WINDLASS ENGINEER & SERVICES PVT. LTD.

SIZING CONTROL SYSTEMS AS PER API 16D 2nd EDITION

FOR 3000 PSI OPERATING SYSTEM
SURFACE BOP STACKS
Method A (Refer API 16D, 2nd Edition Clause No.- 4.2.3.1.2)
Method Used Ideal Gas, Isothermal Discharge, Pressure below 5015 psia, 1.5 Volume Design Factor for Volume-Limited Discharge, 1.0
Volume Design Factor for Pressure-limited Discharge

DESIGN INPUT:- BOP STACK CONFIGURATION

Pressure to Close
Rated Working Closing Volume Opening Volume Against RWP
BOP Stack Description Bore Size (in) Pressure (psig) (Gal) (Gal) Closing Ratio (psig)

Diverter, Shaffer 21-1/4 2000 32.59 NR NR

HCR Valve 7-1/16 2000 NR 1.00 NR

HCR Valve 7-1/16 2000 NR 1.00 NR

TOTAL 32.59 1.00

Functional volume required (FVR) = Total Closing Volume

= 33.59 Gallons

For a standard surface system, the minimum FVR IS 100 % of the power fluid volume required to close, at zero wellbore pressure, the ram BOPs and one annular
BOP, and to open one side outlet valve(s)

Environmental Conditions
Surface Temperature at Precharge 70 °F

Use The Pump Stop Pressure for

Pump Stop Pressure ( Condition 1 Charged Pressure ), (P1) 3000 psig
methods A

Minimum Operating Pressures (MOP), Condition 2

Pressure to close diverter 1500 psig
pressure to open side outlet valve 1200 psig
pressure required, (P2) 1500 psig

1
 Surface Accumulator Bottles (15 gallons)
13.7 gal Gas Type Nitrogen
Gas Volume per Bottle Pressure rating of Bottles 3000 psig

Condition 0 Data
Optimum Precharge = 1.0 /(1.5/P2-0.5/P1) 1214.7 psia 1200 psig @ 70°F
Input Precharge Pressure at Surface Cond.0 @T1 70 °F 1000 psig 1014.7 psia
Pressure at maximum temperature @T2 140 °F 1132 psig 1146.9 psia
Pressure at maximum temperature with ideal gas law P2= P1 X T2/T1

Condition 1 Data Surface Accumulator 3000 psig 3014.7 psia

Volume Limited Pressure Limited

Design Factor Per Table 2 Method A
1.5 1

Calculation Of Volumetric efficiency based upon specified Precharge Pressure

Calculate Basic Data Temp Pressure
°F psig psia

Surface Accumulator 1. Method A

Tabulate ambient air temperature, pressure psig & psia
condition 0 : Precharged Accumulators 70 1000 1014.7
Condition 1: Accumulators Charged 70 3000 3014.7
Condition 2: Pressure Requirement (MOP) 70 1500 1514.7

2. Use Method A pressure -based Volumetric Efficiency formulas

Pressure Limited VEp= (P0/P2-P0/P1)/1.0 Vep 0.333
Volume Limited VEv = (1.0- P0/P1)/1.5 VEv 0.442

3.Volumetric Efficiency VEsurf = min (VEp, VEv) min = VE 0.333

Calculate Number Of Bottles

Minimum required surface accumulator volume = FVR / VE surf
# of bottles Bottle Volume Usable Volume
Surface bottles required 7.4 100.8 gals
Round Up to desired integer 8 109.6 gals 36.53 gals

Performance Table Temp Pressure Volume gals

°F psig psia Gas Liquid
Functional Steps - SURFACE BOTTLES
Condition 0:- Precharge 70 1000 1014.7 109.6 0
Condition 1:- Charged 70 3000 3014.7 36.89 72.71
Condition 2:- MOP 70 1500 1514.7 73.42 36.18
Condition 3:- Fully Discharged 70 1000 1014.7 109.6 0

SUMMARY

Precharge
# OF BOTTLES Pressure psig Temperature ° F
Surface Accumulator 8 1000 70

Liquid Volume ,gal ACTUAL WITH VOLUME FACTOR FVR Meets req' ts ?
Condition 1:- Charged 72.71
Condition 2:- MOP 36.18
FROM CONDITION 1 TO 2 ; PRESSURE DESIGN 72.71 72.71 33.59 YES
Condition 3:- Fully Charged 0
FROM CONDITION 1 TO 3 ; VOLUME DESIGN 72.71 36.5 33.59 YES

2
SIZING THE RESERVOIR
AS Per Return-to-Reservoir Hydraulic Reservoirs 16D 4.2.4.2
The Hydraulic fluid resevoiir usable capacity shall be at least twice the stored hydraulic fluid capacity of the accumulator system.

Therefore the reservoir is sized as follows:

Total accumulator stored capacity 66.9

Therefore minimum mixed fluid reservoir capacity 133.7 Gallons
Reservoir used with UNION pumps, use minimum capacity of: 167.1 Gallons

NOTE;-
1.
2. Air vents control
offshore shall besystem
insalledshall
of sufficient size to avoid
have an audiable and overpressurization of thelow
visible alarm to indicate tank
fluid level activates between 30%--45% usable
capacity remaining.
3. The alarm shall be sound and illuminate at the unit, driller panel and minimum of one auxiliary remote panel
4. As an option a low level alarm/ cutoff may be provided to shut down the pumps before cavitation can occur.

SIZING THE SYSTEM PUMPS

As per
The Pump Systems
manifold pumping16D
unit5.1.2.1a
shall comprise a minumum of two pump systems with at least two independent power systems.
The manifold pumping unit shall satisfy the following requirements.

a. With the accumulators isolated from service and with one pump system or one power system out of service,
the remaining pump system(s) shall have the capacity to, within two minutes: close one annular BOP on open hole,
open the hydraullically operated choke valve(s), and provide final pressure at least equal to the greater of the
minimum operating pressure recommended by the manufacturer(s) of both the annular BOP and choke valve(s).

Determine the pump capacity

Total Fluid Volume Surface Accumulators 66.9 Gallons
Divided by pump-up time 5 Minutes
Total Main Pump Rate Required 13.4 GPM

NOTE: Each pumping system must have a hydraulic output capacity equal to or greater than whichever
flowrate is greater; the "Total Main Pump Rate" divided by 2 or the "Minimum Pump Rate Required".
Using the pump model combinations shown below provides Pump Output
equal to or greater than requirements of previous step:

Pump Quantity Assembly Output Output

Model No. Used Description Pump Total

UET40HT460 1 Electric Triplex 13.7 13.7 GPM

UA8546 3 Air Pumps 5.0 15.0 GPM
TOTAL 28.7 GPM **

As Per
Air APIpump
driven 16D 5.1.2.2
systems shall be capable of charging accumulators to system rated working pressure with 75 psi
air supply to drive the pump.

As per API 16 D 5.1.2.3 each pump system shall be protected from overpressurization by a minimum of two(02) devices

a. one device shall ensure that the pump discharge pressure does not exceed the the system rated working pressure.
b. The second device , normally a relief valve, shall be set to relieve at not more than 10% above system rated pressure.

Notes:
1. Each air pump requires 240 scfm at 75 psi. minimum.

CALCULATED SYSTEM PUMP-UP TIME

b. The cumulative output capacity of the pump system shall be sufficient to charge the entire accumulator system
from precharge pressure to the system rated working pressure within 15 minutes.

Accumulator Size, Gallons 11 Units

Available Fluid Volume
Total of All Accumulators 109.6 Gallons
Total Pump Capacity 28.7 GPM
Pump-up Time = Volume/GPM = 3.8 Minutes

3
AS per API
Primary 16 D shall
pumps 5.1.2.4
automatically start when the actual system working pressure has decreased to approximately 90%of the system rated working pressure ,
and automatically stop between 97%-100% of the system rated working pressure

Secondary pumps shall provide opeartion similar to the primary pumps , except that the set point to start the pump
may be adjusted slightly lower so that both pumps systems do not start simultaneously. The seconadry pump control shall not stop the pump at less that 95%
of the system rated working pressure and shall start the pump automatically prior to the pressure decreasing below 85% of the system rated working pressure.

PRIMARY PUMP DESIGN CRITERIA

Pump Manufacturer's Specifications:
Pump Model BD30 BEAR
Maximum Plunger Load 2825 Pounds
Maximum Pump Speed,Intermittant Duty 500 RPM
Maximum Pressure Rating 3000 psig
Number of Plungers 3 Plungers
Plunger Stroke 2.750 Inches
Plunger Diameter 1.125 Inches

Application Specifications:

Motor HP Req'd @ 100% Eff. (@ 95% Pump Vol. Eff.) 23.96 HP

Motor HP Required @ 90% Efficiency 26.62 HP
Input Horsepower 30 HP
Motor Rating (50 Hz) 440 VAC
Motor Speed 1,500 RPM
Motor Sprocket 19.0 Pitch Dia.
Pump Sprocket 68.0 Pitch Dia.
Drive Ratio 3.579 Ratio
Pump Speed 419 RPM
Design Plunger Load 2982 Pounds
Flow Rate @ 100% Volumetric Efficiency 14.9 GPM
Flow Rate @ 92% Volumetric Efficiency 13.7 GPM