C-MAR SUBSEA TRAINING SCHOOL

CONTENTS

Section 1: Wellhead and Lower Marine Riser Package

Connectors

Section 2: Ram Blowout Preventers

Section 3: Annular (Spherical) Blowout Preventers

Section 4: Gate Valves

Section 5: Riser Systems

Section 6: Diverter Systems

Section 7: BOP Control Systems

Section 8: Motion Compensators

Section 9: Introduction to deepwater

Section 10: Engineering / Reference

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 SECTION 1

WELLHEAD AND LOWER MARINE RISER PACKAGE

CONNECTORS

• General Operating Principles

• Cameron Type 70 and HC Connectors
• Vetco H4 Connectors
• Dril-Quip Type DX Connectors
• Backdriving of Hydraulic Connectors

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Wellhead and Riser Connectors
Connectors are hydraulically operated devices which are used to connect the BOP
stack to the wellhead and the Lower Marine Riser Package (LMRP) to the BOP.
Locking segments are actuated which mesh into the locking profile of the wellhead or
BOP mandrel. With a ring gasket installed, connectors form a tight seal while
withstanding the bending stresses and separation forces caused by well pressure, riser
tension and vessel motion. There are two basic styles of connector, the multiple piston
type and the annular piston type. Each style of connector will, in general, have a
single lock function and two independent unlock functions (some early connectors
were manufactured with only a single unlock function). Connectors are designed so
that the surface area of the unlock side of the piston(s) is greater than the surface area
of the lock side of the pistons. This ensures that a greater unlocking force can be
generated than locking force.

The amount of preload a connector can generate is a function of the connector design
and hydraulic locking pressure. Preload can be defined as the compressive contact
force between the connector upper body and the top of the wellhead (or BOP
mandrel). The greater the preload, the more resistance is in place to withstand bending
and separation forces.

Connectors commonly used in a BOP assembly include the Vetco H4, Cameron
Types 70 and HC, and the Dril-Quip DX connector.

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Cameron Connectors

Type 70 Connector
The Cameron type 70 connector is a multiple cylinder model that locks to the mating
hub on the wellhead or BOP by means of pivoted locking segments shaped like
locking fingers. The segments initially form a funnel which guides the connector into
position on the mating hub. An actuating ring pulled down by the operating cylinders
causes the locking segments to pivot around the hub profile of the connector upper
body (termed “body centre section” by Cameron) and engage the mating hub. The 25
degree angle on the locking segment faces, and the hub profiles, create an adequate
clamping force or preload. When unlocking pressure is applied, the actuating ring
moves upwards rotating the locking segments to the fully open position that can allow
disconnection at angles up to 30 degrees. The type 70 connector is normally fitted
with two manual override rods which can be used to raise the actuator ring and unlock
the connector.

The number of operating cylinders varies with connector size and working pressure,
but is typically six or nine. The 18-3/4” 10K connector has nine operating cylinders
(often called Miller or Carter cylinders) which have a maximum working pressure of
3,000 psi. Six operating cylinders are termed Primary and are connected to actuating
cam ring. These Primary cylinders pull the actuating ring down to lock the connector
and push it up to unlock the connector. The three remaining cylinders are termed
Secondary cylinders and are not attached to the actuating ring. They have no locking
effect, but can push the actuating ring up to provide the secondary unlock function.
By using the secondary unlock function and considering the differential piston area of
the primary cylinders, an unlocking force 80% greater than the locking force can be
achieved.

The various types of Cameron connector all use an AX profile gasket to seal between
the connector and wellhead or BOP mandrel. AX gaskets are available in cadmium
plated steel, plain stainless steel and Teflon coated stainless steel. Cadmium plated
and plain stainless gaskets with resilient gasket inserts (hycar gaskets) are also
available. Gasket retention is via six “hydraulic AX gasket retainers”. Hydraulic
pressure is applied to retract the retainers and release the AX gasket. Venting this
pressure allows a spring in the retainer assembly to extend the retainer pin. Cameron
has published contradictory information regarding the maximum working pressure of
the AX retainers. Both 1,000 psi and 1,500 psi have been quoted. The actual pressure
required to retract the retainer pins should be no more than 200 psi.

Type HC Connector
The type HC (High Capacity) connector uses the same arrangement of locking
segments and actuating ring as the type 70 connector, but is actuated by a single
annular piston which can achieve significantly higher clamping preloads (18-3/4” 15K

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type HC connectors are available but only 10K 18-3/4” type 70’s) Most (though not
all) type HC connectors have a second annular piston installed beneath the primary
piston to provide a secondary unlock function. For the type HC connector, secondary
unlock does not assist primary unlock in providing additional unlocking force. Select
either primary unlock or secondary unlock with the redundant function in vent.

The maximum working pressure of the type HC connector operating system is 3,000
psi with the exception of the AX gasket retainers.

Type DW HC Connector
The type DW HC (Deep Water High Capacity) connector is an enhanced version of
the type HC connector engineered to provide a greater preload to withstand the
additional bending and separation forces encountered when operating in deepwater
and ultra deepwater (12,000,000 lbs of preload can be achieved with the 18-3/4” 15K
DW HC connector against 7,000,000 lbs with the 18-3/4” 15K HC connector). A dual
hub profile has been introduced for the connector upper body and mating hub
(wellhead or BOP mandrel) which provides greater “clamping area” and therefore
greater clamping force. Normal working pressure for the DW HC connector operating
system is 3,000 psi (AX gasket retainers excepted).

The DW HC connector and HC connector are interchangeable in that a HC connector

can be installed on a DW HC hub and a DW HC connector can be installed on a
standard hub.

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Vetco H4 Connector
The Vetco H4 connector is of the multiple piston type, the actual number of pistons
being dependent upon the connector model and pressure rating. The pistons are
connected to a cam ring which, when pulled down, drives a segmented ring of locking
dogs into the locking profile of the wellhead or mandrel. When unlocking hydraulic
pressure is applied to the connector, the pistons push the cam ring up allowing the
locking dogs to retract. The locking dogs are not attached to the cam ring and rely on
a combination of springs installed between the dog segments, and the forces generated
as the connector is pulled off the wellhead or mandrel, to retract the dogs. There are
several styles of H4 connector available.

H4 Connector: A standard drilling connector primarily used to lock the BOP

stack to the wellhead, although also used as an LMRP
connector.

HD H4 Connector: A heavy duty drilling connector which is used for severe and
high pressure (15,000 psi) applications. The unit has larger
pistons than the standard H4 connector and can generate a
greater preload. Often used in “deepwater”.

SHD H4 Connector: Super Heavy Duty H4 connector recently introduced for use
with the MS-700 and SMS-700 wellhead systems. This
connector, with its exceptional bending load capacities and
fatigue life characteristics has been developed for deepwater
and ultra-deepwater service, with up to 7.5 million pounds of
preload available.

HAR H4 Connector: The High Angle Release connector will, as the name implies,
disconnect from a mandrel or wellhead at a greater offset angle
than a standard or HD model. For this reason, it is often
specified as a LMRP connector. A combination of reduced
“swallow” and lower body internal geometry enables
disconnection at up to 10 degrees offset. Early models had the
operating pistons mounted above the cam ring, but current
models have reverted to standard construction with pistons
connected to the bottom of the cam ring.

For each connector, half the operating cylinders are termed Primary with the second
half being termed Secondary. Connectors manufactured prior to 1981 did not have
connecting rods installed to attach the secondary pistons to the cam ring. The
secondary pistons could push the cam ring upwards but could not pull it downwards
and therefore had no locking effect. Connectors manufactured after 1981 have all
cylinders connected to the cam ring which allows greater locking forces and higher
preloads to be achieved. Differential unlock / lock force is achieved by the greater
area of the blind end side of the piston (unlock) compared to the rod end side of the
piston (lock). Each connector, with

the exception of the HD, has four separate and independent hydraulic functions,
primary lock, secondary lock, primary unlock and secondary unlock. It is standard

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industry practice to connect the primary and secondary lock functions together (for
the HD H4, there is only one lock port which connects all the cylinders). Primary and
secondary unlock should remain separate functions to provide redundancy.

VX gaskets are used to seal between the Vetco H4 connector and wellhead or BOP
mandrel. Standard VX gaskets are available in cadmium plated steel for 10K service,
or stainless steel for 15K service (at 250oF). Geometrically interchangeable with the
VX gasket, the VGX gasket, manufactured from a special alloy, is suited for high
pressure (15,000 psi) and high temperature (up to 350oF) service. The third gasket
option is the VT gasket. This has dual sealing surfaces so that the VT profile acts as a
secondary seal in the event of damage to the VX profile.

Gasket retention is normally by four manually operated retainer screws although

hydraulically operated gasket retaining assemblies are available.

The maximum allowable working pressure of the H4 connector operating system is

3,000 psi.

OSP 335
ABB Vetco Gray Operating and Service Procedure 335 provides information on
connector specifications and maintenance requirements.

Vetco H4 Connector Locking Dog / Wear band Clearance

One very important maintenance item not covered in OSP 335 is the maximum
allowable clearance between the locking dogs and the upper wear band. (NB some
early connectors do not have wear bands installed in which case the clearance would
be between the locking dog and the connector upper body). If the clearance is too
small or too large, the connector may not operate correctly, especially when
unlocking, due to the dogs binding or cocking.

The recommended method of measuring this clearance is to remove the locking dogs
from the connector and, using internal and external micrometers, measure the height
of the “dog window” and the OD of the dogs. The clearance is the dog window height
minus the dog OD. This procedure should be performed on an annual basis and also
provides an opportunity to clean any corrosion etc from the dogs and window.
Clearances can be checked with the dogs in place using long feeler gauges but this
method is not as accurate as removing the dogs.

With a few exceptions, the allowable range of clearance is 0.005” to 0.030”

Style E - 10K studded 0.020” to 0.045”

Style E x F – 15K studded 0.011” to 0.036”
High Angle Release 0.014” to 0.039”

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The clearance figures given for studded top connectors are for prior to flanging the
connector to the BOP or LMRP. The initial clearance for studded top connectors can
be significantly reduced due to deflection in the connector upper body during torquing
of the flange nuts.

In all cases, with the connector installed, the ideal clearance is 0.010” to 0.020”

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TYPICAL VETCO H4 CONNECTOR

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Dril-Quip Connectors
DX Connectors

The Dril-Quip DX connector utilises a single annular piston / cam ring to drive a
segmented ring of latch segments into the locking profile on the connector upper body
and wellhead or BOP mandrel. The latch segments are connected to the annular piston
/ cam ring by “spreaders” which positively retract the segments when the connector is
unlocked. A secondary unlock piston is installed which acts on the bottom of the
annular piston / cam ring when functioned. The primary unlock function provides
25% more unlocking force than the initial locking force. The secondary unlock piston
provides 88% more unlocking force than the initial locking force. In common with
other annular piston type connectors, secondary unlock does not combine with
primary unlock to provide additional unlocking force as it does in the multiple piston
type of connector. Secondary unlock should be used as an alternative to the primary
unlock.

The DX connector uses a DX gasket to seal between the connector upper body and the
wellhead. Both the connector upper body and the wellhead have dual sealing surfaces
termed primary and secondary. Under normal circumstances, a primary DX ring
gasket would be used which seals on the primary sealing surfaces. If the primary
sealing surfaces become damaged, a secondary DX gasket can be installed which
seals on the secondary sealing surfaces. The DX gasket is held in place by four
retaining rods, which are connected to the retainer release lever on the OD of the
upper body. The retainer release lever can be operated manually or hydraulically via
an operating cylinder.

Maximum working pressure of the DX connector operating system is 3,000 psi.

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Backdriving - Hydraulic Connectors
Backdriving is a term used to describe the unlocking effect of loads, such as wellbore
pressure, on connectors when the hydraulic locking pressure has been removed.
Backdriving results in the loss of connector preload with the wellhead or BOP
mandrel and may compromise the connector sealing integrity.

During normal drilling operations, lock pressure will be maintained on the wellhead
and LMRP connectors. However, if the LMRP is disconnected due to, for example,
storm conditions or to be pulled for repairs, then hydraulic locking pressure will be
vented from the wellhead connector. The BOP pipe and / or shear rams will be closed
and held closed by the ram locking devices, but the wellhead connector will rely on its
design characteristics to remain fully locked after locking pressure is removed.

All connectors have a cam or actuating ring which is pulled down by the connector
operating piston(s). The cam ring drives the lock segments or dogs into the wellhead
profile thereby transferring the vertical movement of the piston(s) into horizontal or
radial movement of the locking segments. The angle between the cam ring and the
segments is usually 3 or 4 degrees which will provide a "locking taper". With
connector locking pressure vented, the weight of the cam ring and the friction
between the cam ring and locking segments should be such that the connector will
remain fully locked regardless of wellbore pressure. The forces generated by wellbore
pressure acting on the closed pipe or shear rams are transmitted through the connector
to the locking segments which try to move radially outwards. Backdriving occurs
when the "locking taper" fails and the locking segments push the cam ring up.

Figure 1

There are two tests which can be performed to determine if a connector will
backdrive, an unloaded backdrive test and a loaded backdrive test. In an unloaded
backdrive test no wellbore pressure is applied. The connector is locked with 1,500 psi
which is then vented. A dial indicator mounted on the connector indicator rod will
measure any movement of the cam ring. The test is repeated using 3,000 psi locking
pressure. There is no OEM published acceptance criteria for this test but movement
up to 1/8" should be acceptable.

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During a loaded backdriving test wellbore pressure is applied to the BOP / connector
with the connector locking pressure vented. After locking the connector with normal
operating pressure (generally 1,500 psi) and subsequently venting this pressure, a
short hose and pressure gauge should be connected to the connector lock port. As
wellbore pressure is applied, any backdriving will attempt to displace the fluid in the
lock side of the operating cylinder(s) and will be indicated by an increase on the
pressure gauge.

At the first sign of a pressure increase on the gauge, or any motion of the indicator
rod, vent all wellbore pressure and suspend the test.

It should be noted that not all connector manufacturers approve of loaded backdrive
tests "in the field".

Connectors should be lubricated with the product specified by the connector

manufacturer. Using the "wrong" lubricant can reduce the friction between the
connector cam ring and locking segments which could lead to backdriving. For
example, Vetco Grey advise Alco Jet Lube 73 should be used to lubricate H4
connectors (not HD H4's). Jet Lube replaces the previous specified lubricant,
Pyroshield, which was found to have a low co-efficient of friction and be too "slick".

If a connector is found to backdrive, one option would be to install a pilot operated

check valve (POCV) on the lock side of the connector. The POCV will "trap" pressure
in the operating cylinder(s) to maintain connector preload even when the "connector
lock" function is vented. A pilot signal from the unlock function is used to unseat the
check valve and allow the connector to unlock when required.

If a POCV is installed, consideration should be given to the consequences of its

failure. Instead of mounting the POCV directly on the connector lock port, it should
be mounted remotely and connected to the lock port via a hose. If the POCV fails, an
ROV can cut the hose to provide a vent path for the lock fluid displaced when the
connector is functioned unlocked.

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