Koomey s&s Manual

CONVENTIONAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL

STEWART & STEVENSON MODEL SSC-400-3S11 SERIAL NUMBER: 8135 FOR

CROSCO INTEGRATED DRILLING & WELL SERVICES Co., Ltd.

THIS PAGE INTENTIONALLY LEFT BLANK

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

6 ACCUMULATOR UNIT TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 ACCUMULATOR PROBLEMS 6.2 AIR SUPPLY PROBLEMS 6.3 PUMP PROBLEMS 6.4 ELECTRIC MOTOR PROBLEMS 6.5 FOUR-WAY VALVE PROBLEMS 6.6 GAUGE PROBLEMS 6.7 REGULATOR PROBLEMS 6.8 AIR REMOTE CONTROL PANEL PROBLEMS

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

9 SYSTEM SPECIFIC DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 SYSTEM DRAWINGS 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

71 77 81 81 82 83 84 85 86 87 88 89 90

SALES AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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

ACCUMULATOR UNIT ASSEMBLY The primary function of the Accumulator Unit is to provide the atmospheric fluid supply for the pumps and storage of the high pressure operating fluid for control of the BOP stack. It includes accumulators, reservoir, accumulator piping and a master skid for mounting of the air operated pump, electric motor driven pumps and the Hydraulic Control Manifold.

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.

AIR PUMP ASSEMBLY The air pump assembly consists of one (1) or more air operated hydraulic pumps connected in parallel to the accumulator piping to provide a source of high pressure operating fluid for the BOP control system. These pumps are available in a variety of sizes and ratios. For proper sizing of the air pump assembly see Pump Sizing Recommendations

1.3

ELECTRIC PUMP ASSEMBLY The electric pump assembly consists of a duplex or triplex reciprocating plunger type pump driven by an explosion-proof electric motor. It is connected to the accumulator piping to provide a source of high pressure operating fluid for the BOP control system. It is available in a variety of horsepower and voltage ranges. For proper sizing of the electric pump assembly see Pump sizing Recommendations.

1.4

HYDRAULIC CONTROL MANIFOLD ASSEMBLY The hydraulic control manifold consists of hydraulic regulators and directional control valves to direct the flow of high pressure operating fluid to control the BOP stack. Two (2) regulators are usually provided, one (1) for the annular preventer and one (1) for the remainder of the BOP stack functions which is called the manifold regulator. These regulators reduce the 3000 psi accumulator pressure to a pressure compatible with the operating limits of the preventers. The directional control valves are usually 1" with an 1-1/2" size available for annular preventers requiring large volumes of control fluid. The manifold also contains gauges for monitoring the control system's operating pressures, a 10,000 psi bleeder valve and a 3500 psi relief valve.

Produced By: Entrada International, Inc. 2002

Page 1 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 1.5

AIR REMOTE CONTROL PANEL(S) Air remote control panels provide partial or complete control and pressure monitoring of the BOP control system. This enables the accumulator unit and hydraulic control manifold to be placed in a safe area so that it can remain operational in emergency conditions. Multiple air remote control panels can be added to a control system with minimal additional cost to enhance the safety of drilling operations. Air remote control panels can be provided in a wide variety of mixes, styles and configurations to meet specific space and operational criteria. All air remote control panels contain a master control valve which must be operated simultaneously with the selected function to initiate operation. They all contain four-way spring centered air control valves and require a customer furnished air supply, air remote control interface assembly and interconnect cable assembly.

1.6

AIR REMOTE CONTROL INTERFACE ASSEMBLY Air remote control interface assemblies are required when an air remote control panel included with the BOP control system. These assemblies contain all the components that must be added to the hydraulic control manifold for air remote operation. These components include air cylinders, fixed plate half of an air junction box and all necessary stainless steel tubing and fittings. For panels with remote regulation and pressure monitoring, these components also include an air regulator, selector valve and a pressure transmitter assembly. When two (2) air remote panels are included on one BOP control system the interface assembly also includes an additional fixed plate half of an air junction box and air shuttle valves.

1.7

INTERCONNECT CABLE ASSEMBLY Air interconnect cables are used to carry signals from the air operated remote control panels to the air interface assemblies on the accumulator unit. They include a customer specified length of a flame resistant multi-conduct air cable. The air cable consists of a spirally wound 3/8" OD polyethylene air tubing in a polyvinyl chloride (PVC) sheath. The junction boxes consist of a hose and half of an air junction box on each end which mate to the fixed plate halves mounted on the air panels and on the air interface assemblies.


Page 2 of 91


SIZING RECOMMENDATIONS - Normal Pressure and/or Standard Service The approach to correctly sizing accumulator units is to provide ample accumulator capacity (fluid stored under pressure) to immediately control the preventers during an emergency. The pumps are designed to charge these accumulators within a reasonable time period, and to maintain this charge, as pressure is used to control the preventers. The following steps for sizing the BOP control system and selecting the appropriate Mendel numbers have been prepared to assist you in correctly selecting a safe and reliable BOP control system. 1.8.1

Sizing Accumulator Volume The total accumulator volume for a 3000 psi BOP control system should be sized to fully close the annular and all ram preventers with pumps out of service while maintaining a minimum of 1200 psi operating pressure (20 psi above precharge). An additional 50% safety factor is required to compensate for any fluid loss in the control system or preventers. 1. Determine the total gallons to close preventers. EXAMPLE: Preventer Type Annular

Mfg. By

Mfg. Type

Stack Size

Work Press

Gal. to Close

Hydril

GK

13-5/8"

5,000 PSI

17.98

Pipe Ram

Cameron

U

13-5/8"

10,000 PSI

5.54

Blind Ram

Cameron

U

13-5/8"

10,000 PSI

6.78

Pipe Ram

Cameron

U

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

Page 3 of 91

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 [A÷B]

107.52 10.00 10.75 . 11

TOTAL ACCUMULATOR VOLUME

110 Gallons


Page 4 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 1.8.2

Sizing Air and Electric Pump Each pump source for a 3000 PSI conventional BOP control system should be capable of charging the entire system accumulator capacity from 0 to 300 PSI in fifteen minutes or less. The control system should include two independently powered pump sources. 1. Determine the required pump GPM by multiplying the total accumulator volume (obtained in step 2 of 1.09.01) by 0.67 (the actual fluid capacity) and divide by 15 minutes: Total Accumulator Volume (step 2) Actual Fluid Capacity Factor Total Actual Fluid Capacity Divided by 15 Minutes

110.00 Gallons X 0.67 Gallons 73.70 Gallons ÷15 Minutes = 4.9 GPM

TOTAL REQUIRED (EACH PUMP) 4.9 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 specification. EXAMPLE Model No.

Description

Total GPM

A197-602

Air Pump Assy.

7.20*

TPE06-15460

Electric Triplex Pump Assy.

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

Air Supply Pressure

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.


Page 5 of 91


SIZING RECOMMENDATIONS - High Pressure And/or H2S Environment 1.9.1

Sizing Accumulator Volume The total accumulator volume for a 3000 PSI BOP control system operating in a high pressure and/or H2S environment should be sized to fully close, open and close the annular and all ram preventers. This must be done with the pumps out of service while maintaining a minimum 1200 PSI operating pressure (200 PSI above precharge). 1. Determine the total gallons to close, open and close preventers. EXAMPLE Preventer Type

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

U

11"

10,000 PSI

3.31

3.16

Blind Ram

Cameron

U

11"

10,000 PSI

4.23

4.03

Pipe Ram

Cameron

U

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

Total Accumulator Volume

200 Gallons

Model Number For Accumulator Unit - SSBA-200-3S11


Page 6 of 91


Sizing Air And Electric Pumps Each pump source for a 3000 PSI conventional BOP control system operating in a high pressure and/or H2S environment should be capable of closing the annular and opening a hydraulically operated choke line valve in two minutes or less. This must be done with the accumulator out of service while maintaining a minimum 1200 PSI operating pressure (200 PSI above precharge). 1. Determine the number of gallons to close the annular and open the hydraulic choke valve. Refer to the quick reference tables for the annular and use 1 gallon (maximum) for the choke valve. Divide the combined gallons by 2 minutes to arrive at the GPM required from each pump source. Gallons to Close Annular Gallons to Open Choke Valve (est.)

25.10 + 1.00

Combined Gallons Divide by 2 Minutes

÷

TOTAL REQUIRED (EACH PUMP)

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

Air Pump Assy.

15.00

TPE12-30460

Electric Triplex Pump Assy.

14.20

Sizing the Nitrogen Backup System The nitrogen backup system is sized to close the annular and one (1) choke line valve plus 50% safety factor; however, any of the functions may be operated until the nitrogen pressure has be exhausted. 1. Determine the gallons to close the annular. Use 1 gallon (maximum) to open the choke line valve. Preventer Type Annular Choke Valve

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

Model Number NBS-0605 Nitrogen Backup Unit


Page 7 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL Air Pump Assembly Specifications Model No.

Air Motor Dia (in.)

No. Of Pumps

Approx. GPM @ 125 Psi Air Pressure 1200 PSI

2000 PSI

3000 PSI

A197-601

7-3/8"

1

3.90

3.60

3.20

A197-602

7-3/8"

2

7.80

7.20

6.40

A197-603

7-3/8"

3

11.70

10.80

9.60

A9875-601

8-1/2"

1

6.00

5.00

3.90

A9875-602

8-1/2"

2

12.00

10.00

7.80

A9875-603

8-1/2"

3

18.00

15.00

11.70

Electric Pump Assembly Specifications Model No.

HP

Plunger Size

Volts

Approx. Flow @ 3000 PSI

Ph

Hz

DPE21-03460

3

5/8"

460

1.14 GPM

3

60

DPE21-05460

5

3/4"

460

2.19 GPM

3

60

DPE21-07460

7

3/4"

460

2.50 GPM

3

60

TPE06-10460

10

3/4"

460

4.55 GPM

3

60

TPE06-15460

15

3/4"

460

6.40 GPM

3

60

TPE06-20460

20

7/8"

460

8.70 GPM

3

60

TPE21-25460

25

1"

460

11.40 GPM

3

60

TPE21-30460

30

1-1/4"

460

14.20 GPM

3

60


Page 8 of 91

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.


Page 9 of 91


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.

Low precharge reading: (1) Attach the precharge line from the nitrogen bottle to the Charging and Gauging Assembly (DO NOT USE OXYGEN) (2) Slowly open the nitrogen bottle valve and verify that the gauge reading is still 1000 PSI.

b.

High precharge reading: (1) Open the Charging and Gauging Assembly bleeder valve until the precharge drops to 1000 PSI. (2) Close the bleeder valve and verify that the gauge reading is still 1000 PSI.

KEEP A CHARGING AND GAUGING ASSEMBLY ACCESSIBLE TO THE ACCUMULATOR UNIT


Page 10 of 91


Check Air Pumps 1. Check that the air lubricator is full of SAE 10W lubricating oil. 2. Close the air supply valve(s). 3. Close the air pressure switch bypass valve. 4. Purge a 1" air line from the main rig air supply line and connect it to the customer air supply connection on the Accumulator Unit. For Air Supply Requirements see the Installation Data Sheet.

2.2.6

Check Electric Pumps 1. Turn off the electrical power at the Main Generator Panel. 2. Turn the Triplex pump motor starter switch to the OFF position. 3. Ensure that the Accumulator Unit is grounded. 4. Check the resistance, voltage, and current of the power lines to be connected. For Electrical Power Requirements see the Installation Data Sheet. 5. Connect the electrical power lines to the three-phase terminal connections in the triplex pump motor starter (see Starter Wiring Diagram). Similar metal conductors (copper) should be used. Ensure that a good ground connection is made. 6. Check that the triplex pump crankcase is full of oil (weight will vary with the ambient temperature). For Chain Guard Oil Specifications see Maintenance Section. 7. Turn on the electrical power at the main generator panel. 8. Check the rotation of the motor by turning the triplex pump motor starter switch to AUTO and then OFF. If the rotation is backwards from arrow indication on chain guard, swap any two-phase terminal connections to reverse the motor rotation. 9. Use a sealing compound with a melting point of at least 2000 Deg. F and pour the electrical conduit seal. Seal should be at least 5/8" thick.

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

Check Valve Positions 1. Place all four-way control valves on the hydraulic manifold in the CENTER position. 2. Place the manifold regulator bypass valve in the LOW pressure (handle left) position. 3. Open the manifold bleeder valve. 4. Open the suction Valves of all pumps. 5. Check that the air pressure switch bypass valve is closed. 6. Check that the accumulator bank isolation valves are open. 7. Check that the accumulator bank bleeder valves are closed.


Page 11 of 91


Verify Gauges 1. All gauges on the hydraulic manifold should read 0 PSI. 2. Air supply gauge should read 125 PSI.

2.2.10 Start Pumps 1. With the manifold bleeder valve in the OPEN position, alternately open the air supply valve to each pump to ensure that each pump operates smoothly and without leaks. 2. Close the air supply valve to each pump. 3. With the main generator power ON, place the triplex pump motor starter switch to the AUTO position. Check that the pump runs smoothly and without leaks. 4. Close the manifold bleeder valve. 5. Open all air supply valves. 6. Set air lubricator to 6 drops per minute. 7. Pumps should continue running until accumulator pressure reaches 3000 PSI. If problems occur during initial start-up, consult the Troubleshooting Section. 2.2.11 Check Pressure Switches 1. After the system pressure has reached 3000 PSI and the pumps have stopped, open the manifold bleeder valve. 2. Pumps should automatically start when accumulator pressure in 2500 - 2700 PSI. If lower, the pressure switches need adjustment (See Maintenance Section). 3. Close manifold bleeder valve and recharge the system to 3000 PSI. 2.2.12 Check Gauge Readings 1. All accumulator pressure gauges should read 3000 PSI. 2. Manifold pressure gauge should read 1500 PSI, the pressure setting of the manifold regulator. To adjust the manifold regulator setting see Maintenance Section. a.

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.

Return control valves to the CENTER position.

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.

2.2.14 Refill Reservoir 1. Check the fluid level of the reservoir after line flushing. 2. Refill the reservoir to 8" from the top.


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AIR PANEL INSTALLATION 2.3.1

Set up Location 1. Install air panels securely on firm foundation, taking into consideration the following factors. a. b. c. d.

Operation and service accessibility. Illuminated areas. Unobstructed ventilation. Minimal heating effects from surrounding equipment.

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

Air Cable Connection

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.

Make sure the accumulator bleeder valves are closed. Make sure the manifold bleeder valve is open. Make sure pump suction valves are open. Center all four-way control valves. Place the unit/remote selector valve in the REMOTE position. Start pumps. Close the manifold bleeder valve.

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


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INSTALLATION DATA SHEET 2.5.1

Electric Pump Assembly Model No.

Starter Connection

HP

Volts

Full Load Current (Amps)

Ph

Hz

TPE06 -10230

10

1-1/2" FPT

230

26

3

60

TPE06 -10460

10

1-1/2" FPT

460

13

3

60

TPE06-15230

15

1-1/2" FPT

230

42

3

60

TPE06-15460

15

1-1/2" FPT

460

21

3

60

TPE06-20230

20

2" FPT

230

48.70

3

60

TPE06-20460

20

2" FPT

460

24.40

3

60

TPE21-25230

25

2" FPT

230

64.90

3

60

TPE21-25460

25

2" FPT

460

32.45

3

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

Air Pump Assembly Air Motor Dia. (in.)

No. of Pumps

CFM

GPM @ 3000 PSI

A197-601

Model No.

7-3/8"

1

76

1.98

A197-602

7-3/8"

2

160

3.96

A197-603

7-3/8"

3

236

5.94

A1985-601

8-1/2"

1

112

3.20

A1985-602

8-1/2"

2

235

6.40

A1985-602

8-1/2"

3

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

Air Remote Control Panel Assembly(ies) 1. Connection Size - 1" FPT 2. Minimum Air Supply Pressure - 100 PSI


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OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 3 TYPICAL SYSTEM DRAWINGS 3.1

TYPICAL INSTALLATION PICTORIAL FIGURE 3-1


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TYPICAL ACCUMULATOR UNIT ASSEMBLY FIGURE 3-2


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TYPICAL INTERCONNECT SCHEMATIC FIGURE 3-3


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HYDRAULIC SCHEMATIC TYPICAL CONTROL FLUID CIRCUIT FIGURE 3-4


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HYDRAULIC SCHEMATIC TYPICAL CONTROL MANIFOLD CIRCUIT FIGURE 3-5


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STARTER CONTROL SCHEMATIC PUMP ELECTRIC MOTOR FIGURE 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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ACCUMULATORS AND RESERVOIR The master skid assembly of heavy duty steel consists of: (1) accumulators (separator or guided float types), (2) reservoir, and (3) accumulator piping which includes isolator and relief valves. 4.1.1

Accumulators (Item 24 Fig. 4-1) The accumulators are ASME coded vessels of 3000 PSI working pressure that are precharged to 1000 PSI ± 100 PSI of nitrogen at our plant. When there is demand to operate a preventer, the high pressure fluid contained in the accumulator is forced out by the nitrogen. The accumulators are charged to 3000 PSI by the high pressure pumps. Each accumulator should be periodically checked since loss of precharge causes loss of available operational fluid. NEVER USE OXYGEN FOR PRECHARGING. Always keep a charging and gauging assembly readily accessible. If adjustments are required see Maintenance Section. 1. The separator type accumulators house bladders to contain the nitrogen precharge, and come in 5, 10 and 11 gallon capacities. A poppet valve keeps the bladder- from extruding through the port. For applications where bladder type accumulators will be continually subjected to temperatures below 0 Deg. F or for intermittent temperatures below -20 Deg. F, special low temperature bladders should be used. these bladders will provide longer service in the cold weather application. The guided float accumulators are of 80 gallon capacity. the poppet valve contained in the discharge port of the accumulators keeps the nitrogen precharge from escaping with the operational fluid. For proper operation the precharge pressure must be maintained at 1000 PSI (± 100 PSI). Loss of precharge can be caused by aeration of the fluid with the nitrogen. Aeration and float damage can also occur if the accumulators are subjected to tilting movements.

4.2

4.1.2

Reservoir (Item 7 Fig. 4-1) The reservoir is used to sore the fluid supply for operation of the pumps. The BOP control system is a closed-loop system where all vented fluid is returned to the reservoir. Therefore, it is very important to inspect the reservoir periodically for contaminants that may enter form the preventers. Debris can clog pump suction filters and make the control system inoperative, for procedures to clean the reservoir or change the fluid see Maintenance Section.

4.1.3

Accumulator Module Piping Accumulators are mounted in banks and can be isolated with the isolator valves (Item 23 Fig. 4-1). These valves should remain open at all times during normal operation. If it is known an accumulator is faulty, that bank may be isolated until it can be serviced. NEVER TRY TO SERVICE AN ACCUMULATOR UNIT IS PRESSURIZED (see Maintenance Section). Since the accumulators are 3000 PSI working pressure, the accumulator piping includes a 3500 PSI relief valve (Item 21 Fig. 4-1) to protect them against higher pressures. This valve should never be removed. If the valve is faulty, it should be repaired and replaced or a new valve should be installed.

AIR PUMP ASSEMBLY This is one of the high pressure power sources used to pressurize BOP control system. This module normally produces a maximum pressure of 3000 PSI but most are capable of much higher pressures, it is therefore important to know how to operate this assembly, along with when and how to control the use of the higher pressure outputs. These pumps require a customer furnished air supply of sufficient pressure and volume to operate them (see Installation Data Sheet). The air pump assembly consists of: (1) air supply manifold, (2) fluid suction manifold, (3) air pumps, and (4) air pressure switch. 4.2.1

Air Supply Manifold The customer furnished air supply should be connected to the air supply manifold as indicated in the Installation Section. Included in the air supply manifold is: 1. Air filter (Item 1 Fig. 4-1) - which filters the air and removes contaminants that may damage the air pumps. This filter must be cleaned periodically to maintain maximum air flow (see Maintenance Section). 2. Air lubricator (Item 2 Fig. 4-1) - which impregnates the air with oil to lubricate the pumps during operation. This lubricator should also be serviced periodically to replenish the oil (see Maintenance Section). 3. Air supply gauge (Item 3 Fig. 4-1) - 0-300 PSI, mounted in the air supply manifold for monitoring of the customer furnished air supply pressure. 4. Air supply valve - one for each pump to enable independent operation. Under normal operation these valves


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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

Air Pumps (Item 8 Fig. 4-1) Air pump are used to convert lower air pressure into higher hydraulic fluid pressures. They consist of two (2) main components: the air motor and the fluid end. They are sized by the fluid ratio of the piston area in the air motor to the area of the piston in the fluid end. The standard double acting pumps are 60:1 ratio. This means there is 60 times the piston area in the air motor as in the fluid end. Therefore, 1 PSI of air will produce 60 PSI of hydraulic fluid pressure. The pumps have self adjusting packing glands and therefore should require no adjustment in normal operation. The pumps are double acting so air is exhausted on each up stroke and downstroke of the pump. As the pumps exhaust the lubricated air, it is normal to find oil on surrounding equipment, and for the moisture in the exhausted air to cause an ice formation on the air pump. Excessive freezing may cause operational problems (see Troubleshooting Section). Before servicing the pump, bleed off the system pressure. The pump discharge line is fitted with a check valve (Item 9 Fig. 4-1) to allow the system to be repressurized while the pump is being serviced.

4.2.4

Air Pressure Switch (Item 6 Fig. 4-1) Since the air pumps are capable of producing pressures in excess of 3000 PSI, it is necessary to automatically stop the pumps when the discharge pressure reaches 3000 PSI. The air pressure switch senses the discharge pressure and blocks the air supply to the pumps when the set pressure is reached. Normally, the pressure switch is set for 3000 PSI for accumulator units with air pumps only, and 2900 PSI on accumulator units with both air and electric pumps. When the system pressure drops to 2700 PSI, the pressure switch automatically allows the air to flow to start the pumps. To adjust the pressure switch setting see Maintenance Section. The line to the air pressure switch is fitted with a bypass valve to allow the pumps to produce higher fluid pressures. In normal operation this valve should be closed. If pressures in excess of 3000 PSI are required, such as during testing: 1. Close the electric pump isolator valve. 2. Move the manifold regulator bypass valve (Item 26 Fig. 4-1) to the HIGH pressure position. 3. Open the air pressure switch bypass valve. 4. This will produce pressures up to 5500 PSI, which is the setting of the manifold relief valve.

4.3

ELECTRIC PUMP ASSEMBLY The electric pump assembly is a primary, or additional, high pressure pump source. This assembly requires a customer furnished power source, usually 220 or 440 volt, 60 cycles, 3-phase power. The amount of current required depends on the horsepower of the electric motor (see Installation Data Sheet). The pump output remains constant up to the maximum pressure of 3000 PSI, independent of the system back pressure. The electric pump assembly consists of: (1) fluid suction manifold, (2) duplex or triplex pump, (3) electric motor, and (4) drive assembly which includes chain, sprocket, chain guard, motor starter and pressure switch. 4.3.1

Fluid Suction Manifold The fluid suction manifold connects the high pressure pump to the reservoir which contains the operational fluid. This manifold includes: 1. Suction valve (Item 16 Fig. 4-1) - which remains open at all times in normal operation, but is closed to isolate the pump during servicing.


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OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 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

Duplex or Triplex Pump This pumps (Item 14 Fig. 4-1) derive their name from the number of plungers in the pump, duplex - two and triplex three. Duplex pumps are used with 3, 5, and 7-1/2 HP electric motors. Triplex pumps can use motors from 10 to 60 HP. Plunger sizes can be varied to meet the specifications of the particular BOP control system. In normal operation the pumps operate automatically, however; the plunger, packing and crankcase should be inspected periodically, for adjustments (see Maintenance Section). The pump discharge line is fitted with a check valve (Item 18 Fig. 4-1) and an isolator valve. The isolator valve remains open at all times in normal operation but is closed to isolate pumps either for servicing or to bypass the accumulators so pressure higher than 3000 PSI can be reached.

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 MANIFOLD ASSEMBLY The control manifold is connected directly to the BOP stack, and operational mistakes can be costly in terns of lives and property. The manifold directs the flow of the high pressure fluid stored in the accumulators to operate the preventers and gate valves on the blowout preventer (BOP) stack. Most preventers operate at a maximum of 1500 PSI. However, the accumulator pressure is 3000 PSI; therefore, regulators are required to reduce the operating pressure from 3000 PSI to 1500 PSI maximum. Annular (bag type) preventers require different operating pressures from the other functions on the BOP stack, so all control manifold use the double manifold design. The control manifold consists of; (1) control valves, (2) regulators, (3) gauges, and (4) manifold piping which includes a supply header, high pressure strainer, relief valve and bleeder valve. 4.4.1

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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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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OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 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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OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL TYPICAL ACCUMULATOR UNIT ASSEMBLY FIGURE 4-1


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OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL LEGEND - TYPICAL ACCUMULATOR UNIT ASSEMBLY TABLE 4-1 Item #

Customer Locations

A

Customer Air Supply Connection

B

Customer Motor Starter Power Connection

C

4" Fill/Inspection Port

Item #

Description

Item #

Description

1

Air Filter

24

Accumulator

2

Air Lubricator

25

Manifold Regulator

3

Air Supply Pressure Gauge

26

Manifold By-Pass Valve

4

Air Pressure Switch Bypass Valve (Not Shown)

27

Manifold Supply Header

5

Air Supply Valve (Not Shown)

28

4-Way Control Valve

6

Air Pressure Switch

29

Air Cylinders

7

Reservoir

30

Manifold Relief Valve

8

Air Operated Hydraulic Pump

31

Reserved

9

Air Pump Discharge Check Valve

32

Unit/Remote Selector Valve

10

Air Pump Suction Strainer

33

Regulator Air Filter (Not Shown)

11

Air Pump Suction Valve

34

Annular Air Regulator

12

Electric Motor

35

Manifold Pressure Gauge

13

Electric Pressure Switch

36

Manifold Bleeder Valve (Not Shown)

14

Reciprocating Hydraulic Pump (Duplex or Triplex Pump)

37

Annular Pressure Gauge

15

Electric Pump Suction Strainer

38

Accumulator Pressure Gauge

16

Electric Pump Suction Valve

39

Transmitter-Annular Pressure

17

Electric Motor Starter

40

Transmitter-Accumulator Pressure

18

Electric Pump Discharge Check Valve

41

Transmitter-Manifold Pressure

19

Electric Pump Isolator Valve (Not Shown)

42

Transmitter Air Regulator (Not Shown)

20

High Pressure Strainer (Not Shown)

43

Fixed Plate Half-Air Junction Box

21

Accumulator Relief Valve

22

Accumulator Supply Header

23

Accumulator Bank Isolator Valve


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AIR REMOTE CONTROL PANEL ASSEMBLY Air operated remote control panels are used for remote control of the hydraulic control manifold and monitoring of the operating pressures of the BOP control system. These panels are divided into two (2) basic types: Driller's Panel and Auxiliary Panels. The Driller's control panel should be located on the drill floor and provides complete remote control and operating pressure monitoring. The auxiliary panel should be placed in a safe area. This way if the driller's panel is inoperative and the hydraulic control manifold cannot be reached, the well can be controlled from this panel. Since it is used only in emergency situations, it does not contain monitoring of the operating pressures of the control system required during normal operation. Both remote control panels require a customer furnished, 125 PSI air supply. Major components of these panels include: (1) air supply manifold, (2) master control valve, (3) Air control valves, (4) bypass valve, (5) nameplates, (6) gauges, and (7) annular air regulator. 4.5.1

Air Supply Manifold The customer furnished air supply should be connected to the air supply manifold as indicated in the Installation Section. Included in the air supply manifold is a filter (Item 17 Fig. 4-2) and a lubricator (Item 19 Fig. 4-2). The filter is used to remove contaminants in the air supply that can damage air valves. The lubricator is used to lubricate the valves during operation. The filter and lubricator should be serviced periodically to ensure proper operation of the air remote control panel (see Maintenance Section).

4.5.2

Master Air Control Valve (Item 4 Fig. 4-2) This valve is a 1/4", three-way, spring centered valve which must be operated to provide the necessary air supply pressure to the remaining air valves on the remote panel. This valve must be held open to allow the air supply to flow through it while operating the other valves. When the handle is released, it will automatically spring center, shutting off the air supply and venting all of the downstream air pressure. This helps to prevent accidental operation of a BOP function.

4.5.3

Air Control Valves (Item 2 and 3 Fig. 4-2) These valves are 1/4", four-way, spring centered valves to remotely operate the hydraulic control valves on the hydraulic manifold. Operation of these air control valves actuates the air cylinders attached to the hydraulic valves on the manifold. This actuation positions the hydraulic valve to the corresponding operation of the air control valve on the panel. High pressure hydraulic fluid is then directed to operate the selected function. When the air centers, venting the air pressure on the air cylinder thus allowing the hydraulic control valve on the manifold to be manually operated.

4.5.4

Bypass Valve (Item1 6 Fig. 4-2) This 1/4", four-way, spring centered valve remotely operates the manifold regulator bypass valve. When moved to the "Low Pressure" position, regulated pressure is supplied to them.

4.5.5

Nameplates (Items 10 thru 14 Fig. 4-2) The air control valves are arranged on the panel to represent the actual stack configuration. The nameplates for these control valves are also shaped to graphically illustrate each preventer or gate valve function. This helps the operator to quickly an accurately operate the required function.

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

Annular Air Regulator (Item 5 Fig. 4-2) The driller's control panel contains an air regulator for adjusting the operating pressure of the annular preventer. To operate this regulator, the Unit/Remote selector (Item 32 Fig. 4-1) valve on the hydraulic manifold must be placed in the REMOTE position. The operating pressure of the annular can than be adjusted by rotating the air regulator handle clockwise to increase the pressure or counterclockwise to decrease the pressure. Always check the annular pressure gauge when adjusting the air regulator.


Page 31 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL TYPICAL AIR REMOTE CONTROL PANEL FIGURE 4-2


Page 32 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL LEGEND - AIR REMOTE CONTROL PANEL TABLE 4-2

Item

Description

1

Remote Air Control Panel Assembly

2

Air Remote Control Valve - Preventers

3

Air Remote Control Valve - Wing Valves

4

Air Remote Control Valve - Master Air Valve

5

Air Regulator - Annular Pressure

6

Gauge - Air Pressure

7

Receiver Gauge - Manifold Pressure

8

Receiver Gauge - Accumulator Pressure

9

Receiver Gauge - Annular Pressure

10

Graphic Nameplate

11

Graphic Nameplate

12

Graphic Nameplate

13

Graphic Nameplate

14

Graphic Nameplate

15

Reserved

16

Air Remote Control Valve - Manifold Bypass

17

Air Filter

18

Fixed Plate Half - Air Junction Box (Rectangular J-Box shown, Round J-Box is STANDARD)

19

Air Lubricator


Page 33 of 91


AIR REMOTE CONTROL INTERFACE ASSEMBLY Air remote control interface assemblies include additional components necessary on the Accumulator Unit to enable the BOP control system to be remotely controlled and/or monitored from an air panel.

4.7

4.6.1

Cylinders (Item 29 Fig. 4-1) Air cylinders are mounted on each hydraulic four-way control valve on the hydraulic manifold that requires remote operation. The cylinder piston rod is connected to the handle of the control valve. An air pressure signal from the air valve on the air panel causes the cylinder piston rod to extend or retract. This movement causes the handle to rotate thus operating the function. The cylinders should be serviced periodically to ensure proper operation (see Maintenance Section).

4.6.2

Air Junction Boxes (Item 43 Fig. 4-1) All of the signal lines included in the interface assembly terminate at a fixed-plate half of an air junction box which mates to the hose-end half attached to the interconnect cable assembly. This junction box facilitates handling of the BOP control system equipment during rig moves or when relocating equipment.

INTERCONNECT CABLE ASSEMBLY The interconnect cable assembly connect the air remote control panel to the accumulator unit. It consists of a multi-tube bundle with a hose-end half of an air junction box on each end. These junction boxes should be attached to the mating junction boxes on the interface assembly and the air remote control panel. One interconnect cable assembly is required for each air remote control panel. The cable consists of 3/8" OD, 175 PSI working pressure polyethylene tubes spirally wound and encased in 3/16" thick polyvinyl chloride (PVC) outer jacket. Two (2) tubes are required for each function and one (1) each for the pressure regulating and monitoring signals.

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 Backup System The nitrogen backup system - This system connects to the control manifold to provide an emergency pressure power source to close the ram type preventers and gate valves. This system should be used only as the last possible means of control. 1. The nitrogen backup system consists of: a.

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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OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 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.

Rig Test Outlet This assembly provides a 6000 PSI working pressure test outlet from the accumulator unit. 1. The test outlet consists of: a.

Rig test isolator valve - is open during normal operation.

b.

Rig test pressure gauge - 0-10,000 PSI.

c.

Rig test relief valve - 6500 PSI.

d.

Rig test shut-off valve - is closed during normal operation.

e.

Rig test check valve.

2. To operate the rig test outlet:

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.

Close rig test isolator valve.

c.

Open rig test shut-off valve.

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.

Rig Skid Outlet This assembly provides a 3000 PSI outlet for connection to the rig skid control manifold for operation of rig skid cylinders. 1. The skid outlet consists of: a.

Rig skid isolator valve - is open during normal operation.

b.

Rig skid pressure gauge - 0-6000 PSI.

c.

Rig skid shut-off valve - is closed during normal operation.

d.

Rig skid relief valve - 3500 PSI.


Page 35 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 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.

Close the rig skid isolator valve.

c.

Open the rig skid shut-off valve.

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.


Page 36 of 91

OPERATOR'S MANUAL 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.

Exposed electrical terminals.

B.

Remotely operated equipment.

C. High pressure hydraulic lines. a.

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.

FOR SAFETY DURING MAINTENANCE PROCEDURES: A.

Work in pairs so there is a backup in case of emergencies.

B.

Ensure electric tools are grounded.

C. Ensure tool handles are insulated. The instructions below are major steps that must be performed during maintenance and troubleshooting procedures. Wherever these instructions are given, refer to these steps. Stop Pumps 1. Close air supply valves. 2. Turn triplex starter to OFF position. Start Pumps 1. Open air supply valves. 2. Turn triplex starter to AUTO position. The following items should be maintained on a monthly basis until the operator can develop a suitable program based on his specific operating and testing programs. All activity concerning the BOP accumulator unit should be documented. This shall include lubrication, addition of fluid, purging of filters, draining of moisture traps, malfunctions, and repairs, etc. The time, date, and name of person performing the function should be recorded.


Page 37 of 91


SPECIFIC TOOLS LIST Accumulator maintenance and repair requires the use of the following tools: Tool

Part Number

Use

Charging and Gauging Assembly

001-1000

Nitrogen Precharging and precharge checking of accumulators

Valve Core Tool

001-1012

Accumulator valve core replacement and tightening

Bladder Pull Rod

001-1010

Accumulator bladder removal and replacement

Spanner Wrench

001-1011

Accumulator locknut removal and replacement


Page 38 of 91


NITROGEN PRECHARGE INSTRUCTIONS - BLADDER TYPE ACCUMULATORS

1. Stop air pumps by closing air supply valves.

2. Stop electric pump by turning motor starter switch to OFF position.


3. Open all shutoff valves to the accumulator bank.

4. Open manifold bleeder valve to release all system pressure.

Page 39 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 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) Ò.

B.

Screw down T-handle Ó to check nitrogen precharge pressure. It should read 1000 PSI ± 10%. 1.

If pressure is low, attach the precharge Ô line from the Charging and Gauging Assy. to the nitrogen bottle. CAUTION - Gradually open valve Õ to slowly increase precharge pressure to 50 PSI, then proceed increasing precharge to the desired pressure. Then close the valve. If pressure does not increase the bladder faulty and should be replaced. (See Bladder Replacement Instructions)

2.

If pressure is high. Open bleeder valve Ö on gauge Assy. until desired pressure is reached.

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

Charging & Gauging Assy.

Description

Qty. 1

1

001-1030

Gauging & Head Assy.

1

2

601-1001

Swivel Connector

1

3

601-1002

Hose End Fitting

1

4

601-1003

Hose

1

5

601-1004

Coupler

1

6

601-1005

Nut

1

7

601-1006

Gland

8

601-1038

Tank Valve

1

9

601-1037

Adapter

1

10

601-1036

Air Chuck

1

11

601-1039

Bleeder Valve

1

CHARGING AND GAUGING ASSEMBLY

NITROGEN PRECHARGE INSTRUCTIONS


Page 40 of 91


NITROGEN PRECHARGE INSTRUCTIONS - 80 GALLON SPHERICAL TYPE ACCUMULATORS

NOT APPLICABLE


Page 41 of 91


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.

Optional - Circulate a warm-to-hot bactericide solution through the system. f. g. h. i.

5.6

Rinse the system thoroughly with hot water. Refill the system with hydraulic fluid mixture. Start pumps and operate to ensure that pumps are primed. Close manifold bleeder valve.

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.

AIR OPERATED PUMPS 5.6.1

Hydro-Pneumatic Pressure Switch 1. Turn the spring adjustment nut from left to right to increase pressure setting and from right to left to decrease pressure setting. 2. Check air pressure switch bypass valve for 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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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

Hydro-Electric Pressure Switch 1. To adjust the pressure setting for: a.

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.

Pump Shut Off (1) Remove access screw on right hand side of switch. (2) Turn the adjusting screw counterclockwise to increase pressure setting. (3) Turn adjusting screw clockwise to decrease pressure setting.


Page 43 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 2. To replace limit switch: a.

Loosen the set screw(s) on housing stem.

b.

Remove the pressure fitting from housing.

c.

Remove the extension fitting of adjustment screw.

d.

Remove the mounting screws from terminal bracket.

e.

Loosen the screws of terminal wire connections.

f.

Pull away the terminal assembly.

g.

Loosen the retaining nut at base of bourdon tube assembly.

h.

Remove the tube and switch assembly.

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.

Replace the tube and switch assembly.

k.

Tighten retaining socket nut.

l.

Pull wires through terminal assembly.

m. Replace the mounting screws through terminal bracket.

5.7.2

n.

Replace wires to terminal connection screws and tighten.

o.

Replace the extension fitting of adjustment screw.

p.

Replace pressure fitting to housing base.

q.

Tighten the set screws on housing stem.

r.

Replace the leads from starter to pressure switch.

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

7

TPE21-40, TPE21-50, TPE21-60

9

SAE 20 @ 0 Deg. F - 115 Deg. F SAE 10 @ 0 Deg. F - 60 Deg. F

2. Clean the pump crankcase of accumulated sludge. Produced By: Entrada International, Inc. 2002

Page 44 of 91


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.

CHAIN GUARD 0IL SPECIFICATIONS Above 20 Deg. F use SAE 90 Compound Chain Oil. Below 20 Deg. F use SAE 80 Compound Chain Oil.

3. Chain Tension Adjustment and Initial Setting a. Adjust Drive Centers and Chain Tension. (1) Horizontal drives should be installed with an initial sag equal to two percent (2%) of sprocket centers. (2) Vertical center drives should be operated with both spans of chain close to being taut. Periodic inspection of such drives should be made to avoid operation with excessive slack and to maintain proper chain tension. b.

Determine the Amount of Sag. (1) Pull one side of the chain taut, allowing all the excess chain to accumulate in the opposite span. (2) Place a straight edge over the slack span and, pulling the chain down at the center, measure the amount of sag. When necessary, adjust drive centers for proper sag that will result in correct chain tension.

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

Four-Way Control Valves 1. Apply grease to the detents on the four-way control valves. 2. Open view ports and check that control valves are not leaking.


Page 45 of 91


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.


Page 46 of 91


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

AIR JUNCTION BOXES 5.10.1 Check for leaks around gasket. Evenly tighten junction box mounting screws. 5.10.2 Periodically separate junction box plates and ensure ports are clean and clear of sludge.


Page 47 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL 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.


Page 48 of 91


ACCUMULATOR PROBLEMS

Ref.

Problem

Ref.

Possible Cause

1A

Loss of Accumulator Precharge Pressure (Bladder Type)

1.

Faulty precharge valve permits nitrogen to escape

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

Loss of Accumulator Precharge Pressure (Float Type)

1.

Poppet valve being held open by debris

Remedy 1. 2. 3. 4.

2.

Faulty precharge valve permits nitrogen to escape

1. 2. 3. 4.

1C

Float partially filled with fluid.

1.

Premature closing of poppet valve

1. 2. 3. 4. 5. 6.

1D

Poppet Valve Closed

1.

Float fully filled with fluid

1.

2. 3. 4. 5. 6. 7. 8. 9.


Pressure up accumulator to 200 PSI fluid pressure Open bleeder valve to flush out debris Repeat procedure several times If no improvement release all fluid pressure from accumulator, remove poppet and repair Tighten valve core snugly with valve core tool. Precharge accumulator to 1000 PSI Observe precharge pressure on precharge gauge If pressure does not decrease, remove gauge and place a drop of saliva across top of valve core. Thin oil may also be used. If no bubble is observed, valve is holding. Accumulator is ready for service Bleed off precharge Remove poppet valve assembly and guide rod, upset float and drain liquid Replace guide rod and poppet valve assembly Precharge accumulator with nitrogen Close bleeder valve and pressure up accumulator to 3000 PSI fluid pressure Open bleeder valve to expend fluid rapidly. If poppet valve precloses prematurely again, float may be damaged and vessel needs to be repaired After accumulator has been charged with 3000 PSI fluid pressure and any attempt to expend fluid fails, pressure must be bled from accumulator through the precharge valve After pressure has been reduced to zero, disconnect accumulator and remove poppet assembly and guide rod Upset float and drain all liquid from float Re-install removed parts and reconnect accumulator Precharge accumulator with 1000 PSI of nitrogen Close bleeder valve and pressure up accumulator with 3000 PSI of fluid Open bleeder valve to dump fluid rapidly from accumulator If poppet does not close prematurely, accumulator is ready for service If float sinks again, remove accumulator and repair float

Page 50 of 91


AIR SUPPLY PROBLEMS

Ref.

Problem

Ref.

Possible Cause

Remedy

2A

Lack of Air Lubrication

1.

No lubricant in bowl

1. Cut off main air supply to Accumulator Unit 2. Open petcock at bottom of air lubrication bowl 3. Drain off any moisture or emulsified oil 4. Unscrew fill cap and refill lubricator with 10 W motor oil. CAUTION: DO NOT USE SYNTHETIC OR AROMATIC TYPE OIL 5. Open main air supply valve to the unit

2B

Excessive Air Lubrication

1.

Lubricator out of adjustment

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

2C

Air Operated Pumps Icing Over or Freezing

1.

Moisture in rig air supply

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.


Close accumulator isolator valves Turn motor starter to OFF position Open manifold bleeder valve Operate air pumps at full capacity Open lubricator fill cap Use a thin screwdriver to adjust lubricator to provide six (6) drops of oil per minute. Rotation of metering screw: Clockwise - increases flow Counterclockwise decreases flow Close manifold bleeder valve Open accumulator isolator valves Turn motor starter to AUTO position Make sure unit is being supplied with CLEAN, DRY air Cut off main air supply to unit Close accumulator isolator valves Turn motor starter to OFF position Open petcock at bottom of air lubrication bowl and drain accumulated moisture Remove plug from "Y" shaped strainer Open main air supply valve to the unit Open manifold bleeder valve Run air pumps at full capacity until all moisture has been removed Close air supply valves to stop pumps Cut off main air supply to unit Replace plug in "Y" strainer" Open main air supply to unit Close manifold bleeder valve Open accumulator isolator valves Open air supply valves Turn motor starter to AUTO position

Page 51 of 91


PUMP PROBLEMS

Ref. 3A

Problem Pumps Run Excessively

Ref.

Possible Cause

1.

Air pump pressure switch bypass valve open or faulty

Remedy 1. 2.

3.

4. 2.

Hydraulic seals in automatic pressure switch are leaking

1. 2. 3. 4. 5. 6. 7.

3.

Faulty precharge valve (bladder type separator)

1. 2. 3. 4. 5.

6.

7. 8. 4.

Four-Way valve leaking

1. 2. 3. 4. 5. 6.

5.

Relief valve leaking

1. 2. 3. 4.


Close the bypass valve tightly Reset automatic pressure switch (See Maintenance Section) to shut off air pumps at: a. 2900 PSI for units with air and electric pumps b. 3000 PSI for units with air pumps only If air pumps continue operating, bypass valve may be defective a. Loosen tubing connector downstream from air bypass valve b. If air is escaping, replace the bypass valve c. Close bypass valve tightly Check pump shutoff pressure Stop pumps Open manifold bleeder valve and relieve system pressure Remove automatic pressure switch for inspection Replace pressure switch and adjust setting Close manifold bleeder valve Start pumps Check pressure switch settings Stop pumps Open manifold bleeder valve Check precharge pressure on each accumulator and record Tighten each precharge valve assembly by using valve core tool Precharge each accumulator with 1000 PSI of nitrogen starting with accumulator that had highest recorded pressure. This will conserve nitrogen Check all precharge valves for gas leaks by placing drops of saliva across tops of valves. (Light oil may also be used.) And, if: a. Bubbles appear, replace valve core (See Maintenance Section) b. No bubbles appear, accumulators are ready for normal use Close manifold bleeder valve Start pumps Open inspection ports located at each end of reservoir Observe which valve is leaking Manipulate manually several times If leaking persists, remove 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 Open inspection ports at each end of reservoir Observe relief valve return lines to see which one is leaking Note pressure reading on gauge when flow begins to check if setting is incorrect Remote and replace faulty valve

Page 52 of 91


Problem

Ref. 6.

Possible Cause Regulator Leaking

Remedy 1. 2. 3.

7.

Bleeder Valve Leaking

1. 2. 3.

8.


Leaks in Fluid System

Open inspection ports at each end of reservoir Observe regulator return lines to check if leaking Remove and replace faulty regulator Close manifold bleeder valve tightly Check for leakage by looking through inspection ports located at each end of reservoir If valve is leaking, remove and replace it

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


Problem

Ref. 9.

Possible Cause Loss of precharge pressure

Remedy 1. 2. 3. 4.

5.

6. 7. 8. 3B

Pumps Shut Down at Wrong Pressure

1.

Air pump pressure switch out of adjustment

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 2.


Electric pressure switch out of adjustment

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

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 readjust the setting See Maintenance Section

Page 54 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL Ref. 3C

Problem

Ref.

Pump Cannot Reach Full Pressure

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.

Low air supply

1. 2.

3D

Pumps Produce No Pressure

Check rig main air supply gauge for proper air supply pressure (See Installation Data Sheet.) Correct air supply at rig main air compressor.

1.

Loss of pump prime because of low To restore fluid level: fluid level 1. Close accumulator isolator valves if accumulator pressure gauge shows pressure is contained 2. Stop pumps 3. Open manifold bleeder valve and bleed system pressure 4. Add fluid to at least twelve (12) inches above pump suction lines 5. Start one pump and operate at full pressure 6. Observe fluid flow through inspection ports 7. Stop pumps 8. Open isolator valves 9. Check reservoir fluid level. Add oil if needed 10. Close bleeder valve 11. Start pumps and pressure up system

2.

Suction valve closed

Check that pump suction valves are in full open position.

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

Close accumulator isolator valves if accumulator pressure gauge shows pressure is contained Stop pumps Open manifold bleeder valve Open air pump supply valves and start air operated pumps Observe fluid flow through inspection ports. If slight or no fluid flow is observed: a. Stop air pumps b. Close pump suction valve(s) c. Remove "Y" strainer plugs d. Remove strainer elements e. Open pump suction valves and flush out debris from piping f. Close pump suction valves g. Clean and replace strainer and plug h. Start pump and observe fluid flow through inspection ports i. Repeat procedure until system is clean j. Close manifold bleeder valve k. Open accumulator isolator valves l. Start pumps

Page 55 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL Ref. 3E

Problem Pumps Leaking

Ref.

Possible Cause

Remedy

1.

Air Pumps - Plunger packing is worn or damaged

On the older style pumps: 1. Tighten packing nut 2. If leak: a. Stops - Check for proper plunger lubrication. The plunger should be coated with thin film of hydraulic fluid b. Persists - Remove pump and replace

2.

Electric Driven Pump - Worn Packing

Replace packing

3.

Electric Driven Pump - Damaged Valve Cover Gasket or Loose Cover Plate

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


ELECTRIC MOTOR PROBLEMS

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

If power supply had a thermal overload: 1. Turn motor starter to OFF position 2. Press reset button on motor starter 3. Turn motor starter to AUTO position

3.

Loss of Power Supply

1. 2. 3. 4.

4B

Motor Runs Erratically

1.

Voltage Fluctuation

3. 2.

Pressure Switch Span out of Adjustment

Turn motor starter to OFF position Check voltage of power supply to starter at main generator panel Restore power supply from main generator panel Turn motor starter to AUTO position

If pump pressure is at proper desired setting and pump stops frequently, input voltage may be too low. 1. 2.

Turn motor starter of OFF position Check and correct voltage at main generator panel Turn motor starter to AUTO position

If pump continues to stop and start after reaching the proper pressure setting, switch adjustment may be necessary. a. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.


Turn motor starter to OFF position Turn off power at main generator panel or MCC Remove pressure switch explosion proof cover Disconnect leads from electrical pressure switch Check resistance across terminals of pressure switch with an Ohm meter. If resistance is observed, the switch is working properly If no resistance is found, replace the limit switch or, if time is limited, replace the entire pressure switch assembly (See Maintenance Section.) Replace the leads from starter to pressure switch (See Starter Wiring Diagram.) Turn on power at main generator panel or MCC Turn motor starter to AUTO position Check for proper adjustment to settings (See Maintenance Section) Replace pressure switch explosion-proof housing cover

Close air supply valves Check that starter switch is in AUTO position. CAUTION: ELECTRICAL CONTACTS HAVE LIVE POWER Remove pressure switch cover Move white adjustment wheel down or toward the front Open manifold bleeder valve and reduce pressure to desired pump starting pressure Close manifold bleeder valve Move adjustment lever back (up or towards rear) until pump starts After pump stops, check results to make sure proper setting has been obtained Replace pressure switch cover Open air supply valves

Page 57 of 91


FOUR-WAY VALVE PROBLEMS NOTE: VALVE VENTING MAY BE CAUSED BY LEAKING SEALS IN THE PREVENTER.

Ref. 5A

Problem Inter-flowing

Ref. 1.

Possible Cause Debris in the Valve

Remedy 1. 2. 3. 4. 5. 6.

2.

Washed out or damaged seals

1. 2. 3.

3.

Actuator rod out of adjustment

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

Check all interface points for leaks or open connections.

Page 58 of 91


GAUGE PROBLEMS NOTE: ACCEPTABLE INDICATION LIMITS ARE ± 50 PSI FROM TRUE PRESSURE.

Ref.

Problem

Ref.

6A

Gauge Out of Adjustment Manifold or Annular Pressure Gauges

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.

Shock due to rough treatment

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12. 13. 14. Gauge Out of Adjustment - Fluid Filled Gauges

1.

Shock due to rough treatment

1. 2.

Close accumulator isolator valves Stop pumps Open bleeder valve and bleed off manifold pressure Remove gauge face covering Adjust gauge indicator to zero setting with a thin screwdriver blade Replace gauge face cover Loosen gauge fitting and bleed off any trapped air Re-tighten fitting Close bleeder valve Open accumulator isolator valves Start pumps and pressure up system After full pressure is indicated: a. Close accumulator isolator valves b. Stop pumps c. Open manifold bleeder valve and bleed off pressure in 500 PSI increments d. Observe gauge reaction each time e. When no manifold pressure remains, gauge should read zero (0) PSI Close manifold bleeder valve Open accumulator isolator valves Start pumps and restore system pressure Stop pumps Open bleeder valve and bleed off manifold pressure Remove gauge face covering Adjust gauge indicator to zero setting with a thin screwdriver blade Replace gauge face cover Loosen gauge fitting and bleed off any trapped air Re-tighten fitting Close bleeder valve Open accumulator isolator valves Start pumps and pressure up system After full pressure is indicated: a. Stop pumps b. Open manifold bleeder valve and bleed off pressure in 500 PSI increments c. Observe gauge reaction each time d. When no manifold pressure remains, gauge should read zero (0) PSI Close manifold bleeder valve Open accumulator isolator valves Start pumps and restore system pressure Remove defective gauge and replace with a known working unit Send the defective gauge to vendor for factory calibration.

An alternate method of checking a faulty gauge can be used: 1. 2. 3.


Connect the faulty gauge supply line to a common manifold with a gauge of known accuracy. Adjust faulty gauge if possible. Acceptable indication limits are ± 50 PSI from true pressure

Page 59 of 91

OPERATOR'S MANUAL BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL Ref. 6B

Problem

Ref.

Possible Cause

Remedy

-

1.

Supply line or snubber clogged Accumulator Pressure

When gauge responds slowly or in an erratic manner during operation: 1. Stop pumps 2. Close accumulator isolator valves 3. Open manifold bleeder valve to relieve system pressure 4. Disconnect gauge supply line. If pressure gauge is installed with a snubber: a. Remove snubber from gauge and connect to gauge supply line b. Start air operated pump c. Slowly close bleeder valve d. If fluid does not pass through snubber it is blocked and should be replaced i. Stop pump ii. Open manifold bleeder valve iii. Remove snubber and install a new one on the gauge 5. Purge supply line with hydraulic fluid by starting one air operated pump only 6. Reconnect supply line to gauge assembly 7. Close bleeder valved 8. Open accumulator isolator valves 9. Operate air pump 10. If gauge is still sluggish or erratic, replace the gauge

Gauge Responds Slowly - Manifold and Annular Gauges

1.

Supply line or snubber clogged Manifold and Annular Gauges

1. 2.

Gauge Responds Slowly Accumulator Pressure Gauges

3. 4. 5.

6. 7. 8.


Place valves in center position Reduce hydraulic pressure to zero (0) by adjusting regulators Remove tubing and snubber from gauge If gauge indicates pressure, re-calibrate to zero (0) While hydraulic tubing is disconnected from gauge, increase pressure from regulator, if: a. Fluid flows freely from open tube: i. Reduce pressure back to zero (0) ii. Attach snubber to the hydraulic tubing iii. Increase pressure b. No fluid escapes, the snubber is blocked and should be replaced Reassemble tubing, snubber and gauge Cycle regulated fluid pressure to 1000 PSI and back down again to zero Check that gauge indicates zero (0). If it does not, replace gauge with a known working unit

Page 60 of 91


REGULATOR PROBLEMS

Ref.

Problem

Ref.

Possible Cause

Remedy

7A

Air Operated Hydraulic Regulator Manually Operated Hydraulic Regulator

1.

Damaged Seals or Debris on Sealing Surfaces of Air Operated Hydraulic Regulator

When hydraulic fluid pressure remains stable, and regulator continues to vent to reservoir: 1. 2. 3. 4. 5. 6. 7.

2.

Diaphragm Housing of Pressure Regulating Valve Is Leaking Air

This condition may be caused by a damaged or loose gasket in the diaphragm housing: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

3.

Manual Air Regulator Leaking

Close accumulator isolator valves Stop pumps Open manifold bleeder valve and relieve pressure Reduce pressure on air regulator to zero Remove air pilot line from top of diaphragm housing Remove upper half of diaphragm housing Remove and inspect gasket Replace gasket if damaged Reassemble and tighten bolts evenly around the diaphragm housing flange Connect air pilot line to top of diaphragm housing Check all connections for potential air leaks Close bleeder valve Open isolator valves Start pumps and pressure up system

The air regulator is located on top of the hydraulic manifold next to the Unit-Remote selector lever: 1. 2. 3. 4. 5. 6.


Place function control valves on control manifold in center position Observe return lines through inspection ports Locate air regulator which supplies pilot pressure to the fluid pressure regulator Turn the air regulator handle from closed to full open Repeat this procedure several times If venting of air operated hydraulic regulator valve continues, the valve should be replaced or repaired If valve regulates properly, place function valves in normal DRILL AHEAD position (see Installation Section.)

Place Unit-Remover selector valve in UNIT position Regulate air pressure up and down from zero to maximum Observe for fluctuation in gauge response Check for air leaks on air regulator Replace faulty air regulator Replace Unit-Remote selector valve in REMOTE position

Page 61 of 91


Problem

7B

Ref.

Possible Cause

Remedy

1.

Internal Parts Not Moving Properly Because of Extended Inactivity

If the regulator has been out of use over a long period of time, the seals may be preventing the regulator from returning to its original setting: 1. 2.

3. 2.

Seals Are Damaged or Washed out or Debris in Seal Area

1. 2. 3. 4.


Place function valves on control manifold in center position Adjust regulator from zero to full pressure several times. This action will establish a new seat and will also flush out any debris from the seal area Replace control valves to previous positions Place control valves in center position Cycle manual adjustment from zero to full open pressure several times Observe for venting through inspection ports of reservoir If venting persists, replace the regulator

Page 62 of 91


AIR REMOTE CONTROL PANEL PROBLEMS

Ref. 8A

Problem Slow or No Function Operation

Ref.

Possible Cause

Remedy

1.

Low Air Supply Pressure to Panel

Check Air Supply Pressure to Panel. Air supply pressure to panel should be at least 90 PSI for proper operation

2.

Obstruction Preventing Movement of Handle on Hydraulic Control Valve on Manifold

Inspect and remove any articles which may have been inadvertently placed on the four-way control valves which prevent them from operating properly.

3.

Faulty Actuator

See Troubleshooting Section 5A 3 and 5A 4

4.

Clogged Junction Box

Separate junction box plates on both the Air Panel and the Accumulator Unit. Clean ports and inspect junction box gasket. Stand clear of area and purge lines by operating valves from panel. Reconnect junction boxes

5.

Damaged Air Cable

Check entire length of air cable from the Air Panel to the Accumulator Unit for physical damage.

6.

Leaking Control Connections

Repair or replace as necessary Valve

or

Check valves for leaks and repair as necessary. Check all tubing and air cable connections in Air Panel, junction boxes and air cylinders on Accumulator Unit

8B

Valve Handles Hard to Move

1.

No Lubricant in Air Lubricator

Fill lubricator bowl with 10W oil. If condition persists, repair or replace valve

8C

Transmitter Out Of Adjustment

1.

Shock to remote gauge during shipment

1. The transmitter is a reliable but delicate instrument which is easily affected by rough treatment. To correct adjustment, reduce hydraulic pressure on the corresponding gauge to zero 2. Remove transmitter cover. Use a thin screwdriver to adjust valve setting until air receiver gauge on remote panel indicates zero pressure 3. Increase hydraulic pressure in system to 1000 PSI. Adjust receiver gauge on remote panel to corresponding setting 4. Increase hydraulic pressure by 1000 PSI increments until 3000 PSI maximum has been reached 5. Make adjustments to obtain corresponding pressure reading. Use manifold bleeder valve to reduce pressure in 500 PSI increments until pressure drops to zero 6. Make final adjustment to receiver gauge on remote panel CAUTION: DO NOT CHANGE SETTING OF AIR REGULATOR TO TRANSMITTER. MAXIMUM PRESSURE SHALL NOT EXCEED 18 PSI. HIGHER PRESSURES MAY CAUSE DAMAGE TO PIPING INSIDE THE TRANSMITTER

8D

Receiver Gauge Indicates Low or No Pressure


1.

Small hoses inside the transmitter have burst or become disconnected

1. Remove cover from transmitter 2. Listen for escaping air. Locate damaged or disconnected hose and repair 3. Re-calibrate gauge by following steps outlined in the GAUGE PROBLEMS Section of the Guide 4. Observe pressure limit caution.

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

Shut-down of BOP Systems 1. Turn off pumps by closing air supply valves and turning electric motor starter to OFF position. 2. Open manifold bleeder valve to vent all fluid pressure in the system. 3. Disconnect swivel joint assemblies and securely plug the 1” outlets in back of unit. 4. Drain and clean reservoir as thoroughly as possible. 5. Drain oil from crankcase of triplex pump.

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.

CAUTION: USE NITROGEN ONLY, DO NOT USE OXYGEN 7.3.2

Air Pump Assembly 1. Plug the air supply connections. 2. Drain the oil from the lubricator. 3. Open air supply and air pressure switch bypass valves. 4. Open suction valves. 5. Grease exposed pump shaft with rust preventive grease.

7.3.3

Electric Pump Assembly 1. Drain chain guard oil. 2. Open suction valves and electric pump isolator valve. 3. Plug all openings in the motor starter. Remove starter box cover and install fresh corrosion inhibitor and check that drain and breather plugs are open. Replace door. 4. Grease exposed pump arid motor shafts and plunger rod with rust preventive grease.


Page 65 of 91


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.

CAUTION: USE NITROGEN ONLY, DO NOT USE OXYGEN. 7.3.5

Solenoid Valve Box (J-Box) 1. Plug all openings. 2. Open needle supply valve. 3. Open solenoid valve box door and install fresh supply of corrosion inhibitor and check that drain and breather plugs are open. Close door.

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

Nitrogen Backup Assembly 1. Close shutoff valves of each nitrogen bottle. 2. Open nitrogen backup isolator valve.

7.3.8

Low Accumulator Pressure Alarm 1. Plug all openings. 2. Remove alarm box cover and lubricate contacts with dry film electrical lubricant. Replace cover.

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.

7.3.10 Electric Cable 1. Protective caps should be replaced on each of the cable connector plugs. 2. The cable should be stored to protect it from direct sunlight and extreme environmental conditions. This includes ground moisture.


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

CHECKOUT AND RECONDITIONING The following storage of the BOP Control System it is necessary to checkout and recondition it to resume normal operation. 7.4.1

Removing from Storage 1. To remove the external film of protective fluid on the accumulator unit wash with an emulsion cleaner. 2. Visually inspect the accumulator unit, cable and electric panel for physical damage.

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

HYDRAULIC & PNEUMATIC SYMBOLS


Page 68 of 91


ELECTRICAL SYMBOLS


Page 69 of 91


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

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

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


GLOSSARY OF TERMS Ambient Temperature -

The temperature of the all encompassing atmosphere within given areas.

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.

Accumulator Bank Isolator Valve -

The opening and closing device located upstream of the accumulators in the accumulator piping which stops flow of fluids and pressure in piping.

Accumulator Relief Valve -

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.

Air Pressure Switch Bypass Valve -

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.

Air Pump Suction Valve -

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.

Air Supply Valve -

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 -

The device located in the annular manifold header to enable adjustment of pressure levels which will flow past to control the amount of closure of the annular preventer.

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 -

A partition plate inside the reservoir to prevent unbalancing by sudden weight shifting of the hydraulic fluid.

Bleeder Valve -

An opening and closing device for removal of pressurized fluid.

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 -

A valve that permits flow in only one direction.

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 -

An electrical switching device able to carry an electrical current and automatically brake the current to interrupt the electrical circuit if adverse conditions such as shorts or overloads occur.

Conductivity -

The capability of a material to carry an electrical charge. Usually expressed as a percentage of copper conductivity (copper being on hundred percent (100%). conductivity is expressed for a standard configuration of conductor.

Conductor -

The substance or body capable of transmitting electricity, heat, light, or sound.

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 -

The uninterrupted flow of current in a conductor,,

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 -

Any substance which slows or prevents the chemical reactions of corrosion.

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 ói rain, operating within a cylindrical chamber.

Discharge Check Valve -

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.

Electric Pump Suction Valve -

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) -

Apparatus used to clean air flow of dirt, moisture an other contaminants.

Filter (Hydraulic) -

A device whose function is the retention of insoluble contaminants from a fluid.

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.

Full Load Current -

The amount of current used by an electrical circuit is operating at its designed of rated maximum capacity.

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 -

A standard method of specifying the physical size of a conductor (wire) diameter based on the circulator mil system. 1 mil equals 0.001". The higher the number, the smaller the diameter.

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 -

The cavity of a stuffing box.

Ground -

An electrical term meaning to connect to the earth or another large conducting body to serve as earth, thus making a complete electrical circuit. The conducting connection of a circuit to the earth.

Hydrostatic -

Relating to liquids at test and the pressures they exert.

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 -

A non-conductive material usually surrounding or separating the current-carrying parts from each other or from the core.

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.


Page 73 of 91

OPERATOR'S MANUAL 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.

Manifold Regulator Bypass Valve -

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.

Manifold Relief Valve -

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 -

An instrument, operated by an electrical signal, that indicates a measurement of pressure.

Meter Circuit Board -

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 -

A unit of electrical resistance, the resistance of a circuit in which a potential difference of one volt produces a current of one ampere.

Ohmmeter -

The measuring instrument which indicates resistance in chins.

Petcock -

The small faucet or valve used to release compression or drain moisture accumulated in the anterior chamber of the lubricator.

Phase (3-Phase Motor) -

A particular stage or point of advancement in an electrical cycle. The fractional part of the period through which the time has advanced, measured from some arbitrary point usually expressed in electrical degrees where 360/ represents on cycle.

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 -

A liquid is suitable for drinking.

Pressure Switch (Air) -

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) -

An electrical switch, operated by fluid pressure, which automatically starts and stops the electrical pup when the preset pressures are reached.

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 -

An automatic device that reads and records pressure outputs continually on a revolving chart to provide continuous evidence of pressures.

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 opening/closing device which is activated by an electrical signal to control liquid or gas pressure d flow to be sent to open or close the 4-Way control valves. The valve position is controlled by an electromagnetic bar, enclosed by a coil.

Solenoid Valve Box -

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 -

Grouped electrical conductor endings where screw connections are made.

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 -

A device that is positioned as either open or closed, depending on the position of a lever connected to a buoyant material sitting in the fluid to be monitored.

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 -

A valve that opens at a preset pressure to relieve excessive pressures within a vessel or line whose primary function is to limit system pressure.

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 -

A measure of the internal friction or the resistance of a fluid to flow.

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


CONVERSION FACTORS TO CONVERT UNIT(1)

TO UNIT(2)

MULTIPLY UNIT(1) BY:

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.

MULTIPLY UNIT(1) BY: 0.3937

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.

MULTIPLY UNIT(1) BY: 0.06804

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

Celsius °C = 5/9 (°F - 32)

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

4

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.

grams/ cu. cm.

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


Assy. BOP CONTROL SYSTEM, MODEL SSC400-3S11 Dwg. No.: 00000050


Page 82 of 91


INSTALLATION SPECIFICATION BOP CONTROL SYSTEM, Dwg. No.: 00000064


Page 83 of 91


Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 1


Page 84 of 91

Page 84 of 91


Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 2


Page 85 of 91


SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 1


Page 86 of 91


SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 2


Page 87 of 91


Assy. DRILLER'S AIR REMOTE PANEL, Dwg. No.: 00000052


Page 88 of 91


Assy. AIR HOSE BUNDLE FOR DRILLER'S REMOTE PANEL, Dwg. No.: 00000053


Page 89 of 91


Assy. HYDRAULIC HOSE, BOP TYPE 1" SIZE X 50 FT. LONG, Dwg. No.: 00000054


Page 90 of 91


SALES AND SERVICE

PO Box 219143 Houston, Texas 77218-9143 USA Ph: (281) 856-6100 Fax: (281) 856-6200 Parts Sales: [email protected] Service & Technical Support: [email protected]


Page 91 of 91

Koomey s&s Manual

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