Beruflich Dokumente
Kultur Dokumente
CROSCO
INTEGRATED DRILLING & WELL SERVICES Co., Ltd.
TABLE OF CONTENTS
1 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 ACCUMULATOR UNIT ASSEMBLY
1.2 AIR PUMP ASSEMBLY
1.3 ELECTRIC PUMP ASSEMBLY
1.4 HYDRAULIC CONTROL MANIFOLD ASSEMBLY
1.5 AIR REMOTE CONTROL PANEL(S)
1.6 AIR REMOTE CONTROL INTERFACE ASSEMBLY
1.7 INTERCONNECT CABLE ASSEMBLY
1.8 SIZING RECOMMENDATIONS - Normal Pressure and/or Standard Service
1.9 SIZING RECOMMENDATIONS - High Pressure And/or H2S Environment
1
1
1
1
1
2
2
2
3
6
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 INSTALLATION INTRODUCTION
9
2.2 ACCUMULATOR UNIT
10
2.3
AIR PANEL INSTALLATION
14
2.4 DRILL AHEAD
15
2.5 INSTALLATION DATA SHEET
16
3 TYPICAL SYSTEM DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 TYPICAL INSTALLATION PICTORIAL
3.2 TYPICAL ACCUMULATOR UNIT ASSEMBLY
3.3 TYPICAL INTERCONNECT SCHEMATIC
3.4 HYDRAULIC SCHEMATIC TYPICAL CONTROL FLUID CIRCUIT
3.5 HYDRAULIC SCHEMATIC TYPICAL CONTROL MANIFOLD CIRCUIT
3.6 STARTER CONTROL SCHEMATIC PUMP ELECTRIC MOTOR
17
17
18
19
20
21
22
4 OPERATION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 ACCUMULATORS AND RESERVOIR
4.2 AIR PUMP ASSEMBLY
4.3 ELECTRIC PUMP ASSEMBLY
4.4 CONTROL MANIFOLD ASSEMBLY
4.5 AIR REMOTE CONTROL PANEL ASSEMBLY
4.6 AIR REMOTE CONTROL INTERFACE ASSEMBLY
4.7 INTERCONNECT CABLE ASSEMBLY
4.8 ACCESSORIES
23
24
24
25
26
31
34
34
34
5 MAINTENANCE INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 INTRODUCTION
5.2 SPECIFIC TOOLS LIST
5.3 NITROGEN PRECHARGE INSTRUCTIONS - BLADDER TYPE ACCUMULATORS
5.4 NITROGEN PRECHARGE INSTRUCTIONS - 80 GALLON SPHERICAL TYPE ACCUMULATORS
5.5 ACCUMULATOR UNIT
5.6 AIR OPERATED PUMPS
5.7 ELECTRIC PUMPS
5.8 CONTROL MANIFOLD
5.9 AIR PANELS
5.10 AIR JUNCTION BOXES
37
37
38
39
41
42
42
43
45
46
47
48
49
51
52
57
58
59
61
63
7 STORAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 INTRODUCTION
7.2 INITIAL PREPARATION
7.3 FINAL PREPARATION
7.4 CHECKOUT AND RECONDITIONING
64
64
64
65
67
8 REFERENCE MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 HYDRAULIC & PNEUMATIC SYMBOLS
8.2 ELECTRICAL SYMBOLS
8.3 ABBREVIATIONS
68
68
69
70
8.4
8.5
GLOSSARY OF TERMS
CONVERSION FACTORS
71
77
81
81
82
83
84
85
86
87
88
89
90
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
1 SYSTEM DESCRIPTION
A Blowout Preventer (BOP) Control System is a high pressure hydraulic power unit fitted with directional control valves to safely
control kicks and prevent blowouts during drilling operations. We offer a wide variety of equipment to meet the customer's specific
operational and economic criteria. A typical BOP Control System consists of the following equipment:
1.1 Accumulator Unit Assembly
1.2 Air Pump Assembly
1.3 Electric Pump Assembly
1.4 Hydraulic Control Manifold Assembly
1.5 Air Remote Control Panel(s)
1.6 Remote Control Interface Assembly(ies)
1.7 Interconnect Cable Assembly(ies)
1.1
1.2
1.1.1
Accumulators
Accumulators are ASME coded pressure vessels for storage of high pressure fluid. These accumulators are
available in a variety of sizes, types, capacities and pressure ratings. The two (2) basic types are bladder and float
which are available in cylindrical or ball styles. The accumulators can either be bottom or top loading. Top loading
means the bladder or float can be removed from the top while it is still mounted on the Accumulator Unit. Bottom
loading accumulators must be removed from the Accumulator unit to be serviced. Bladder and buoyant float type
accumulators can be repaired in the field without destroying their stamp of approval.
1.1.2
Reservoir
A rectangular reservoir is provided for storage of the atmospheric fluid supply for the high pressure pumps. It
contains baffles, fill and drain ports and troubleshooting inspection ports. For filling and cleaning procedures see
the Maintenance Section.
1.1.3
Accumulator Piping
This piping connects the high pressure discharge lines of the pumps to the accumulators and the hydraulic
manifold. It is comprised of 1" or 1-1/2" Schedule 80 or 160 pipe, isolator valves and a 3500 psi relief valve to
protect the accumulators form being over-pressured. Cylindrical type accumulators are mounted on machined
headers to minimize line restrictions and leaks.
1.3
1.4
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
1.5
1.6
1.7
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
1.8
Mfg. By
Mfg. Type
Stack Size
Work Press
Gal. to Close
Hydril
GK
13-5/8"
5,000 PSI
17.98
Pipe Ram
Cameron
13-5/8"
10,000 PSI
5.54
Blind Ram
Cameron
13-5/8"
10,000 PSI
6.78
Pipe Ram
Cameron
13-5/8"
10,000 PSI
5.54
TOTAL
35.84
The total system accumulator capacity should meet or exceed the following requirements:
Total Gallons to Close
50% Safety Factor
Total Gallons of Usable Fluid Required (VR)
35.84
+ 17.92
53.76 Gallons
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2. Calculate the total accumulator volume (nitrogen and fluid) required (derived form Boyle's Law, P1, V1 = P2V2
):
P1 = Maximum pressure of accumulator when completely charged (3000 PSI)
P2 = Minimum operating pressure of accumulator (1200 PSI)
P3 = Nitrogen precharged pressure (1000 PSI)
V1 = Volume of nitrogen at maximum pressure
V2 = Volume of nitrogen at minimum pressure
V3 = Total accumulator volume of (nitrogen and fluid)
VR = Total usable fluid required including safety factor
V3 =
VR
53.76
=
= 107.52 110 Ga.
P3 P3
1000 1000
P2 P1
1200 3000
3. Determine the number of accumulators required by deriving the total accumulator volume (nitrogen and fluid)
by the nominal accumulator capacity. The nominal accumulator capacity is the accumulator size in gallons,
less 1 gallon to allow for bladder/float displacement.
EXAMPLE (USING 11 GALLON ACCUMULATORS)
(A) Total accumulator volume
(B) Nominal accumulator capacity (11 - 1 = 10)
(C) Number of Eleven Gallon Accumulators [AB]
107.52
10.00
10.75 . 11
110 Gallons
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
1.8.2
110.00 Gallons
X 0.67 Gallons
73.70 Gallons
15 Minutes = 4.9 GPM
Description
Total GPM
A197-602
7.20*
TPE06-15460
6.40
* NOTE:
Air pump output is based on 125 PSI air input to the air motor and the
output at 2000 PSI (2000 PSI is the average rate between the 1000 PSI
precharge and the 3000 PSI operating pressure).
It is not recommend air pump ratios less than 50:1. Rig air pressure may drop as low as 60 PSI under normal
operating conditions which would not allow lower ratio pumps to attain the required 3000 PSI output.
EXAMPLE
Pump Ratio
Stall Pressure
60:1
60 PSI
3600 PSI
50:1
60 PSI
3000 PSI
40:1
60 PSI
2400 PSI
35:1
60 PSI
2100 PSI
It is not recommend air operated pumps with 10 inch or larger air motors. Each of these motors require 300 SCFM
or more air supply to maintain 3000 PSI operating pressure. The combined air demand of two or three of these
pumps would often exceed the available air supply of many floating drilling rigs.
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
1.9
Mfg. By
Mfg.
Type
Stack Size
Gal. to
Close
Work Press
Gal. to Open
Annular
Hydril
GK
11"
10,000 PSI
25.10
18.07
Pipe Ram
Cameron
11"
10,000 PSI
3.31
3.16
Blind Ram
Cameron
11"
10,000 PSI
4.23
4.03
Pipe Ram
Cameron
11"
10,000 PSI
TOTAL
3.31
3.16
35.95
28.42
The total system accumulator capacity should meet or exceed the following requirements:
Gallons to close all preventers
Gallons to open all preventers
Gallons to close all preventers
Total Gallons of Usable Fluid Required (VR)
35.95
28.42
+35.95
100.32
2. Calculate the total accumulator volume (nitrogen and fluid) required (derived from Boyle's Law, P1V1 = P2V2):
V3 =
VR
P3 P3
P2 P1
100.32
= 200.64 200 Ga.
1000 1000
1200 3000
Quick Calculation:
Multiply gallons to close-open-close by 2. 100.32 X 2 = 200.64
3. Determine the number of accumulators required by dividing the total accumulator volume (nitrogen and fluid)
by the nominal accumulator capacity. The nominal accumulator capacity is the accumulator size in gallons,
less 1 gallon to allow for bladder/float displacement.
EXAMPLE - (USING 11 GALLON ACCUMULATORS)
Total Accumulator Volume
Nominal Accumulator Capacity [11 - 1 = 10]
Number of Eleven Gallon Accumulators
200.64
20.00
20.06 . 20
200 Gallons
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
1.9.2
25.10
+ 1.00
Combined Gallons
Divide by 2 Minutes
26.10
2
13.05 GPM
2. Select the pump model numbers each with a pump output greater than the total GPM required above. See Air
Pumps and Electric Pumps for additional specifications..
EXAMPLE
Model No.
1.9.3
Description
Total GPM
A1985-603
15.00
TPE12-30460
14.20
Mfg. By
Mfg. Type
Stack Size
Work Press
Gal. to Close
Hydril
GK
13-5/8"
5,000 PSI
17.98
1.00
TOTAL
a.
18.98
Multiply the total gallons to close by 1.5 to arrive at the total gallons required including the safety factor.
EXAMPLE.
Total Gallons Required
50% Safety Factor
Total Volume Required (V3)
18.98
+ 9.49
28.47 Gallons
The nitrogen bottle has been calculated to equate to 6.23 equivalent usable fluid gallons. To determine
the number of nitrogen bottles required, divide the total volume, including safety factor, by the equivalent
usable fluid gallons per bottle.
TOTAL VOLUME
Divide by Usable Gallons
Number of Nitrogen Bottles
28.47
6.23
4.56 . 5
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Air Pump Assembly Specifications
Model No.
No. Of Pumps
2000 PSI
3000 PSI
A197-601
7-3/8"
3.90
3.60
3.20
A197-602
7-3/8"
7.80
7.20
6.40
A197-603
7-3/8"
11.70
10.80
9.60
A9875-601
8-1/2"
6.00
5.00
3.90
A9875-602
8-1/2"
12.00
10.00
7.80
A9875-603
8-1/2"
18.00
15.00
11.70
HP
Plunger Size
Volts
Ph
Hz
DPE21-03460
5/8"
460
1.14 GPM
60
DPE21-05460
3/4"
460
2.19 GPM
60
DPE21-07460
3/4"
460
2.50 GPM
60
TPE06-10460
10
3/4"
460
4.55 GPM
60
TPE06-15460
15
3/4"
460
6.40 GPM
60
TPE06-20460
20
7/8"
460
8.70 GPM
60
TPE21-25460
25
1"
460
11.40 GPM
60
TPE21-30460
30
1-1/4"
460
14.20 GPM
60
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2 INSTALLATION
2.1
INSTALLATION INTRODUCTION
The following Installation Instructions explain how to hookup and checkout a standard Manual/Air Remote BOP Control
System. These guidelines will ensure that all the equipment is operational so that drilling operations may begin safely.
The Installation Instructions are divided into two (2) main topics, the Accumulator Unit and the Air Remote Control Panels.
At the end of the instructions are Installation Data Sheets containing specifications for customer supplied power requirements.
Located in the Equipment Section of this manual are drawings containing information which is necessary to properly install
the equipment. These drawings are:
Typical Installation Pictorial
Typical Accumulator Unit Assembly
Typical Interconnect Schematic
Hydraulic Schematic Typical Control Fluid Circuit
Hydraulic Schematic Typical Control Manifold Circuit
Starter Control Schematic Pump Electric Motor
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
The Typical Installation Pictorial shows the typical installation placement of the BOP Control System. The Interconnect
Diagram shows the typical pipe and air cable connections and the Electric Motor Wiring Diagram specifies wire size and
terminal connections.
To identify specific component parts referenced in the text, it may be necessary to review the assembly drawings and material
lists located in the Equipment Section.
There are a couple of major steps that must be performed during all phases of equipment use. Wherever the following
instructions are given, refer to these steps.
Stop Pumps
(1) Close air supply valves.
(2) Turn triplex pump motor starter to OFF position.
Start Pumps
(1) Open air supply valves.
(2) Turn triplex pump motor starter to AUTO position.
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2.2
ACCUMULATOR UNIT
2.2.1
Set up Location
1. The distance recommended to provide maximum protection of the accumulator unit during a blowout of other
emergencies is approximately 100 to 150 feet from the well bore.
2. Location placement should consider maintenance and service:
a. Accessibility
b. Illumination
c. Ventilation
3. Accumulator Unit SHOULD NOT BE:
a. Placed near oxygen storage.
b. Where there would be high heating effects from surrounding equipment.
4. After initial installation the following steps are recommended.
2.2.2
Inspect Reservoir
1. Open the 4" inspection/fill ports on the sides of the fluid reservoir and make sure the tank is free of any debris
that could contaminate the system. A clean reservoir reduces maintenance costs. For reservoir cleaning
procedures see Maintenance Section.
2. Make sure all reservoir connections are tightly secured
2.2.3
Fill Reservoir
1. Fill with a high quality SAE 10 Hydraulic Oil to 8" from the top of the reservoir.
2.2.4
Check Accumulator Precharge (See Nitrogen Precharge Instructions in the Maintenance Section)
1. Open the manifold bleeder valve.
2. Open the accumulator bank isolation valves.
3. Remove the guard from the valve stem of the accumulator and attach a Charging and Gauging Assembly.
4. Screw on gauge and screw down T-handle.
5. Gauge pressure reading should be 1000 PSI 100 PSI.
a.
b.
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2.2.5
2.2.6
2.2.7
Interconnect Piping
1. Lay interconnect piping and sufficient size and pressure rating from the Accumulator Unit to the connections
on the Blowout Preventer Stack.
2. Connect swivel-joint assemblies to the 1" function outlets on the back of the Accumulator Unit. DO NOT
CONNECT TO BOP STACK.
2.2.8
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2.2.9
Verify Gauges
1. All gauges on the hydraulic manifold should read 0 PSI.
2. Air supply gauge should read 125 PSI.
Alternately decrease and increase the settings of the manifold regulator and verify the correct response
on the manifold pressure gauge.
b.
Move the manifold bypass valve into the HIGH pressure (handle right) position, and verify that the
manifold pressure gauge increases to 3000 PSI.
3. Annular pressure gauge should indicate the pressure setting recommendations of the annular preventer
manufacturer to adjust the annular regulator see Maintenance Section.
a.
Place annular unit/remote selector valve located in the gauge housing on the hydraulic manifold to the
UNIT position.
b.
Adjust annular regulator through various operating pressures and check for correct response on the
annular pressure gauge.
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2.2.13 Connect to BOP Stack
1. Move the manifold bypass valve into the LOW pressure (handle left) position.
2. Stop pumps.
3. Open Manifold bleeder valve and relieve system pressure.
4. Make sure swivel-joint and hammer union connections on function outlets are tight and secure.
5. Start pumps.
CAUTION: DO NOT FLUSH WITH HIGH PRESSURE
6. OPEN each four-way control valve to flush the OPEN function line.
7. CLOSE each four-way control valve to flush the CLOSE function line.
8. Return the control valves to the CENTER position.
9. Open the 4" inspection/fill ports and check the control valves for leaks.
10.
Connect but do not tighten each swivel-joint assembly to its correct inlet on the BOP stack.
11.
Operate each function to ensure correct function operation and to purge BOP stack. Make sure a joint of
drill pipe is in the hole to prevent damage to rubber element of the annular preventer.
12.
13.
Securely tighten the swivel-joint assemblies and hammer union connections at the BOP stack.
14.
Stop pumps.
15.
Open the manifold bleeder valve and relieve all system pressure.
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2.3
Set up Location
1. Install air panels securely on firm foundation, taking into consideration the following factors.
a.
b.
c.
d.
2. Driller's panel should be installed on the drill floor at or near the Driller's position.
2.3.2
Panel Preparation
1. Fill the lubricator with SAE 10 lubricating oil.
2. Connect a 1" ID, 125 PSI air supply line to air supply inlet of the panel.
2.3.3
1.
The air interconnect cable assembly connects the air remote control panel to the Accumulator Unit. It should be
installed in a manner to avoid damage and stress at the termination fittings, normal traffic flow and other mechanical
equipment. Do not hang over sharp edges or bend around sharp corners.
2.
At the panel, inspect the junction boxes and gasket for damage and/or debris.
3.
Connect junction box on the air cable to the mating junction box on the panel using the alignment pin as a guide and
evenly tighten the mounting bolts.
4.
Before connecting the remaining end of the junction box, hold down panel master air valve and open and close each
function. This will purge the air tubing of any debris. Then repeat steps 2 and 3 for Accumulator Unit end of the air
interconnect cable assembly.
2.3.4
Panel Checkout
1. With Accumulator Unit pumps turned off and accumulator pressure at 0 PSI, hold down panel air master valve
and operate (open and close) each function.
2. Verify that the panel valve operates the corresponding valve on the hydraulic manifold correctly.
3. Check the air panel, air cable, junction boxes and air cylinders on hydraulic manifold for leaks. Repair if
necessary.
4. At the Accumulator Unit:
a.
b.
c.
d.
e.
f.
g.
5. When accumulator pressure has reached 3000 PSI, Driller's Panel gauges and gauges on hydraulic manifold
should match. Gauges on the Driller's panel should read:
a. Accumulator pressure - 3000 PSI.
b. Manifold pressure - 15000 PSI.
c. Annular pressure - Operating pressure recommendations of the annular preventer manufacturer.
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6. Using Driller's Panel Annular air regulator, adjust operating pressure of annular to various pressure settings. Verify
that Driller's Panel annular gauge and hydraulic manifold gauge correspond throughout the various pressure
settings.
7. From the panel hold down the air master valve and operate each function (open and close) several times. Check
that the control valves on the hydraulic manifold are not inter-flowing. Return flow to the reservoir can be detected
by viewing through the inspection/fill ports on the reservoir.
8. See Drill Ahead.
CAUTION:
MAKE SURE THAT DRILL PIPE IS IN THE HOLE WHEN OPERATING THE ANNULAR PREVENTER SO AS NOT
TO DAMAGE THE RUBBER ELEMENT.
2.4
DRILL AHEAD
The following list identifies the normal operating position of the shutoff valves and control valves of the BOP control system.
2.4.1
Shutoff Valves
1. Air pump supply valves - OPEN
2. Air and electric pump suction valves - OPEN
3. Accumulator bank isolator valves - OPEN
4. Accumulator bank bleeder valves - CLOSED
5. Manifold bleeder valve - CLOSED
6. Air pressure switch bypass valve - CLOSED
2.4.2
Control Valves
1. Annular - OPEN
2. Pipe rams - OPEN
3. Choke and kill Valves - CLOSE
4. Manifold regulator bypass valve - LOW PRESSURE (handle left)
5. Annular Unit/Remote selector valve - REMOTE
Page 15 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
2.5
Starter
Connection
HP
Volts
Full Load
Current (Amps)
Ph
Hz
TPE06 -10230
10
1-1/2" FPT
230
26
60
TPE06 -10460
10
1-1/2" FPT
460
13
60
TPE06-15230
15
1-1/2" FPT
230
42
60
TPE06-15460
15
1-1/2" FPT
460
21
60
TPE06-20230
20
2" FPT
230
48.70
60
TPE06-20460
20
2" FPT
460
24.40
60
TPE21-25230
25
2" FPT
230
64.90
60
TPE21-25460
25
2" FPT
460
32.45
60
1. Customer to furnish wiring to meet applicable codes and standards for installation.
2. Maximum allowable voltage variation is 10%.
3. Maximum allowable frequency variation is 5%.
4. Combined voltage and frequency variation is 10% (with no more than 5% frequency variation).
5. Similar metal conductors (copper) should be used.
2.5.2
No. of Pumps
CFM
A197-601
Model No.
7-3/8"
76
1.98
A197-602
7-3/8"
160
3.96
A197-603
7-3/8"
236
5.94
A1985-601
8-1/2"
112
3.20
A1985-602
8-1/2"
235
6.40
A1985-602
8-1/2"
347
9.60
1. Flow capacities approximate based upon minimum air supply pressure of 90 PSI.
2. Connection - Size 1" FPT.
3. Customer should ensure that the air supply is clean and dry. Excessive moisture and other contaminants can
cause operational problems.
2.5.3
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
3 TYPICAL SYSTEM DRAWINGS
3.1
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
3.2
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
3.3
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3.4
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3.5
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3.6
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OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
4 OPERATION INSTRUCTION
The BOP Control System is a hydraulic power unit with controls necessary to operate the Blowout Preventers during drilling
operations. These units can be packaged in a variety of sizes and configurations to meet the specific requirements dictated by size,
quantity and working pressure of the preventers, the drilling location itself, as well as by the specifications generated by various
regulatory agencies. The operation of all of these units is essentially the same, and understanding the proper operation is very
important to save lives and property in emergency situations.
The hydraulic control manifold directs the flow of the high pressure fluid to operate the preventers. Air remote control panel
assemblies can be included with the BOP control system to enhance the safety in drilling operation. Operational accessory safety
features can also be added to the system to provide additional operational capabilities. To better understand the function and
operation of each assembly, operation of the BOP control system has been divided into the following sections:
4.1 Accumulators and Reservoirs
4.2 Air Pump Assembly
4.3 Electric Pump Assembly
4.4 Control Manifold Assembly
4.5 Air Remote Control Panel Assembly
4.6 Air Remote Control Interface Assembly
4.7 Interconnect Cable Assembly
4.8 Accessories
The following operation descriptions include item numbers which refer to the illustrations following the text.
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4.1
4.2
4.1.2
4.1.3
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4.2.2
should remain in the open position at all times. The air pumps can be stopped by rotating the valve handles
clockwise to the closed position.
Fluid Suction Manifold
The fluid suction manifold is used to connect the high pressure pumps to the reservoir which contains the
operating fluid. The manifold includes:
1. Suction valve (Item 11 Fig. 4-1) - that is used to isolate the pump during servicing. In normal operation.
2. Suction strainer (Item 10 Fig. 4-1) - to remove impurities in the fluid. Impurities can enter the system through
the preventers and return to the reservoir with the vented fluid. This strainer should be serviced periodically
to prevent clogging which could damage the pumps by running them dry (see Maintenance Section).
4.2.3
4.2.4
4.3
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2. Suction strainer (Item 15 Fig. 4-1) - which removes impurities that may have entered the system with the
vented fluid from the preventers. Strainer should be serviced periodically (see Maintenance Section) to prevent
clogging and damage to the pump by running it dry.
4.3.2
4.3.3
Electric Motor
All electric motors (Item 12 Fig. 4-1) used in the pump assemblies are of the explosion-proof design. These
motors are either 50 or 6 0 cycle turning at speeds of 1500 and 1800 RPM respectively. Because most pumps
cannot turn at these speeds, reducing drive assemblies are used.
4.3.4
Drive Assembly
1. Sprockets - reduce the speed of the motor to the operating limits of the pump.
2. Chain complete with oil bath chain guard - used in place of belts to eliminate slippage and prolong service life.
Oil level in the chain guard oil specifications see Maintenance Section.
3. Motor starter (Item 17 Fig. 4-1) - controls the power to the electric motor and is housed in an explosion-proof
enclosure. The starter control switch should always be in the AUTO position during normal operation.
4. Electric pressure switch (Item 13 Fig. 4-1) - stops the electric motor when discharge pressure reaches 3000
PSI and automatically restarts the motor when discharge pressure drops to 2700 PSI. This protects the pump
from over pressuring which can damage the packing or the power frame. Pressure switch settings have a
tendency to drift and require periodic calibration. This is especially true when the equipment has been moved
to a different location. To adjust the pressure switch setting see Maintenance Section.
4.4
Control Valves
The control valves (Item 28 Fig. 4-1) are 1" four-way, three-position shear seal selector type valves. They have
90' handle rotation with 45 Deg. detents, there is one for each preventer and gate valve, complete with an
aluminum nameplate stating function name with OPEN and CLOSE positions marked in relation to handle
position. The control valves should always be in either the OPEN or CLOSE position. Never leave the valves in
the center position as this blocks both function ports of the control valve. To operate the valve from CLOSE to
OPEN or from OPEN to CLOSE, move the handle in one swift motion. Pausing will cause the valve to inter-flow,
thus venting some of the supply fluid and delaying function operation. The center position should be used to block
further pressure drop of the system if a regulator malfunctions while operating a preventer. The control valves
should be serviced periodically to ensure proper operation (see Maintenance Section).
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4.4.2
Regulators
The double manifold, designed to accommodate variable pressure requirements, consists of a manifold regulator
assembly, bypass valve assembly and an annular regulator assembly.
1. Manifold regulator assembly - the manifold regulator (Item 25 Fig. 4-1) reduces the 3000 PSI fluid pressure
from the accumulator to a maximum of 1500 PSI. This regulated pressure is the supply to operate the ram
type preventers and gate valves; pressures greater than 1500 PSI cannot be regulated. The pressure setting
of this regulator must be manually adjusted; to do this:
a.
b.
c.
d.
Loosen the locknut on the adjustment handle and hold with one hand.
Rotate the regulator adjustment handle with other hand.
(1) To increase pressure, rotate clockwise.
(2) To decrease pressure, rotate counterclockwise.
Read manifold pressure gauge (Item 35 Fig. 4-1) for pressure setting of the regulator. Set at desired
pressure.
Tighten the locknut of the adjustment handle.
2. Bypass valve assembly - to operate with pressures up to 3000 PSI, the manifold regulator assembly is fitted
with a quick-opening bypass valve (Item 26 Fig. 4-1) that can shut off supply through the manifold regulator
to supply direct accumulator fluid pressure to the ram preventers and gate valves. In normal operation this
valve should be in the regulated LOW pressure position, for pressures up to 3000 PSI, the valve must be in
the HIGH pressure position.
3. Annular Regulator Assembly - The Annular Regulator (Item 34 Fig. 4-1) reduces the accumulator fluid pressure
from 3000 PSI to a maximum of 1500 PSI for the operation of the annular preventer. The annular preventer
is used for stripping operations along with well control. Therefore, it is necessary to consult the annular
preventer manufacturer's recommendation for maximum operating pressure so as to ensure and prolong the
life of the element. The manually operated annular regulator is adjusted in the same manner as the manifold
regulator described above. Read the annular pressure gauge (Item 38 Fig. 4-1) when adjusting pressure
setting of the annular regulator.
The regulation of the annular operating pressure is often needed at an accessible control panel on the drill
floor. This remote operation requires fitting an air regulator on the control manifold to regulate pilot pressure
to the Air Operate Annular Regulator (Item 34 Fig. 4-1).
To remotely regulate the annular operating pressure the unit/remote selector valve (Item 32 Fig. 4-1) must be
in the REMOTE position. To adjust the annular operating pressure from the unit, it must be in the UNIT
position. An air filter is mounted in the 1/4" O.D. tubing supply line of the annular regulator assembly. This filter
must be serviced periodically (see Maintenance Section).
4.4.3
Gauges
The gauges are either 6 inch panel mounted or mud pump style. The panel mounted gauges are connected to the
pressure pickup points by stainless steel tubing. The mud pump style gauges mount directly into the manifold for
pickup points on the annular and manifold pressure. The accumulator gauge pickup point is connected by
stainless steel tubing. Gauges provided on the control manifold are to monitor:
1. Accumulator pressure 0-6000 PSI (Item 38 Fig. 4-1).
2. Manifold pressure, 0-10,000 PSI (Item 35 Fig. 4-1).
3. Annular pressure, 0-3000 PSI (Item 37 Fig. 4-1).
4.4.4
Manifold Piping
Consists of a manifold header, high pressure strainer, bleeder valve and relief valve.
1. Manifold Header (Item 27 Fig. 4-1) - for the control valves; made of 2 inch Schedule 160 pipe and welded so
as to eliminate possible leaks.
2. High Pressure Strainer - to remove debris from the fluid that could damage the regulators and control valves.
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The strainer must be serviced periodically to ensure proper operation (see Maintenance Section).
3. Manifold Bleeder Valve - which is in the closed position during normal operation and is opened to bleed
pressure off the BOP control system before servicing.
4. Manifold Relief Valve (Item 30 Fig. 4-1) - protects the control manifold from pressures in excess of 3300 PSI
that may cause component and system failure or damage.
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
TYPICAL ACCUMULATOR UNIT ASSEMBLY
FIGURE 4-1
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
LEGEND - TYPICAL ACCUMULATOR UNIT ASSEMBLY
TABLE 4-1
Item #
Customer Locations
Item #
Description
Item #
Description
Air Filter
24
Accumulator
Air Lubricator
25
Manifold Regulator
26
27
28
29
Air Cylinders
Reservoir
30
31
Reserved
32
10
33
11
34
12
Electric Motor
35
13
36
14
37
15
38
16
39
Transmitter-Annular Pressure
17
40
Transmitter-Accumulator Pressure
18
41
Transmitter-Manifold Pressure
19
42
20
43
21
22
23
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4.5
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
Gauges
Gauges are provided on the control panel to remotely monitor the operating pressures of the control system. Four
(4) 4-1/2" face gauges are provided on the driller's panel for:
1. Air Supply Pressure, 0-300 PSI (Item 6 Fig. 4-2)
2. Accumulator Pressure, 0-6000 PSI - Receiver type gauge (Item 8 Fig. 4-2)
3. Manifold Pressure, 0-6,000 PSI - Receiver type gauge (Item 7 Fig. 4-2)
4. Annular Pressure, 0-3000 PSI - Receiver type gauge (Item 9 Fig. 4-2)
4.5.7
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
TYPICAL AIR REMOTE CONTROL PANEL
FIGURE 4-2
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
LEGEND - AIR REMOTE CONTROL PANEL
TABLE 4-2
Item
Description
10
Graphic Nameplate
11
Graphic Nameplate
12
Graphic Nameplate
13
Graphic Nameplate
14
Graphic Nameplate
15
Reserved
16
17
Air Filter
18
Fixed Plate Half - Air Junction Box (Rectangular J-Box shown, Round J-Box is STANDARD)
19
Air Lubricator
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4.6
4.7
4.6.1
4.6.2
4.8
ACCESSORIES
There are optional items that can be added to the BOP control system to increase the functional capability. Accessories
include: (1) nitrogen backup system, (2) rig test outlet, (3) rig skid outlet and (4) alarms. The following will provide functional
descriptions and operation instructions:
4.8.1
Nitrogen bottles - charged to 2200 PSI. The nitrogen bottles connect to the manifold on the high pressure
supply side of the manifold regulator bypass valve. This direct the nitrogen pressure to flow through the
control valve(s) to operate the preventers even though hydraulic pressure is not available. The bottle
valves are in full open position during normal operation.
b.
Shut-off valves - which are closed during normal operation, and must be manually opened to begin
nitrogen flow. This valve location should be familiar to operator personnel to enable quick and correct use.
c.
Check valves - which direct nitrogen toward control valves only and do not allow back-flow to fill up the
accumulators.
d.
Nitrogen pressure gauge - 0-5000 PSI. This gauge reading should be observed daily. Nitrogen pressure
should be maintained at 2200 PSI.
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2. To operate the nitrogen backup system during emergency situations.
4.8.2
a.
Move the Manifold Regulator Bypass Valve (Item 26 Fig. 4-1) to HIGH pressure position. Perform this
operation from point of quickest access. If possible operate from the remote panel before power supplies
are shut down.
b.
Open the nitrogen system shutoff valve. This operation must be done manually at the unit.
c.
Operate the desired ram preventers or gate valves. Do not attempt to operate the annular. Nitrogen flow
is not directed through this function and will only waste time and pressure.
b.
c.
d.
e.
4.8.3
a.
Connect a 6000 PSI line fitted with 6000 PSI bleeder valve (supplied by customer) from rig test outlet to
equipment to be tested and a return line to the reservoir for vented fluid.
b.
c.
d.
Check that Air Pump Suction Valve (Item 11 Fig. 4-1) is open and customer furnished bleeder valve is
closed.
e.
Open the air supply valve for the air pump connected to the rig test outlet and then shut it when test
pressure is reached.
f.
Slowly open customer furnished bleeder valve and vent fluid back to reservoir.
b.
c.
d.
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2. To operate the rig skid outlet to the rig skid outlet:
4.8.4
a.
Connect 3000 PSI line from the rig skid outlet to the rig skid control manifold and a return line to the
reservoir from the rig skid control manifold.
b.
c.
d.
Operate the control valves of the rig skid manifold several times to purge the system of air.
Alarms
Alarm Systems of audio (horn) and visual (flashing red light) signal can be added to the BOP control system.
These alarms require a customer supplied 120 volt AC power supply hookup at installation with cable connection
of 0.375" to 0.500" diameter. The alarms include use of the lamp test/acknowledge button which deactivates the
horn alarm. The flashing red light signals until the system is restored to normal operating conditions. The alarms
are activated by pressure switches.
1. The low accumulator pressure alarm pressure switch is activated when the system pressure drops to 2200
PSI.
2. The low fluid level alarm pressure switch is activated by a float switch in the reservoir. When fluid level is low,
the float switch vents the air supply to the pressure switch.
3. The low air pressure alarm pressure switch is activated when the rig air supply pressure drops to 35-50 PSI.
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
5 MAINTENANCE INSTRUCTION
5.1
INTRODUCTION
A regularly scheduled maintenance Program must be developed to sufficiently maintain the BOP Control System. The
operator must develop an appropriate program based on the operating, testing and drilling programs, The entire control
system should be tested a minimum of once a week, This may simply involve operating alt functions (remotely as well as
from the unit) and noting gauge and meter readings. A good maintenance program must be developed whether the operator
chooses a very simple or a very thorough test program.
Installation, maintenance repairs and adjustments around high pressure and electrical equipment must be done with careful
concentration and caution to ensure the safety of all personnel. Pay particular attention to all notes, cautions, and bold type
words as these are to ensure safety during all phases of equipment use.
PAY PARTICULAR ATTENTION WHEN WORKING AROUND AREAS WITH:
A.
B.
Remove all pressure from lines before disconnecting Fittings or splicing. Verify line pressure is released
before attempting to disconnect.
b.
Protect system and lines when welding in nearby areas. Weld solder will damage the hose as well as
contaminate the system fluid.
B.
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5.2
Part Number
Use
001-1000
001-1012
001-1010
Spanner Wrench
001-1011
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5.3
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WARNING: USE NITROGEN ONLY - DO NOT USE OXYGEN!
A.
Remove the valve guard and secondary valve cap from the
accumulator and attach a Charging and Gauging Assy. (Part
No. 001-1000) .
B.
2.
C. Remove charging and gauging Assy. and check valve core for
leaks.
D. Replace valve guard and secondary valve cap on accumulator.
CHARGING AND GAUGING ASSEMBLY PARTS LIST
Item
P/N
Assy.
001-1000
Description
Qty.
1
001-1030
601-1001
Swivel Connector
601-1002
601-1003
Hose
601-1004
Coupler
601-1005
Nut
601-1006
Gland
601-1038
Tank Valve
601-1037
Adapter
10
601-1036
Air Chuck
11
601-1039
Bleeder Valve
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5.4
NOT APPLICABLE
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5.5
ACCUMULATOR UNIT
5.5.1
Fluid Reservoir
1. The fluid reservoir should be checked regularly, drained, and cleaned to eliminate sludge build-up. The control
fluid should be kept clean and free of debris. A high quality SAE 10W hydraulic oil or a suitable light weight
oil should be used in the system. NEVER use fuel oil, kerosene, or salt water in the reservoir.
2. To clean the reservoir use the following procedure:
a.
b.
c.
d.
e.
Stop pumps.
Open manifold bleeder valve and release system pressure.
Drain the fluid from the system. Remove any sludge/slime or other material from the reservoir.
Flush the entire system with 140 Deg. F hot water (60 Deg. C).
Circulate a mixture of hot water and Trisodium phosphate (2 pounds in 5 gallons water) until the sludge
and oil are removed from the metal parts.
5.6
5.5.2
Relief Valves
Check the high pressure relief valve(s) for leaks. Open the 4"inspection ports on the side of the reservoir and
check the vent lines from the relief valves for leakage.
5.5.3
Piping
Visually check all fluid lines and connections for possible leaks.
5.6.2
Air Lubricator
1. Check the air lubricator to make sure it is full of SAE 10W lubricating oil.
2. Open the petcock of lubricator to drain moisture that may have accumulated.
3. Check that drip setting flows 6 drops per minute. To adjust setting (See Troubleshooting Section).
5.6.3
Filters
1. Drain and flush accumulated moisture. Open the manual drain on the filter housing, as pumps are running.
2. Clean elements.
a.
b.
c.
d.
Stop pumps.
Unscrew housing, lift out O-Ring and louver.
Remove filter elements and wash in warm water or kerosene. Dry elements and check that bowl gasket
is in good condition.
Replace parts and housing.
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5.6.4
Strainers
1. Clean "Y" strainers. Ensure lines are free of pressure before attempting maintenance.
a.
b.
c.
d.
e.
f.
g.
h.
i.
Stop pumps.
Close pump suction valves.
Remove "Y" strainer plugs.
Remove strainer elements.
Open pump suction valves to flush piping, then close valves.
Clean strainer elements in warm water or kerosene.
Replace elements and "Y" strainer plugs.
Open pump suction valves.
Start pumps.
5.6.5
Pump Packing
The pump packing is spring loaded and spring adjusted. No maintenance is required.
5.6.6
Air Exhaust
1. Clean sludge buildup.
2. Check end caps for leaks.
5.7
ELECTRIC PUMPS
5.7.1
Pump Start Up
(1) Close air supply valves.
(2) Remove the explosion-proof cover of electric pressure switch.
(3) Open manifold bleeder valve and bleed system pressure to desired start-up pressure.
(4) Close manifold bleeder.
(5) Move the adjustment wheel upward until the pump comes on, reaches shutoff pressure, and stops.
(6) Open manifold bleeder and check that start-up is at proper pressure.
(7) Close manifold bleeder valve.
(8) Replace explosion-proof cover.
(9) Open air supply valves.
b.
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2. To replace limit switch:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Replace with new tube and switch assembly from the repair kit. If replacing the limit switch only:
(1) Remove the screws of switch mounting bracket to bourdon tube.
(2) Pull off switch assembly.
(3) Replace new switch assembly to bourdon tube.
(4) Replace mounting bracket screws.
j.
k.
l.
5.7.2
n.
o.
p.
q.
r.
Crankcase
1. Check the pump crankcase to make sure it is full of good, clean engine oil. (Weight will vary depending on the
ambient temperature.)
DUPLEX AND TRIPLEX PUMP CRANKCASE OIL SPECIFICATIONS
Pump Model
Capacity (Qts.)
DPE21-05
DPE21-07
TPE06-10, TPE06-15,
TPE06-20, TPE21-25
Oil Type
4
5-1/2
TPE21-30
TPE21-40, TPE21-50,
TPE21-60
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5.7.3
Chain Guard
1. Remove the lower drain plug and check for water or sludge build-up.
2. Check the oil level in the oil bath chain guard. It should be filled up to the spill plug.
a.
b.
5.7.4
Motor Bearings
Disassemble motor and lubricate bearings.
5.7.5
Pump Packing
The packing glands should be right enough to eliminate leaking and loose enough to lubricate the plungers with
a fine oily film. OVER TIGHTENING THE PACKING WILL DAMAGE THE MOTORS.
5.7.6
Strainers
1. Clean "Y" strainers. Ensure lines are free of pressure before attempting maintenance.
a. Stop pumps.
b. Close pump suction valves.
c. Remove "Y" strainer plugs.
d. Remove strainer elements.
e. Open pump suction valves to flush piping, then close valves.
f. Clean strainer elements in warm water or kerosene.
g. Replace elements and "Y" strainer plugs.
h. Open pump suction valves.
i. Start pumps.
5.8
CONTROL MANIFOLD
5.8.1
Regulators
1. Fully operate the regulating valve through the entire operating pressure range and reset to the desired
operating pressure. Vary the setting to eliminate permanent seating wear to the shear seals (See Operation
Section).
2. Apply 10 W oil to regulator adjustment screws.
3. Check that surge dampener contains 400 PSI nitrogen precharge. (WARNING: DO NOT USE OXYGEN)
5.8.2
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5.8.3
Air Cylinders
1. Clean piston rods of corrosion by wiping with an emery cloth.
2. Lubricate the piston rods on the air cylinders with a good quality silicone based lubricant.
3. Grease the mounting bolt on the air cylinder.
5.8.4
Filters
1. Drain and flush accumulated moisture. Open the manual drain on the filter housing, as pumps are running.
2. Clean elements.
a.
b.
c.
d.
e.
5.8.5
Stop pumps.
Unscrew housing, lift out o-ring and louver.
Remove filter elements and wash in warm water or kerosene.
Dry elements and check that bowl gasket is in good condition.
Replace parts and housing.
Gauges
1. Check that system pressures are maintained at proper levels.
2. When there is no pressure in system ensure that gauges are properly zeroed. On panel mount style gauges,
use zero adjustment screw on gauge face to zero needle.
3. When system is pressurized ensure that gauges on the Control Manifold match gauges on the remote control
panel(s).
5.8.6
Air Transmitters
1. The air regulator for the air transmitters should be set a 15 psi.
2. If gauges on the Control Manifold do not match the readings of the air receiver gauges on the air remote
control panel(s), adjust the setting of the transmitter air regulator until readings correspond.
5.9
AIR PANELS
5.9.1
Air Lubricator
1. Check the air lubricator to make sure it is full of SAE 10W lubricating oil.
2. Open the petcock of lubricator to drain accumulated moisture.
3. Check that drip setting flows 6 drops per minute. To adjust setting see Troubleshooting Section.
5.9.2
Air Filter
1. Drain and flush accumulated moisture. Open the manual drain on the filter housing, as pumps are running.
2. Clean elements.
a.
b.
c.
d.
e.
Stop pumps.
Unscrew housing, lift out O-ring and louver.
Remove filter elements and wash in w-arm water or kerosene.
Dry elements and check that bowl gasket is in good condition.
Replace parts and housing.
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5.9.3
Gauges
1. Ensure that gauges are properly zeroed when there is no pressure in the system. Use zero adjustment screw
on face of gauge to zero needle.
2. If the readings of the air receiver gauges on the air remote control panel do not match the readings of the
gauges on the Control Manifold, adjust the setting of the transmitter air regulator until readings correspond.
5.9.4
Check-Out
1. Visually check ail connections for possible leaks.
2. Repair as necessary.
5.10
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6 ACCUMULATOR UNIT TROUBLESHOOTING GUIDE
INTRODUCTION
The purpose of the Accumulator Unit Troubleshooting Guide is to enable the Unit Operator to quickly identify and correct specific
malfunctions. The action(s) taken will result in minimum downtime and prevention of additional damage to the Unit.
This Guide will also help you better understand the systems and components which make up the BOP Control System.
Although the information in this Guide is comprehensive, other problems may arise for which there are no listed remedies. As these
are solved, either locally or with the aid of a Field Service Technician, all steps taken should be documented and inserted into the
System Operating Manual.
Some repairs may void the MANUFACTURER'S WARRANTY on certain components. Before such repairs are contemplated,
contact us by email, fax or phone and write down the time, date and person contacted, as well as the subject discussed. This
information may be vital for future reference.
The Troubleshooting Guide contains information presented in three (3) categories:
1. Problem - Specific problems or general problem areas for a specific component.
2. Probable Cause - The most common cause(s) for a given Problem.
3. Remedy - Step-by-step description of the proper corrective action to be taken.
In preparing this Troubleshooting Guide, it is assumed that normal preventative maintenance procedures have been followed. This
includes the use of clean and dry air and maintaining a sufficient level of properly prepared hydraulic fluid.
It may be necessary to consult other sections of the manual to become familiar with the BOP Control System. For a general system
overview, consult the INTRODUCTION SECTION. The OPERATION SECTION includes a more detailed description of the system
operation.
Pay particular attention to notes, cautions and bold type words as these are added to ensure safety during all phases of equipment
use.
The instructions below are major steps that must be performed during the maintenance and troubleshooting procedures. Wherever
these instructions are given, refer to these steps.
Stop Pumps
a. Close air supply valves.
b. Turn triplex pump motor starter to OFF position.
Start Pumps
a. Open the air supply valves.
b. Turn triplex pump motor starter to AUTO position.
NOTE:
THE TROUBLESHOOTING PROCEDURES SHOULD BE PERFORMED ONLY AT TIMES THAT WILL NOT AFFECT THE SAFETY
OF DRILLING OPERATIONS. REMEMBER TO REPLENISH THE FLUID SUPPLY AFTER FLUSHING LINES.
CAUTION:
DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO BOP CONTROL SYSTEM.
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6.1
ACCUMULATOR PROBLEMS
Ref.
Problem
Ref.
Possible Cause
1A
1.
Remedy
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
2.
Ruptured bladder
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Stop pumps
Open manifold bleeder valve and relieve all
system pressure
Check precharge pressure on each
accumulator and record
Tighten valve cores snugly with valve core tool
Precharge each accumulator with 1,000 PSI of
nitrogen, starting with accumulator that had
highest recorded pressure. This will conserve
nitrogen. (WARNING: DO NOT USE
OXYGEN)
Observe precharge pressure on precharge
gauge. If pressure does not decrease, remove
gauge
Check all precharge valves for gas leaks by
placing drops of saliva across tops of valves
(light oil may also be used.)
If valve:
bubbles, nitrogen is escaping. Replace valve
core. (See Maintenance Section.)
does not bubble, accumulators are ready for
normal use
Close manifold bleeder valve
Start pumps. Stop pumps
Stop pumps
Bleed fluid system pressure by slowly opening
bleeder valve
Listen for poppet valves to close while
observing accumulator pressure gauge
If poppet valves do not close at precharge
pressure, and pressure continues to drop to
zero, at least one accumulator has lost its
precharge
Check and record precharge pressure of each
accumulator
Those with zero precharge may have faulty
bladders. To check this
Tighten valve cores snugly with valve core tool;
Precharge with 200 PSI of nitrogen. If pressure
does not decrease;
Precharge with 1,000 PSI of nitrogen
If an accumulator does not sustain 200 PSI
precharge, the bladder is ruptured and must be
replaced. (See Maintenance Section.)
Close manifold bleeder valve
Start pumps
Page 49 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
Problem
Ref.
Possible Cause
1B
1.
Remedy
1.
2.
3.
4.
2.
1.
2.
3.
4.
1C
1.
1.
2.
3.
4.
5.
6.
1D
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page 50 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.2
Ref.
Problem
Ref.
Possible Cause
Remedy
2A
1.
No lubricant in bowl
2B
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
2C
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Page 51 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.3
PUMP PROBLEMS
Ref.
3A
Problem
Pumps Run Excessively
Ref.
Possible Cause
1.
Remedy
1.
2.
3.
4.
2.
1.
2.
3.
4.
5.
6.
7.
3.
1.
2.
3.
4.
5.
6.
7.
8.
4.
1.
2.
3.
4.
5.
6.
5.
1.
2.
3.
4.
Page 52 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
Problem
Ref.
6.
Possible Cause
Regulator Leaking
Remedy
1.
2.
3.
7.
1.
2.
3.
8.
Visually inspect:
1.
All piping and connections on the accumulator
unit
2.
All connecting lines to the BOP stack
3.
Relieve all system pressure
4.
Repair all fluid leaks
Page 53 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
Problem
Ref.
9.
Possible Cause
Loss of precharge pressure
Remedy
1.
2.
3.
4.
5.
6.
7.
8.
3B
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
2.
Stop pumps
Bleed fluid system pressure by slowly opening
bleeder valve
Listen for poppet valves to close while
observing accumulator pressure gauge
If poppet valves do not close at precharge
pressure, and pressure continues to drop to
zero, at least one accumulator has lost its
precharge
Check and record precharge pressures of each
accumulator. Those with zero precharge may
have faulty bladders. To check this:
a. Tighten valve cores snugly with valve core
tool
b. Precharge with 200 PSI of nitrogen. If
pressure does not decrease
c. Precharge with 1000 PSI of nitrogen
If an accumulator does not sustain 200 PSI
precharge, the bladder is ruptured and must be
replaced (See Maintenance Section.)
Close manifold bleeder valve
Start pumps
Stop pumps
Close accumulator isolator valves
Make sure air bypass valve is tightly closed
Open manifold bleeder valve to relieve system
pressure
Close manifold bleeder valve
Open air pump supply valves
Adjust pump shutoff pressure setting (See
Maintenance Section) until pump stops running
when the desired fluid pressure has been
reached on accumulator gauge
Bleed off manifold pressure through bleeder
valve and repeat procedure to check accuracy
of setting
Open accumulator isolator valves
Turn motor starter to AUTO position
Page 54 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
3C
Problem
Ref.
1.
Possible Cause
Faulty check valve in air pump
Remedy
If pump discharge pressure reaches a certain point
and pump still continues to run, the check valve in the
pump is stuck in open position or has been damaged:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
2.
1.
2.
3D
1.
2.
3.
Fluid Contamination
1.
2.
3.
4.
5.
Stop pumps
Close isolator valves with pressured up
accumulators
Open bleeder valve and bleed off manifold
pressure
Remove suspected air pump
Clean, repair, or replace as necessary
Reinstall pump
Start air pump and operate with bleeder valve
open to make sure that the pump is properly
primed
Close bleeder valve
Open isolator valves
Start pumps and pressure up system
Page 55 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
3E
Problem
Pumps Leaking
Ref.
Possible Cause
Remedy
1.
2.
Replace packing
3.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Stop pumps
Close pump suction valve
Remove valve cover plate
Remove and inspect valve cover gaskets
Replace gaskets if they appear to be distorted,
washed out, or compressed excessively
If gaskets appear to be good, invert and
reinstall
Replace cover plate and tighten bolts
Open suction valve
Open manifold bleeder valve
Turn motor starter to AUTO position
Operate pump and check for new leaks
Open air supply valves
Close manifold bleeder valve
Page 56 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.4
Ref.
4A
Problem
Motor Fails to Start
Ref.
1.
Possible Cause
Pressure Switch Faulty
Remedy
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
2.
Starter Tripped
3.
1.
2.
3.
4.
4B
1.
Voltage Fluctuation
3.
2.
Page 57 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.5
Ref.
5A
Problem
Inter-flowing
Ref.
1.
Possible Cause
Debris in the Valve
Remedy
1.
2.
3.
4.
5.
6.
2.
1.
2.
3.
3.
1.
2.
4.
Actuator faulty
1.
2.
3.
4.
5.
5.
Insufficient Pressure
Stop pumps
Open manifold bleeder valve
Dislodge debris by manually shifting the valve
handle through the full range
Repair shifting several times until Interflow has
been cleared up
Close manifold bleeder valve
Start pumps
Remove and replace the valve
Use special repair kits containing necessary
parts for overhaul
The maintenance instructions supplied with the
kit must be consulted for proper assembly.
Improper or reverse assembly can result in high
pressure and cause injury
Adjust clevis locknut so actuator rod obtains full
travel
Check lever travel
a. Start pumps
b. Pressure up system
c. Operate function from remote panel
Remove cylinder
Inspect for debris, wear or other damage
If dirt wiper is blown out, either:
a. The rod seal is leaking
b. There is excess grease in the grease fitting
Repair or replace as necessary
Replace cylinder
Page 58 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.6
GAUGE PROBLEMS
NOTE: ACCEPTABLE INDICATION LIMITS ARE 50 PSI FROM TRUE PRESSURE.
Ref.
Problem
Ref.
6A
1.
Possible Cause
Shock due to rough treatment
Remedy
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Gauge Out of Adjustment
Accumulator Pressure Gauges
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Gauge Out of Adjustment - Fluid
Filled Gauges
1.
1.
2.
Page 59 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
6B
Problem
Ref.
Possible Cause
Remedy
1.
1.
1.
2.
3.
4.
5.
6.
7.
8.
Page 60 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.7
REGULATOR PROBLEMS
Ref.
Problem
Ref.
Possible Cause
Remedy
7A
1.
2.
3.
Page 61 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Ref.
Problem
7B
Ref.
Possible Cause
Remedy
1.
3.
2.
1.
2.
3.
4.
Page 62 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
6.8
Ref.
8A
Problem
Slow or No Function Operation
Ref.
Possible Cause
Remedy
1.
2.
3.
Faulty Actuator
4.
5.
6.
Leaking Control
Connections
or
8B
1.
8C
1.
8D
1.
Page 63 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
7 STORAGE INSTRUCTIONS
7.1
INTRODUCTION
It sometimes is necessary to store BOP Control System equipment for periods up to one (1) year. To minimize recondition
time and cost following storage, it is necessary to properly prepare the equipment for storage. This preparation is required
because the systems are designed for continuous operation. In storage the normal lubricating systems cannot provide
protection against internal corrosion over long periods of time. Most problems encountered during storage relate to internal
and external corrosion. The following procedures give instructions for preparing the BOP Control System equipment for
storage. These procedures are divided into three (3) categories:
7.2 Initial Preparation
7.3 Final Preparation
7.4 Checkout and Reconditioning
Each category has instructions relating to the individual subassemblies of the system. This ensures that each component
is properly prepared and protected for storage.
Personnel performing the preparation operations should be familiar with the normal system operation and maintenance
requirements. The procedures required the use of special preserving fluids which should be obtained to insure optimum
results.
Some principles in the preserving procedure should be followed even during temporary storage of the equipment. However,
it is not intended to replace normal maintenance functions. It also will not eliminate all possible component malfunctions.
7.2
INITIAL PREPARATION
There are several pre-storage operations that must be performed while power is still connected to the BOP Control System.
The pumps must be operational to circulate a rust preventive fluid to protect the internal surfaces of the control system.
7.2.1
7.2.2
Internal Protection
1. Add sufficient quantity of rust preventive fluid into the reservoir to pressurize system (approximately 150 gallons).
Use BOP Control Rust Shield or equivalent.
2. Fill electric pump crankcase with internal combustion engine preservative and break-in fluid that meets
specification MIL 21260-B.
3. Open air supply valves and turn electric motor starter to AUTO position.
4. Circulate the rust preventive fluid for 2-3 minutes then close manifold bleeder valve and allow system to pressure
up to 3,000 PSI.
5. Alternately open and close all the 4-way control valves manually from the control manifold.
6. Manually adjust both regulators on the control manifold through their full operating range 2-3 times.
7. Alternately open and close all the 4-way control valves by using the push buttons on the electric control panel.
Page 64 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
8. Adjust the annular regulator Increase/Decrease push button through its full operating range 2-3 times from the
electric control panel.
9. Turn off pumps by closing air supply valves and turning electric motor starter to OFF position.
7.2.3
10.
Open manifold bleeder valve to vent all fluid pressure in the system.
11.
Drain the rust preventive fluid form the reservoir. This fluid should be retained as it will be used in later
operations to protect the external surfaces of the equipment.
Disconnect Panel
1. Turn off circuit breaker on solenoid valve box.
2. Disconnect cable connector from solenoid valve box and install protective cap on both the receptacle and plug
assemblies.
7.2.4
Disconnect System
1. Turn off main air compressor supply to BOP Control System.
2. Turn of power to electric motor starter at main generator panel.
7.3
FINAL PREPARATION
The BOP Control System equipment can be moved to a suitable storage location if necessary to complete the final stages
of preparation for long term storage. If the equipment is to remain on sit, all possible steps should be used to protect the
equipment from severe environmental conditions. This includes no direct sunlight and protective cover from moisture in the
air. The equipment should also be protected from any collection of ground moisture.
7.3.1
Accumulators
1. A 1,000 PSI pre-charge of nitrogen should be maintained on the accumulators during storage.
2. Check each accumulator pre-charge and add nitrogen if necessary.
7.3.3
Page 65 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
7.3.4
Manifold Assembly
1. Place all lever operated control valves in OPEN (handle-left) position. This includes bypass, Unit/Remote
selector and accumulator isolator valve.
2. Grease exposed cylinder shaft with rust preventive grease.
3. Open manifold bleeder valve.
4. Adjust regulator handles counterclockwise as far as possible.
5. Ensure that pre-charge on surge dampener is 400 PSI.
7.3.6
Transformer Box
1. Plug all openings.
2. Open transformer box door and install fresh supply of corrosion inhibitor ad check that drain and breather
plugs are open. Close door.
7.3.7
7.3.8
7.3.9
Accumulator Unit
1. Inspect all painted surfaces for unprotected metal. These spots should be sanded, primed and painted before
storage.
2. Use BOP Control Rust Shield or equivalent to coat (spray) entire external surface of accumulator unit.
3. Remove chain guard cover to spray chain and sprockets then replace cover.
Page 66 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
7.3.11 Electric Panel
1. Panel should be stored to protect it from direct sunlight and external environmental conditions. This includes
ground moisture.
2. Panel should be stored in the vertical position.
3. Replace protective cap on connector receptacle.
4. Plug all openings.
5. Open panel door and install fresh supply of corrosion inhibitor and check that drain and breather plugs are
open. Coat all contacts with dry film electrical lubricant. Close door.
7.4
7.4.2
Recondition
1. The BOP Control System should be checked using the normal installation procedures. All operational
characteristics should be checked prior to subjecting them to actual load conditions.
2. The electric pump crankcase fluid should be replace after it has been run for twenty - thirty minutes. This will
allow the special preservative and break-in fluid to re-coat all the internal parts.
Page 67 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
8 REFERENCE MATERIAL
8.1
Page 68 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
8.2
ELECTRICAL SYMBOLS
Page 69 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
8.3
ABBREVIATIONS
ADJ . . . . . .
AMB . . . . .
AR . . . . . . .
ASME . . . .
ASSY . . . .
AWG . . . . .
BOP . . . . .
BRZ . . . . . .
/C .......
CD PL . . . .
CFM . . . . .
CFS . . . . . .
CG . . . . . .
CHK . . . . .
CLN . . . . . .
DR . . . . . . .
EH . . . . . . .
EP . . . . . . .
/F .......
GPM . . . . .
HP
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Hz
ID . . . . . . . . . . . . . . . . . . .
INC/DEC
K ...
MTD
NC . .
NO .
NPT .
OD .
PL . .
PPM
PSI .
RPM
SAE .
SCH
SPM
STD .
UNC
VAC
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VDC . . . . . . . . . . . . . . . . .
WOG . . . . . . . . . . . . . . . . .
adjust
ambient
as required
American Society of Mechanical Engineering
assembly
American Wire Gage
blowout preventer
bronze
Celsius scale for temperature measurement
cadmium plate
cubic feet per minute
cubic feet per second
center of gravity
check
clean
drain
electro-pneumatic
electro-pneumatic
Fahrenheit scale for temperature measurement
gallons per minute
horsepower - A unit for measuring the power of motors. One horsepower equals 33,000
foot-pounds of work per minute.
hertz - Preferred terminology for cycles per second, the frequency of an electrical wavelength.
inside diameter
increase/decrease. The control function that regulates the pressure to be applied to the annular
valve on the BOP stack.
wire abbreviation. Relay coil; signal relay. Constant used to denote insulation resistance.
mounted
normally closed
normally open
national pipe thread
outside diameter
plate - The application of one metal over another.
parts per million
pounds per million
revolutions per minute
Society of Automotive Engineers
schedule - Pipe classifications.
strokes per minute - Sub-plate mounted.
standard
United National Coarse - The measuring standard for pipe threads.
volts alternating current - An electric current that continually reverses its direction, giving a
definite plus and minus wave-form at fixed intervals.
volts direct current - An electrical current that flows in one direction only.
water, oil, or gas
Page 70 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
8.4
GLOSSARY OF TERMS
Ambient Temperature -
Accumulator -
A vessel containing both hydraulic fluid and gas stored under pressure as a source
of fluid power to operate opening and closing of blowout preventer rains and
annular preventer elements. Accumulators supply energy for connectors and
valves remotely controlled.
Accumulator Unit -
The assembly of pumps, valves, lines accumulators, and other items necessary
to open and close the blowout preventer equipment.
The opening and closing device located upstream of the accumulators in the
accumulator piping which stops flow of fluids and pressure in piping.
The automatic device located in the accumulator piping that opens when the preset
pressure limit has been reached so as to release the excess pressure and protect
the accumulators.
Air Breather -
A device permitting air movement between the atmosphere and the component in
which it is installed.
The opening and closing device located in the air supply line which blocks air flow
in one line to be redirected through another. In open position, air flow is not routed
through the air pressure switch for automatic shutoff thereby allowing the air
pumps to continue to run.
The opening and closing device located in the piping line that draws fluid from the
reservoir into the fluid end of the pump when the air motor is operating.
Air Regulator -
The adjusting device to vary the amount of air pressure entering as to the amount
to be discharged down the piping lines.
The opening arid closing deice in the connecting line of the compressed air routed
to flow into the accumulator system lines as a power source for components.
Ampere -
The unit used for measuring the quantity of an electric current flow. One ampere
represents a flow of one coulomb per second.
Annular -
A large valve, usually installed above the rain preventers, that forms a seal in the
space between the pipe in a wellbore, the outer wall of which may be the wall of
either the borehole or the casing.
Annular Regulator -
Blowout Preventer -
The equipment installed at the wellhead to enable the driller to prevent damage at
the surface while restoring the balance between the pressure exerted by the
column of drilling fluid and formation pressure. The BOP allows the well to be
sealed to confine the well fluids and prevent the escape of pressure either in the
annular space between the casing and drill pipe or in an open hole. The blowout
preventer is located beneath the rig at the land s surface on land rigs or at the
water s surface on jack-up or platform rigs and on the sea floor for floating offshore
rigs.
BOP Stack -
The assembly of well control equipment including preventers, spools, valves, and
nipples connected to the top of the casing head.
Page 71 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Baffle -
Bleeder Valve -
Blowout -
A uncontrolled flow of gas, oil, or other well fluids into the atmosphere. A blowout,
or gusher, occurs when formation pressure exceeds the pressure applied to it by
the column of drilling fluid.
Chain Guard -
The metal enclosure surrounding the electric pump driving chain to protect and
contain an oil lubricate for the chain.
Check Valve -
Choke -
A variable diameter orifice installed in a line through which high pressure well fluids
can be restricted or released at a controlled rate. Chokes also control the rate of
flow of the drilling mud out of the hole when the well is closed in with the blowout
preventer and a kick is being circulated out of the hole.
Circuit Breaker -
Conductivity -
Conductor -
Contact Block -
The conductor located in the electric panels which bring together the electrical
connections of the operation pushbuttons with those of the operator valves.
Continuity -
Control Manifold -
The system of valves and piping used to control the flow of pressured hydraulic
fluid to operate the various components of the blowout preventer stack.
Corrosion Inhibitor -
Cylinder -
A device which converts fluid or air power into linear mechanical force and motion.
It consists of a movable element such as a piston and piston rod, plunger rod,
plunger i rain, operating within a cylindrical chamber.
The device located in the expelling line of a pump (air or electric) which allows fluid
to flow out only and thereby prevents a back flow of fluid into the pump.
Drain Port -
The plugged openings on the lower side portions of the reservoir which can be
opened to empty or release the hydraulic fluid, and through which the reservoir can
be cleaned.
Dust Cap -
The screw on covering for the electric panel connector receptacles which protect
the electrical contacts from foreign matter and moisture.
The opening and closing device located in the piping line that draws fluid from the
reservoir into the pump inlet when the motor is operating.
Element (Filter) -
The substance o porous nature which retains foreign particles that pass through
the containing chamber to separate and clean the gas or liguid flow.
Fill Port -
The plugged opening in the top of the fluid reservoir through which hydraulic oil is
added.
Page 72 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Filter (Air) -
Filter (Hydraulic) -
Flow Rate -
The volume, mass, or weight of a fluid passing through any conductor, such as
pipe or tubing, per unit of time.
Flowmeter -
A device which indicates either flow rate, total flow, or a combination of both, that
travels through a conductor such as pipe or tubing.
Fluid -
A substance that flows and yields to any force tending to change its shape. Liquids
and gases are fluids. The accumulator system pressurizes fluid to be used as a
source of power to open and close valves and rams on the BOP stack.
Function -
The term given to the duty of operating the control valves of the accumulator
system. The action performed by the control valves when operating the ream
preventers or gate vales.
Gage -
Gauge -
An instrument for measuring fluid pressure that usually registers the difference
between atmospheric pressure and the pressure of the fluid by indicating the effect
of such pressures on a measuring element (as a column of liquid, a bourbon tube,
a weighted piston, a diaphragm, or other pressure-sensitive devices).
Gland -
Ground -
Hydrostatic -
Indicating Light -
The bulbs of the electric control panels that shine to point out which electrical
contacts have made a circuit. The electric panel bulbs make circuit contacts
through pressure switches, transducers, and solenoid valves to demonstrate
activation.
Inspection Port -
The plugged openings on the sides of the fluid reservoir which can be opened to
view the interior fluid level and return lines from the relief, bleeder, control valves,
and regulators.
Insulation -
Kick -
The increase in pit volume caused by the entrance of formation liquids or gas in
the wellbore. Without corrective measures, this condition can result in a blowout.
Kill Line -
A high-pressure fluid line connecting the mud pump and the wellhead at some
point below a blowout preventer. This line allows heavy drilling fluids to be pumped
into the well or annulus with the blowout preventer closed to control a threatened
blowout.
Lubricator (Air) -
A device which adds controlled or metered amounts of a substance into the air line
of a fluid power system to prevent or lessen friction.
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BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Manifold Bleeder Valve -
The opening and closing deice in the piping that connects the manifold header and
the reservoir, and which can be opened to release the fluid pressure and Vent it
back into the reservoir.
Manifold Header -
The piping system which serves to divide a flow through several possible outlets.
The 4-Way control valve inlets connect to the piping so that high pressure fluid is
available to pass through any or all of the valves.
Manifold Regulator -
The device located in the manifold header which can vary the amount of pressure
that enters and exits its chamber. The manifold regulator controls the pressure
level of the fluid flowing through and out the 4-Way control valves.
The opening and closing device which blocks flow in one line to be redirected
through another. This valve is located in the manifold piping so that in the open
position the high pressure fluid does not flow through the regulator in the manifold
header, thereby allowing higher pressure fluid to be available to the 4-Way control
valves.
The automatic opening device located on the manifold header that opens when the
preset pressure limit has been reached so any excess pressure is released, thereby
protecting the manifold bleeder.
Meter -
Printed circuit board used with the electrical meters to provide the circuits
necessary for calibration meter.
Micron -
(A millionth of a meter or about 0.00004 inch). The measuring unit of the porosity
of filter elements.
Mil -
A measurement used in determining the are of wire. The area of a circle one
1/thousandth inch in diameter.
Motor starter -
Automatic device which starts or tops the electric motor driving the duplex or triplex
pump which works in conjunction with the automatic electrical pressure switch for
pressure limits or pump start-up and shutoff.
Needle valve -
A shutoff (2-Way) vale that incorporates a needle point to allow fine adjustments.
Ohm -
Ohmmeter -
Petcock -
Pipe rack -
The connecting pipelines between the control valve outlets and the BOP stack
preventers which carry the high pressure operating fluid. The lines of pipe are laid
together and are often covered with a grating to crate a walkway.
Potable -
The automatic device to start and stop the air pump operation when the preset
pressure limits are reached.
Page 74 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Pressure Switch (Electric) -
Pressure Transmitter -
Device which sends a pressure signal to be converted and calibrated to register the
equal pressure reading on a gauge. the air output pressure is proportional to the
hydraulic input pressure.
Pump (Air) -
A device that increases the pressure on a fluid or raises it to a higher level by being
compressed in a chamber by a piston operated with an air pressure motor.
Pump (Electric) -
A device that increases the pressure on a fluid and moves it to a higher level using
compression force from a chamber and piston that is driven by an electric motor.
Pushbutton/Indicating Light -
The control valve operates with bulbs on the electrical remote panel which change
and indicate the position of the control valves.
Ram -
The closing and sealing component on a blowout preventer. One of three types blind, pipe, or shear - may be installed in several preventers, mounted in a stack
on top of the wellbore. Blind rams, when closed, form a seal on a hole that has no
drill pipe in it; pipe rams, when closed, seal around the pipe; shear rams cut
through drill pipe and then form a seal.
Recorder -
Regulator -
A device that varies and controls the amount of pressure of a liquid or gas that
passes through its chambers.
Relay -
An electrical device that varies and controls the amount of pressure of a liquid or
gas that passes through its chambers.
Relay Socket -
A device used to interconnect a relay with its circuitry and which allows quick and
easy removal of the relay without special tools.
Reservoir -
The container for storage of liquid. The reservoir houses hydraulic fluid at
atmospheric pressure as the supply for fluid power.
Rupture Disk -
A device whose braking strength (the point at which it physically comes apart)
works to relieve pressure in the system. The rupture disk is contained as a safety
device for the test unit system.
Solenoid Valve -
The explosion proof enclosure, located on the accumulator unit, which contains the
electrically powered actuators for the remote control electrical panel. The box is
wired to the electrical supply, and houses solenoid valves, pressure switches and
transducers.
Span Adjustment -
The control to vary the space between the electrical contact points in the electrical
pressure switch.
Stainer -
A porous material which retains contaminants passing through a line along with the
gas or liquid flow.
Suction Strainer -
The porous element, located in a "Y" shaped fitting of the pump suction lines,
which cleans the hydraulic fluid or air of contaminants before entering the pumps.
Page 75 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Surge Damper -
The one quart capacity bladder accumulator used to absorb the shock and waves
caused by an initial flow of high pressure fluid. Located in the downstream line of
the annular regulator.
Swivel Joint -
A connecting device, joining parts so that each can pivot freely. Swivel joints are
used at the ends of the pipe rack to ease connections to the control valve outlets
and to the BOP stack.
Terminal Strip -
Transducer -
The device located in the solenoid valve box which is actuated by hydraulic
pressure and converts the force to an electrical force for indication on a meter. The
electrical output signals is in proportion to the hydraulic input pressure.
Unit/Remote Selector -
The vale located on the manifold header whose ports allow flow into the annular
regulator. The valve position determines the source of flow supply and
subsequently controls the location of operation.
Valve, Float -
Valve, Manipulator -
A control device having three positions, giving four direction selections for flow
which alternately pressurizes and vents the pressure outlets. The manipulator style
valve vents all pressure outlets when placed in the center position.
Valve, Selector -
A control device having three positions, giving four direction selections for flow
which alternately pressurizes and vents the pressure outlets. The selector style
valve blocks all pressure points if placed in the center position.
Valve, Poppet -
The opening and closing device in a line of flow which restricts flow by lowering a
piston type plunger into the valve passageway.
Valve, Precharge -
The device located on the accumulator bladder ports which open and close for the
nitrogen pressure contained.
Valve, Relief -
Valve, Shutoff -
A valve which operates fully open or fully closed to control the flow through the
lines.
Valve, Shuttle -
A connective valve which selects one of tow or more circuits because flow or
pressure changes between the circuits.
Viscosity -
Watt -
A unit of electrical power; the power of one ampere of current pushed by one volt
of electromotive force.
Zero Adjustment -
The control to move the meter gauge indicator for resetting calibration accuracy.
Control used to make the meter read 0 by applying an offset voltage to the meter
to offset any positive voltage present at the meter, even though there is no
pressure at the input of the transducer.
Page 76 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
8.5
CONVERSION FACTORS
TO CONVERT
UNIT(1)
TO UNIT(2)
AREA CONVERSIONS
sq. cm.
sq. in.
0.155
sq. cm.
sq. ft.
0.001076
sq. in.
sq. cm.
sq. in.
sq. ft.
6.452
0.006944
sq. ft.
sq. in.
sq. ft.
sq. mts.
144
sq. ft.
acres
0.0000229568
sq. ft.
sq. in..
0.00000003587
0.0929
sq. yds.
sq. mts.
0.8361
sq. km.
sq. ml.
0.3861
sq. mts.
acres
sq. mts.
sq. mi.
sq. mi.
sq. ft.
0.000002788
sq. mi.
acres
640
sq. mi.
sq. km.
2.59
acre
sq. ft.
43,560.00
acre
sq. mi.
0.001562
0.0002471
0.00000038610
Page 77 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
TO CONVERT
UNIT(1)
LENGTH CONVERSIONS
cm.
in.
cm.
meters
0.01
in.
cm.
2.54
in.
yds.
0.02778
ft.
cm.
ft.
meters
ft.
miles (stat.)
yd.
ft.
yd.
meters
0.9144
yd.
meters
0.6214
meter
ft.
30.48
0.3048
0.00189
3
39.37
meter
yds.
meter
miles (stat.)
rod
ft.
16.5
mile (stat.)
ft.
5,280.00
mile (stat.)
yd.
1,760.00
mile (stat.)
km
1.609
furlong
ft.
furlong
rods
fathom
ft.
fathom
meters
league
miles (approx.)
Light Years
miles
TO CONVERT
UNIT(1)
POWER AND FLOW CONVERSIONS
TO UNIT(2)
1.094
0.00621
660
40
6
TO UNIT(2)
1.828804
3
0.000000000059
MULTIPLY UNIT(1) BY:
hp.
hp.(metric)
1.014
hp.
watts
745.7
hp.
ft. lbs./min.
33,000.00
hp.
BUTS/min.
42.44
BTU
ft. lbs.
BUTS/min.
hp.
BUTS/min.
watts
watt
hp.
watt
BTU/min.
watt
ft. lbs./min.
kW/hr.
ft. lbs.
kW/hr.
BTU
GPM
CFRN
778.26
0.02356
17.57
0.001341
0.05692
44.26
0.000002655
3415
0.13368
Page 78 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
TO CONVERT
UNIT(1)
PRESSURE CONVERSIONS
TO UNIT(2)
PSI
Atm.
PSI
ft. H2O
PSI
kg./sq. cm
Atm.
ft. H2O
Atm.
PSI
Atm.
kg./sq. cm
1.0333
ft. H2O
Atm.
0.0295
ft. H2O
PSI
0.4335
kg./sq. cm
PSI
14.22
2.307
0.07031
33.9
14.7
TEMPERATURE CONVERSIONS
Fahrenheit F = (9/5 * C) + 32
Kelvin K = C + 273.15
Rankin R = F + 459.67
TO CONVERT
UNIT(1)
VOLUME CONVERSIONS
TO UNIT(2)
2 oz.
approx. drops
(oil)
oz.
cu. in.
oz.
liters
Cu. in.
approx. drops
(oil)
Cu. in.
gallons
Cu. in.
liters
0.01639
Cu. ft.
cu. meter
0.02832
Cu. ft.
liters
Cu. ft.
gallons
Cu. ft.
liters
600
1.805
0.02957
330
0.004329
28.32
7.48052
9.463
Cu. ft.
gallons
gallons
quart
7.48052
gallons
cu. in.
231
gallons
cu. in.
0.1337
gallons
cu. ft.
3.785
ga. (H2O)
lb. (H2O)
liter
gallon
1.057
liter
gallon
1.2642
liter
cu. in.
61.02
barrel (oil)
gallons
42
barrel
gallons
31.5
8.3453
Page 79 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
TO CONVERT
UNIT(1)
WEIGHT CONVERSIONS
TO UNIT(2)
oz.
lbs.
0.0625
oz.
grains
437.5
oz.
grains
28.349527
grams
oz.
0.03527
grams
lbs.
0.002205
grams/ liter
lbs./cu. ft.
0.062427
ft. H2O
lbs./cu. Ft.
lbs.
oz.
62.43
16
lbs.
grams
453.5924
lbs.
grains
7,000.00
lbs.
tons (short)
0.0005
lbs./in.
grams/ cm.
178.6
lbs./ft.
kg./ meter
1.488
lbs./cu. In.
27.68
lbs./cu. ft.
kg./cu. Meter
16.02
lbs./ H2O
gallons
lbs.
Cu. ft.
kg.
lbs.
kg.
tons short)
0.1198
0.01
2.205
0.001102
tons (short)
lbs.
2,000
tons (short)
kg.
907.18486
tons (short)
tons (long)
0.89287
tons (long)
lbs.
2,240.00
tons (long)
kg.
1,016.00
tons (long)
tons(short)
1.12
Page 80 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9 SYSTEM SPECIFIC DRAWINGS
9.1
SYSTEM DRAWINGS
The following Drawings are specific to System Serial Number: 8135.
9.1.1 - Assy. BOP CONTROL SYSTEM, MODEL SSC400-3S11 Dwg. No.: 00000050
9.1.2 - INSTALLATION SPECIFICATION BOP CONTROL SYSTEM, Dwg. No.: 00000064
9.1.3 - Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 1
9.1.4 - Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 2
9.1.5 - SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 1
9.1.6 - SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 2
9.1.7 - Assy. DRILLER'S AIR REMOTE PANEL, Dwg. No.: 00000052
9.1.8 - Assy. AIR HOSE BUNDLE FOR DRILLER'S REMOTE PANEL, Dwg. No.: 00000053
9.1.9 - Assy. HYDRAULIC HOSE, BOP TYPE 1" SIZE X 50 FT. LONG, Dwg. No.: 00000054
Page 81 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.1
Page 82 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.2
Page 83 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.3
Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 1
Page 84 of 91
Page 84 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.4
Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 2
Page 85 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.5
Page 86 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.6
Page 87 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.7
Page 88 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.8
Assy. AIR HOSE BUNDLE FOR DRILLER'S REMOTE PANEL, Dwg. No.: 00000053
Page 89 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
9.1.9
Assy. HYDRAULIC HOSE, BOP TYPE 1" SIZE X 50 FT. LONG, Dwg. No.: 00000054
Page 90 of 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
PO Box 219143
Houston, Texas 77218-9143 USA
Ph: (281) 856-6100
Fax: (281) 856-6200
Parts Sales: sales@entradaintl.com
Service & Technical Support: support@entradaintl.com
Page 91 of 91