG, BLEEDER
32 1 GLAND, BLEEDER
33 1 WASHER
34 1 RING, RETAINER
35 1 WEAR RING, OPERATING PISTON
36 1 PACKING, PLASTIC
37 1 SEAL, BONNET
38 2 PIN, RAM GUIDE
39 2 PIPE PLUG

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WARNING:
WHEN TROUBLESHOOTING OR MAKING REPAIRS WITH PRESSURE ON THE SYSTEM, TAKE ALL
POSSIBLE PRECAUTIONS TO AVOID INJURY PERSONNEL OR DAMAGE TO THE EQUIPMENT

8.0 TROUBLESHOOTING
8.1 GENERAL INFORMATION

The troubleshooting section enables the operator to quickly identify and correct each malfunction and
prevent additional damage. All troubleshooting steps taken need to be documented and inserted in this
manual. Common malfunctions are covered in this section. For problems with no listed remedies,
contact T3 Energy Services for support.

8.2 COMMON PROBLEMS

Problem #1: Well bore fluid leaks at top or bottom outlet.

Cause #1: Connector flange bolts are not tight enough.

Solution #1: Tighten bolts to the proper torque.

Cause # 2: Gasket groove and/or flange face is not sealed.

Remove the BOP from stack. Remove ring gaskets. Clean the flange face and ring
Solution #2:
groove. Replace the gaskets and reinstall the BOP.

Cause #3: Ring gasket needs to be replaced.

Remove the BOP the from stack. Remove ring gaskets. Clean the flange face and ring
Solution #3:
groove. Replace the old gasket with new ring gasket. Reinstall the BOP.

Problem #2: Well bore fluid leaks through the ram packers when the rams are closed.

Cause #1: System operating pressure is not up to that required to properly close the rams.
Solution #1: Increase the system pressure until the rams are adequately closed, but DO NOT
EXCEED 3000 PSI.

Cause # 2: Ram packers need to be replaced.

Solution #2: Loosen and unscrew the bonnet bolts until their threads are no longer engaged in the
body. Apply closing pressure to the BOP operating system until the bonnet is fully open.
Use the lift eye to lift the ram off the operating piston. Loosen the top seal by using a
screw driver between the ram block and top seal. Pull the top seal up and out. Loosen
the front packer by prying it loose using two screw drivers on each side of the rear
section. (Note: remove the top seal before changing the front packer). Drive the front
packer out with a soft mallet. Clean the ram block and lubricate the packer hole areas.
Lubricate the replacement front packer pins. Match the “top” of the front packer with the
“top” side of the ram, then insert the front packer in the slot and tap it with a soft faced
mallet to engage the pins and seat. Lubricate the top seal pins and ram. Position the top
seal over the slot and rap it into place.

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

Problem #3: Hydraulic fluid leaks out the weep hole on the bottom side of the intermediate flange.

Cause #1: Connecting rod o-ring (Item 15 in Figures 5 & 7) needs to be replaced.
Solution #1: Loosen the bonnet bolts. Unscrew the bonnet bolts until their threads are no longer engaged
in the body. Apply closing pressure to the BOP operating system until the bonnet is fully
open. Remove the bonnet from the body by unscrewing the ram change pistons. Remove the
intermediate flange by unscrewing the socket head cap screws. Remove the retainer ring
from the intermediate flange. Using the appropriate tools to remove the intermediate flange
from the bonnet. Install a new seal kit.

Problem #4: Well bore fluid leaks out the weep hole on the bottom side of the intermediate flange.

Cause #1: Connecting rod seal ring (Item 30 in Figure 6 & 7) needs to be replaced.
Solution #1: Loosen the bonnet bolts. Unscrew the bonnet bolts until their threads are no longer engaged
in the body. Apply closing pressure to the BOP operating system until the bonnet is fully
open. Remove the ram from the bonnet. Using the appropriate tools, remove the retainer
ring, washer, and seal from the intermediate flange. Install a new seal and reassemble
washer and retainer ring. NOTE: A secondary packing is provided for emergency use only.
Plastic packing is injected into a sealing ring by turning the set screw (Item 26 in Figure 6)
clockwise. Doing this provides a temporary seal until proper maintenance can be performed.

Problem #5: Well bore fluid leaks between the intermediate flange and the BOP body.

Cause #1: Bonnet bolts are not tight enough.

Solution #1: Tighten bolts to the proper torque.

Cause #2: Bonnet seal is contaminated by foreign substances.

Solution #2: Bonnet seal may be replaced with ram retracted, extended, or removed from the piston.
Remove the old gasket by inserting a small screwdriver or similar tool between the gasket
and the intermediate flange. Remove the gasket carefully with the caution not to damage the
intermediate flange with the tool. Clean the groove and apply a light coat of grease. Reinstall
old gasket.

Cause #3: Bonnet seal needs to be replaced.

Solution #3: Bonnet seal may be replaced with ram retracted, extended, or removed from the piston.
Remove the old gasket by inserting a small screwdriver or similar tool between the gasket
and the intermediate flange. Remove the gasket carefully with the caution not to damage the
intermediate flange with the tool. Clean the groove and apply a light coat of grease. Install a
new gasket. Do not bend or damage metal part of the gasket during installation.

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 Operation & Maintenance Manual
T3 Model 6012 Ram BOP
© T3 Energy Services All Rights Reserved

Problem #6: Hydraulic fluid leaks between the intermediate flange and the bonnet.

Cause #1: Seals on operating cylinder/ or ram change cylinder (Items 14, 21 or 22 in Figures 5 & 7)
need to be replaced.
Solution #1: Loosen the bonnet bolts. Unscrew the bonnet bolts until their threads are no longer engaged
in the body. Apply closing pressure to the BOP operating system until the bonnet is fully
open. Remove the bonnet from the body by unscrewing the ram change pistons. Remove the
intermediate flange by unscrewing the socket head cap screws. Remove the retainer ring
from the intermediate flange. Using the appropriate tools to remove the intermediate flange
from the bonnet. Replace O-rings or install a complete seal kit.

Problem #7: Hydraulic fluid leaks around the locking screw housing.

Cause #1: O-ring and seal (Item 17 and 18 in Figures 5 & 7) need to be replaced.
Solution #1: Loosen the bonnet bolts. Unscrew the bonnet bolts until their threads are no longer engaged
in the body. Apply closing pressure to the BOP operating system until the bonnet is fully
open. Remove the bonnet from the body by unscrewing the ram change pistons. Remove the
intermediate flange by unscrewing the socket head cap screws. Remove the compression
retainer ring from the intermediate flange. Using the appropriate tools to remove the
intermediate flange from the bonnet. Remove the operating piston. Replace O-ring and seal
or install complete seal kit.

Problem #8: Fluid leaks around any pipe plug.

Cause #1: Pipe plug is not tight.

Solution #1: Tighten pipe plug to proper torque without system pressure in BOP

Cause # 2: Thread sealing tape needs replacing

Solution #2: Decrease all operating pressure to 0 PSI. Remove the pipe plug. Clean the threads on the
plug and in the pipe tap. Re-tape the pipe plug and install to proper torque.

Page 20 of 20 T3-1251035 REV C