RAM BOP

Chasovoy
User's Manual
© Copyright 2004 Varco International, Inc.

All rights reserved. This publication is the property of, and contains information proprietary to,
Varco® International, Inc. No part of this publication may be reproduced or copied in any form, or
by any means, including electronic, mechanical, photocopying, recording, or otherwise without the
prior written permission of Varco International, Inc.

All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.

Information in this manual is subject to change without notice.

General Information 1

Introduction 2

Installation And 3
Operation

Maintenance 4

Storage 5

Specifications And 6
Parts Lists
1 General Information

2 Introduction

3 Installation And
Operation

4 Maintenance

5 Storage

6 Specifications And
Parts Lists
 General Information

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Chasovoy™ Ram BOP

 General Information

Shaffer
 General information

This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. Varco® International, Inc., will not be held liable for errors in this 1
material, or for consequences arising from misuse of this material.

Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information, and to advise
the reader to take specific action to protect personnel from potential injury or lethal
conditions. They may also inform the reader of actions necessary to prevent equipment
damage. Please pay close attention to these advisories.
Note:

i
The note symbol indicates that additional information is
provided about the current topics.

Caution:

!
The caution symbol indicates that potential damage to
equipment or injury to personnel exists. Follow instructions
explicitly. Extreme care should be taken when performing
operations or procedures preceded by this caution symbol.

Warning:

The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
observe and follow proper procedures could result in
serious or fatal injury to personnel, significant
property loss, or significant equipment damage.

Illustrations
Illustrations (figures) provide a graphical representation of equipment components or
screen snapshots for use in identifying parts or establishing nomenclature, and may or
may not be drawn to scale.
For component information specific to your rig configuration, see the technical drawings
included with your Varco documentation.

Chasovoy™ Ram BOP 1-1

 General Information

Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
1 Procedures outlined in Varco manuals are the recommended methods of performing
operations and maintenance.

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

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,
tool operation, and maintenance to ensure their safety.

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

Contact the Varco Drilling Equipment 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. Varco recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures or using tools not specifically recommended by Varco.

General System Safety Practices

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

!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.

R Isolate energy sources before beginning work.

R Avoid performing maintenance or repairs while the equipment is in operation.
R Wear proper protective equipment during equipment installation, maintenance, or
repair.

1-2 Shaffer
 General information

Replacing Components
R Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
R Replace failed or damaged components with Varco certified parts. Failure to do so 1
could result in equipment damage or injury to personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for
maintenance recommendations.

!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.

Proper Use of Equipment

Varco equipment is designed for specific functions and applications, and should be used
only for its intended purpose.

Chasovoy™ Ram BOP 1-3

 General Information

1-4 Shaffer
 Introduction

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1

Chasovoy™ Ram BOP

 Introduction

Shaffer
 Introduction

Introduction
General Description
The Chasovoy™ (U.S. Patent No. 5,505,426) blowout preventer (BOP) (see Figure 2-1) is
rated at 7 1/16" and 7 7/8", 5,000 psi (180 mm and 200 mm, 340 atm) and 7 1/16" and 7 7/8",
3,000 psi (180 mm and 200 mm, 204 atm). Its unique design permits either manual
operation or hydraulic operation and is ideal for well servicing, work over, fracking, and
drilling operations (for conversion from manual operation to hydraulic operation see the
section titled "Manual to Hydraulic Conversion" on page 4-33). The Chasovoy BOPs are
also suitable for internal H2S service and meet National Association of Corrosion 2
Engineers (NACE) and American Petroleum Institute (API) requirements.
The ability of the Chasovoy to close or open the rams manually makes it truly unique. To
close both rams simultaneously, in the manual operation mode, requires the single
T-handle to be activated. To close the rams, turning the T-handle clockwise (this moves
the master piston inward and displaces fluid to the close side of the slave piston). Turning
the T-handle counter clockwise-opens the rams. The maximum torque to close and seal
the rams is only 735 ft lb (996.48 N-m) To operate the Chasovoy ram BOP hydraulically,
follow the conversion procedures in the section titled "Manual to Hydraulic Conversion" on
page 4-33 and connect the accumulator unit to the open and close ports of the preventer.
The Chasovoy can be converted from manual operation to hydraulic operation in the field.
Each ram consists of a ram block and a two-piece molded ram rubber seal, which seals
against the top of the ram cavity and across the wellbore. The ram assemblies are
available in pipe sizes from CSO (complete shutoff) to 5 1/2" (140 mm) OD pipe. Ram
change accessibility is accomplished by removing the operator body bolts and sliding the
operator away from the body along the two support studs. This permits quick ram change
and ram rubber replacement.

Chasovoy™ Ram BOP 2-1

 Introduction

Figure 2-1. Chasovoy BOP

Safety Precautions
Exposure to the daily hazards of drilling can lead rig crews and service personnel to
disregard or overlook hidden hazards. The following safety precautions should be
observed at all times.

T-Handle Operation
Be sure there are no obstructions near where the manual operated T-handle is used on
the Chasovoy BOP. The area should be kept clear, so that quick, easy access and free
turning of the T-handle may be performed.

Replacement Parts
Many of the Chasovoy BOP components, though apparently similar to commercial
hardware, are manufactured to system design specifications. To avoid possible hazardous
failures, use only Shaffer replacement parts or assemblies. Refer to section titled
"Specifications and Parts Lists" on page 6-1 for recommended spare parts.

2-2 Shaffer
 Installation And
Operation

Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
Operating the Chasovoy BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Locking the Manual BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Wellbore Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Transporting the Chasovoy BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
2

Chasovoy™ Ram BOP

 Installation And
Operation

Shaffer
 Installation And
Operation

Installation and Operation

Pre-Installation
Prior to installing the Chasovoy BOP perform the steps listed below:
1. Clean the Chasovoy BOP before starting the drilling operations.
2. Inspect the ram blocks and cavity for physical damage.
3. Inspect the ram rubbers for excessive wear.

i
If excessive wear or damage is evident, refer to section
titled "Maintenance" on page 4-1 for corrective
maintenance. 3

4. Clean and inspect the ring grooves.

i
Use a fine emery cloth to remove rust or small nicks, and
apply a light film of oil with a cloth.

5. Clean and inspect the studs and nuts.

i
Be sure the threads are not stripped and the all studs are
tight.

6. Check the bore for gouges or other damage. If minor damage is evident, smooth
with emery clothe.

i
Cleaning, inspection and testing of the Chasovoy BOP
immediately after completion of the drilling operations
reduces installation time on the next well.

Installation
The following procedures should be performed when installing the Chasovoy BOP:

Chasovoy™ Ram BOP 3-1

 Installation And
Operation

1. For proper installation, be sure the Chasovoy BOP is installed right side up:
R With the lifting lug marked ’TOP’ and with the side outlets below the ram
assemblies, the Chasovoy is in the correct position to install on the well (see
Figure 3-1).
R The skids in the ram compartments (located internally) are below the rams, and
the ram-sealing seat is located in the top of the ram cavity.

Slave Operator Master Operator

Master Operator Slave Operator

Figure 3-1. Chasovoy BOP

i
Lifting lugs are provided to lift the Chasovoy BOP.

2. Installing the flange connections:

R Install the ring gasket.
R Install the mating flange.
R Install the studs and nuts.
R Tighten all nuts uniformly in a diametrically staggered pattern as shown in
Figure 3-2.
R Apply 600 ft-lb (813 N-m) of torque to each nut for 3,000 psi (340 atm) end
connections.
R Apply 1,200 ft-lb (1,627 N-m) of torque to each nut for 5,000 psi (204 atm) end
connections.

3-2 Shaffer
 Installation And
Operation

3. Before placing the Chasovoy BOP in service, a wellbore pressure test is

recommended (see section titled "Wellbore Pressure Test" on page 3-4).

Figure 3-2. Flange Connection

Operating the Chasovoy BOP

Before and during operation of the Chasovoy BOP, follow all safety precautions in section
titled "Safety Precautions" on page 2-2 of this manual.
1. To close the rams, turn the T-handle clockwise. This moves the rams into the
wellbore.
2. To open the rams, turn the T-handle counterclockwise. This moves the rams out of
the wellbore.

!
Always check that the slave operator-locking shaft is fully
rotated counterclockwise then rotated 1/4 turn clockwise.
This ensures that the rams are in the unlocked condition.

Chasovoy™ Ram BOP 3-3

 Installation And
Operation

i
The master operator is the operator with the T-handle, the
slave operator has no T-handle.

3. Ensure that the rams are fully retracted from the wellbore.

!
Failure of the rams to fully retract may cause damage to
3 the ram blocks by the drill pipe and drill bit.

Locking the Manual BOP

The purpose of the locking shaft (14) on the slave operator is to manually lock the ram
assemblies in the closed position. When the ram assemblies are closed, rotating the
locking shaft clockwise on the ’slave operator’ will prevent the ram assemblies from
opening.

i
On the manually operated BOP, this will require removing
the T-handle from the master operator to the slave
operator-locking shaft.

!
Tighten the lock shaft with the short T handle lever
supplied with the BOP by hand. Do not use a pipe
extension or excessive force.

Wellbore Pressure Test

This test is performed prior to placing the Chasovoy BOP in service. To conduct the test,
the Chasovoy BOPs can be placed on a test stump, blind flange, or per operator’s
requirements.
The test pressure is the lowest-rated working pressure of any component or connection
which is pressurized during the test this may include one or more of the following:
R BOPs

3-4 Shaffer
 Installation And
Operation

R Wellhead
R Casing string-if it is pressurized during the test or should a leak in the test tool cause
it to pressurize.
R Test tool collapse pressure, if made of pipe.
R All connections
The use of fresh water is recommended for the wellbore pressure test.

i
Two wellbore pressure tests are recommended, a low-
pressure and a high-pressure test.

3
Low Pressure Test
1. Lower a test tool plug through the Chasovoy BOP until it stops on the test stump.

i
If the Chasovoy BOP is on the wellhead, lower the test tool
plug until it stops in the wellhead housing.

2. Fill the wellbore with fresh water.

3. Close the rams.
4. Apply approximately 100 psi (7 atm) well bore pressure; maintain this pressure for
at least three minutes.
5. To check for low-pressure leaks, observe the pressure gauge for any decrease in
pressure. Inspect the rams, bonnet, side outlets, and end connections for possible
leaks.
6. Reduce the pressure to 0 psi (0 atm).

i
If leaks are detected, refer to section titled
"Troubleshooting" on page 4-32.

High Pressure Test

1. Apply the test pressure in 500 psi (34 atm) increments, until the rated test pressure
is reached (3,000 psi (204 atm) maximum or 5,000 psi (340 atm) maximum).

Chasovoy™ Ram BOP 3-5

 Installation And
Operation

Do not exceed the rated working pressure of the

preventer. Check the data plate on the body.

2. Maintain the test pressure for at least three minutes.

3. To check for pressure leaks, observe the pressure gauge for any decrease in
pressure. Inspect the rams, bonnet, side outlets, and end connections for possible
leaks.

3
i
If leaks are detected, refer to section titled
"Troubleshooting" on page 4-32.

Transporting the Chasovoy BOP

1. Lift the Chasovoy BOP by the lifting lugs (see Figure 3-1 on page 3-2).
2. For a flange-type Chasovoy BOP, protect the flange face with a flange protector
before lowering it down.
3. For a stud-type Chasovoy BOP, protect the studs by using a stand, which allows
clearance for the studs.
4. Secure Chasovoy BOP and stand.

3-6 Shaffer
 Maintenance

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassembly of the Chasovoy BOP . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
Assembly of the Chasovoy Manual BOP . . . . . . . . . . . . . . . . . . . 4-10
Bleeding the Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Procedure for Changing Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Manual to Hydraulic Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 2
Hydraulic BOP Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Manual Locking the Hydraulic BOP . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Hydraulic Fluid for Chasovoy BOP’s . . . . . . . . . . . . . . . . . . . . . . . 4-38

Chasovoy™ Ram BOP

 Maintenance

Shaffer
 Maintenance

Maintenance
Preventive Maintenance
Early detection and repair of irregularities in the Chasovoy BOP can prevent failure during
its operation. Cleaning, inspection and testing of the Chasovoy BOP immediately after
completion of the drilling operation is recommended. Refer to section titled "Pre-
Installation" on page 3-1 for pre-installation procedures.
All maintenance and replacement of parts for the Chasovoy BOP can be performed with
standard mechanic’s tools, unless otherwise specified.
The procedures described below should be performed to prevent failure during operation
of the Chasovoy BOP.

Pipe Rams
1. Thoroughly clean the ram assemblies before inspecting them.
2. Inspect the ram rubber for excessive wear or cracks.

i
Do not disassemble the pipe rams unless the rubbers need 4
replacing.

Between Wells
1. Clean and inspect the rams; replace the ram rubber if necessary.
2. Clean and grease the ram assembly before installation.
3. Thoroughly clean the ram cavity and inspect for damage.
4. Inspect the bonnet seals and replace if damaged.
Complete Overhaul
When wear becomes excessive, or after one year of continuous service, a complete
overhaul should be performed.
1. Disassemble and inspect all the parts.
2. Replace any parts, that are excessively worn or damaged.
Disassembly of the Chasovoy BOP
All items numbers correspond to the parts list and figure shown in the "Specifications and
Parts Lists" section of this manual. Check the recommended spare parts list in the
"Specifications and Parts Lists" section to be sure replacement parts are available.

i
As the Chasovoy BOP is disassembled, tag or mark each
part to correspond with the number given in this procedure.

Chasovoy™ Ram BOP 4-1

 Maintenance

Removing the Ram Assemblies

1. Open the rams to the fully open position.
2. Remove the two bonnet cap screws (see Figure 4-1).
3. Remove the two bonnet nuts (see Figure 4-2 on page 4-3).
4. Remove the two bonnet sleeves (see Figure 4-3 on page 4-3).

!
It is not necessary to remove the operator from the body
for routine inspection or changing of the ram assemblies.
In the event the operator is removed from the body, refer to
section titled "Manual BOP Port Connections" on page 4-
22.

5. As a safety precaution, screw the two bonnet nuts onto the body studs which will
prevent the operator assembly from accidentally being pulled off of the body studs.
Pull the bonnet and ram assembly outward until the ram assembly clears the body
4 face.
6. Slide the ram assembly sideways off the piston shaft.
Removing the Operator Assembly
1. Remove the bonnet cap screws (see Figure 4-1).
2. Remove the bonnet nuts (see Figure 4-2 on page 4-3).
3. Remove the bonnet sleeves (see Figure 4-3 on page 4-3).
4. Arrange appropriate lifting slings under the operator and lift the operator assembly
clear (see Figure 4-4 on page 4-4).

Figure 4-1. Remove Bonnet Cap Screws

4-2 Shaffer
 Maintenance

Figure 4-2. Remove Bonnet Nuts

Figure 4-3. Remove Bonnet Sleeves

Chasovoy™ Ram BOP 4-3

 Maintenance

Figure 4-4. Remove Operator Assembly

Disassembly of the Operator

1. Remove the four cylinder nuts (11) (see Figure 4-5).

4 2. Using the T-handle, rotate the locking shaft clockwise to lift the cylinder head (17)
from the intermediate cylinder head (15).
3. Using a screwdriver or a bar, carefully pry between the cylinder head and the
intermediate cylinder head, until the cylinder head clears the cylinder studs (10)
(see Figure 4-6).
4. Unscrew the cylinder head from the locking shaft and remove.
5. Tap the intermediate cylinder head clear of the cylinder studs using a hammer and a
hard wood block (see Figure 4-7 on page 4-6).
6. Slide the inner shaft (12) sideways from the center of the piston (2) then lift the inner
shaft and intermediate cylinder head upwards out of the piston (see Figure 4-8 on
page 4-6 and Figure 4-9 on page 4-7).
7. Remove the wear plate (13) (see Figure 4-10 on page 4-7).
8. Tap the inner shaft out of the intermediate cylinder head.
9. Remove the hydraulic seal (16) from the cylinder head (see Figure 4-11 on page 4-
8).
10. Lift the bonnet and place it on its side.
11. With a hammer and hard wood block alternately tap the end of the piston shaft (2)
and around the outside of the cylinder (5) until the piston and cylinder are free from
the bonnet (1).
12. Place the bonnet upright and remove the cylinder (see Figure 4-12 on page 4-8).

4-4 Shaffer
 Maintenance

Figure 4-5. Remove Cylinder Nuts

Figure 4-6. Lifting Cylinder Head

Chasovoy™ Ram BOP 4-5

 Maintenance

4
Figure 4-7. Remove Intermediate Cylinder Head

Figure 4-8. Inner Shaft in Piston

4-6 Shaffer
 Maintenance

Figure 4-9. Slide Inner Shaft Sideways and Lift out of Piston 4

Figure 4-10. Remove Wear Plate

Chasovoy™ Ram BOP 4-7

 Maintenance

Figure 4-11. Remove Hydraulic Seal from Cylinder Head

Figure 4-12. Remove Cylinder from Bonnet

13. Use a soft face hammer to tap the piston out of the cylinder.
14. Remove the manifold pipe (8) (see Figure 4-13) and cylinder studs (10) (see Figure
4-14).
15. Remove the hydraulic seal from the bonnet (see Figure 4-15 on page 4-10 and
Figure 6-2 on page 6-7).
16. Turn the bonnet over on its opposite side and remove the ram shaft seal assembly
(3) (see Figure 4-16 on page 4-10).

4-8 Shaffer
 Maintenance

Figure 4-13. Remove Manifold Pipe

Figure 4-14. Remove Cylinder Studs

Chasovoy™ Ram BOP 4-9

 Maintenance

Figure 4-15. Remove Hydraulic Seal from Bonnet

Figure 4-16. Remove Ram Shaft Seal Assembly

Assembly of the Chasovoy Manual BOP

For the BOP to function as a manually operated BOP, one operator assembly is
designated as the ’master’ operator while the other operator assembly is designated as
the ’slave’ operator. It is important to understand that the master operator is the operator
that has the inner shaft bolted to the locking shaft, while the slave operator is the operator
where the inner shaft is free of the locking shaft (see Figure 4-36 on page 4-22).

!
Do not install two master operators on the same cavity.
The BOP will not function as intended. Always install a
slave operator on a cavity with a master operator. The
master operator should always have the T-handle attached
to the locking shaft when in normal operation.

4-10 Shaffer
 Maintenance

i
The master and slave operator assemblies may be
installed on either side of a single BOP body. On a double
BOP body, the master operator on the upper cavity and
lower cavity must be installed on opposite sides, to insure
free movement of the T-handles.

Assembly of the Master Operator

1. Place the bonnet on a suitable workbench. Locate the bonnet (1), ram shaft seal
assembly (3), and door seal (see Figure 4-17).
2. Install the door seal into the groove machined in the bonnet. Use a thin coat of
grease to hold the door seal in place.
3. Coat the ram shaft seal assembly (3) and the inside of the bonnet seal cavity with
light oil. Install the ram shaft seal assembly (see illustrated drawing and parts list in
section titled "Specifications and Parts Lists" on page 6-1) into the bonnet (see
Figure 4-18).
4
Ram Shaft Assembly

Door Seal

Figure 4-17. Bonnet, Ram Shaft Seal Assembly, and Door Seal

Chasovoy™ Ram BOP 4-11

 Maintenance

Figure 4-18. Ram Shaft Seal Assembly in Bonnet

Figure 4-19. Install Hydraulic Seal in Bonnet

Figure 4-20. Install Cylinder Studs

4-12 Shaffer
 Maintenance

4. Turn the bonnet over, lubricate the hydraulic seal with light oil, and install the
hydraulic seal into the groove of the bonnet (see Figure 4-19 on page 4-12 and
Figure 6-2 on page 6-7).
5. Install the 4 cylinder studs (10) (see Figure 4-20).
6. Place wood blocks under the bonnet to elevate the bonnet approximately 4 inches
(101 mm) above the workbench. Position the blocks so that they are clear of the
ram shaft seal assembly opening.
7. Locate the cylinder (5), cylinder O-rings (6) and cylinder backup rings (7). Lubricate
the cylinder groove and O-rings with light oil. Install the O-rings into the cylinder
grooves. Install the backup rings (see Figure 4-21).

i
The O-rings (6) face outward on the cylinder while the
back-up rings (7) face inward on the cylinder.

8. Locate the piston (2) and piston seal (4). Lubricate the piston seal with light oil and
install on the piston (see Figure 4-22).
4
9. Lubricate the inside of the cylinder with light oil, and with a rubber mallet, tap the
piston into the cylinder (see Figure 4-23 on page 4-14).
10. Locate the manifold pipe (8) and O-rings (9). Lubricate the O-rings with light oil and
install on the manifold pipe. Install the manifold pipe into the bonnet (see Figure 4-
24 on page 4-15).

Figure 4-21. Install Cylinder O-ring and Backup Ring on Cylinder

Chasovoy™ Ram BOP 4-13

 Maintenance

Seal

Figure 4-22. Install Piston Seal on Piston

4

Figure 4-23. Install Piston into Cylinder

4-14 Shaffer
 Maintenance

Figure 4-24. Install Manifold Pipe

11. Lubricate the piston (2) shaft with light oil. 4

12. Carefully install the piston shaft into the ram shaft seal assembly located in the
bonnet (see Figure 4-25 and Figure 4-26).
13. Locate the inner shaft (12), locking shaft (14) and three socket head cap screws
(24). Attach the locking shaft to the inner shaft using the three socket head cap
screws; tighten (see Figure 4-27 on page 4-17).
14. Locate the intermediate cylinder head (15) and cylinder head seal (16). Lubricate
the seal and intermediate cylinder head groove with light oil.
15. Install the seal into the cylinder head (see Figure 4-28 on page 4-17).
16. Lubricate the master operator inner shaft (12) with light oil.
17. Using a rubber mallet, tap the master operator assembly through the cylinder head
seal, located in the intermediate cylinder head (see Figure 4-29 on page 4-17).
18. Install the inner shaft wear plate (13) into the end of the inner shaft-a light coating of
grease will hold the wear plate to the inner shaft (see Figure 4-30 on page 4-18).

Chasovoy™ Ram BOP 4-15

 Maintenance

4 Figure 4-25. Install Cylinder onto Bonnet

Figure 4-26. Install Cylinder into Bonnet

4-16 Shaffer
 Maintenance

Figure 4-27. Assembly of the Inner Shaft and Locking Shaft

Figure 4-28. Install Hydraulic Seal in Cylinder Head

Figure 4-29. Installing Locking Shaft/Inner Shaft

Chasovoy™ Ram BOP 4-17

 Maintenance

Figure 4-30. Install Wear Plate

19. The locking shaft/inner shaft/intermediate cylinder head assembly may now be lifted
above the bonnet studs (see Figure 4-31). Ensure the hydraulic port of the
intermediate cylinder head is correctly aligned with the manifold pipe.
20. Lower the inner shaft into the slot in the center of the piston (see Figure 4-32 on
4 page 4-19) and slide it into the recess of the piston. Be careful not to dislodge the
wear plate (see Figure 4-33 on page 4-20).

!
Caution must be observed to ensure the cylinder O-rings
and manifold O-rings are not cut during the above
procedures.

21. Using a hammer and a block of hard wood, tap the intermediate cylinder head over
the studs. Continue to tap the cylinder head until it bottoms out on the cylinder.
22. Apply Shaffer thread lubricant (P/N 121602) to the stud threads and locking shaft
threads. Screw the cylinder head (17) onto the locking shaft thread until the cylinder
head almost reaches the bonnet studs (see Figure 4-34 on page 4-20).
23. Rotate the cylinder head on the locking shaft and position it so that the large
opening is on the same side as the manifold pipe.
24. Align the cylinder head stud holes over the bonnet studs.
25. Using a block of hard wood and a hammer tap the cylinder head over the studs.
26. Install the four cylinder nuts (11) and torque the cylinder head to 260 ft-lb
(353 N-m) (see Figure 4-35 on page 4-21).
27. Locate the T-handle and turn the locking shaft counterclockwise until the piston (2)
bottoms out and will not move. Turn the T-handle 1/4 turn clockwise.

4-18 Shaffer
 Maintenance

4
Figure 4-31. Installing Intermediate Cylinder Head

Figure 4-32. Install Inner Shaft into Piston

Chasovoy™ Ram BOP 4-19

 Maintenance

4
Figure 4-33. Slide Inner Shaft to Center of Piston

Figure 4-34. Screw Cylinder Head on the Locking Shaft

4-20 Shaffer
 Maintenance

Figure 4-35. Install Cylinder Nuts

Assembly of the Slave Operator

To assemble the slave operator, refer to section titled "Assembly of the Master Operator"
on page 4-11 and follow step 1 - 12, and step 14 - 27 of the master operator assembly
procedure. Note that step 13 is omitted as the slave operator inner shaft must not be
bolted to the locking shaft (see Figure 4-36). The slave operator must be loose, thus
allowing free operation controlled by the master operator.

Chasovoy™ Ram BOP 4-21

 Maintenance

Master Operator Slave Operator

Figure 4-36. Master Operator/Slave Operator Comparison

Manual BOP Port Connections

The hydraulic ports are located on the face of the bonnet and the body. They are
connected when the operator is bolted to the preventer body. The built-in quick
disconnects prevent hydraulic fluid loss, when the operator is removed from the preventer
body or the operator is pulled away from the body to allow access to the rams. (see Figure
4-37 and Figure 4-38).
In the event the operator or operators are removed from the preventer body, they must be
reinstalled to their original placement, in order to correctly align the open and close
hydraulic ports. The correct alignment of the hydraulic ports can be identified by the
stamped ’Open’ and ’Close’ marks located on the side of the bonnet and verified for
manual operation as described below (see Figure 4-39).
When facing the preventer front or back, the left operator bonnet reads ’Open’ and the
right operator bonnet must read ’Close’. In this configuration, the preventer is in themanual
operation mode (see Figure 3-1 on page 3-2 and Figure 4-39 on page 4-24).
For remote hydraulic operation mode refer to the section titled "Manual to Hydraulic
Conversion" on page 4-33.

4-22 Shaffer
 Maintenance

i
The master operator is the one with the T handle installed
and the locking shaft bolted to the inner shaft; the slave
operator has the locking shaft free of the inner shaft (see
Figure 4-36).

Figure 4-37. Quick Disconnect-(Male) On Operator Bonnet

Figure 4-38. Quick Disconnect-(Female) On BOP Body

Chasovoy™ Ram BOP 4-23

 Maintenance

Figure 4-39. Open/Close Port

Figure 4-40. Installing Operator Assembly

Installing the Operator Assemblies

i
The master and slave operator assemblies may be
installed on either side of a single BOP body. On a double
BOP body the master operator on the upper cavity and
lower cavity must be installed on opposite sides, thus
allowing free movement of the T-handles.

1. Place lifting slings under the operator and lift the operator assembly onto the
preventer body (see Figure 4-40 on page 4-24). As a safety precaution, screw two
bonnet nuts a few threads on the body studs to prevent the operator assembly from
accidentally being pulled off the bonnet studs.

4-24 Shaffer
 Maintenance

2. Slide the T-handle over the hex of the locking shaft (14) and secure by means of the
locking screw.
3. Install the ram assembly (see section titled "Installing the Ram Assemblies" on page
4-27).
4. Lubricate the body bonnet faces of the master operator assembly and the slave
operator assembly with a coating of light oil.
5. Push the operator assembly inward until the bonnet meets the body.

!
While closing the bonnets, exercise care not to damage
the bonnet to body seal face and the male/female
hydraulic quick-disconnect fittings.

i 4
Ensure the door seals are in their correct position and do
not get trapped between the bonnet and the body.

6. Remove the two nuts from the body studs and install the bonnet sleeves (see Figure
4-41).
7. Lubricate the body studs with Shaffer thread lubricant (P/N 121602) and install the
bonnet nuts (see Figure 4-42).
8. Lubricate the bonnet hex head cap screws with Shaffer thread lubricant (P/N
121602) and install in bonnet (see Figure 4-43 on page 4-27).
9. Torque the bonnet nuts and bonnet cap screws to 1,350 ft-lb (1,830 N-m).
10. Repeat the procedure for the other operator.

Chasovoy™ Ram BOP 4-25

 Maintenance

Figure 4-41. Install Bonnet Sleeves

Figure 4-42. Install Bonnet Nuts

4-26 Shaffer
 Maintenance

Figure 4-43. Install Bonnet Cap Screws

Installing the Ram Assemblies

1. The operator should be resting on the bonnet studs, with two bonnet nuts on the
studs, to prevent the bonnet from falling off (see section titled "Removing the Ram
4
Assemblies" on page 4-2).
2. Lift the ram assembly and slide it sideways over the slotted end of the operator
piston shaft.
3. Install the operator to the BOP body (see section titled "Manual BOP Port
Connections" on page 4-22)
4. Repeat the procedure to install the ram assembly on the other operator.
Bleeding the Operators

i
One operator of the cavity must be set up as the ’master’
operator for this procedure.

i
The ram assemblies must be removed from the cavity
before this procedure is started.

1. To set up a ’master’ operator, on one operator only, connect the locking shaft to the
intermediate shaft using the three socket head cap screws (see Figure 4-36 on
page 4-22).

Chasovoy™ Ram BOP 4-27

 Maintenance

i
The other bonnet assembly will be the ’slave’ operator; the
locking shaft and intermediate shaft are not connected
(see Figure 4-36 on page 4-22).

2. It is recommended that the fluid transfer pump (P/N 064194) be utilized for this
procedure.
3. On both the ’master’ and ’slave’ operators, open the bleed plug (21) on the top of the
intermediate flange. Disconnect all lines, if applicable, from the open and close ports
on both operators. Rotate the locking shafts on both ’master’ and ’slave’ operators in
a clockwise direction until their respective pistons bottom out.
4. Starting with the ’master’ operator:
R Install the transfer pump to the close port.
R Slowly pump fluid (Shaffer P/N 185186) into the operator until all air is expelled
through the bleeder plug on top of the flange.
R Close the bleeder plug on the ’master’ operator.
4
R Disconnect the transfer pump from the close port of the ’master’ operator.
R Reinstall the pipe plug into the close port.
5. Repeat Step 4 with the ’slave’ operator.
6. Install pipe plugs into the open ports of the ’master’ and ’slave’ operators.
7. Turn the locking shaft of the ’slave’ operator in a counter-clockwise direction, move
the locking shaft to the open and unlocked position.
8. With the ’master’ operator, manually cycle the unit three times to the full close
position and full open position. This is done by turning the locking shaft clockwise
until the piston stops (rams closed) and turning the locking shaft counter-clockwise
until the piston stops (rams open).
9. With the ’master’ operator, turn the locking shaft clockwise until the piston stops and
the unit is in the full closed position.
10. On the ’slave’ operator, turn the locking shaft clockwise until it stops and locks.
11. Finally, with the ’master’ operator:
R Remove the plug from the close port.
R Install the transfer pump to the close port.
R Slowly pump fluid (Shaffer P/N 185186) into the operator until all air is expelled
through the bleeder plug on top of the intermediate flange.
R Close the bleeder plug on the ’master’ operator.
R Disconnect the transfer pump from the close port of the ’master’ operator.
R Reinstall the pipe plug into the close port.
12. Repeat Step 11 on the ’slave’ operator.
13. Move the locking shaft of the ’slave’ operator to the unlocked position.
14. Install the ram assemblies.

4-28 Shaffer
 Maintenance

15. Cycle the ’master’ operator to the close position by turning the locking shaft
clockwise until the ram assemblies come together causing the pistons to stop.
Visually inspect the ram assemblies are together and check the position of the shaft
of the ’slave’ operator.
16. Turn the ’master’ operator locking shaft counter-clockwise until the piston stops.
Verify the rams are in the fully open position and clear of the wellbore.
Procedure for Changing Rams
Remove Pipe Rams
1. The rams must be in the fully opened position.
2. See section titled "Removing the Ram Assemblies" on page 4-2 for ram removal
procedure.
3. Place the pipe ram assembly right side up on a level surface (see Figure 4-44).
4. Wedge a screwdriver between the top seal assembly and the face seal assembly
(see Figure 4-45).
5. Remove the top seal assembly.
6. Wedge a screwdriver between the face seal and the ram block (see Figure 4-46).
7. Remove the face seal assembly (see Figure 4-47).
8. To remove the top seal assembly and the face seal assembly from the other ram 4
block, repeat Steps 3-7

Figure 4-44. Place Pipe Ram Assembly Right-Side-Up

Chasovoy™ Ram BOP 4-29

 Maintenance

Figure 4-45. Remove Top Seal Assembly

Figure 4-46. Pry Face Seal Out of Ram Block

4-30 Shaffer
 Maintenance

Figure 4-47. Remove Face Seal

Clean and Inspect

Clean and inspect the ram block and seals for excessive wear or damage. Replace if
damaged. See section titled "Specifications and Parts Lists" on page 6-1, Figure 6-3 on 4
page 6-8 and table titled "3,000/5,000 psi Chasovoy Pipe Ram Assembly" on page 6-9 for
ram assembly.

Rubber Installation
1. Install the new face seal assembly; the ram block (see Figure 4-48).
2. Install the outer ram rubber assembly and tap with a rubber mallet until it bottoms
out (see Figure 4-49).
3. See section titled "Installing the Ram Assemblies" on page 4-27 for ram installation
procedure.

Figure 4-48. Install New Face Seal Assembly

Chasovoy™ Ram BOP 4-31

 Maintenance

Figure 4-49. Install New Outer Ram Rubber Assembly

Troubleshooting
See the "Troubleshooting" table below for troubleshooting information.
4
Troubleshooting

Problem Possible Cause Corrective Action

BOP will not hold Check ram rubbers for wear; replace if
Bad ram rubbers
wellbore pressure damaged.

Leaking hydraulic Replace hydraulic seals. Replace piston

seals seals.

Check the body seat sealing area for cuts

Damaged seal sealing
and scratches. Smooth minor damage
surfaces
with an emery cloth.

Inspect the end and side outlet with the

End and side outlet
BOP under pressure. Replace leaking
leaks
seals. Check nuts for torque.

Bleed system (see section titled

Air in BOP operators
"Bleeding the Operators" on page 4-27).

Inspect the wellbore for cement,

Foreign substance in
Rams will not close fragments of metal, etc. Thoroughly
wellbore area
clean the wellbore.

Bleed system (see section titled

Air in BOP operators
"Bleeding the Operators" on page 4-27).

Inspect the wellbore for cement,

Foreign substance in
Rams will not open fragments of metal, etc. Thoroughly
wellbore area
clean the wellbore.

4-32 Shaffer
 Maintenance

Troubleshooting (Continued)

Problem Possible Cause Corrective Action

Bleed system (see section titled

Air in BOP operators
"Bleeding the Operators" on page 4-27).

Rotate the locking shaft on the slave

Locking shaft on slave
operator counter- clockwise, ¼ turn
operator activated
clockwise.

Manual to Hydraulic Conversion

To convert the preventer from manual operation to remote hydraulic operation, proceed
according to the steps listed below:
1. Remove the operator from the preventer body and rotate the operator 180 degrees
(see Figure 4-50).

i 4
Only one operator must be removed; either the left side
operator or right side operator may be removed.

2. Install the operator on the preventer body.

3. On the master operator, remove the three socket head cap screws (24) that connect
the locking shaft (14) to the inner shaft (12) (see Figure 4-51).

!
When the BOP is to be functioned using remote
hydraulics, the left side operator and right side operator
inner shafts (12) must not be bolted to the locking shafts
(14). These inner shafts must be free to travel with the
piston (2) as the rams are opened and closed.

4. Remove the plug on the bonnet side stamped ’Open’; connect the open hydraulic
line (see Figure 4-52).

i
The open or close port on either side of the preventer may
be selected. Only one open and one close line is
necessary.

Chasovoy™ Ram BOP 4-33

 Maintenance

5. Remove the plug on the bonnet side stamped ’Close’ and connect the close
hydraulic line.
6. Prior to operating the Chasavoy BOP, ’Close’ and ’Open’ the BOP three (3) times to
purge any trapped air from the BOP operators.

4 Rotate Bonnet
Assembly
180°

Figure 4-50. Operator Rotated 180 degrees

4-34 Shaffer
 Maintenance

Slave Master

Figure 4-51. Remove Cap Screws on Master

Hydraulic Port

Figure 4-52. Remove Plug on Bonnet Side ‘Open’

Hydraulic BOP Port Connections

The hydraulic ports are located on the face of the bonnet and the body; they are
connected when the operator is bolted to the preventer body. The built-in quick
disconnects prevent hydraulic fluid loss, when the operator is removed, from the preventer

Chasovoy™ Ram BOP 4-35

 Maintenance

body or the operator is pulled away from the body to allow access to the rams (see Figure
4-53 and Figure 4-54).
During routine inspection of the ram assemblies, it is not necessary to remove the
operator from the body. Therefore the connecting hydraulic ports for the open and close
function of the preventer are always correctly connected for hydraulic operation of the
preventer.
In the event the operator or operators are removed from the preventer body, they must be
reinstalled in their original positions in order to correctly align the open and close hydraulic
ports. The correct alignment of the hydraulic ports can be identified by the stamped ’open’
and ’close’ marks located on the side of the bonnet, and verified for remote hydraulic
operation as follows (see Figure 4-55).
When facing the preventer front, the left operator bonnet reads ’Open’ and the right
operator bonnet reads ’Open’ and when facing the preventer back, the left operator bonnet
reads ’Close’ and the right operator bonnet reads ’Close’. In this configuration the
preventer is in the remote hydraulic operation mode.
For manual operation mode refer to section titled "Manual BOP Port Connections" on
page 4-22.

Figure 4-53. Built-in Quick Disconnets Prevent Hydraulic Fluid Loss

4-36 Shaffer
 Maintenance

Figure 4-54. Built-in Quick Disconnets Prevent Hydraulic Fluid Loss

Figure 4-55. Hydraulic Ports Easily Identified by Correct Alignment

Manual Locking the Hydraulic BOP

The purpose of the locking shafts (14) are to prevent the ram assemblies from opening, in
the event hydraulic pressure is lost or removed. When activated, the locking shafts will
prevent the ram assemblies from opening.
To activate the manual locks on the hydraulic BOP perform the following steps:
1. Close the rams with 1,500 psi (102 atm) hydraulic pressure. The left side operator
and right side operator inner shafts (12) will move inward indicating the rams have
closed
2. Turn the left side operator-locking shaft (14) clockwise until it contacts the inner
shaft.
3. Turn the right side operator-locking shaft (14) clockwise until it contacts the inner
shaft.

Chasovoy™ Ram BOP 4-37

 Maintenance

!
Tighten the locking shaft by hand, using the short T handle
lever supplied with the BOP. Do not use a pipe extension
or excessive force.

Hydraulic Fluid for Chasovoy BOP’s

Shaffer Hydraulic Fluid Properties
Shaffer can supply our customers a hydraulic fluid for temperatures from -49 ºF to 140 ºF
(-45 ºC to 60 ºC).
R Ready to use-no mixing prior to use.
R High solubility-water based so it can be easily flushed from contaminated surfaces.
R Excellent fire and explosion resistance-does not ignite in test temperatures up to
824 ºF (450 ºC).
R Compatible with metals-inhibitors prevent corrosion on both ferrous and non-ferrous
4 metals. Even in the vapor phase above the fluid surface it won't corrode metal
surfaces.
R Compatible with packing and sealing materials-excellent anti-scruff and anti-wear
properties keep it from affecting pure synthetic rubber packings and seals made of
materials such as NBR, EPR, VITON®, Teflon®, neoprene, nylon, silicone, natural
rubber.
R Resistant to microorganisms-contains components that inhibit growth.
R Stable in use-is not affected by filters; even those rated as small as three microns.
R Compatible with paints-may be used with cured epoxy, phenolic and nylon based
paints. Even less resistant paints may be used if spills are washed down
immediately with water.
Check the physical properties and you'll see that Shaffer hydraulic fluid delivers the kind of
performance our customers will want to know about.

Spill or Leak Procedures

The following steps should be taken in case material is released or spilled. Flush with
water until the spill is diluted, removed or use absorbent material such as sand. Clean up
immediately as the wet area will be very slippery. Dispose of all residue in accordance with
federal, state and local regulations.
Material data sheets for all fluids are available upon request from:
Shaffer Material Handling
P.O. Box 1473
Houston, Texas 77251.
Quality Control Monitoring Service for Shaffer Hydraulic Fluid
Shaffer will implement a laboratory monitoring service on samples of Shaffer hydraulic
fluid by issuing a written report to users on the following aspects of the fluid condition:

4-38 Shaffer
 Maintenance

R Bacteria and fungi contamination levels

R Anti-corrosion properties
R Dilution level
R Glycol (pour point depressant) level
R General condition of fluid
This service will be provided at no charge. This will enable maintenance personnel to
carry out a preventive maintenance program on fluids thus ensuring maximum efficiency
of the hydraulic system.

i
Sterile bottles are available upon request. Contact Shaffer
Technical Services for a sample kit with instructions.

Figure 4-56. Shaffer Hydraulic Fluid P/N 185187

Chasovoy™ Ram BOP 4-39

 Maintenance

4-40 Shaffer
 Storage

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Blowout Preventer Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Storage and Inspection of Rubber Parts . . . . . . . . . . . . . . . . . . . 5-1 1

Chasovoy™ Ram BOP

 Storage

Shaffer
 Storage

Storage
Blowout Preventer Storage
Upon completion of the drilling operations and before storing the Chasovoy blowout
preventer, it is recommended that the Chasovoy BOP be disassembled, inspected,
cleaned and lubricated thoroughly with a non-petroleum-base oil. The ram shaft packing
and seal rings should be replaced, and the unit reassembled. Cover the wellbore and
store the Chasovoy BOP in an enclosed area.

i
A cover is included and located on the bore of the
Chasovoy BOP when it is shipped from the factory.

Storage and Inspection of Rubber Parts

Shaffer rubber parts are specially compounded to give maximum storage life under normal
conditions. Proper storage minimizes deterioration while increasing the life of these items.
Aging of rubber parts is based on several factors, such as atmosphere, light, temperature,
and size. Ozone in the atmosphere reacts with rubber parts and hastens deterioration.
Rubber parts should never be stored around electrical equipment because of the
occurrence of ozone.
Direct light, especially ultraviolet emitting sunlight, is very harmful and must be avoided.
All rubber parts undergo several kinds of changes when they are exposed to low
5
temperatures. At a temperature of -40 ºF (-40 ºC), the rubber becomes brittle and will
shatter when dropped or handled roughly. Some changes occur immediately while others
occur after prolonged exposure. All are reversible-the rubber regains its original properties
when it is returned to 65 ºF (18 ºC) or room temperature.
Heat causes a gradual hardening of the rubber, especially when ozone or oxygen is
present. In warm humid climates, particularly the tropics, fungi and bacteria attack the
organic content on reinforced rubber parts.
The size, composition and function of rubber parts prevents an accurate estimate of shelf
life. Large rubber parts might suffer the same amount of deterioration as small parts and
still be usable; whereas small parts become useless and should be thrown away.
Both natural and synthetic rubber parts are susceptible to deterioration from various
solvents, e.g. oilfield liquid hydrocarbon, which causes swelling or shrinkage.
In the final analysis, personal judgment determines whether a rubber part should be used.
If there is doubt, replace the part.

Storage of Rubber Parts

1. Store rubber parts in a dark place, indoors and away from sunlight, windows, and
direct artificial lighting should be avoided.
2. Store in a cool location 65 ºF (18 ºC) away from the heaters, electrical machinery or
any high voltage equipment.
3. Store rubber parts according to their natural shape. Do not hang O-rings on nail or
hooks.

Chasovoy™ Ram BOP 5-1

 Storage

4. Storage areas should be kept as dry as possible. Oil, grease or other fluids should
be stored elsewhere to avoid spillage.
5. If storage is for a long duration, it is recommended that rubber parts be placed in
sealed containers. A protective surface covering impervious to temperature or light,
will extend the shelf life of rubber parts.
6. Rubber parts should be used on a first-in, first-out basis.
Inspection of Rubber Parts
1. Each rubber part must be inspected before usage.
2. Bend, stretch or compress each part; look for cracks.

i
Some cracks are obvious, although when the rubber part is
bent, stretched or compressed, very minute cracks will
become apparent.

3. A chalky hard skin may form, or small bark like cracks may appear. It is therefore
very important to manually inspect all rubber parts carefully.

5-2 Shaffer
 Specifications and
Parts Lists

Specifications and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exploded Views and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
2

Chasovoy™ Ram BOP

 Specifications And
Parts Lists

Shaffer
 Specifications and
Parts List

Specifications and Parts Lists

Parts Identification
All parts required for maintenance or repairs are available from Shaffer. Assembly
drawings and exploded views correspond to the parts list, which identifies each part by
number. Using this part number and part name will ensure procurement of the proper part
when ordering spare parts.

Customer Service
Direct all correspondence to one of the addresses provided below.

Mailing Address
Shaffer
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

Parts Identification
All parts required for maintenance or repair are available from Shaffer. Assembly drawings
correspond to the parts list, which identifies each part by number. Using this part number
and part name will ensure procurement of the proper part when ordering parts.

Ordering Replacement Parts

When ordering replacement parts, please specify the following information:
R Part name – list part name as called out on the applicable drawing
6
R Part number – list part number as called out on the applicable drawing
R Drawing number – list engineering drawing number and the item number for the
drawing
R Quantity – list the quantity needed
R Serial number – list the serial number (if applicable) as shown on the nameplate
Recommended Spare Parts
The table titled "Chasovoy Recommended Spare Parts Kit (P/N 185183) for 2 Year
Service" below provides recommended spare parts coverage for the Chasovoy.

Chasovoy Recommended Spare Parts Kit (P/N 185183)

for 2 Year Service

Qty. P/N Description

2 185294 Door Seal

Chasovoy™ Ram BOP 6-1

 Specifications and
Parts List

Chasovoy Recommended Spare Parts Kit (P/N 185183)

for 2 Year Service (Continued)

Qty. P/N Description

2 141365 Spiral Retaining Ring

2 032005 Wiper Ring

2 032004 Wellbore Seal

4 032009 Seal, Hydraulic

2 032006 Piston Seal

4 030928 Cylinder O-Ring

4 032008 Cylinder Backup Ring

8 030653 Manifold O-Ring

8 5019416 O-Ring, Quick Disconnect

* 185183 Spare Parts Kit

* Spare Part Kit is for one operator only.

i
The quantities specified in the table above are for a single
cavity. A double BOP will require two kits.

6
Chasovoy Optional Spare Parts for 2 Year Service

Qty. P/N Description

1 064194 Fluid Transfer Pump

1 185187 Hydraulic Fluid

12 050000 Plastic Stick Packing

4 025056 Copper Washer

4 185186 Bleeder Plug

4 1500389 Quick Disconnect, Female

4 1500390 Quick Disconnect, Male

8 5019416 O-Ring, Quick Disconnect

12 010639 Soc. Head Screw

6-2 Shaffer
 Specifications and
Parts List

i
The quantities specified in the table above are for a single
cavity. A double BOP will require two kits.

Exploded Views and Parts Lists

Recommended Tool Kit (P/N 185105)

Item Qty. P/N Description

1 1 051158 Heavy Duty Tool Box

2 1 050823 BOP Door Wrench

3 1 050820 BOP Door Wrench

4 1 050822 BOP Door Wrench

5 1 051150 Set Hand Tools

6 1 050849 Set Allen Wrenches

Set Plain and Phillips

7 1 051068
Screwdrivers

8 1 9002046 Crescent Wrench, 12"

9 1 9002059 Pipe Wrench, 14"

10 1 050919 Ballpeen Hammer

11 1 051203 Socket Wrench, 1/2" Drive 6

12 1 051204 Deep Socket, 13/16"

13 1 051205 Deep Socket, 5/8"

14 1 064194 Hand Pump Assembly

15 6 5240008 Teflon Tape

16 1 9002043 Crescent Wrench, 6"

17 1 051215 Punch and Chisel Set

Chasovoy™ Ram BOP 6-3

 Specifications and
Parts List

24 12 16 6 7 4 13 5
6
7

22
23

20 21

19
6

24

14 17 11 18 15 10 8 1

Figure 6-1. Chasovoy 7 1/16", 3,000/5,000 psi

Hydraulic/Manual Operator Assembly

6-4 Shaffer
 Specifications and
Parts List

Chasovoy 7 1/16", 3,000/5,000 psi

Hydraulic/Manual Operator Assembly

Item No. P/N Description Qty.

1 — Body —

2 20001363 Operator Assembly —

3* 185177 Bonnet Sleeve 4

4* 011339 Screw 4

5* 020013 Nut 4

6 185294 Door Seal 2

7* 1500389 Quick Disconnect, Female 4

8** 065002 Plug 4

9** 050000 Plastic Stick Packing 6

10** 130368 Check Valve 2

11** 010004 Screw 2

12* 185181 T-Handle —

13* 8006838 Set Screw 4

14 064078 7-5M Stud Protector (Plastic) 2

15 064174 7-3M Stud Protector (Plastic) 2

16* 29100118 IOM Manual 1

6
Operator Assembly (reference Figure 6-1 on page 6-4)

1 185546 Bonnet 2

2 185165 Piston 2

3 185174 Ram Shaft Seal Assembly 2

4 032006 Piston Seal 2

5 185095 Cylinder 2

6 030928 Cylinder O-Ring 4

7 032008 Cylinder Backup Ring 4

8 185096 Manifold Pipe 2

9 030653 Manifold O-Ring 8

10 185169 Cylinder Stud 8

Chasovoy™ Ram BOP 6-5

 Specifications and
Parts List

Chasovoy 7 1/16", 3,000/5,000 psi

Hydraulic/Manual Operator Assembly (Continued)

Item No. P/N Description Qty.

11 020001 Cylinder Nut 8

12 185166 Inner Shaft 2

13 185176 Inner Shaft Wear Plate 2

14 185167 Locking Shaft 2

15 185097 Intermediate Cylinder Head 2

16 032009 Seal 2

17 185163 Cylinder Head 2

18 065008 Pipe Plug 4

19 065001 1 4
/2" Plug

20 025056 Copper Washer 4

21 185185 Bleeder Plug 4

22* 1500390 Quick Disconnect, Male 3/8 S.A.E. 4

23* 5019416 O-Ring, Quick Disconnect 4

24*** 010639 Soc. Head Screw 6

25 20001356 Bonnet Locating Pin 2

* Items not shown.

6
** Optional
*** Not used when preventer is in the remote hydraulic operation mode.

i
The quantities specified in the table above are for a single
cavity. A double cavity BOP will require two kits.

6-6 Shaffer
 Specifications and
Parts List

Hydraulic Seal

Adapter

Welbore Seal

Wiper Ring

Wiper Ring Holder

Spiral Retaining Ring

Figure 6-2. Ram Shaft Seal Assembly (P/N 185174)

Ram Shaft Seal Assembly (P/N 185174)

Item # P/N Description Qty.

Spiral
1 141365 Retaining 1
Ring

Wiper Ring
2 185172 1
Holder

3 032005 Wiper Ring 1 6

4 032004 Wellbore Seal 1

5 185173 Adapter 1

Hydraulic
6 032009 1
Seal

Hand Wheel Extension Assembly (P/N 722196)

Item # P/N Description Qty.

1 722151 Hand wheel 1

2 722199 Yoke 2

3 722197 Block 1

Chasovoy™ Ram BOP 6-7

 Specifications and
Parts List

Hand Wheel Extension Assembly (P/N 722196) (Continued)

Item # P/N Description Qty.

4 722198 Pin 4

5 010208 Bolt 1

i
2 3/8" (60.0 mm) pipe for hand wheel extension is furnished
by customer.

Top Seal

Ram Block

6
Face Seal

Figure 6-3. Pipe Ram Block Assembly

6-8 Shaffer
 Specifications and
Parts List

3,000/5,000 psi Chasovoy Pipe Ram Assembly

Pipe OD Complete Ram Block Face Seal Top Seal

Assembly Assembly Seal
Assembly

http://cgi.ebay.com/ws/
eBayISAPI.dll?ViewItem&item=3075191862&category=11050&sspagename=STRK%3AME
BWA%3AIT&rd=17 1/16", 3,000/5,000 psi, (180 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 722193 722181

5 1/2", 140 mm 722235 722167 722194 722181 6

7 7/8", 3,000/5,000 psi, (200 mm)

2 7/8", 73 mm 185104 185138 185144 185140

3 1/2", 89 mm 185103 185137 185143 185140

4 1/2", 114 mm 185102 185136 185142 185140

6 5/8", 168 mm 185101 185135 185141 185140

Chasovoy™ Ram BOP 6-9

 Specifications and
Parts List

B1
B2

Figure 6-4. Chasovoy Dimensions - Top View

A A

Figure 6-5. Chasovoy Dimensions - Flange X Flange Side View

6-10 Shaffer
 Specifications and
Parts List

A
A

Figure 6-6. Chasovoy Dimensions - Stud X Stud Side View

A
A
6

Figure 6-7. Chasovoy Dimensions - Stud X Flange Side View

Dimensions and Weights

Flange X Stud X Stud Stud X

Flange Flange

Single, lb
Approximate Weight 1,600 (726) 1,400 (635) 1,500 (680)
(kg)

Chasovoy™ Ram BOP 6-11

 Specifications and
Parts List

Dimensions and Weights (Continued)

Flange X Stud X Stud Stud X

Flange Flange

Double, lb
2,800 (1270) 2,600 (1,180) 2,700 (1,225)
(kg)

A) Overall Height, less Single, in.

24.63 (625.6) 11.25 (285.5) 18.00 (457.2)
studs (mm)

Double, in.
33.88 (860.6) 20.50 (520.7) 27.25 (692.2)
(mm)

B1) Overall Length, in. (mm), Bonnets 64.50 64.50 64.50

Closed, Locked (1638.3) (1638.3) (1638.3)

B2) Overall Length, in. (mm), Ram 80.75 80.75 80.75

Change, Both Bonnets Open (2051.0) (2051.0) (2051.0)

C) Overall Width, in. (mm) 20.62 (523.7) 20.62 (523.7) 20.62 (523.7)

D) Opening through Preventer, in. (mm) 7.062 (179.4) 7.062 (179.4) 7.062 (179.4)

Working Pressure*, psi (bar) 5,000 (345) 5,000 (345) 5,000 (345)

Test Pressure, psi (bar) 10,000 (690) 10,000 (690) 10,000 (690)

Maximum Torque to Close and Seal the

735 (996) 735 (996) 735 (996)
Rams, ft-lb (N-m)

* Working pressure may be 3,000 psi (207 bar) depending on end connection.

Chasovoy BOP Hydraulic Cylinder

6 To Close To Open

Maximum Operating
3,000 (207) 3,000 (207)
Pressure, psi (bar)

Ratio 8.47:1 8.47:1

Volume of Fluid, US gal

.6 (2.27) .6 (2.27)
(liters)

4.062
Piston Stroke, in. (mm) 4.062 (103.2)
(103.2)

6-12 Shaffer
 Specifications and
Parts List

UPS/Battery Enclosure Assembly, 24VDC Zone 1

Item No. Part UM Quantity Description

Number

1 20006615 ea 1.00 Encl., E EX D, Aluminium Alloy

J-Box Assy, E EX E/E EX E, 1300MM x

2 20005052 ea 1.00
1100MM x 350MM

3 20006989 ea 2.00 Conduit Nipple

4 20006990 ea 2.00 Union

5 20015661 ea 1.00 Charger, Battery, Automatic 24VDC, 50A

6 20006076 ea 20.00 Blk, Term 2.5

7 20006618 ea 2.00 Term, 16MM Sgl Deck

8 20006617 ea 2.00 Term, 6MM Sgl Deck

9 20006073 ea 1.00 Isolator, 2 Pole, 125 AMP

10 20005060 ea 2.00 Circuit Brkr, 2 Pole, 10A, Type C

11 20011405 ea 1.00 Brkr, Circuit, 50 AMP, 2 Pole, Type C

Encl, Battery, 24V 40AH, E EX E

12 20015586 ea 1.00
Certified

13 20015587 ea 2.00 Battery, Dryfit, 12V 40AH

Chasovoy™ Ram BOP 6-13

 Specifications and
Parts List

6-14 Shaffer