OPERATORS

MANUAL

6609B (6671A)

DATA FOR INSTALLATION, OPERATION, MAINTENANCE & PARTS

Annular Blowout Preventer

GK 11 Bore Size
5000 PSI

OPERATOR'S MANUAL
6609B (6671A)

GK 11"-5000 psi Annular Blowout Preventer

Hydril Company LP/ P.O. Box 60458 / Houston, Texas 77205

Phone: (281) 449-2000 / FAX: (281) 985-2828 / WEB: www.hydril.com
2001 HYDRIL COMPANY LP

PRINTED IN U.S.A.

REV B, JANUARY 2002

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Annular Blowout Preventer

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Standard
Hookup
Closing
Pressure
Opening
Pressure

Control Pressures
Surface Control Pressure psi
WELL PRESSUREpsi

Initial*
Closure

500

1500

2500

3500

5000

2 3/8

900

825

650

475

300

50

2 7/8"

800

725

550

375

200

50

3 1/2"

825

450

275

100

50

50

4 1/2"-5 "

450

375

225

100

50

50

5 1/2"-8 5/8"

350

275

125

50

50

50

1150

1150

Pipe Size

Close cautiously to prevent collapse of casing.

CSO

1150

1150

1150

1150

*Use closing pressure shown at initial closure to establish seal off and reduce closing pressure proportionally as
well pressure is increased. Well pressure will maintain closure after exceeding the required level. See Section 1 for
control pressure graph. Closing pressures are average and will vary slightly with each packing unit.
Optimum stripping is obtained by adjusting the Control Pressure to achieve a slight drilling fluid leakage as the tool
joint passes through the packing unit.

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Annular Blowout Preventer

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ANNULAR BOP TESTING AND OPERATION

Proper Procedure for pressure testing any annular blowout preventer (BOP) ensures subsequent seal off and
maximum packing unit life. Reliable seal off tests are made
by initially closing the packing unit with prescribed closing
chamber pressure on the recommended size test pipe,
proportionally reducing closing pressure as well pressure is
increased, and by determining the remaining piston travel
after seal off is achieved. Optimum packing unit life is
obtained by testing at low rubber stress levels. Minimum
packing unit stress is achieved by use of the minimum
closing chamber pressure that will initiate and maintain
seal off on the recommended size test pipe.
The GK blowout preventer is designed to be well
pressure assisted in maintaining packing unit seal off once
initial seal off has been effected. Initial seal off is effected
by applying pressure to the closing chamber. As well
pressure or test pressure is increased, the closing force on
the packing unit also increases. As well pressure exceeds
the required level the packing unit is maintained closed on
the recommended size test pipe by well pressure alone.
Once initial seal off is achieved, it is recommended that
closing pressure be proportionally reduced as well pres-

sure is increased in order to maintain the optimum closing

force on the packing unit. Optimum closing forces for high
well pressures may require careful application of pressure
to the opening chamber. Closing pressure required to
effect initial seal off may vary slightly between individual
packing units. Begin the test with the recommended initial
closing pressure.
Piston Stroke can be measured on GK blowout
preventers through a vertical passage in the top of the BOP
head.* The maximum and minimum distances from the top
of the head to the top of the piston are stamped on the BOP
head and are also listed in the table below. Piston stroke
remaining at seal off is a direct indicator of remaining
packing unit life. Record the piston stroke and the closing
pressure at seal off for each test. Compare with previous
results and with maximum piston stroke for the BOP to
ensure subsequent seal offs. A valid test on any annular
BOP is only achieved when the remaining piston stroke is
measured at test seal off.

*0lder model BOPs may not have vertical passage in head.

See Section 4.3 for information on field modification.

OPERATIONAL DATA
Bore

11 in.

279.4 mm

Closing Chamber
Volume

9.81
gal. (U.S.)

37.1
liters

Opening Chamber
Volume

8.08
gal. (U.S.)

30.6
liters

Recommended Test
Pipe Size

3 1/2 in.

88.9 mm

Full Piston Stroke

7 1/8 in.

181 mm

TAPE
MEASURE

5/16" ROD

Distance From Top of Head To Top of Piston

Maximum Piston Full
Down

11 1/8 in.

283 mm

Minimum Piston at Full

Stroke

4 in.

102 mm

Sales Headquarters / P.O. Box 60458 / Houston, Texas 77205 / Telephone: (281) 449-2000
FAX: (281) 985-2828
Eastern Hemisphere / Hydril U.K. Ltd. Minto Avenue Altens Industrial Estate Aberdeen, AB1 4JZ
Scotland / Telephone: +441-224-878-824 / FAX: +441-224-898-524

OPERATORS MANUAL
GK 11-5000 psi
Annular Blowout Preventer

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WEAR PLATE

PACKING UNIT

HEAD

OPENING
CHAMBER

PISTON

CLOSING
CHAMBER

Figure 1-1
Cutaway view of GK
with packing unit
fully open.

OPERATORS MANUAL

The Hydril GK blowout preventer is an annular blowout

preventer which will close and seal off on drill pipe, tool joints,
tubing, casing, or wireline in the wellbore or completely seal
off the open hole to full rated working pressure by compression of a reinforced elastomer packing element. This
preventer has been developed for use on surface installations and it can also be used subsea. In addition, the GK
meets the requirements of API Recommended Practices
R.P. 53*.
Hydraulic pressure applied to the closing chamber (refer to
Figures 1-2 through 1-6) raises the piston forcing the packing unit into a sealing engagement. Wellbore pressure (or
test pressure) acting on the piston from below the sealed off
packing unit further increases the closing force. Drill pipe can
be rotated and tool joints stripped through a closed packing
unit while maintaining a full seal on the pipe.
Any normal closing unit having a separate pressure regulator valve for the annular blowout preventers and sufficient
accumulator volume (see Section 2.1 of this manual for
chamber volumes) can be used to operate the GK blowout
preventer. The hydraulic operating fluid may be clean, light
petroleum hydraulic oil, or water with water soluble oil
added. In cold climates, antifreeze should be added to
prevent freezing.
The closing time of the preventer is determined by the rate
at which the hydraulic fluid can be delivered to the closing
chamber. Minimum closing time is achieved by using short,
large diameter control lines, large bore control valves, and a
large accumulator volume. An excessively high setting on
the pressure regulator valve will have little effect on BOP
closing time.

Figure 1-2

*API Recommended Practices for Blowout Prevention Equipment Systems - R.P 53 is available from the American
Petroleum Institute, Production Department, 1220 L Street,
Northwest, Washington, DC 20005.

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Upward force exerted

by the piston squeezes
packing unit rubber inward into
a sealing engagement.

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OPERATORS MANUAL

Figure 1-3. Cutaway view of GK BOP with packing

unit fully open. The Hydril GK opens to full bore to allow
passage of large-diameter tools through open bore as well
as maximum annulus flow of drilling fluids. Packing unit
always returns to the open position due to normal resiliency of rubber packing unit. Retention of opening chamber pressure will provide positive control of piston and
reduce wear caused by vibration.

Figure 1-4.

Figure 1-5.

Figure 1-6.

Cutaway view of GK BOP with packing

unit closed on square kelly. The packing unit seals off on
square or hexagonal kellys to rated pressure.

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Annular Blowout Preventer

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Cutaway view of GK BOP with packing

unit closed on drill pipe. The packing unit seals off on tool
joints, drill pipe, casing, tubing, or wireline to rated pressure.

Cutaway view of GK BOP with packing

unit closed on open hole. Complete closure of packing unit
safely holds well pressure, without leakage, equal to the
rated working pressure of the preventer.

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OPERATORS MANUAL

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Annular Blowout Preventer

1.1 Surface Operation

1.1.1 Surface Hookup
The surface hookup of the GK shown in Figure 1-7
connects the hydraulic control lines to the opening and
closing chambers of the BOP
Pressure applied to the closing chamber raises the
piston and effects the initial seal between the packing unit
and drill pipe. Well pressure or test pressure also acts on
the piston below the sealed off packing unit and further
increases the closing force acting on the packing unit. As
the well pressure or test pressure exceeds the required
level the preventer is maintained closed by well pressure
alone. As well pressure further increases, the closing force
on the packing unit also increases. Closing pressure
should be proportionally reduced as well pressure is
increased in order to maintain optimum closing force on
the packing unit and prolong packing unit life.
The Control Pressure Graph, Figure 1-8, shows the
relationship of closing pressure and well pressure required
to effect optimum seal off for the GK 11-5000 BOP.
During normal drilling operations, it is recommended that
the pressure regulator valve for the GK be set at the initial
closing pressure shown for the size pipe being used. This

Opening
Pressure

Figure 1-7
pressure will ensure that initial seal off is achieved should
a kick be encountered.
During BOP testing operations, once initial seal off is
achieved, closing pressure should be proportionally
reduced as well pressure is increased.

CLOSING PRESSURE-PSI

1500

CSO

1000
*Closing pressures are average and will vary slightly with each
packing unit. Use closing pressure shown at initial closure to establish seal
off and reduce closing pressure proportionally as well pressure is increased.
Well pressure will maintain closure after exceeding the required level.
**Close cautiously to prevent collapse of casing.
Operating pressure may vary at temperatures other than 70oF.

500

23

/8"

2 7/

**5 1

/2" th

ru 8

4 1/
2" th
ru 5
"

5/8"

PIPE

3 1/

2" P

PIP
E

PIP

8" P

IPE

IPE

0
0

1000

2000

3000

WELL PRESSURE-PSI

Figure 1-8:

Average Control Pressure GK 11"-5000

4000

5000

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OPERATORS MANUAL

1.1.2 Surface Stripping Operations

Drill pipe can be rotated and tool joints stripped through a
closed GK packing unit while maintaining a full seal off on
the pipe. Longest life for the packing unit is obtained by
adjusting the closing forces low enough to maintain a seal
on the drill pipe with a slight amount of drilling fluid leakage
as the tool joint passes through the packing unit. This
drilling fluid leakage indicates optimum seal off for minimum packing unit wear and provides lubrication for the drill
pipe motion through the packing unit.

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Slow tool joint stripping speeds reduce surge pressures,

and thus prolong packing unit life. The pressure regulator
valve should be set to provide and maintain the proper
control pressure. If the pressure regulator valve does not
respond fast enough for effective BOP control, a surge
absorber (accumulator) should be installed in the closing
chamber control line adjacent to the blowout preventer.
Precharge the accumulator to one-half of the closing pressure required to effect a seal off at the existing well pressure
for the pipe size in use.

Surface Hookup

Closing Pressure

Closing Pressure

Opening Pressure

Opening Pressure

Example Precharge Calculation:

500 psi well pressure, 3 1/2" drill pipe
Precharge = 0.50 (Closing Pressure).
From Figure 1-8:
Closing Pressure = 450 psi
Precharge = 0.50 x 450 psi
Precharge = 225 psi

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GK 11-5000 psi
Annular Blowout Preventer

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2.1 Engineering Data

English

Metric

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 inches
Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5000 psi

279.4 mm
351.55 kg/cm2

Shell Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 psi

Closing Chamber Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . . . 5000 psi

703.1 kg/cm2
351.5 kg/cm2

Opening Chamber Test Pressure (Factory Test Only) . . . . . . . . . . . . . . . . . . . . . . 5000 psi

VolumeClosing Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.81 gallons

351.5 kg/cm2
37.1 liters

VolumeOpening Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.08 gallons

Piston Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1/8 inches

30.6 liters
181.0 mm

Port Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NPT*

Weight-Single (Approximatevaries with connectors . . . . . . . . . . . . . . . . . . . . . . . 8,200 lb

3720 kg

* 1 1/4" or 1 1/2" NPT available on request

2.2 Bolt and Wrench Data

Ref.
No.

Description

Thread

Wrench
Size

17

Pipe PlugPiston Indicator

1/2" NPT

3/8" Hex Key

18

Slotted Body Sleeve Bolt

1/2"-13UNC

3/4" Hex

19

Head Lock Screw

1"-8UNC

30

Wear Plate Cap Screw

...

Recommended Torque
Lb/Ft
Kg-m
50

6.9

55-75

7.6-10.4

1 1/4" Hex

100

13.8

1/2-13UNC

1/2" -12pt.
Socket

70

9.6

Eyebolt, Piston x 17" Lg.

5/8"-11NC

....

Snug

Snug

...

Eyebolt, Head x 1 3/4" Lg.

1 1/4"-7NC

....

Snug

Snug

...

Protector Plate Screw

1/2"-13UNC

3/4" Hex

Snug

Snug

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OPERATORS MANUAL

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Annular Blowout Preventer

2.3 Outside Dimensions

H AS CAST
J
K

E
F

A AS CAST

C STUDDED

B CLAMP HUB

D
AS
CAST

*OPENING
PORT

*CLOSING
PORT
M AS
CAST

N AS CAST
O AS CAST
* 1" NPT, 1 set of ports, 45o from lifting lug unless otherwise specified.
NOTE: Lifting lugs split lower connection stud holes and are equally spaced 90o apart.
Lifting lugs are 1-1/4" thick with 1-1/2" diameter holes.

Nominal Dimensions Inches

A

19 1/16

5 11/16

13 3/16

5M

10M

5M

10M

5M

10M

47 3/4

48 1/2

44 7/8

51 1/2

39 5/8

40 1/4

11 13/16

44 1/4

37 1/2

35 3/4

...

32

36 3/4

Lower Connector Pressure Rating

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Annular Blowout Preventer

2.4 Inside Dimensions

L
M

H
B
C

D
F

NOMINAL
DIMENSION

Bore

O.D.
Upper
Piston

INCHES

11

NOMINAL
DIMENSION

INCHES

I.D.
Upper
Body

24 1/4
J

Packing
Unit
Height

Stroke

12

7 1/8

I.D.
Piston

I.D.
Lower
Body

Piston
Height

Top of
Sleeve
To Bottom
of Head

30 3/4

13 3/4

23 1/4

23 1/4

12 3/16

Top of Head
to Top
of Piston
(Full Down)
11 1/8

Head
Height

Top of Head
to Bottom
of Wear
Plate

Piston
Taper

14 7/16

6 5/8

20o

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OPERATORS MANUAL

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Annular Blowout Preventer

2.5 API Ring Joint Flange Connections

B
A

Studded Flange,
Using Studs.

Bolted Flange,
Using Stud Bolts.

FLANGE
Nominal
Size
(Inches)

Bore
Dia.
(Inches)

Max. API
Service
Pressure
Rating (PSI)

11

11

5000

11

11

10,000

SEAL RING
O.D.
(Inches)

Thickness
(Inches)

Dia. C
(Inches)

API
Ring

23

4 11/16

12 3/4

RX54

25 3/4

5 9/16

14.064

BX158

BOLTS & STUDSa

No.
Req.

Lengthb
(Inches)

Size

Stud Bolts
A

Studs
B

Bolt
Circle
Dia.
(Inches)

12

1 7/8

14 1/2

10 1/4

19

16

1 3/4

15 3/4

10 1/4

22 1/4

POINT HEIGHT OF STUD BOLTS

Bolt Diameter, Inches

Max. Point Height Inches

1/2 to 7/8 . . . . . . . . . . . . . . . . . . . . . .
Over 7/8 to 1 1/8 . . . . . . . . . . . . . . . .
Over 1 1/8 to 1 5/8 . . . . . . . . . . . . . .
Over 1 5/8 to 1 7/8 . . . . . . . . . . . . . .
Over 1 7/8 to 2 1/2 . . . . . . . . . . . . . .

1/8
3/16
1/4
5/16
3/8

Bolt material shall be of a quality and strength not

less than specified by ASTM A-193, Grade B7.
Nuts shall be of a quality not less than ASTM
A-194, Grade 2H. Stud bolts are threaded full
length.

Lengths shown herein are overall lengths,

including point at both ends, as shown in table.
Dimensions shown are outside diameters of 6BX
flange grooves.

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OPERATORS MANUAL

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Annular Blowout Preventer

2.6 Clamp Hub Connections

HUB
Bore
Size
A
(Inches)

Rated
Working
Pressure
(PSI)

11

11

11

11

Hub
Size
(Inches)

Seal Ring No.

Hub Dimensions (Inches)

RX Only
Standoff
D
C

RX

BX

5000

53

...

16 1/4

3 3/4

15/32

...

10,000

...

158

16 1/4

...

...

3 5/8

NOTE: API 16A 1st Edition Nov 1, 1986 Does Not Include Clamps.

Clamp Dimensions (Inches)

20 13/16

28 1/2

6 3/4

...

20 13/16

28 1/2

6 3/4

...

Clamp dimensions may vary from those shown.

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Annular Blowout Preventer

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Annular Blowout Preventer

3-1

3.1 Packing Units

The heart of the GK blowout preventer is the packing
unit. The unit is manufactured by Hydril from high
quality rubber, reinforced with flanged steel segments.
Each unit has a large volume of tough, feedable rubber
to meet any requirement.
The molded-in steel segments have flanges at the top
and bottom These segments anchor the packing unit
within the blowout preventer and control rubber extrusion and flow when sealing off well pressures. Since the
rubber is confined and kept under compression, it is

Figure 3-1
Cutaway drawing showing
how rubber is molded around
steel segments.

resistant to tears and abrasion.

All annular blowout preventer packing units are subjected to wear during closure and stripping. The design of
the Hydril GK blowout preventer causes closure wear to
occur on the outside of the packing unit while stripping wear
occurs on the inside. Because the packing unit uses the
principle of feeding rubber from the back of the packing unit
to the bore, stripping life may be affected by a packing unit
that is worn on the backside.

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OPERATORS MANUAL

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Annular Blowout Preventer

3.1.1 Packing Unit Selection

Because of the importance of the packing unit to the
operation of the blowout preventer and to the safety of the
crew and rig, only genuine Hydril packing units should be
used as replacements for original equipment. All Hydril
packing units are tested to full rated pressure inside a test
blowout preventer at the factory as part of standard performance tests before being furnished to the consumer.
Packing units for Hydril blowout preventers are manufactured from compounded natural rubber or nitrile rubber.
Natural Rubber is compounded for drilling with waterbase drilling fluids. Natural rubber can be used at operating
temperatures down to 30oF (35oC). When properly
applied, the compounded natural rubber packing unit will
usually provide the longest service life. This all-black
packing unit is identified by a serial number with the suffix
"R" or "NR."
Nitrile Rubber (a synthetic compound) is for use with oilbase or oil-additive drilling fluids. It provides the best
service with oil-base muds, when operated at temperatures
below 20oF (7oC). The nitrile rubber packing unit is
identified by a red colored band and a serial number with
the suffix "S" or "NBR."
Seals for Hydril blowout preventers are manufactured
from a special nitrile rubber material which provides long,
trouble-free service in sealing against oil gas, or water.
Expected H2S Service does not affect selection of
packing unit material. H2S service will reduce the service
life of rubber products, but the best overall service life is
obtained by matching the packing unit material with the
requirements of the specific drilling fluid.
Performance of elastomeric materials can vary significantly, depending on the nature and extent of exposure to
hydrogen sulfide. The operator should monitor pressure
sealing integrity by frequently performing a packing unit
seal test to assure no performance degradation has occurred. Hydril recommends replacement of all rubber
goods after H2S exposure.
Storage Conditions such as light, heat or adverse
conditions are significant factors in the storage life of
packing units, as covered in Section 6.3 and should be
avoided.

No Band

Figure 3-2
Natural Rubber Packing
Unit No Band

Red Band

Figure 3-3
Synthetic Rubber Packing
Unit Red Band

OPERATORS MANUAL

3.1.2 Packing Unit Replacement

Screwed Head
To replace the packing unit, use the following
procedure:
1. Remove head lock screw.
2. Unscrew blowout preventer head (counterclockwise).
3. Lift off blowout preventer head.
4. Lift out packing unit.
5. Lubricate piston bowl.
6. Install new packing unit.
7. Clean and lubricate head and body threads
with zinc base API modified tool joint
lubricant.
8. Replace head and tighten to align hole for
lock screw.
9. Install head lock screw and torque to 100
lb-ft.

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Annular Blowout Preventer

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OPENING TORQUE

Figure 3-5

NOTE: If the head was improperly installed at last

reassembly, it may be necessary to apply considerably more torque on the head by the use of a
catline or winch while alternately applying and releasing pressure to the opening chamber (1500 psi
maximum). Do not attempt to loosen the head by
applying heat. Refer to Assembly/Disassembly
Section for further information.

Figure 3-6

Figure 3-7

OPERATORS MANUAL

3.1.3 Splitting Packing Units

Packing unit replacement is also possible with pipe in the
hole. After removing worn packing unit, cut new packing
unit completely and smoothly through one side between
any two steel segments perferably 90o from eyebolt holes
to achieve easier handling. Cut should be made with a
sharp knife as this will not affect the efficiency of the
packing unit. Spring segment apart with a pry bar to put
rubber in tension for easier cutting. Do Not use a saw or
other rough cutting tool. Spring packing unit open sufficiently to pass around pipe, drop unit into position in
blowout preventer body, and replace head.

Figure 3-9

Figure 3-8
Photo shows proper method for
cutting through packing unit
with a sharp knife.

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Annular Blowout Preventer

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Annular Blowout Preventer

3-5

3.2 Seals
The seal rings for Hydril blowout preventers are manufactured from a special synthetic rubber material for long
trouble-free sealing service. To prevent seal damage, Do
Not use synthetic fluids in the hydraulic operating system.
The hydraulic operating fluid may be clean, light petroleum
hydraulic oil, or water with soluble oil added. In cold
climates, antifreeze should be added to prevent freezing.

The dynamic seals are all molded, lip-type, pressureenergized rings.

The static seals are of O-ring or square ring configuration.
For seal replacement procedure, see Section 5.2.
For seal maintenance and testing, refer to Section 4.0.

DYNAMIC SEALS

STATIC SEALS

DOUBLE U-SEAL
cross-section
with
nonextrusion
rings

U-SEAL
cross-section

O-RING
cross-section

SQUARE RING
cross-section

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Annular Blowout Preventer

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Annular Blowout Preventer

4-1

4.1 Maintenance
Prior to placing the GK blowout preventer into service, the
following visual inspections should be performed:
1. Inspect upper and lower connections for pitting, wear,
and damageespecially in ring grooves and stud bolt
holes. Worn or damaged ring grooves must be welded,
machined, and stress relieved. Worn or damaged stud bolt
holes can be drilled and tapped to the next larger size and
fitted with step-studs.
NOTE: The Hydril GK blowout preventer is a primary pressure vessel. The blowout preventer surfaces exposed to wellbore fluids will meet NACE
Standard MR-01-75. Proper handling and repair are
required to maintain any original integrity. Field
welding is not recommended as it induces undesirable stresses which must be relieved by proper heat
treating procedure or controlled by special welding
procedures.
2. Check the body for wear and damageespecially in the
internal cylinder walls for pits and vertical scores. Minor pits
and scores can be removed in the field with emery cloth.
Repaired surface should be coated with silicon grease or
castor oil. Severe pits and scores may require machining
and/or welding which should be performed in a machine
shop. Cracks must be corrected.
3. Inspect the vertical bore for wear and damage from drill
string and drill toolsespecially in the area of the ring
grooves. If wear is excessive, the area must be repaired.
4. Check the inner body sleeve for wear, damage, and
looseness. Check slots in sleeve for cuttings which may
restrict piston movement. Some model BOPs have a welded
body sleeve and may be field repaired by conversion to a
bolted sleeve (see Section 4.4).

5. Check for piston damage and wearespecially the

inner and outer walls for pits and vertical scores and the
tapered bowl for pits and gouges.
Minor pits and scores on the walls can be removed in the
field with emery cloth. Repaired surface should be coated
with silicon grease or castor oil. Severe pits and scores may
require machining and/or welding which should be performed in a machine shop.
Pits and gouges in the tapered bowl should be filled with
a permanent type adhesive, such as epoxy. Sharp or rolled
edges should be removed with emery cloth or a grinder.
Repair will be satisfactory when a relatively smooth surface
is achieved.
6. Check the wear plate in the inner bottom face of the
head for wear. In addition to the aging process of time and
use, wear of this metal surface is produced by the combination of vertical (upward thrust) and lateral forces. These
forces are generated each time the packing unit is closed.
Severe wear is exhibited in the form of grooves or channels
shaped by the steel segments of the packing unit.
The inner bottom face of the head serves as a wall to
prevent upward movement of the packing unit. Friction
between these metal surfaces is controlled at a level which
does not impair lateral movement of the packing unit.
Repair of this surface is accomplished by replacing the
wear plate. Some models of this BOP do not have the wear
plate, but may be converted.
7. Inspect the packing unit for wear, cracking, hardness,
and correct elastomer composition. See Section 3 for
packing unit information and Section 4.3 for packing unit
testing.
8. Check seal ring for nicks, cuts, fraying of lips, and
abrasion. Worn or damaged seal rings should be replaced.
See Section 4.2 for pressure testing of seals.
6

5
8

Figure 4-1

OPERATORS MANUAL

4.2 Seal Testing

When it is known or suspected that a seal within the GK
blowout preventer is leaking, it is recommended that all
seals be replaced. However, if only the seal in question is
to be replaced, it must first be determined which seal is
leaking. The following procedure is provided:
1. Test seals 9 (lower) and 10 (upper).
a. Pressurize closing chamber. The test pressure to
be used in the closing chamber should be the
initial closing pressure required using the recommended test mandrel if a packing unit is installed
(1500 psi if no packing unit is installed).
b. Open opening chamber to atmosphere.
IF: Closing fluid is seen at opening chamberseal 9
(lower) is leaking.
IF: Closing chamber pressure gauge is dropping and
no fluid is seen at opening chamberseal 10
(upper) is leaking.
2. Test seals 8 (lower), 9 (upper), and 6.
a. Pressurize opening chamber (1500 psi).
b. Open closing chamber to atmosphere.
IF: Fluid is seen coming from area between body and
headseal 6 is leaking.
IF: Fluid is seen coming into the wellboreseal 8
(lower) is leaking.
IF: Fluid is seen at closing chamberseal 9 (upper)
is leaking.
3. Test seals 8 (upper) and 10 (lower).
a. Open closing chamber to atmosphere.
b. Open opening chamber to atmosphere.
c. Pressurize wellbore (5000 psi maximum). (Requires blind flange on top, as packing unit is
open.)
IF: Fluid is seen coming from the opening chamber
seal 8 (upper) is leaking.
IF: Fluid is seen coming from the closing chamber
seal 10 (lower) is leaking.
4. For packing unit testing, see Section 4.3.

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PAGE

8 UPPER

8 LOWER

9 UPPER
9 LOWER
10 UPPER
10 LOWER

Figure 4-2

PAGE

OPERATORS MANUAL

4.3 Packing Unit Testing

Proper procedure for pressure testing any annular blowout
preventer ensures subsequent seal off and maximum
packing unit life. Reliable pressure seal off tests are made
by closing the packing unit with prescribed closing chamber pressure on recommended size test pipe and by

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4-3

determining the remaining piston travel after seal off is

achieved. Optimum packing unit life is obtained by
testing at low rubber stress levels. Minimum packing
unit stress is achieved by use of the minimum closing
chamber pressure that will initiate and maintain a seal
off on the recommended size test pipe.

4.3.1 Packing Unit TestingSurface

The GK blowout preventer is designed to be well pressure
assisted in maintaining packing unit seal off once initial seal
off has been effected. Initial seal off is effected by applying
pressure to the closing chamber. As well pressure or test
pressure increases, the closing force on the packing unit
also increases.
As well pressure exceeds the required level, the packing
unit is maintained closed on pipe by well pressure alone.
During routine BOP testing, once initial seal off is achieved,
closing pressure should be proportionally reduced as well
pressure is increased (see the Control Pressure Graph,
Figure 1-8).
Closing pressure required to effect initial seal off may
vary between packing units. Begin the test with the recommended initial closing pressure shown in Figure 1-8,
depending on the style packing unit installed.
Piston Stroke can be measured on GK blowout preventers through a vertical passage in the top of the BOP
head. The maximum and minimum distances from the top
of the head to the top of the piston are stamped on the BOP
head and are also listed in the table below. Piston stroke
remaining at seal off is a direct indicator of remaining
packing unit life. Record the piston stroke and the closing
pressure at initial seal off for each test. Compare with
previous results and with maximum piston stroke for the
BOP to ensure subsequent seal offs. A valid test on any
annular BOP is only achieved when the remaining piston
stroke is measured at test seal off.

TAPE MEASURE

5/16" ROD

Distance From Top of Head to Top of Piston

Maximum (piston in full down position)
Minimum (piston at full stroke)

11-1/8"
4"

Figure 4-3: Piston Stroke Measurement

Older model BOPs may not have the Piston Indicator Hole
as shown in Figure 4-3 above. See Section 4.4 for
modilcation.

PAGE

OPERATORS MANUAL

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4-4

4.4 BOP Modifications

4.4.1 Piston Indicator Hole Modification
Older Model BOPs without piston indicator holes may be
modified as shown in Figure 4-4 below.

R 11.968"

.719 DRILL
1/2"-14NPT TAP

CL PISTON INDICATOR

BOP CL

.339" DIA.
DRILL THROUGH

Figure 4-4: Field modification for addition of Piston

Indicator Hole to older model BOPs.

The procedure* for adding the piston indicator hole is as

follows:
1. Drill one .339" diameter hole through the BOP head at a
point located on R=11.968" radius from the centerline
( CL) of the BOP Head.

2. Counterbore with .719 " diameter drill. x 1 3/8" deep.

3. Tap the .719" diameter hole with a 1/2"-14 NPT tap.
4. Insert a 1/2"-14NPT pipe plug and torque to 50 lb-ft.
* A drill press should be used.

PAGE

OPERATORS MANUAL

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4-5

4.4.2. Bolted Body Sleeve Modification

To maintain original integrity without welding, older model
BOPs having a welded body sleeve may be repaired
through conversion to a bolted sleeve. This conversion is
accomplished by using the Field Replacement Sleeve Kit,
part number 1006100.
The Field Replacement Sleeve Kit contains the following:
1. 1Drill Template
2. 127/64" Dia. Pilot Drill
3. 119/32" Dia. Counterbore Drill
4 11/2"-13UNC Tap
5. 1Bolted Body Sleeve
6. 121/2"-13UNC X 1 1/4" Lg. Hex Head Cap Screws
The procedure for converting the BOP from a slotted
body sleeve to a bolted sleeve is as follows:
1. Remove old body sleeve.
2. Grind out all weld from the counterbore and the 20o
Grind All Weld From
o
Counterbore And 20 Bevel

bevel that would interfere with the new sleeve (see

Figure 4-5).
3. Insert drill template as shown in Figure 4-6.
4. Drill one 27/64" diameter hole, 1 1/4" deep, through one
of the 27/64" diameter holes in the template.
NOTE: Template has eleven 27/64" diameter holes
and one 9/16" diameter hole.
5. Remove the template and counterbore hole with 19/32"
diameter drill (see Figure 4-7).
6. Tap the hole with 1/2"-13UNC tap, 1" deep.
7. Re-insert the template and bolt to the BOP through the
9/16" hole in the template.
8. Drill a 27/64" diameter hole, 1 1/4" deep, in the 11
remaining places.
9. Remove the template and counterbore 19/32" diameter
in 11 places.
10. Tap 11 holes with 1/2"-13UNC tap.
11. Install new sleeve and bolt down tight (see Figure 4-8).
27/64" Dia. Drill

Figure 4-5

Drill Template

Figure 4-6
13 1/8 +/ 1/16" To Top Of Body

19/32" Dia. Counterbore Drill

With 27/64" Dia. Pilot
Bolted
Body Sleeve

Figure 4-7

9/16" Hole
19/32" Counterbore
1/2"-13UNC Thread
27/64" Dia.

Figure 4-8

OPERATORS MANUAL
GK 11-5000 psi
Annular Blowout Preventer

QUICK REF.

1-1

PAGE

OPERATORS MANUAL

5.1 Disassembly
5.1.1 HEAD REMOVAL (ITEM 1)
Close and open the packing unit to break loose any
accumulation of drilling fluid or debris which may be restricting full downward travel of the piston.
Vent opening and closing chambers to atmosphere
ensuring that no trapped pressure exists which will cause
personnel and/or equipment damage. Open valves in control system to have an exhaust and/or loosen hydraulic
connections to allow leakage.
Release head by removing the head lock screw (item
19). Install two (1 1/4"-7NC) eyebolts in the top of the head
in the holes provided. Use a piece of strong pipe or rod (3"
-4" pipe) 10 to 12 feet long as a lever against the eyebolts
to apply counterclockwise torque (left hand) on the head.
Rotate head (approximately 10 turns) to release, then lift
clear of BOP. A vertical lift may be applied to the eyebolts
to take the weight of the head off of the threads while
applying torque to the head. This lift will reduce the required
opening torque. If the head was improperly installed at the
last reassembly, it may be necessary to apply considerably
more torque on the head by the use of a winch or catline
while alternately applying and releasing pressure to the
opening chamber (1500 psi maximum).
DO NOT attempt to loosen the head by applying heat on
the thread area.
5.1.2 PACKING UNIT REMOVAL (ITEM 2)
Install two (5/8"-11UNC) eyebolts into packing unit. Lift
packing unit out of piston. Use a sling of adequate length to
prevent side loading of eyebolts.
5.1.3 PISTON REMOVAL (ITEM 3)
Install two (5/8"-11UNC) eyebolts in top of piston. Place a
wooden spacer block (approximately 1/2" thick) between
each eyebolt and the piston wall to protect the piston
sealing surface.
Gently lift piston vertically to free from preventer body. If
a vertical lift is unfeasible or if the piston does not freely lift
out, slowly apply low (50 psi) hydraulic pressure to the
closing chamber-DO NOT USE AIR OR GAS!
5.1.4 SLOTTED BODY SLEEVE REMOVAL (ITEM 4)
Remove the six slotted body sleeve bolts (item 18) from
around the slotted body sleeve. Lift out slotted body
sleeve with a sling and hooks under the slots. Some
model BOPs have a welded body sleeve which is not
removable.

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5-1

NOTE: Seal Rings MUST BE installed in position

shown by cross-section.
17

19

1
6
8
29
30
2

1
3

9
10

18

Figure 5-1:
Exploded View GK 11"-5000 psi

PAGE

OPERATORS MANUAL

5.2 Assembly
5.2.1 CLEAN AND INSPECT ALL PARTS BEFORE
ASSEMBLY
Inspect all seals and replace any damaged seals or seals
in use over one year.
Seal rings MUST BE installed in positions shown by
cross section! Lubricate all seal rings prior to installation.
(Silicon grease or castor oil is best).
5.2.2 SLOTTED BODY SLEEVE INSTALLATION
(ITEM 4)
Install slotted body sleeve (item 4) into inside bottom of
blowout preventer body. Install six slotted body sleeve bolts
(item 13) and torque to 70-90 lb-ft. Some model BOPs have
a welded body sleeve which is not removable.
5.2.3 PISTON INSTALLATION (ITEM 3)
Lubricate and install lower U-seals (item 10) in seal grooves
in lower segment of piston.
Lubricate and install middle U-seals (item 9) in seal
grooves in middle segment of piston.
Install two (5/8"-11UNC) eyebolts in top of piston with
wooden spacer blocks between eyebolt and piston wall.
Lubricate all mating surfaces before lowering piston into
body. Install piston into preventer body. Ensure that vertical
alignment between piston and body is achieved prior to
lowering piston. After proper alignment is obtained, the
weight of the piston alone will take the piston its full normal
stroke to the bottom of the preventer body. Be careful to
prevent seal damage during assembly.
Remove eyebolts and spacer blocks.
5.2.4 PACKING UNIT INSTALLATION (ITEM 2)
Lubricate piston bowl.
Lift packing unit with two (5/8"-11UNC) eyebolts and set
into piston bowl, already installed in preventer.
5.2.5 HEAD INSTALLATION (ITEM 1)
Lubricate and install upper U-seals (item 8) in seal grooves
on inside of head.
Lubricate and install head gasket (item 6) on outside of
head just above screw threads. Clean threads of foreign
matter and check threads for burrs or rough edges. Apply
a generous coating of zinc base (lead-free) tool joint
lubricant to the threads of head and body. This lubrication
will ensure easy head removal at the next disassembly.
Locate and mark hole in body for the head lock screw
(item 19).
Lift head using the two (1 1/4" -7NC) eyebolts and chain
sling assembly.
Align the lead thread of the head with the lead thread in
the body.
Screw head clockwise (right hand) into body until it
shoulders against top of body. Line up lock screw hole in
head with hole in body and install head lock screw (item 19).
Remove eyebolts from head. Preventer is ready for use/
testing.

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Annular Blowout Preventer

5-2

NOTE: Seal Rings MUST BE installed in position

shown by cross-section.
17

19

1
6
8
29

30
2

1
3

9
10

18

Figure 5-2:
Exploded View GK 11-5000 psi

OPERATORS MANUAL

Pipe Plug (17)

Head Lock Screw (19)

BOP Head Screwed (1)
Head Gasket (6)
Wear Plate Capscrew (30)
Wear Plate (29)
U-Seal, Upper (8)
Packing Unit (2)
Piston (3)
U-Seal, Middle (9)
Body (5)

Slotted Body Sleeve (4)

U-Seal, Lower (10)

Slotted Body Sleeve Capscrew (18)

Figure 5-3: Cutaway

of GK 11-5000 BOP
Showing Position of Parts

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OPERATORS MANUAL
GK 11-5000 psi
Annular Blowout Preventer

QUICK REF.

1-1

PAGE

OPERATORS MANUAL

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Annular Blowout Preventer

6-1

6.1 Parts List Screwed Head

Item
No.

Part Name

No.
Req.

Approx.
Net Wt.
(Lb)

Part
Number

17

BOP Assembly
BOP Head -

8,200

1002140

Screwed
Packing Unit-

1,880

1002143

Natural (NR)
Packing Unit-

305

31401-R

Nitrile (NBR)
Packing Unit-

311

31401-S

Neoprene
Piston

1
1

311
1,380

4**

Slotted Body
Sleeve

...

1004201

5
6

Body
Head Gasket

1
1

4,645
2

1002141
31402

8
9
10

U-Seal , Upper
U-Seal, Middle
U-Seal, Lower

2
2
2

2.13
2
1.75

17

Pipe Plug, Piston

Indicator

...

190006505

Slotted Body
Sleeve Capscrew

12

...

192002612012

19
29*

Head Lock Screw

Wear Plate

1
1

30*

Wear Plate
Capscrew

Field Replacement
Sleeve Kit
...

1
2

18**

19

31401-N
1002145-1

30
2

31403
30736
32599

9
10

1002149
1004203

.13

192002608007

18

...

1006100

14.41

1002150

45

33565-M

1.94

30952

4.25

32006

Protector Plate
Protector Plate

66

31406
1900043-

Figure 6-1:

Screw

.13

08010

Screwed Head GK 11"-5000 psi

Seal Kit- Complete

1.19
24.15

29

ACCESSORIES
...
...

...

Chain Sling
Assembly
Eyebolt Piston
5/8"-11 UNC
x 10" Lg.
Eyebolt, Head
1 1/4"-7 NC x
1 3/4" Lg.

...
...

Recommended Spares for One Year Foreign Service.

For converting welded sleeve on some model BOPs to bolted

sleeve only. Sleeve does not interchangee with Item 4.

* Requires head conversion to accept wear plate; some models

of this BOP do not have the wear plate.
** Some BOPs are equipped with Sleeve P/N 1004075 and
Capscrew 1920026-12016. Check P/N stamped on bottom of
sleeve for replacement.

PAGE

OPERATORS MANUAL

6.3 Preventer Storage

At the conclusion of each well, or prior to placing the
blowout preventer in storage for even a brief period, it is
recommended that the preventer be disassembled, cleaned,
inspected, lubricated thoroughly with non-petroleum base
oil such as castor oil, silicon oil, or rapeseed oil, and
reassembled. Replacement of worn packing units, or packers, seal rings, and other parts can be made conveniently
at this time.
Flange or Hub faces and ring grooves should be protected with wooden covers and ports should be plugged.

6.4 Rubber Goods Storage

The term rubber goods includes synthetic compounds such
as Nitrile Copolymers and Neoprene, as well as natural
rubber parts.
The ideal storage situation for rubber goods would be in
vacuum-sealed containers maintained in a cool, dry, dark
storage area. Atmosphere, light, and heat accelerate deterioration of rubber goods. The term aging means cumulative effects of all three attacking agents over a period of
time. The rubber goods are also affected by stretching or
bending from normal shape, extreme cold, or chemical
reactions with solvents and petroleum products.
The following recommendations will allow vendors and
users of oil field equipment to maximize normally available
storage facilities for rubber goods.
1. Keep the rubber storage area as dark as possiblepreferably indoors, not outdoors, and away from direct
sunlight, skylights, windows, and direct artificial lighting.
The ultraviolet content of the light spectrum accelerates
cracking.
2. Select a cool location (ideally below 90oF) that is away
from heaters, stoves, and direct blasts of space heaters.
Heat causes a gradual hardening of rubber goods. The
process is greatly accelerated when ozone or oxygen is
present. In extremely cold climates, some rubber goods
become so brittle they will shatter when dropped or handled
roughly.
3. Keep rubber goods away from electrical machinery (motors, switch gear, or any high voltage equipment producing
corona). Avoid locations susceptible to drafts that will carry
the atmosphere from electrical machinery to the rubber
goods storage area.
Exposure to the atmosphere allows oxygen and thus
ozone (O3), a very active form of oxygen, to react with and
be especially detrimental to rubber goods. Two principal
sources of ozone are (1) atmospheric ozone, and (2) ozone
created by electrical discharges such as lightning, high
voltage corona, and electrical machinery.

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6-2

Points of strain in rubber goods attacked by ozone are

characterized by deep cracks. Ozone and oxygen (O2)
attack rubber goods much as steel rusts. Oxidation is
characterized by a hard skin which eventually crazes in
small cracks and may turn chalky or assume a barklike
appearance.
4. The practice of first-in, first-out is essential with rubber
goods.
5. Store rubber goods in a relaxed position in their normal
shape; stretching or bending of rubber goods will result in
accelerated aging or cracking. For example, do not hang 0rings on pegs, glands, BOP testers, or operator parts.
Periodically inspect and treat with age resistant compounds the rubber goods that must be stored in a stretched
attitude to detect aging signs.
6. Rubber goods storage areas should be kept as dry as
possible. Remove oil, grease, or other foreign materials
from the storage area to preclude spillage on rubber goods.
Rubber goods, both natural and synthetic, possess some
degree of susceptibility to deterioration from various solvents, especially oil field liquid hydrocarbons, which cause
swelling/shrinkage.
7. If storage for extended periods is anticipated, sealed
containers are recommended. Impervious surface coverings such as waxing will increase shelf life.
Since the aging of a rubber product is dependent upon all
of the above factors plus its size, specific composition, and
function, no precise figure is available for storage life.
Generally, the greater the ratio of surface area to volume,
the more susceptible a part is to being rendered useless by
aging. For example, a relatively large part (by volume),
such as a packing unit, might be expected to have a much
longer useful shelf life than a thin-walled, large-diameter 0ring.
No general rule can be drawn regarding usability. A
large, heavy part might suffer the same total amount of
aging as a small, light piece and still be usable, whereas the
light piece would be rendered useless. Thus, judgement
becomes the rule and where there is doubt-replace the
part.
Prior to using rubber goods that have been stored for
periods of time, these checks should be made:
1) Is there chalking or barking?
2) Has the part developed a hard skin?
3) Do cracks appear? (Sometimes cracks will be obvious;
stretch or bend the part in question so that any incipient
cracks or very thin cracks will be revealed.)
4) Will a suspect part pass a hardness test? (In the
event that the hardness runs 15 points higher than the
normal hardness of the part, it is considered nonusable.)
Note: Hardness is affected by temperature, and readings
should be taken with the rubber part at 70o to 100oF.

HYDRIL COMPANY LP
3300 N. Sam Houston Pkwy. E.
Houston, Texas 77032-3411
(281) 449-2000