Diverter System

Pages
HUGHES KFDS ............................................................................................................. 12
HYDRIL DIVERTER FS 21-500 ..................................................................................... 13
MARINE RISER SYSTEM ............................................................................................. 13
TELESCOPIC JOINTS .................................................................................................. 14
MARINE RISER HANDLING EQUIPMENT ................................................................... 15
MARINE RISER SYSTEM FAILURE ............................................................................. 15
BALL JOINTS, FLEX JOINTS, RISER ADAPTERS ...................................................... 16
FIGURES 1 THRU 22 .................................................................................... 17 thru 129

DIVERTER SYSTEM

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Chapter 1

CHAPTER ONE

Diverter System

he diverter system is designed to divert shallow gas kicks away from the rig and personnel.
The system provides some protection prior to setting the casing string which the wellhead
and B.O.P. stack are installed on.
Any wellbore kick would be diverted through vent lines to the opposite extremities of the vessel,
either port and starboard or fore and aft. The valves in the vent lines must be fully opening and be
selectively sequenced in operation, thereby preventing total shut in of the wellbore, which could
breakdown the weak shallow formations.
The flowline carries the return wellbore fluid flow to either the trip tank, the shale shakers, the
degasser or overboard depending on the drilling operation. Trip tank, shale shaker and degasser
isolation valves are provided to direct the flow as required.
The vent lines tee off the flowline, and vent line isolation valves are provided to direct the flow to
the desired vent line. Vent line selection is dependant upon the prevailing wind direction.

The ideal diverter vent line would be designed without bends, would be as large as practically
possible and be internally flush, thereby keeping back pressure on the wellbore to a minimum.
Since the ideal is not always practical the, API RP64 1991 edition, recommends a minimum vent
line I.D. of 10 inches, with a preferred minimum I.D. of 12 inches or larger for floating vessels.
Figure 1 shows example vent/flowline installations.

HUGHES KFDS
Figures 2 and 2A show the Hughes KFDS diverter system which is the most commonly used.
This system consists of a fixed housing located below the rotary table, with the return mud
flowline permanently attached. A diverter assembly, which contains a hydraulic outer packer, a
removable packer insert which closes and seals around the drill pipe, radial flowline seals and a
mechanism for locking the removable packer insert in place.
All the valves in the system are selectively sequenced in operation. Selective sequencing ensures that when the diverter close function is selected firstly, both vent line isolation valves open
and secondly, the shale shaker and trip tank valves close. This valve sequence is completed prior
to the hydraulic closing pressure being applied to the outer packer and is designed to prevent
total shut in of wellbore pressure, which could result in formation breakdown.

Figure 3 shows a closing pressure graph. It can be seen that the minimum closing pressure
required to effect a seal on 5 inch drill pipe is relative to wellbore fluid pressure.
Minimum closing time is approximately 5 seconds when maximum closing pressure of 1000 p.s.i.
is used. Figure 4 shows how closing time increases as closing pressure is decreased.

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Closing pressure should never be applied to the outer packer unless the packer insert is installed, as
this could rupture the outer packer and cause injury to personnel. As a safety precaution, a pilot
operated check valve should be installed in the packer insert closing circuit. The pilot signal required
to open the check valve and allow hydraulic fluid flow to the outer packer would be provided from the
lock side of the packer insert lockdown dogs. This ensures that the outer packer can only receive fluid
pressure while the packer insert lockdown dogs are in the locked position.
A diverter ball joint or flex joint is required to provide a flexible link between the marine riser
telescopic joint and the fixed diverter housing. The ball/flex joint prevents bending loads being
exerted on the diverter housing and telescopic joint inner barrel, while permitting lateral movement of the vessel from directly over the well. The ball/flex joint has to have the same internal
wellbore pressure rating as the diverter system and must be capable of retaining this pressure at
its maximum design angle. Figure 5 shows the Hughes D R I ball joint.

HYDRIL DIVERTER FS 21-500

Figures 6,7,8, and 9 show the Hydril FS 21-500 diverter system which offers an alternative to the
Hughes KFDS. The permanently attached housing has two separate connections for the mud
return flowline and the overboard vent lines.
The diverter packer piston design is such that in the open position the mud return flowline is open
and the overboard vent line is closed, for normal drilling operations. As the piston is moved to the
closed position the flowline is closed off and sealed by the piston sleeve, the vent line is opened
and the packer element is closed around the drill pipe, all in one operation. As this action is taking
place, the vent line opens prior to the flowline and packer closing fully, which prevents total shut in
of the well. This feature, combined with a specially designed flow selector valve eliminates the
need for selectively sequenced flowline and vent line valves.

MARINE RISER SYSTEM

The main functions of a marine riser system are to provide a return fluid flow path from the
wellbore, i.e. an extension of the wellbore from the seabed, guide the drill string and tools to the
wellhead and provide support for the B.O.P. stack assembly as it is being run to, or retrieved from
the wellhead on the ocean floor.
The marine riser must have adequate strength to withstand:
a)
b)
c)
d)
e)

Dynamic loads while supporting the B.O.P. stack.

Lateral forces from currents and vessel offset.
Cyclic forces from wave and vessel motion.
Axial loads from riser weight, drilling fluid weight and free standing pipe within the riser.
Axial tension from the tensioning system at the surface.

Figure 10 shows the principal forces acting on a marine riser system.

DIVERTER SYSTEM

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The internal pressure rating of the marine riser system should be at least equal to the working pressure of the diverter system, plus the maximum difference in hydrostatic pressure of the drilling fluid
and sea water at the ocean floor. In deep water drilling, riser collapse resistance has to be considered in the event of lost circulation or disconnection of the riser while full of drilling fluid.
Riser pipe connections must have the same strength and pressure integrity as the riser pipe
section and provide a means of quick reliable make up and break out.

Figures 11, 12, 13, and 14 show the Vetco and Cameron riser connectors which use the same
principles in make up. The actuator bolts force locking rings or dogs radially inwards, which engage
mating grooves in the pin end of the connector. By applying the appropriate torque to the actuator bolt,
the pin and box assembly are pre- loaded to the design load rating. By pre- loading the assembly
in this manner the risk of joint separation is minimised, even when the maximum design load is
reached.
A mechanical lock is provided for the actuator bolts to prevent loss of torque due to vibration etc.
The integral high pressure choke and kill lines which provide the high pressure communication
between the B.O.P. stack and the choke and kill manifold on board the vessel, are permanently
installed on the riser joints so that they are simultaneously made up when the riser connector is
made up. Provision is made through the use of test caps, to allow testing of the choke and kill
lines as the riser and B.O.P. are being run to the wellhead.
Lip type seals or chevron type packings are used in the box ends to seal the choke and kill line
connections. The pins of the choke and kill lines have a colmonoy or other hard wearing overlay
which provides high abrasion and corrosion resistance. Colmonoy is a nickel/chrome mixture
applied to the parent metal at approximately 1150 C.
Prior to running the marine riser, the riser pipe connections must be cleaned and inspected for
damage to the sealing surfaces and locking rings etc. The choke and kill line box and pins must
also be inspected for damage.
Periodic N.D.T. inspection should be carried out and results documented under the planned
maintenance program.

TELESCOPIC JOINTS
The telescopic joint is used at the top of the marine riser and has the following functions:
a)

It compensates for vertical motion of the vessel.

b)

It provide a means of connecting the diverter assembly to the riser system.

c)

It provides terminations for the flexible choke and kill lines.

d)

It provides the attachments for the riser tensioning system.

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

The telescopic joint is comprised of an outer barrel which is attached to the top joint of marine
riser and an inner barrel which is attached to the diverter ball joint.
The outer barrel includes the support ring or fixed pad eyes for attaching the riser tensioner lines.
The effective stroke length of telescopic joints varies from 45 feet to 55 feet depending on manufacturer. Telescopic joints normally have the same load capabilities as the riser system in the
closed or fully extended position. Handling of the B.O.P. system, i.e. landing the B.O.P. and riser
string on the wellhead with the inner barrel fully extended, is not a recommended practise, as the
condition of the inner barrel load shoulder or shoe, is not always known.
The inner barrel can be mechanically locked in the closed position for B.O.P. handling, transportation and ease of handling on the rig.
The outer barrel houses pressure energised resilient packing elements which when energised
effect a seal around the inner barrel. These packing elements must have the same internal wellbore
pressure rating as the diverter system. Figures 15, 15A, and 16 show the Cameron and Vetco
telescopic joints.

MARINE RISER HANDLING EQUIPMENT

The handling equipment for marine riser systems is simple in design, but none the less has to be
capable of supporting the full weight of the B.O.P. stack and full marine riser system. The support
spiders are designed to fit the various sizes of rotary tables and generally have four or six support
arms which locate the support flange on the box or pin end of the riser joint, the support arms are
either manually, hydraulically or pneumatically retracted to allow the riser joints to pass through,
or extended to support each joint. Figure 17 shows a manual four arm support spider.
The riser handling tools are basically a pin or box end connector with a transition sub to 5 inch drill
pipe box end, this allows the use of 5 inch elevators directly on the handling tool or if required a
stand of 5 inch heavi-wate drill pipe can be made up to the box end of the tool for landing the
B.O.P. and riser assembly on the wellhead, with the telescopic joint locked in the closed position,
Figure 18 shows the Cameron and Vetco riser handling tools.

MARINE RISER SYSTEM FAILURE

a)

Seal Failure:
Riser pipe connector seal failure causing loss of drilling fluid can have a serious effect
on well control. The resultant loss of hydrostatic head could reduce bottom hole pressure sufficiently to allow the well to flow. This is especially true where high mud weights
are required.
Choke and kill line sealing is also vital to well control. Failure in this area while circulating out a kick could have catastrophic effects on both the rig and personnel.

DIVERTER SYSTEM

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b)

Riser Joint Separation

The results of joint separation are obviously very serious, ranging from the loss of the
B.O.P. assembly to the loss of communication with the well. Some of the causes of joint
separation are:
1)

Human error while making up connections.

2)

Weld failure.

3)

Riser pipe collapse.

4)

Loss of pre-load.

5)

Keyseating of the riser pipe.

In deep water the riser pipe can be collapsed due to the outside hydrostatic pressure of
the sea water when the drilling fluid inside the riser is lost. Loss of drilling fluid can be
caused by:
1)

Lost circulation.

2)

Disconnecting the riser from the B.O.P. while full of drilling fluid.

BALL JOINTS, FLEX JOINTS, RISER ADAPTERS

A flexible joint is required at the bottom of the marine riser system, which will minimise bending
stresses on the marine riser and B.O.P. assembly. This is normally placed at the top of the B.O.P.
assembly and has an angular freedom of up to 10 degrees, which must be accomplished with
minimum resistance even under full load. Ball type joints require a pressure balancing system to
offset unbalanced forces such as tensile load, drilling fluid density and sea water density. This
pressure balancing also lubricates the load-bearing areas of the ball and housing. Figure 19
shows the Hughes CRI ball type joint, Figure 20 shows the pressure balance requirements.
Flex type joints are available which achieve their flexibility by using a series of laminated metal
plates bonded to a resilient material. These flex type joints have the advantage of not being
affected by the unbalanced forces, as do the ball type, and do not require pressure balance or
lubrication, Figures 21 and 21A show the Oil States flex joint.
Riser adapters provide a means of terminating the marine riser at the flex joint. These can be
welded directly to the neck of the flex joint or, in the case of the ball joint, connected with a clamp
hub type arrangement. Figure 22 shows typical riser adapters.

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 1

Vent/Flowline Installations

DIVERTER SYSTEM

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Figure 2

CONTROL SYSTEM
(ON RIG FLOOR)

DIVERTER
HOUSING

DIVERTER
FLOWLINE

BALL (FLEX)
JOINT

MARINE RISER
(BELOW SLIP JOINT)

SLIP
JOINT

Hughes KFDS
Diverter System

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 3

WELL PRESSURE (PSI)

400

5" DRILLPIPE WITH 10" ID INSERT

200

0
0

200

400

600

800

1000

CLOSING CHAMBER PRESSURE (PSI)

MINIMUM PRESSURE TO SEAL WITH REGAN KFDS DIVERTER

Figure 4

CLOSING TIME (SEC.)

15

10

15
5

0
0

200

400

600

800

1000

1200

CLOSING PRESSURE (PSI)

REGAN KFDS DIVERTERCLOSING TIMES
FOR 10" INSERT PACKER CLOSING ON 5" PIPE

DIVERTER SYSTEM

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Figure 5

Hughes "DRI" Ball Joint

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 6

Hydril FS 210 Diverter System

DIVERTER SYSTEM

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1-11

Figure 7

HYDRIL DIVERTER
with integral valve
functions and
switchable target.

STARBOARD
VENT

SHALE
SHAKER

Always open
flow selector

DIVERTER
WITH INTEGRAL
VALVE
FUNCTIONS

PORT
VENT

SEQUENTIAL
DIVERTER
SYSTEM

SHALE
SHAKER

DIVERTER

STARBOARD
VENT

PORT VENT
FLOW
TARGET

Valve Function
1. Diverter valve
2. Flowline valve
3. Block valve
4. Port vent valve
5. Starboard vent valve

A Hydril diverter system significantly decreases risk of malfunction through its integral valve design, top. The upward
movement of one component, the piston, stops upward flow and opens the overboard vent simultaneously. Sequential diverters,
bottom, have remote valves and linkages with sequencing steps which create chances for malfunction.

FLOW SELECTOR
FS DIVERTER

FLEX JOINT

DRILL PIPE

During normal drilling operations,

mud returns flow upward, into the
diverter, and out the flowline outlet.
When diverting, the valve sleeve
moves up and closes the flowline outlet
and opens the ventline to the optional
Flow Selector through which the flow
is directed port or starboard.

Hydril FS 21-500

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 8

Running the diverter and riser.

The diverter and riser are run
through the 49!/2 inch rotary, and
the diverter permanent housing.
The handling tool will support the
weight of the riser and B.O.P. stack
assembly. When the diverter is
latched in place, all diverter functions
are immediately operable. Then the
diverter can be pressure tested with
the handling tool. Internal pressure
is conducted through the top of the
handling tool. The diverter is latched
in place through actuation of four
hydraulically operated, high strength
segments.

HANDLING
TOOL

FS 21-500
MARINE RISER
DIVERTER

HOUSING

PACKING
UNIT

FLOW
LINE

VENT
LINE
DRILL
PIPE

U.S. PATENTS
4,444,401
4,456,062
4,456,063

DIVERTER SYSTEM

SIDE
SEAL

Hydril FS 21-500

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1-13

Figure 9

The Flow Selector is

connected to the vent line.
It always remains open in
preselected position for
downwind discharge.

FLOW
SELECTOR

INSTALLATION
DATA

View C-C
Side Mount

Hydril FS 21-500

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1-14

View B-B
Bottom Mount

DIVERTER

Overboard

Overboard

Vent

Vent

TWO-POSITION
TARGET PLUG

DIVERTER
EXHAUST

U.S. PATENTS
4,566,494

CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 10

TENSIONERS

WAVE
VELOCITY

CURRENT
VELOCITY

RIG FLOOR

TELESCOPIC JOINT

PULL OF
TENSIONERS

NET WEIGHT
OF WAVES
AND CURRENT
FORCES

NET WEIGHT OF
RISER IN WATER

NET WEIGHT OF
MUD IN WATER

NET WEIGHT
OF SUSPENDED
DRILL PIPE
CONNECTOR

BALL JOINT

BOP STACK

GUIDE BASE

Main Forces Acting on Riser System

DIVERTER SYSTEM

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1-15

Figure 11

Vetco Riser Connector

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 12

Vetco Riser Connector

DIVERTER SYSTEM

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1-17

Figure 13

Riser Connector

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 14

Riser Connector

DIVERTER SYSTEM

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1-19

Figure 15

RELEASED

LOCKED

VIEW A-A

DETAIL B

(INNER
BARREL
ENGAGED
IN END
CONNETOR

Cameron Telescopic Joint

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 15A

Packing Element

DIVERTER SYSTEM

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Figure 16

Vetco Telescopic Joint

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 17

Four Arm Support Spider

DIVERTER SYSTEM

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Figure 18

Handling Tools

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 19

Hughes CRI Ball Type Joint

DIVERTER SYSTEM

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Figure 20

Pressure Balance Requirements

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 21

ANTI-ROTATION PINS

FLEXIBLE
URETHANE
SHIELD

ELEMENT RETAINER
FLANGE
STATIC O-RING SEAL

FLEX ELEMENT

WEAR BUSHING

"Oil States" Flex Joint

DIVERTER SYSTEM

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Figure 21A

SHIELD

BACK
FLANGE
O-RINGS

RETAINER
FLANGE
NUTS

NIPPLE
FLEX ELEMENT
ASSEMBLY
ANTI-ROTATION
PIN

RETAINER
FLANGE
STUDS

BACK FLANGE
FLEX ELEMENT
SHIELD
SPACER
BOLTS

WEAR
RING
WEAR RING
ANTI-ROTATION
PIN

SHIELD
SPACER
GUIDES

BODY

RETAINER
FLANGE

"Oil States" Flex Joint

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CHAPTSUBSEA EQUIPMENT TRAINING MANUAL

Figure 22

Typical Riser Adapter

DIVERTER SYSTEM

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