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
1.1 ACCUMULATOR UNIT ASSEMBLY 1
1.2 AIR PUMP ASSEMBLY 1
1.3 ELECTRIC PUMP ASSEMBLY 1
1.4 HYDRAULIC CONTROL MANIFOLD ASSEMBLY 1
1.5 AIR REMOTE CONTROL PANEL(S) 2
1.6 AIR REMOTE CONTROL INTERFACE ASSEMBLY 2
1.7 INTERCONNECT CABLE ASSEMBLY 2
1.8 SIZING RECOMMENDATIONS - Normal Pressure and/or Standard Service 3
1.9 SIZING RECOMMENDATIONS - High Pressure And/or H
2
S Environment 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 TYPICAL INSTALLATION PICTORIAL 17
3.2 TYPICAL ACCUMULATOR UNIT ASSEMBLY 18
3.3 TYPICAL INTERCONNECT SCHEMATIC 19
3.4 HYDRAULIC SCHEMATIC TYPICAL CONTROL FLUID CIRCUIT 20
3.5 HYDRAULIC SCHEMATIC TYPICAL CONTROL MANIFOLD CIRCUIT 21
3.6 STARTER CONTROL SCHEMATIC PUMP ELECTRIC MOTOR 22
4 OPERATION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 ACCUMULATORS AND RESERVOIR 24
4.2 AIR PUMP ASSEMBLY 24
4.3 ELECTRIC PUMP ASSEMBLY 25
4.4 CONTROL MANIFOLD ASSEMBLY 26
4.5 AIR REMOTE CONTROL PANEL ASSEMBLY 31
4.6 AIR REMOTE CONTROL INTERFACE ASSEMBLY 34
4.7 INTERCONNECT CABLE ASSEMBLY 34
4.8 ACCESSORIES 34
5 MAINTENANCE INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 INTRODUCTION 37
5.2 SPECIFIC TOOLS LIST 38
5.3 NITROGEN PRECHARGE INSTRUCTIONS - BLADDER TYPE ACCUMULATORS 39
5.4 NITROGEN PRECHARGE INSTRUCTIONS - 80 GALLON SPHERICAL TYPE ACCUMULATORS 41
5.5 ACCUMULATOR UNIT 42
5.6 AIR OPERATED PUMPS 42
5.7 ELECTRIC PUMPS 43
5.8 CONTROL MANIFOLD 45
5.9 AIR PANELS 46
5.10 AIR JUNCTION BOXES 47
6 ACCUMULATOR UNIT TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1 ACCUMULATOR PROBLEMS 49
6.2 AIR SUPPLY PROBLEMS 51
6.3 PUMP PROBLEMS 52
6.4 ELECTRIC MOTOR PROBLEMS 57
6.5 FOUR-WAY VALVE PROBLEMS 58
6.6 GAUGE PROBLEMS 59
6.7 REGULATOR PROBLEMS 61
6.8 AIR REMOTE CONTROL PANEL PROBLEMS 63
7 STORAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.1 INTRODUCTION 64
7.2 INITIAL PREPARATION 64
7.3 FINAL PREPARATION 65
7.4 CHECKOUT AND RECONDITIONING 67
8 REFERENCE MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.1 HYDRAULIC & PNEUMATIC SYMBOLS 68
8.2 ELECTRICAL SYMBOLS 69
8.3 ABBREVIATIONS 70
8.4 GLOSSARY OF TERMS 71
8.5 CONVERSION FACTORS 77
9 SYSTEM SPECIFIC DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.1 SYSTEM DRAWINGS 81
9.1.1 Assy. BOP CONTROL SYSTEM, MODEL SSC400-3S11 Dwg. No.: 00000050 82
9.1.2 INSTALLATION SPECIFICATION BOP CONTROL SYSTEM, Dwg. No.: 00000064 83
9.1.3 Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 1 84
9.1.4 Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 2 85
9.1.5 SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 1 86
9.1.6 SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 2 87
9.1.7 Assy. DRILLER'S AIR REMOTE PANEL, Dwg. No.: 00000052 88
9.1.8 Assy. AIR HOSE BUNDLE FOR DRILLER'S REMOTE PANEL, Dwg. No.: 00000053 89
9.1.9 Assy. HYDRAULIC HOSE, BOP TYPE 1" SIZE X 50 FT. LONG, Dwg. No.: 00000054 90
SALES AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
OPERATOR'S MANUAL
BOP CONTROL SYSTEM WITH AIR REMOTE CONTROL
Produced By: Entrada International, Inc. 2002 Page 1 of 91
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.
1.1.1 Accumulators
Accumulators are ASME coded pressure vessels for storage of high pressure fluid. These accumulators are
available in a variety of sizes, types, capacities and pressure ratings. The two (2) basic types are bladder and float
which are available in cylindrical or ball styles. The accumulators can either be bottom or top loading. Top loading
means the bladder or float can be removed from the top while it is still mounted on the Accumulator Unit. Bottom
loading accumulators must be removed from the Accumulator unit to be serviced. Bladder and buoyant float type
accumulators can be repaired in the field without destroying their stamp of approval.
1.1.2 Reservoir
A rectangular reservoir is provided for storage of the atmospheric fluid supply for the high pressure pumps. It
contains baffles, fill and drain ports and troubleshooting inspection ports. For filling and cleaning procedures see
the Maintenance Section.
1.1.3 Accumulator Piping
This piping connects the high pressure discharge lines of the pumps to the accumulators and the hydraulic
manifold. It is comprised of 1" or 1-1/2" Schedule 80 or 160 pipe, isolator valves and a 3500 psi relief valve to
protect the accumulators form being over-pressured. Cylindrical type accumulators are mounted on machined
headers to minimize line restrictions and leaks.
1.2 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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
1.8 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 Mfg. By Mfg. Type Stack Size Work Press Gal. to Close
Annular 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 35.84
50% Safety Factor + 17.92
Total Gallons of Usable Fluid Required (VR) 53.76 Gallons
OPERATOR'S MANUAL
2. Calculate the total accumulator volume (nitrogen and fluid) required (derived form Boyle's Law, P
1
, V
1
= P
2
V
2
):
P
1
= Maximum pressure of accumulator when completely charged (3000 PSI)
P
2
= Minimum operating pressure of accumulator (1200 PSI)
P
3
= Nitrogen precharged pressure (1000 PSI)
V
1
= Volume of nitrogen at maximum pressure
V
2
= Volume of nitrogen at minimum pressure
V
3
= Total accumulator volume of (nitrogen and fluid)
V
R
= Total usable fluid required including safety factor
R
3
3 3
2 1
V 53.76
V = = = 107.52 110 Ga.
P P 1000 1000
P P 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 107.52
(B) Nominal accumulator capacity (11 - 1 = 10) 10.00
(C) Number of Eleven Gallon Accumulators [AB] 10.75 . 11
TOTAL ACCUMULATOR VOLUME 110 Gallons
OPERATOR'S MANUAL
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) 110.00 Gallons
Actual Fluid Capacity Factor X 0.67 Gallons
Total Actual Fluid Capacity 73.70 Gallons
Divided by 15 Minutes 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.
OPERATOR'S MANUAL
1.9 SIZING RECOMMENDATIONS - High Pressure And/or H
2
S 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 Work Press
Gal. to
Close
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 3.31 3.16
TOTAL 35.95 28.42
The total system accumulator capacity should meet or exceed the following requirements:
Gallons to close all preventers 35.95
Gallons to open all preventers 28.42
Gallons to close all preventers +35.95
Total Gallons of Usable Fluid Required (V
R
) 100.32
2. Calculate the total accumulator volume (nitrogen and fluid) required (derived from Boyle's Law, P
1
V
1
= P
2
V
2
):
R
3
3 3
2 1
V 100.32
V = = = 200.64 200 Ga.
P P 1000 1000
P P 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 200.64
Nominal Accumulator Capacity [11 - 1 = 10] 20.00
Number of Eleven Gallon Accumulators 20.06 . 20
Total Accumulator Volume 200 Gallons
Model Number For Accumulator Unit - SSBA-200-3S11
OPERATOR'S MANUAL
1.9.2 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 25.10
Gallons to Open Choke Valve (est.) + 1.00
Combined Gallons 26.10
Divide by 2 Minutes 2
TOTAL REQUIRED (EACH PUMP) 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. Description Total GPM
A1985-603 Air Pump Assy. 15.00
TPE12-30460 Electric Triplex Pump Assy. 14.20
1.9.3 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 Mfg. By Mfg. Type Stack Size Work Press Gal. to Close
Annular Hydril GK 13-5/8" 5,000 PSI 17.98
Choke Valve - - - - 1.00
TOTAL 18.98
a. Multiply the total gallons to close by 1.5 to arrive at the total gallons required including the safety factor.
EXAMPLE.
Total Gallons Required 18.98
50% Safety Factor + 9.49
Total Volume Required (V
3
) 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 28.47
Divide by Usable Gallons 6.23
Number of Nitrogen Bottles 4.56 . 5
Model Number NBS-0605 Nitrogen Backup Unit
OPERATOR'S MANUAL
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
OPERATOR'S MANUAL
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 Figure 3-1
Typical Accumulator Unit Assembly Figure 3-2
Typical Interconnect Schematic Figure 3-3
Hydraulic Schematic Typical Control Fluid Circuit Figure 3-4
Hydraulic Schematic Typical Control Manifold Circuit Figure 3-5
Starter Control Schematic Pump Electric Motor 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.
OPERATOR'S MANUAL
2.2 ACCUMULATOR UNIT
2.2.1 Set up Location
1. The distance recommended to provide maximum protection of the accumulator unit during a blowout of other
emergencies is approximately 100 to 150 feet from the well bore.
2. Location placement should consider maintenance and service:
a. Accessibility
b. Illumination
c. Ventilation
3. Accumulator Unit SHOULD NOT BE:
a. Placed near oxygen storage.
b. Where there would be high heating effects from surrounding equipment.
4. After initial installation the following steps are recommended.
2.2.2 Inspect Reservoir
1. Open the 4" inspection/fill ports on the sides of the fluid reservoir and make sure the tank is free of any debris
that could contaminate the system. A clean reservoir reduces maintenance costs. For reservoir cleaning
procedures see Maintenance Section.
2. Make sure all reservoir connections are tightly secured
2.2.3 Fill Reservoir
1. Fill with a high quality SAE 10 Hydraulic Oil to 8" from the top of the reservoir.
2.2.4 Check Accumulator Precharge (See Nitrogen Precharge Instructions in the Maintenance Section)
1. Open the manifold bleeder valve.
2. Open the accumulator bank isolation valves.
3. Remove the guard from the valve stem of the accumulator and attach a Charging and Gauging Assembly.
4. Screw on gauge and screw down T-handle.
5. Gauge pressure reading should be 1000 PSI 100 PSI.
a. 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
OPERATOR'S MANUAL
2.2.5 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.
OPERATOR'S MANUAL
2.2.9 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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
2.3 AIR PANEL INSTALLATION
2.3.1 Set up Location
1. Install air panels securely on firm foundation, taking into consideration the following factors.
a. Operation and service accessibility.
b. Illuminated areas.
c. Unobstructed ventilation.
d. 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. Make sure the accumulator bleeder valves are closed.
b. Make sure the manifold bleeder valve is open.
c. Make sure pump suction valves are open.
d. Center all four-way control valves.
e. Place the unit/remote selector valve in the REMOTE position.
f. Start pumps.
g. 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.
OPERATOR'S MANUAL
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
OPERATOR'S MANUAL
2.5 INSTALLATION DATA SHEET
2.5.1 Electric Pump Assembly
Model No. HP
Starter
Connection
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
Model No. Air Motor Dia. (in.) No. of Pumps CFM GPM @ 3000 PSI
A197-601 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
OPERATOR'S MANUAL
3 TYPICAL SYSTEM DRAWINGS
3.1 TYPICAL INSTALLATION PICTORIAL
FIGURE 3-1
OPERATOR'S MANUAL
3.2 TYPICAL ACCUMULATOR UNIT ASSEMBLY
FIGURE 3-2
OPERATOR'S MANUAL
3.3 TYPICAL INTERCONNECT SCHEMATIC
FIGURE 3-3
OPERATOR'S MANUAL
3.4 HYDRAULIC SCHEMATIC TYPICAL CONTROL FLUID CIRCUIT
FIGURE 3-4
OPERATOR'S MANUAL
3.5 HYDRAULIC SCHEMATIC TYPICAL CONTROL MANIFOLD CIRCUIT
FIGURE 3-5
OPERATOR'S MANUAL
3.6 STARTER CONTROL SCHEMATIC PUMP ELECTRIC MOTOR
FIGURE 3-6
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
4.1 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.
4.1.2 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.
4.2 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
OPERATOR'S MANUAL
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.
4.2.2 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.
OPERATOR'S MANUAL
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).
OPERATOR'S MANUAL
4.4.2 Regulators
The double manifold, designed to accommodate variable pressure requirements, consists of a manifold regulator
assembly, bypass valve assembly and an annular regulator assembly.
1. Manifold regulator assembly - the manifold regulator (Item 25 Fig. 4-1) reduces the 3000 PSI fluid pressure
from the accumulator to a maximum of 1500 PSI. This regulated pressure is the supply to operate the ram
type preventers and gate valves; pressures greater than 1500 PSI cannot be regulated. The pressure setting
of this regulator must be manually adjusted; to do this:
a. Loosen the locknut on the adjustment handle and hold with one hand.
b. Rotate the regulator adjustment handle with other hand.
(1) To increase pressure, rotate clockwise.
(2) To decrease pressure, rotate counterclockwise.
c. Read manifold pressure gauge (Item 35 Fig. 4-1) for pressure setting of the regulator. Set at desired
pressure.
d. 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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
TYPICAL ACCUMULATOR UNIT ASSEMBLY
FIGURE 4-1
OPERATOR'S MANUAL
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
OPERATOR'S MANUAL
4.5 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.
OPERATOR'S MANUAL
TYPICAL AIR REMOTE CONTROL PANEL
FIGURE 4-2
OPERATOR'S MANUAL
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
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
OPERATOR'S MANUAL
4.6 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.
4.6.1 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.
4.7 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.
OPERATOR'S MANUAL
2. To operate the nitrogen backup system during emergency situations.
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.
4.8.2 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:
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.
4.8.3 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.
OPERATOR'S MANUAL
2. To operate the rig skid outlet to the rig skid outlet:
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.
4.8.4 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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
5.2 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
OPERATOR'S MANUAL
5.3 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.
OPERATOR'S MANUAL
CHARGING AND GAUGING ASSEMBLY
NITROGEN PRECHARGE INSTRUCTIONS
WARNING: USE NITROGEN ONLY - DO NOT USE OXYGEN!
A. Remove the valve guard and secondary valve cap from the
accumulator and attach a Charging and Gauging Assy. (Part
No. 001-1000) .
B. Screw down T-handle to check nitrogen precharge pressure.
It should read 1000 PSI 10%.
1. If pressure is low, attach the precharge line from the
Charging and Gauging Assy. to the nitrogen bottle.
CAUTION - Gradually open valve 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 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 Description Qty.
Assy. 001-1000 Charging & Gauging Assy. 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
OPERATOR'S MANUAL
5.4 NITROGEN PRECHARGE INSTRUCTIONS - 80 GALLON SPHERICAL TYPE ACCUMULATORS
NOT APPLICABLE
OPERATOR'S MANUAL
5.5 ACCUMULATOR UNIT
5.5.1 Fluid Reservoir
1. The fluid reservoir should be checked regularly, drained, and cleaned to eliminate sludge build-up. The control
fluid should be kept clean and free of debris. A high quality SAE 10W hydraulic oil or a suitable light weight
oil should be used in the system. NEVER use fuel oil, kerosene, or salt water in the reservoir.
2. To clean the reservoir use the following procedure:
a. Stop pumps.
b. Open manifold bleeder valve and release system pressure.
c. Drain the fluid from the system. Remove any sludge/slime or other material from the reservoir.
d. Flush the entire system with 140 Deg. F hot water (60 Deg. C).
e. 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. Rinse the system thoroughly with hot water.
g. Refill the system with hydraulic fluid mixture.
h. Start pumps and operate to ensure that pumps are primed.
i. 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.
5.6 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. Stop pumps.
b. Unscrew housing, lift out O-Ring and louver.
c. Remove filter elements and wash in warm water or kerosene. Dry elements and check that bowl gasket
is in good condition.
d. Replace parts and housing.
OPERATOR'S MANUAL
5.6.4 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.
5.6.5 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.
OPERATOR'S MANUAL
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.
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.
5.7.2 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.) Oil Type
DPE21-05
DPE21-07
4
SAE 20 @ 0 Deg. F - 115 Deg. F
SAE 10 @ 0 Deg. F - 60 Deg. F
TPE06-10, TPE06-15,
TPE06-20, TPE21-25
5-1/2
TPE21-30 7
TPE21-40, TPE21-50,
TPE21-60
9
2. Clean the pump crankcase of accumulated sludge.
OPERATOR'S MANUAL
5.7.3 Chain Guard
1. Remove the lower drain plug and check for water or sludge build-up.
2. Check the oil level in the oil bath chain guard. It should be filled up to the spill plug.
CHAIN GUARD 0IL SPECIFICATIONS
a. Above 20 Deg. F use SAE 90 Compound Chain Oil.
b. 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.
OPERATOR'S MANUAL
5.8.3 Air Cylinders
1. Clean piston rods of corrosion by wiping with an emery cloth.
2. Lubricate the piston rods on the air cylinders with a good quality silicone based lubricant.
3. Grease the mounting bolt on the air cylinder.
5.8.4 Filters
2. Clean elements.
a. Stop pumps.
b. Unscrew housing, lift out o-ring and louver.
c. Remove filter elements and wash in warm water or kerosene.
d. Dry elements and check that bowl gasket is in good condition.
e. Replace parts and housing.
5.8.5 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
2. Clean elements.
a. Stop pumps.
b. Unscrew housing, lift out O-ring and louver.
c. Remove filter elements and wash in w-arm water or kerosene.
d. Dry elements and check that bowl gasket is in good condition.
e. Replace parts and housing.
OPERATOR'S MANUAL
5.9.3 Gauges
1. Ensure that gauges are properly zeroed when there is no pressure in the system. Use zero adjustment screw
on face of gauge to zero needle.
2. If the readings of the air receiver gauges on the air remote control panel do not match the readings of the
gauges on the Control Manifold, adjust the setting of the transmitter air regulator until readings correspond.
5.9.4 Check-Out
1. Visually check ail connections for possible leaks.
2. Repair as necessary.
5.10 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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
6.1 ACCUMULATOR PROBLEMS
Ref. Problem Ref. Possible Cause Remedy
1A Loss of Accumulator Precharge
Pressure (Bladder Type)
1. Faulty precharge valve permits
nitrogen to escape
1. Stop pumps
2. Open manifold bleeder valve and relieve all
system pressure
3. Check precharge pressure on each
accumulator and record
4. Tighten valve cores snugly with valve core tool
5. 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)
6. Observe precharge pressure on precharge
gauge. If pressure does not decrease, remove
gauge
7. Check all precharge valves for gas leaks by
placing drops of saliva across tops of valves
(light oil may also be used.)
8. If valve:
9. bubbles, nitrogen is escaping. Replace valve
core. (See Maintenance Section.)
10. does not bubble, accumulators are ready for
normal use
11. Close manifold bleeder valve
12. Start pumps. Stop pumps
2. Ruptured bladder 1. Stop pumps
2. Bleed fluid system pressure by slowly opening
bleeder valve
3. Listen for poppet valves to close while
observing accumulator pressure gauge
4. If poppet valves do not close at precharge
pressure, and pressure continues to drop to
zero, at least one accumulator has lost its
precharge
5. Check and record precharge pressure of each
accumulator
6. Those with zero precharge may have faulty
bladders. To check this
7. Tighten valve cores snugly with valve core tool;
8. Precharge with 200 PSI of nitrogen. If pressure
does not decrease;
9. Precharge with 1,000 PSI of nitrogen
10. If an accumulator does not sustain 200 PSI
precharge, the bladder is ruptured and must be
replaced. (See Maintenance Section.)
12. Start pumps
OPERATOR'S MANUAL
1B Loss of Accumulator Precharge
Pressure (Float Type)
1. Poppet valve being held open by
debris
1. Pressure up accumulator to 200 PSI fluid
pressure
2. Open bleeder valve to flush out debris
3. Repeat procedure several times
4. If no improvement release all fluid pressure
from accumulator, remove poppet and repair
2. Faulty precharge valve permits
nitrogen to escape
1. Tighten valve core snugly with valve core tool.
2. Precharge accumulator to 1000 PSI
3. Observe precharge pressure on precharge
gauge
4. 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
1C Float partially filled with fluid. 1. Premature closing of poppet valve 1. Bleed off precharge
2. Remove poppet valve assembly and guide rod,
upset float and drain liquid
3. Replace guide rod and poppet valve assembly
4. Precharge accumulator with nitrogen
5. Close bleeder valve and pressure up
accumulator to 3000 PSI fluid pressure
6. Open bleeder valve to expend fluid rapidly. If
poppet valve precloses prematurely again, float
may be damaged and vessel needs to be
repaired
1D Poppet Valve Closed 1. Float fully filled with fluid 1. 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
2. After pressure has been reduced to zero,
disconnect accumulator and remove poppet
assembly and guide rod
3. Upset float and drain all liquid from float
4. Re-install removed parts and reconnect
accumulator
5. Precharge accumulator with 1000 PSI of
nitrogen
6. Close bleeder valve and pressure up
accumulator with 3000 PSI of fluid
7. Open bleeder valve to dump fluid rapidly from
accumulator
8. If poppet does not close prematurely,
accumulator is ready for service
9. If float sinks again, remove accumulator and
repair float
OPERATOR'S MANUAL
6.2 AIR SUPPLY PROBLEMS
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. Close accumulator isolator valves
2. Turn motor starter to OFF position
3. Open manifold bleeder valve
4. Operate air pumps at full capacity
5. Open lubricator fill cap
6. Use a thin screwdriver to adjust lubricator to
provide six (6) drops of oil per minute. Rotation
of metering screw:
7. Clockwise - increases flow
8. Counterclockwise decreases flow
10. Open accumulator isolator valves
11. Turn motor starter to AUTO position
2C Air Operated Pumps Icing Over or
Freezing
1. Moisture in rig air supply 1. Make sure unit is being supplied with CLEAN,
DRY air
2. Cut off main air supply to unit
3. Close accumulator isolator valves
5. Open petcock at bottom of air lubrication bowl
and drain accumulated moisture
6. Remove plug from "Y" shaped strainer
7. Open main air supply valve to the unit
9. Run air pumps at full capacity until all moisture
has been removed
10. Close air supply valves to stop pumps
11. Cut off main air supply to unit
12. Replace plug in "Y" strainer"
13. Open main air supply to unit
16. Open air supply valves
OPERATOR'S MANUAL
6.3 PUMP PROBLEMS
3A Pumps Run Excessively 1. Air pump pressure switch bypass
valve open or faulty
1. Close the bypass valve tightly
2. 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
3. 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
4. Check pump shutoff pressure
2. Hydraulic seals in automatic
pressure switch are leaking
1. Stop pumps
2. Open manifold bleeder valve and relieve system
pressure
3. Remove automatic pressure switch for
inspection
4. Replace pressure switch and adjust setting
6. Start pumps
7. Check pressure switch settings
3. Faulty precharge valve (bladder
type separator)
1. Stop pumps
3. Check precharge pressure on each
accumulator and record
4. Tighten each precharge valve assembly by
using valve core tool
5. Precharge each accumulator with 1000 PSI of
nitrogen starting with accumulator that had
highest recorded pressure. This will conserve
nitrogen
6. 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
8. Start pumps
4. Four-Way valve leaking 1. Open inspection ports located at each end of
reservoir
2. Observe which valve is leaking
3. Manipulate manually several times
4. If leaking persists, remove valve
5. Use special repair kits containing necessary
parts for overhaul
6. 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
5. Relief valve leaking 1. Open inspection ports at each end of reservoir
2. Observe relief valve return lines to see which
one is leaking
3. Note pressure reading on gauge when flow
begins to check if setting is incorrect
4. Remote and replace faulty valve
OPERATOR'S MANUAL
6. Regulator Leaking 1. Open inspection ports at each end of reservoir
2. Observe regulator return lines to check if
leaking
3. Remove and replace faulty regulator
7. Bleeder Valve Leaking 1. Close manifold bleeder valve tightly
2. Check for leakage by looking through
inspection ports located at each end of
reservoir
3. If valve is leaking, remove and replace it
8. Leaks in Fluid System 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
OPERATOR'S MANUAL
9. Loss of precharge pressure 1. Stop pumps
2. Bleed fluid system pressure by slowly opening
bleeder valve
3. Listen for poppet valves to close while
observing accumulator pressure gauge
4. If poppet valves do not close at precharge
pressure, and pressure continues to drop to
zero, at least one accumulator has lost its
precharge
5. 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
6. If an accumulator does not sustain 200 PSI
precharge, the bladder is ruptured and must be
replaced (See Maintenance Section.)
8. Start pumps
3B Pumps Shut Down at Wrong
Pressure
1. Air pump pressure switch out of
adjustment
1. Stop pumps
3. Make sure air bypass valve is tightly closed
4. Open manifold bleeder valve to relieve system
pressure
6. Open air pump supply valves
7. Adjust pump shutoff pressure setting (See
Maintenance Section) until pump stops running
when the desired fluid pressure has been
reached on accumulator gauge
8. Bleed off manifold pressure through bleeder
valve and repeat procedure to check accuracy
of setting
2. Electric pressure switch out of
adjustment
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
OPERATOR'S MANUAL
3C Pump Cannot Reach Full Pressure 1. Faulty check valve in air pump 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. Stop pumps
2. Close isolator valves with pressured up
accumulators
3. Open bleeder valve and bleed off manifold
pressure
4. Remove suspected air pump
5. Clean, repair, or replace as necessary
6. Reinstall pump
7. Start air pump and operate with bleeder valve
open to make sure that the pump is properly
primed
8. Close bleeder valve
9. Open isolator valves
10. Start pumps and pressure up system
2. Low air supply 1. Check rig main air supply gauge for proper air
supply pressure (See Installation Data Sheet.)
2. Correct air supply at rig main air compressor.
3D Pumps Produce No Pressure 1. Loss of pump prime because of low
fluid level
To restore 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
9. Check reservoir fluid level. Add oil if needed
2. Suction valve closed Check that pump suction valves are in full open
position.
3. Fluid Contamination 1. Close accumulator isolator valves if
accumulator pressure gauge shows pressure is
contained
2. Stop pumps
4. Open air pump supply valves and start air
operated pumps
5. 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
OPERATOR'S MANUAL
3E Pumps Leaking 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. Stop pumps
2. Close pump suction valve
3. Remove valve cover plate
4. Remove and inspect valve cover gaskets
5. Replace gaskets if they appear to be distorted,
washed out, or compressed excessively
6. If gaskets appear to be good, invert and
reinstall
7. Replace cover plate and tighten bolts
8. Open suction valve
11. Operate pump and check for new leaks
OPERATOR'S MANUAL
6.4 ELECTRIC MOTOR PROBLEMS
4A Motor Fails to Start 1. Pressure Switch Faulty 1. Turn motor starter to OFF position
2. Turn off power at main generator panel or MCC
3. Remove pressure switch explosion proof cover
4. Disconnect leads from electrical pressure
switch
5. Check resistance across terminals of pressure
switch with an Ohm meter. If resistance is
observed, the switch is working properly
6. If no resistance is found, replace the limit
switch or, if time is limited, replace the entire
pressure switch assembly (See Maintenance
Section.)
7. Replace the leads from starter to pressure
switch (See Starter Wiring Diagram.)
8. Turn on power at main generator panel or MCC
10. Check for proper adjustment to settings (See
Maintenance Section)
11. Replace pressure switch explosion-proof
housing cover
2. Starter Tripped If power supply had a thermal overload:
2. Press reset button on motor starter
3. Loss of Power Supply 1. Turn motor starter to OFF position
2. Check voltage of power supply to starter at
main generator panel
3. Restore power supply from main generator
panel
4B Motor Runs Erratically 1. Voltage Fluctuation If pump pressure is at proper desired setting and
pump stops frequently, input voltage may be too low.
1. Turn motor starter of OFF position
2. Check and correct voltage at main generator
panel
2. Pressure Switch Span out of
Adjustment
If pump continues to stop and start after reaching the
proper pressure setting, switch adjustment may be
necessary. a.
1. Close air supply valves
2. Check that starter switch is in AUTO position.
CAUTION: ELECTRICAL CONTACTS HAVE
LIVE POWER
3. Remove pressure switch cover
4. Move white adjustment wheel down or toward
the front
5. Open manifold bleeder valve and reduce
pressure to desired pump starting pressure
7. Move adjustment lever back (up or towards
rear) until pump starts
8. After pump stops, check results to make sure
proper setting has been obtained
9. Replace pressure switch cover
OPERATOR'S MANUAL
6.5 FOUR-WAY VALVE PROBLEMS
NOTE: VALVE VENTING MAY BE CAUSED BY LEAKING SEALS IN THE PREVENTER.
5A Inter-flowing 1. Debris in the Valve 1. Stop pumps
3. Dislodge debris by manually shifting the valve
handle through the full range
4. Repair shifting several times until Interflow has
been cleared up
6. Start pumps
2. Washed out or damaged seals 1. Remove and replace the valve
2. Use special repair kits containing necessary
parts for overhaul
3. 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
3. Actuator rod out of adjustment 1. Adjust clevis locknut so actuator rod obtains full
travel
2. Check lever travel
a. Start pumps
b. Pressure up system
c. Operate function from remote panel
4. Actuator faulty 1. Remove cylinder
2. Inspect for debris, wear or other damage
3. If dirt wiper is blown out, either:
a. The rod seal is leaking
b. There is excess grease in the grease fitting
4. Repair or replace as necessary
5. Replace cylinder
5. Insufficient Pressure Check all interface points for leaks or open
connections.
OPERATOR'S MANUAL
6.6 GAUGE PROBLEMS
NOTE: ACCEPTABLE INDICATION LIMITS ARE 50 PSI FROM TRUE PRESSURE.
6A Gauge Out of Adjustment -
Manifold or Annular Pressure
Gauges
1. Shock due to rough treatment 1. Close accumulator isolator valves
2. Stop pumps
pressure
4. Remove gauge face covering
5. Adjust gauge indicator to zero setting with a
thin screwdriver blade
6. Replace gauge face cover
7. Loosen gauge fitting and bleed off any trapped
air
8. Re-tighten fitting
12. 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
15. Start pumps and restore system pressure
Gauge Out of Adjustment -
Accumulator Pressure Gauges
1. Shock due to rough treatment 1. Stop pumps
pressure
3. Remove gauge face covering
4. Adjust gauge indicator to zero setting with a
thin screwdriver blade
5. Replace gauge face cover
6. Loosen gauge fitting and bleed off any trapped
air
7. Re-tighten fitting
11. 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
14. Start pumps and restore system pressure
Gauge Out of Adjustment - Fluid
Filled Gauges
1. Shock due to rough treatment 1. Remove defective gauge and replace with a
known working unit
2. Send the defective gauge to vendor for factory
calibration.
An alternate method of checking a faulty gauge can be
used:
1. Connect the faulty gauge supply line to a
common manifold with a gauge of known
accuracy.
2. Adjust faulty gauge if possible.
3. Acceptable indication limits are 50 PSI from
true pressure
OPERATOR'S MANUAL
6B Gauge Responds Slowly -
Accumulator Pressure Gauges
1. Supply line or snubber clogged -
Accumulator Pressure
When gauge responds slowly or in an erratic manner
during operation:
1. Stop pumps
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
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. Place valves in center position
2. Reduce hydraulic pressure to zero (0) by
adjusting regulators
3. Remove tubing and snubber from gauge
4. If gauge indicates pressure, re-calibrate to zero
(0)
5. 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
6. Reassemble tubing, snubber and gauge
7. Cycle regulated fluid pressure to 1000 PSI and
back down again to zero
8. Check that gauge indicates zero (0). If it does
not, replace gauge with a known working unit
OPERATOR'S MANUAL
6.7 REGULATOR PROBLEMS
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. Place function control valves on control
manifold in center position
2. Observe return lines through inspection ports
3. Locate air regulator which supplies pilot
pressure to the fluid pressure regulator
4. Turn the air regulator handle from closed to full
open
5. Repeat this procedure several times
6. If venting of air operated hydraulic regulator
valve continues, the valve should be replaced or
repaired
7. If valve regulates properly, place function valves
in normal DRILL AHEAD position (see
Installation Section.)
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:
2. Stop pumps
3. Open manifold bleeder valve and relieve
pressure
4. Reduce pressure on air regulator to zero
5. Remove air pilot line from top of diaphragm
housing
6. Remove upper half of diaphragm housing
7. Remove and inspect gasket
8. Replace gasket if damaged
9. Reassemble and tighten bolts evenly around
the diaphragm housing flange
10. Connect air pilot line to top of diaphragm
housing
11. Check all connections for potential air leaks
3. Manual Air Regulator Leaking The air regulator is located on top of the hydraulic
manifold next to the Unit-Remote selector lever:
1. Place Unit-Remover selector valve in UNIT
position
2. Regulate air pressure up and down from zero to
maximum
3. Observe for fluctuation in gauge response
4. Check for air leaks on air regulator
5. Replace faulty air regulator
6. Replace Unit-Remote selector valve in
REMOTE position
OPERATOR'S MANUAL
7B 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. Place function valves on control manifold in
center position
2. 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
3. Replace control valves to previous positions
2. Seals Are Damaged or Washed out
or Debris in Seal Area
1. Place control valves in center position
2. Cycle manual adjustment from zero to full open
pressure several times
3. Observe for venting through inspection ports of
reservoir
4. If venting persists, replace the regulator
OPERATOR'S MANUAL
6.8 AIR REMOTE CONTROL PANEL PROBLEMS
8A Slow or No Function Operation 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.
Repair or replace as necessary
6. Leaki ng Cont rol Valve or
Connections
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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
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.
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.
7.2.3 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.
OPERATOR'S MANUAL
7.3.4 Manifold Assembly
1. Place all lever operated control valves in OPEN (handle-left) position. This includes bypass, Unit/Remote
selector and accumulator isolator valve.
2. Grease exposed cylinder shaft with rust preventive grease.
3. Open manifold bleeder valve.
4. Adjust regulator handles counterclockwise as far as possible.
5. Ensure that pre-charge on surge dampener is 400 PSI.
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
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
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.
OPERATOR'S MANUAL
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.
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.
OPERATOR'S MANUAL
8 REFERENCE MATERIAL
8.1 HYDRAULIC & PNEUMATIC SYMBOLS
OPERATOR'S MANUAL
8.2 ELECTRICAL SYMBOLS
OPERATOR'S MANUAL
8.3 ABBREVIATIONS
ADJ . . . . . . . . . . . . . . . . . . adjust
AMB . . . . . . . . . . . . . . . . . ambient
AR . . . . . . . . . . . . . . . . . . . as required
ASME . . . . . . . . . . . . . . . . American Society of Mechanical Engineering
ASSY . . . . . . . . . . . . . . . . assembly
AWG . . . . . . . . . . . . . . . . . American Wire Gage
BOP . . . . . . . . . . . . . . . . . blowout preventer
BRZ . . . . . . . . . . . . . . . . . . bronze
/ C . . . . . . . . . . . . . . . . . . . Celsius scale for temperature measurement
CD PL . . . . . . . . . . . . . . . . cadmium plate
CFM . . . . . . . . . . . . . . . . . cubic feet per minute
CFS . . . . . . . . . . . . . . . . . . cubic feet per second
CG . . . . . . . . . . . . . . . . . . center of gravity
CHK . . . . . . . . . . . . . . . . . check
CLN . . . . . . . . . . . . . . . . . . clean
DR . . . . . . . . . . . . . . . . . . . drain
EH . . . . . . . . . . . . . . . . . . . electro-pneumatic
EP . . . . . . . . . . . . . . . . . . . electro-pneumatic
/ F . . . . . . . . . . . . . . . . . . . Fahrenheit scale for temperature measurement
GPM . . . . . . . . . . . . . . . . . gallons per minute
HP horsepower - A unit for measuring the power of motors. One horsepower equals 33,000
foot-pounds of work per minute.
Hz hertz - Preferred terminology for cycles per second, the frequency of an electrical wavelength.
ID . . . . . . . . . . . . . . . . . . . inside diameter
INC/DEC increase/decrease. The control function that regulates the pressure to be applied to the annular
valve on the BOP stack.
K . . . . . . . . . . . . . . . . . . . . wire abbreviation. Relay coil; signal relay. Constant used to denote insulation resistance.
MTD . . . . . . . . . . . . . . . . . mounted
NC . . . . . . . . . . . . . . . . . . . normally closed
NO . . . . . . . . . . . . . . . . . . normally open
NPT . . . . . . . . . . . . . . . . . . national pipe thread
OD . . . . . . . . . . . . . . . . . . outside diameter
PL . . . . . . . . . . . . . . . . . . . plate - The application of one metal over another.
PPM . . . . . . . . . . . . . . . . . parts per million
PSI . . . . . . . . . . . . . . . . . . pounds per million
RPM . . . . . . . . . . . . . . . . . revolutions per minute
SAE . . . . . . . . . . . . . . . . . . Society of Automotive Engineers
SCH . . . . . . . . . . . . . . . . . schedule - Pipe classifications.
SPM . . . . . . . . . . . . . . . . . strokes per minute - Sub-plate mounted.
STD . . . . . . . . . . . . . . . . . . standard
UNC . . . . . . . . . . . . . . . . . United National Coarse - The measuring standard for pipe threads.
VAC volts alternating current - An electric current that continually reverses its direction, giving a
definite plus and minus wave-form at fixed intervals.
VDC . . . . . . . . . . . . . . . . . volts direct current - An electrical current that flows in one direction only.
WOG . . . . . . . . . . . . . . . . . water, oil, or gas
OPERATOR'S MANUAL
8.4 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.
OPERATOR'S MANUAL
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 i 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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
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.
OPERATOR'S MANUAL
8.5 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. 6.452
sq. in. sq. ft. 0.006944
sq. ft. sq. in. 144
sq. ft. sq. mts. 0.0929
sq. ft. acres 0.0000229568
sq. ft. sq. in.. 0.00000003587
sq. yds. sq. mts. 0.8361
sq. km. sq. ml. 0.3861
sq. mts. acres 0.0002471
sq. mts. sq. mi. 0.00000038610
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
OPERATOR'S MANUAL
TO CONVERT
UNIT(1)
LENGTH CONVERSIONS cm. in. 0.3937
cm. meters 0.01
in. cm. 2.54
in. yds. 0.02778
ft. cm. 30.48
ft. meters 0.3048
ft. miles (stat.) 0.00189
yd. ft. 3
yd. meters 0.9144
yd. meters 0.6214
meter ft. 39.37
meter yds. 1.094
meter miles (stat.) 0.00621
rod ft. 16.5
mile (stat.) ft. 5,280.00
mile (stat.) yd. 1,760.00
mile (stat.) km 1.609
furlong ft. 660
furlong rods 40
fathom ft. 6
fathom meters 1.828804
league miles (approx.) 3
Light Years miles 0.000000000059
TO CONVERT
UNIT(1)
POWER AND FLOW CONVERSIONS hp. hp.(metric) 1.014
hp. watts 745.7
hp. ft. lbs./min. 33,000.00
hp. BUTS/min. 42.44
BTU ft. lbs. 778.26
BUTS/min. hp. 0.02356
BUTS/min. watts 17.57
watt hp. 0.001341
watt BTU/min. 0.05692
watt ft. lbs./min. 44.26
kW/hr. ft. lbs. 0.000002655
kW/hr. BTU 3415
GPM CFRN 0.13368
OPERATOR'S MANUAL
TO CONVERT
UNIT(1)
PRESSURE CONVERSIONS PSI Atm. 0.06804
PSI ft. H
2
O 2.307
PSI kg./sq. cm 0.07031
Atm. ft. H
2
O 33.9
Atm. PSI 14.7
Atm. kg./sq. cm 1.0333
ft. H
2
O Atm. 0.0295
ft. H
2
O PSI 0.4335
kg./sq. cm PSI 14.22
TEMPERATURE CONVERSIONS Celsius C = 5/9 (F - 32)
Fahrenheit F = (9/5 * C) + 32
Kelvin K = C + 273.15
Rankin R = F + 459.67
TO CONVERT
UNIT(1)
VOLUME CONVERSIONS
2 oz.
approx. drops
(oil)
600
oz. cu. in. 1.805
oz. liters 0.02957
Cu. in.
approx. drops
(oil)
330
Cu. in. gallons 0.004329
Cu. in. liters 0.01639
Cu. ft. cu. meter 0.02832
Cu. ft. liters 28.32
Cu. ft. gallons 7.48052
Cu. ft. liters 9.463
Cu. ft. gallons 7.48052
gallons quart 4
gallons cu. in. 231
gallons cu. in. 0.1337
gallons cu. ft. 3.785
ga. (H
2
O) lb. (H
2
O) 8.3453
liter gallon 1.057
liter gallon 1.2642
liter cu. in. 61.02
barrel (oil) gallons 42
barrel gallons 31.5
OPERATOR'S MANUAL
TO CONVERT
UNIT(1)
WEIGHT CONVERSIONS 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. H
2
O lbs./cu. Ft. 62.43
lbs. oz. 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./ H
2
O gallons 0.1198
lbs. Cu. ft. 0.01
kg. lbs. 2.205
kg. tons short) 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
OPERATOR'S MANUAL
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
OPERATOR'S MANUAL
9.1.1 Assy. BOP CONTROL SYSTEM, MODEL SSC400-3S11 Dwg. No.: 00000050
OPERATOR'S MANUAL
9.1.2 INSTALLATION SPECIFICATION BOP CONTROL SYSTEM, Dwg. No.: 00000064
OPERATOR'S MANUAL
Produced By: Entrada International, Inc. 2002 Page 84 of 91 Produced By: Entrada International, Inc. 2002 Page 84 of 91
9.1.3 Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 1
OPERATOR'S MANUAL
9.1.4 Assy. BOP ACCUMULATOR WITH 8-FUNCTIONS AND 1 AIR REMOTE PANEL, Dwg. No.: 00000051 Pg. 2
OPERATOR'S MANUAL
9.1.5 SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 1
OPERATOR'S MANUAL
9.1.6 SCHEMATIC Assy. BOP ACCUMULATOR, Dwg. No.: 00000063 Pg. 2
OPERATOR'S MANUAL
9.1.7 Assy. DRILLER'S AIR REMOTE PANEL, Dwg. No.: 00000052
OPERATOR'S MANUAL
9.1.8 Assy. AIR HOSE BUNDLE FOR DRILLER'S REMOTE PANEL, Dwg. No.: 00000053
OPERATOR'S MANUAL
9.1.9 Assy. HYDRAULIC HOSE, BOP TYPE 1" SIZE X 50 FT. LONG, Dwg. No.: 00000054
OPERATOR'S MANUAL
SALES AND SERVICE

PO Box 219143
Houston, Texas 77218-9143 USA
Ph: (281) 856-6100
Fax: (281) 856-6200
Parts Sales: sales@entradaintl.com
Service & Technical Support: support@entradaintl.com

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