Koomey Unit Manuel

Electric-pneumatic Liquid Type Control System for Surface BOP Stacks
User Manual
Overview
Introduction to the Use of Electric-pneumatic Liquid Type Remote Console
Ordering Instructions
Main Hydraulic and Pneumatic Components
QB21-60 and QB21-80 Crankshaft Plunger Pumps
JYS21-25 and JYSQ21-25 Relief Valves
JYSQM21-25 Relief Valve
QYB 40-120L Pneumatic Pump
34ZS21-25 3-position and 4-way Rotary Valve
Illustrations of Wearing Parts of Other Hydraulic Valves
Main Electrical Components
BQD6-T Magnetic Starter
BKX6-T Explosion-proof Control Box
FBYK-165 Explosion-proof Pressure Controller
A7-3136-4021 Driller's Control Cabinet/Auxiliary Driller's Control Cabinet
Division of Hazardous Areas
Bus Connector Connecting Method
T800 Tablet PC
Wireless Remote Control Software for Driller's Station
Technical Support
Shanghai Shenkai Petroleum Equipment Co., Ltd.

Content
Overview ..................................................................................... 5
Operating Instructions .............................................................. 7
Ordering Instructions .............................................................. 28
Main Hydraulic and Pneumatic Components ...................... 31
QB21-60 and QB21-80 Crankshaft Plunger Pumps ....................................................................... 32
Relief Valve ................................................................................................................................... 38
JYSQM21-25 Relief Valve ............................................................................................................ 43
QYB 40-120L Pneumatic Pump..................................................................................................... 46
34ZS21-25 3-position and 4-way Rotary Valve ............................................................................. 51
Illustrations of Wearing Parts of Other Hydraulic Valves ............................................................. 56
Main Electrical Components .................................................. 61

BQD6-T Explosion-proof Electromagnetic Starter ........................................................................ 62
BKX6-T Explosion-proof Control Box .......................................................................................... 67
FBYK-165 Explosion-proof Pressure Controller ........................................................................... 71
A7-3136-4021 Driller's Control Cabinet/Auxiliary Driller's Control Cabinet ............................... 73
Simple Daily Maintenance Manual for Electrical Parts ................................................................. 79
Division of Hazardous Areas ......................................................................................................... 81
Bus Connector Connecting Method ............................................................................................... 84
T800 Tablet PC ........................................................................ 86

I. Before You Begin ........................................................................................................................ 87
II. Getting the Tablet PC Running .................................................................................................. 87
III. System Recovery ...................................................................................................................... 90
IV. Taking Care of the Tablet PC .................................................................................................... 90
Wireless Remote Control Software ........................................ 95

I. Overview ..................................................................................................................................... 96
II. Installation Configuration .......................................................................................................... 97
III. Basic Operations .................................................................................................................... 102
IV. FAQs ....................................................................................................................................... 106

Technical Support .................................................................. 108

Safety Guideline
The manual includes precautions that should be followed to ensure personnel safety and prevent products and
connected devices from being damaged.
For these precautions, symbols are used for alarm purpose and the following descriptions will be given depending
on severity:
Attention:
It indicates that without proper preventive measures, death, serious physical injury or major property loss will
possibly occur.
Attention:
Arouse your attention to important information on products and to specific parts of products or files.
Qualified Personnel
Only qualified personnel are allowed to install and operate the equipment. Qualified personnel refer to those who,
with experience in field well control, can install, test run and operate equipment according to established safety
practices and standards.
Correct Operation
Attention:
The equipment and its components can only be used for description of product catalog or technical specification
and can only be connected to facilities or components recognized or recommended by Shenkai Company.
The equipment can function correctly and safely only when transported, stored, assembled, installed correctly and
run and maintained as recommended.
Trademark
, , is the registered trademark of Shenkai Company.
Any use of other names related to the trade marks herein by any third party for its own purpose will infringe interest of the
trademark owner.
Copyright © 2009 Shenkai Company, All rights reserved.
Without the express written permission, it is forbidden to copy, transmit or use this manual or part of it.
Any violation of the above will be disciplined. All rights, including patent rights, utility model or appearance design patent
rights, are reserved.
Shanghai Shenkai Petroleum Equipment Co., Ltd. hereby declares that contents of this manual are verified and compliant
with the said product. Mistakes, however, are unavoidable, so complete consistence can’t be guaranteed. Contents of this
manual are subject to periodic review and will be modified in the next version. Your opinions on improvement are welcome.
Copyright © 2009 Shenkai Company. The information in this manual is subject to change without notice.

Technical Support Department
Customer service hotline: +86(21)64290467 Fax: +86(21)34030004

Website: www.shenkai.com Zip code: 201114
Overview
I. Introduction
The control system for surface BOP stacks (hereafter abbreviated to hydraulic control system) is very
important equipment which controls BOP stacks and gate valves controlled by hydraulic pressure especially in
drilling and workover operations. It is necessary to accurately operate and maintain the hydraulic control system.
The hydraulic control system manufactured by Shenkai Company can be divided into 3 types:
1. Directly manually operated FK series hydraulic control system
The hydraulic control system not fitted with a driller’s console is applicable to drilling or workover operations
and is simple and portable. The hydraulic control system can be fitted with a mechanical anti-lifting device (see the
operation manual for the anti-lifting device).
2. Pneumatic liquid type FKQ hydraulic control system
This hydraulic control system is fitted with a driller's console or an auxiliary driller's console (optional).
Alarm type and non-alarm type driller's console and auxiliary driller's console can be installed as demanded by
users. Air pipe bundles are used to connect the remote console with the driller’s console and the remote console
with the auxiliary driller's console for the pneumatic liquid type hydraulic control system, so that the hydraulic
control system can be remotely controlled on the driller's console and the purpose of opening and closing BOPs
can be achieved. This hydraulic control system is generally used in drilling operations. The hydraulic control
system can be fitted with a mechanical anti-lifting device (see the operation manual for the anti-lifting device).
3. Electrical and pneumatic liquid type FKDQ hydraulic control system
The remote console is fitted with a driller's console or an auxiliary driller's console (optional). In addition,
explosion-proof driller's console and auxiliary driller's console applicable to hazardous and explosive gas
environment area I or II can be installed as demanded by users.
This hydraulic control system is Siemens PLC controlled and runs stably and reliably. Fire-resistant four-core
ship cables and standard Profibus communication connection are used to connect the remote console with the
driller’s console and the remote console with the auxiliary driller's console for the hydraulic control system. In
addition, a touch screen driller’s console and a PN-T remote console status self-recording module can be installed
as demanded by users. The hydraulic control system can be fitted with an electrical or mechanical anti-lifting
device (see the operation manual for the anti-lifting device).
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The manual introduces the electric-pneumatic liquid type hydraulic control system (also applies to FK series
hydraulic control system).
II. Model designation
The model of the control system for surface BOP stacks is expressed as follows (taking FKDQ640-6 as an
example):
FK DQ 640 6
Numberofcontrolledobjects: (6fortheexample)
Total capacityoftheaccumulator(640L)
Remote control type (―Q‖ represents pneumatic control liquid type. ,―DQ‖ represents electric control
type)
Product code of surface-mounted BOP stacks control system
III. Conversion of Metering Units
1. Mass
1kg＝2.2lbS
1lbs＝0.454kg
2. Volume
1L＝0.264 US gal＝61 cu.in
1US gal=3.785L=231 cu.in
3. Pressure
1MPa=145 psi
1psi=0.0069 MPa
4. Length
1m＝3.28ft＝39.37 in
1ft＝0.305 m
IV. Recommended Hydraulic Oil for the Hydraulic System for BOP Stacks
 ISO Brand: HM32 (used for plunger pump system with low or no Zn)
 Mobil Brand: D.T.E24 (used for plunger pump system with low or no Zn)
 Shell Brand: Tellus32 (used for plunger pump system with low or no Zn)
Note: The kinematic viscosity of hydraulic oil is 17-33mm2/s when the temperature is at 50oC.
6
Electric-pneumatic Liquid Type Remote Console
Operating Instructions
Main Technical Parameters
Configuration Parameters
Functional Configuration Table
Structure and Features
Operating Principle and Instructions
Installation and Test Run
Operation, Maintenance and Lubrication
Failure and Troubleshooting
7
I. Main Technical Parameters
Normal pressure of the system: 21 Mpa 3000 psi
Pressure regulating range of the

0~14 Mpa 0~2000 psi
system:
Nitrogen charging pressure of

7±0.7 Mpa 1000±100 psi
accumulator:
Pressure switch setting range: 18.9~21 Mpa 2700~3000psi
Hydraulic/pneumatic switch setting

18.9~21 Mpa 2700~3000psi
range:
Air supply pressure: 0.65~0.8 Mpa 93~115psi
380±19V / 50Hz
Power supply:
Optional as required by customers
Control power supply: 24V DC
Battery capacity: 10Ah
Communication interface: Profibus-Dp
II. Configuration Parameters
Pump system
Accumulator unit
Number displacement Rated Maximum
Explosion-proof
of Available working working
Model Total motor Power Triplex Pneumatic
controlled liquid Installation pressure pressure
volume (kw) pump pump
objects volume mode (MPa) (MPa)
(L) (mL/r) (mL/stroke)
(L)
FKDQ1600-14 14 80×20 800 Side/rear 18.5×2 80×2 120×4 21 31.5
FKDQ1600-12 12 80×20 800 Side/rear 18.5×2 80×2 120×4 21 31.5
FKDQ1600-10 10 80×20 800 Side/rear 18.5×2 80×2 120×4 21 31.5
FKDQ1440-14 14 60×24 720 Side/rear 18.5×2 80×2 120×4 21 31.5
FKDQ1280-10 10 80×16 640 Side/rear 18.5×2 80×2 120×3 21 31.5
FKDQ1280-9 9 80×16 640 Side/rear 18.5×2 80×2 120×3 21 31.5
8
FKDQ1280-8 8 80×16 640 Side/rear 18.5×2 80×2 120×2 21 31.5
FKDQ1280-7 7 80×16 640 Side/rear 18.5×2 80×2 120×2 21 31.5
FKDQ1200-9 9 60×20 600 Side/rear 18.5×2 80×2 120×3 21 31.5
FKDQ1200-8 8 60×20 600 Side/rear 18.5×2 80×2 120×2 21 31.5
FKDQ960-8 8 60×16 480 Side/rear 18.5×2 80×2 120×2 21 31.5
FKDQ960-7 7 60×16 480 Side/rear 18.5×2 80×2 120×2 21 31.5
To be continued
Pump system
Accumulator unit
Number displacement Rated Maximum
Explosion-proof
of Available working working
Model Total motor Power Triplex Pneumatic
controlled liquid Installation pressure pressure
volume (kw) pump pump
objects volume mode (MPa) (MPa)
(L) (mL/r) (mL/stroke)
(L)
FKDQ800-8 8 40×20 400 Side/rear 18.5 80 120 21 31.5
FKDQ
7 40×20 400 Side/rear 18.5 80 120 21 31.5
800-7
FKDQ 6 40×20 400 Side/rear 18.5 80 120 21 31.5
800-6
FKDQ720-7 7 60×12 360 Side/rear 18.5 80 120 21 31.5
FKDQ 6 60×12 360 Side/rear 18.5 80 120 21 31.5
720-6
FKDQ 6 40×16 320 Side/rear 18.5 80 120 21 31.5
640-6
FKDQ 5 40×16 320 Side/rear 18.5 80 120 21 31.5
640-5
FKDQ 5 40×12 240 Side/rear 18.5 80 120 21 31.5
480-5
FKDQ 4 40×12 240 Side/rear 18.5 80 120 21 31.5
480-4
9
FKDQ320-5 5 40×8 160 Side/rear 15 60 120 21 31.5
FKDQ320-4 4 40×8 160 Side/rear 15 60 120 21 31.5
FKDQ320-3 3 40×8 160 Side/rear 15 60 120 21 31.5
FKDQ240-3 3 40×6 120 Side/rear 15 60 120 21 31.5
FKDQ200-4 4 25×8 100 Side/rear 15 60 120 21 31.5
FKDQ160-3 3 40×4 80 Side/rear 15 60 120 21 31.5
FKDQ150-2 2 50×3 75 Side/rear 15 60 120 21 31.5
FKDQ125-3 3 25×5 62.5 Side/rear 7.5/11 28 × 21 21
FKDQ80-3 3 40×2 40 Side/rear 7.5 28 × 21 21
FKDQ80-2 2 40×2 40 Side/rear 7.5 28 × 21 21
FKDQ75-2 2 25×3 62.5 Side/rear 7.5 28 × 21 21
FKDQ63-2 2 63×1 31.5 Side/rear 7.5 28 × 21 21
FKDQ50-2 2 25×2 25 Side/rear 7.5 28 × 21 21
FKDQ40-2 2 40×1 20 Side/rear 7.5 28 × 21 21
FKDQ25-2 2 25×2 12.5 Side/rear 7.5 28 × 21 21
FKDQ25-1 1 25×2 12.5 Side/rear 7.5 28 × 21 21
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III. Functional Configuration Table
Pipe PN-T Zero

Electric Manual Standby
Pneumatic Alarm Protection Insulated Driller’s Auxiliary rack automatic pressure
Model oil oil nitrogen
oil pump device house House console console and recording starting
pump pump system
hose module module
FKDQ1600-14 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1600-12 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1600-10 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1440-14 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1280-10 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1280-9 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 1280-8 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1280-7 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1200-9 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ1200-8 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ960-8 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ960-7 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ800-8 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 800-7 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 800-6 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ720-7 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 720-6 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 640-6 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 640-5 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 480-5 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ 480-4 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ320-5 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ320-4 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
11
FKQ320-3 ● ● ○ ○ ○ ● ○ ● × ○ ○ ○
FKDQ240-3 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
PN-T Zero
Electric Pneumat Manu Standby Prote Insulat Driller’ Auxilia Pipe
Alarm automatic pressure
Model oil ic oil al oil nitrogen ction ed s ry rack and
device recording starting
pump pump pump system house House console console hose
module module
FKDQ200-4 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ160-3 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ150-2 ● ● ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ125-3 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ80-3 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ80-2 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ75-2 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ63-2 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ50-2 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ40-2 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ25-2 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
FKDQ25-1 ● × ○ ● ○ ● ○ ● ○ ○ ○ ○
Attention:
1. In the above table lists the basic configuration of product types of our company, ―●‖ means basic
configuration and ―○‖ optional configuration.
2. The optional configuration in the table doesn’t mean that each model can realize the optional function.
This shall be determined through negotiation when signing the Contract.
3. Please contact related technical people about the maximum width of the protection house .
Attention:
4. The basic configuration items in the above can also be designed and manufactured
according to customers’ special requirements.
12
5. The auxiliary driller's console can be either button type or touch screen type.
6. FKDQ series hydraulic control system is not fitted with a pneumatic pump, but as a
pneumatic control system, the remote console must be fitted with an air source interface.
IV. Structure and Features
FKQ series control system for surface BOP stacks consists of the following:
1. Remote console (generally fitted with a protection house)
2. Driller’s console (button type)
3. Auxiliary driller’s console (button type, touch screen type)
4. Signal cable and power cable
5. Hydraulic lines including hose lines or pipe racks
The hydraulic control system connection is shown in Figure 1.
4.1 Remote console
The remote console consists of oil tank,
pump unit, accumulator unit, manifolds,
various valves, instrumentation and electric
cabinet etc. The primary function of the remote
console is to receive high-pressure fluid from
the pump unit and to store the fluid in the
accumulator unit. The high-pressure control
fluid from the accumulator is distributed into
each controlled object (BOP or control Figure 1 Connecting of control

system for surface mounted BOP
manifold) via the 3-positon and 4-way rotary valve of the manifold when there is a need for opening and closing
stacks
BOPs.
The FKDQ remote console has the following features:
4.1.1 Fitted with two sets of independent power sources. The FKDQ series remote console is fitted with an
electric oil pump and a pneumatic oil pump; even if
electric power supply is shut-off, the control part of the
system can still work for over 2 hours with the support of large capacity backup power.
4.1.2 The accumulator unit is provided with sufficient high-pressure fluid to open or close BOPs. The
13
accumulator system is divided into four groups in total. The loss of capacity is no greater than 25% its
total capacity when an individual accumulator or one group loses effectiveness; in addition, a pressure
isolation valve and a pressure relief valve are installed on each group accumulator line, and the pressure
relief valve is fitted with a pressure relief line which can release pressure outside.
4.1.3 Both the electric oil pump and the pneumatic oil pump can be automatically started up or shut down. The
relief valve can immediately realize overflow to ensure system safety even if the automatic control unit
is out of order during normal operation.
4.1.4 Each BOP is controlled by a relevant 3-position and 4-way rotary valve to open or close. FKDQ series
hydraulic control system can be changed directly by either hand or electric remote control equipment.
4.1.5 FKDQ electric remote console functions in forcibly shutting down motors and pneumatic pumps in case
of an alarm, thus greatly improving system’s safety.
4.2 Driller’s console
The electric liquid type hydraulic control system can be fitted with an optional driller's console and an
optional auxiliary driller's console. The driller's console is generally installed on drill floor so that the driller can
remotely control BOPs very conveniently. The auxiliary driller's console is generally installed on the toolpusher
room for emergent use. The button type drillers’ console can choose two types of explosion proof grades, which
are respectively applicable to class II, area 1 and class II, area 2. Users can determine the explosion proof grade of
the button type driller’s console according to the appendix or by consulting our company. The auxiliary driller's
console can be the same as the driller's console or be touch screen type. The touch screen type auxiliary driller’s
console can be manufactured into that used only in a safety area or applicable to class II and area 2 environment as
demanded. The features of the button type driller’s console:
4.2.1 Adopt 24V DC power supply, being safe and reliable.
4.2.2 The driller’s console is small for convenience of installation; e.g., the external dimension of FKDQ640-7
driller’s console: 650X400X210mm (length*width*depth).
4.2.3 Have position feedback function. After each 3-position and 4-way pneumatic rotary value realizes
reversing of direction to the specified position, it feeds back in the form of lamp highlighting, so that
operation personnel can understand the last operating state.
4.2.4 Two-step operation mode is used for each rotary valve of the driller’s console to ensure correct operation
of BOP stacks. The first step is to press the main control button; meanwhile, each operating button is
pressed to make a corresponding controlled object act.
14
4.2.5 The electric driller’s console is fitted with an alarm system, which can send out an audible and visual
alarm when accumulator pressure, motor running state and air source pressure etc. are abnormal. In
addition, the system can forcibly lock startup of pneumatic pumps and electric pumps in case of low
liquid level and high system pressure.
4.3 Connecting cable
Electric pipe cables are used to connect the power circuit and signal circuit between the remote console and
the driller’s console. Signal cables use standard Siemens FC cables, and power cables use fire resistant armored
four-core ship cables. The two ends of power cables are connected using a socket connector. (As required by
customers) signal cables are led in the box body of the driller's console.
4.4 Hydraulic lines
In general, the remote console is 40m away from wellhead BOP stacks and thus they need to be connected by
using a group of hydraulic lines. Hard line connection mode and hose connection mode can be used.
The hard lines include pipe racks and flexible lines etc. Hard line connection has such advantages as safety
and reliability and such disadvantages as inconvenient installation and arrangement. Hose connection has such
advantages as simplicity and convenience etc., but attention shall be paid to its safety during operation. You can
use hoses and hard pipes together according to actual site situation.
Pipe racks are designed specially to protect high pressure control fluid lines. Number of controlled objects * 2
high pressure tubings are placed on each pipe rack to connect the remote console and BOP stacks. The tubings
between pipe racks are connected by using quick couplers, which can be hammered and tightened very
conveniently. Baffle plates are installed on both ends of a pipe rack to prevent quick couplers from being damaged
during transportation.
The flexible line can be connected with BOP body and also with a pipe rack at the remote console outlet.
Both ends of a hose are self-sealing quick couplers which replace the hard lines such as pipe racks and closed
bent pipes etc. and thus connect the control system with BOPs.
The connecting thread of the two ends of all lines is 1LP (Petroleum Line Pipe Thread GB/T 9253.2—1999),
and quick union joints or quick couplers are used to connect pipelines.
V. Operating Principles and Instructions
5.1 The control principle of the hydraulic control system
The pressured oil stored in the accumulator unit flows from the accumulator isolating valve (high-pressure
15
ball valve), oil filer, and relief valve into the control manifold, then to the 3-position and 4-way rotary valve, and
finally to inlet. At the same time, the pressure oil from the accumulator unit enters the relief valve for controlling
the annual BOP via the oil filter; after pressure reduction, the pressure oil is used specially for the annular BOP.
The relief pressure oil is only used by annual BOP. Operator just easily pushes the handle of 3-position and 4-way
rotary valve to ―open‖ or ―close‖ BOP.
Operator can remotely control the turning of 3-position and 4-way rotary valve at the driller’s console. Firstly
press the main control button on the driller's console while operating other control buttons so that signals control
the solenoid valve on the remote console to perform reversing of direction via PLC. This action causes compressed
air to enter a corresponding control circuit and to control air cylinders, thus achieving the purpose of controlling
the 3-position and 4-way rotary valve to perform reversing of direction. After completing reversing of direction,
the 3-position and 4-way rotary valve feeds back to the flashlight on the driller’s console via a position sensor, so
that users can read out the current on-off state.
Attention:
A two-step operation mode is used for the button on the driller’s console. In other words, when pressing
the button of each controlled objector, the operator must press the main control button at the same time.
After pressing the button, it is necessary to ensure the corresponding switch indication light is on to
indicate accurate reversing of direction, and then the button can be loosened.
The outlet pressure range of the manual relief valve on controlling manifold is 0-14MPa (2000Psi). In general,
the operator adjusts pressure to be 10.5MPa (1500Psi). The pressure of controlling manifold will be the same as
the pressure of the system, when turning the bypass valve from ―close‖ to ―open‖. At this time, the relief valve
does not work.
The pneumatic/manual relief valve of controlling annual BOP can be selected as ―manual‖ or
―pneumatic/manual‖ valve. When the system is installed with a ―pneumatic/manual‖ relief valve, the operator can
pneumatically adjust the outlet pressure of the ―pneumatic/manual‖ valve on the remote console or the driller’s
console.
During manual adjustment, the output pressure can be adjusted to be the setting pressure by turning the
handwheel on the upper end of the manual relief valve. Turning down is to increase the outlet pressure. Turning up
is to decrease the outlet pressure.
Pneumatic/manual pressure adjustment is described as follows:
16
1. When the air pressure is zero, manually adjust the pressure to 10.5MPa a (1500psi) or the pressure what the
operator needs, and then lock the adjusting rod.
2. The electric remote console is fitted with an air motor type/manual relief valve. Users can control annular
pressure directly on the driller’s console. The air motor type pneumatic/manual relief valve will be detailed
hereof later.
Attention:
1. During pneumatic pressure adjustment, turn and press down the handwheel of the pneumatic/manual
relief valve when the air pressure is zero, so that the control pressure is set at the operating pressure (e.g.,
10.5MPa(1500psi)) recommended by the annular BOP manufacturer. Then lock up the adjusting rod and
start pneumatic pressure adjustment.
2. During pneumatic pressure adjustment, the variation of the outlet pressure of the relief valve lags
slightly due to long pneumatic pipeline. Take care to observe the outlet pressure and slowly operate the
valve.
The ―O‖ type 3-positong and 4-way valve (hydraulic rotary value) can be used on the remote console of the
electric-pneumatic liquid type hydraulic control system. When the handle of the rotary valve is at middle position,
the cavities of the valve are not connected. While the handle is at ―open‖ or ―close‖ position, the compressed oil
flows into the side of oil tank of BOP, the other sides of oil flow into reservoir by 3-position and 4-way rotary
valve.
5.2 Controlling the ―start‖ or ―stop‖ of the electric oil pump
When turning the main switch of electric box on the remote console to ―automatic‖ position, the system is in
automatic state. In this time, the pressure controller will automatically start the electric oil pump, if the pressure of
the system is below 18.9MPa (2700Psi). The pressure oil is supplied to the accumulator unit via the non-return
valve (before this, the accumulator isolating valve must be opened). When the system pressure is up to 21MPa
(3000Psi), the pressure controller automatically turns off the power supply so that the electrical oil pump stops oil
supply. When the system pressure is decreased to 18.9Mpa (2700psi), the electric oil pump will restart oil supply.
When the system is in ―automatic‖ state, the pressure controller makes the pressure of accumulator bank at
18.9-21MPa (2700-3000Psi) in order to open or close BOP at any time.
Attention:
When the master switch is at ―Manual‖ position, the electric oil pump will not stop automatically, so
17
Operators shall take care to observe the system pressure and when needed, turn the switch to the ―Stop‖
position to stop the electric l oil pump.
5.3 Controlling the pneumatic oil pump
The electric-pneumatic liquid type hydraulic control system is equipped with a pneumatic oil pump. The
system pressure can be supplied by the pneumatic oil pump or the manual oil pump when there is no power or
power supply is not allowed.
To open air supply switch, then to close the bypass valve, the compressed air flows from pneumatic cells
into air/liquid switch in system with the pneumatic oil pump. When the manifold pressure is below 18.9MPa
(2700Psi), the air/liquid switch will be automatically opened. The compressed air flows into the pneumatic oil
pump to drive it start. The discharged pressure oil flows into the manifold via a check valve. When the system
pressure is increased to around 21MPa (3000Psi), the air/liquid switch will be automatically closed under the
action of pressure oil so as to cut off the air source. Then the pneumatic oil pump is shut down.
In several cases, when the pressure which the system needs is over 21MPa (3000Psi), the operator can only
use the system with the pneumatic oil pump. Firstly, close the isolating valve of the accumulator on the pipeline to
prevent compressed oil from entering the accumulator. Meanwhile, turn the bypass valve of the relief valve on the
control manifold to ―open‖ position from ―close‖ position. Open the bypass valve of the air/liquid switch so that
the air/liquid switch does not work. The compressed air can directly flow into the pneumatic oil pump.
Attention:
Operator must make sure the relief valve works normally, when using the pneumatic oil pump. When
necessary, the valve shall be tested firstly so as to ensure it can realize full-open relief at 34.5MPa
(5000Psi).
Attention:
When the manifold pressure is higher than 2lMPa (3000psi), the accumulator unit isolating valve (ball
valve) on the pipeline must be closed; otherwise, the safety of the equipment and personnel will be
affected.
18
5.4 Alarm system
The electric-pneumatic liquid type hydraulic control system is fitted with an alarm system which is
integrated into a control program. The alarm system can send out an alarm in case of low air source pressure, low
accumulator pressure, low liquid level and UPS use. In case of low liquid level, the alarm system can forcibly shut
down motors and pneumatic pumps (optional). When any circuit alarm is given, the corresponding alarm lamp on
the remote console and the driller's console is on and the trembler makes a sound at the same time. Press the alarm
confirmation button to silence the trembler. When the main control button and the alarm confirmation button are
pressed at the same time, all tremblers and flashlights can be tested.
Attention:
Don’t make the alarm trembler work for a long period of time. In case of an alarm ring, timely press
down the alarm confirmation button to avoid burning the trembler.
VI. Installation and Test Run
6.1 Installation
6.1.1 When the remote console with a protective house is hoisted, it is needed to install 4 wire ropes at the 4
feet of the pedestal. Take care to hoist it smoothly. Wire ropes shall pass through or hook lifting lugs to
hoist the driller’s console or pipe racks.
6.1.2 The remote console shall be installed at the proper position over 30m from the wellhead (referring to
relevant standards and specifications). The driller’s console shall be installed at the position of the drill
floor for the convenience of driller’s operation.
6.2 Tubing connection
It is recommended to connect pipelines successively from BOP body. This can arrange pipelines tidily, adjust
strike direction easily and avoid reworking. In addition, importance must be attached to purging and cleaning of all
tubings and casings with compressed air before their installation. Each tubing is welded with ―O‖ or ―C‖ mark
over channel steel on the base of the remote console. ―O‖ means ―Open‖ and ―C‖ ―Close‖. Therefore, when the
tubings are connected, operators watch not only the mark ―blind ram‖, ―pipe ram‖ and ―annular‖ the same with the
show of valve on remote console, but also the mark ―o‖ or ―c‖ corresponding the open or close of BOP.
Attention:
19
1. Wrong connection of a controlled object or wrong switching direction of connection will result in a
wrong action, so the controlled object and switching direction must be identified carefully before
pipeline connection.
2. Be sure that pipeline joints shall not be blocked or leaked and there should not be dirt in pipelines
during connection; otherwise, the system will be affected.
6.3 Cable connection
Signal cables and power cables need to be connected to the FKDQ hydraulic control system. Power cables
can be inserted to the socket of the driller’s consoler via socket connectors. Signal cables are led into the gland,
and then the bus connector is connected again. (See the appendix for the bus connector connecting method.)
Finally tighten the gland.
6.4 Power connection
380V 50HZ AC power supply shall be used. If the remote console is a specially designed product, please
connect the power supply according to the voltage specified in the technical agreement. The ground wire terminal
of the electric control cabinet shall be grounded reliably according to relevant electrical regulations so as to avoid
personnel accidents.
Before connection, the main switch of the electric power control box on the remote console shall be turned at
the ―stop‖ position to prevent immediate startup of the motor after power-on from resulting in an accident.
Attention:
Before the system is connected with the power supply, be sure that the master switch on the electric
control cabinet is at the ―Stop‖ position so as to avoid emergent accidents. Before power-on, be sure that
the control system has been grounded reliably.
Carefully check whether all connecting pipelines are connected reliably and various union joints and
connections have been tightened after completing equipment installation. Then test run can be performed.
6.5 Test run preparations
The preparation work before the test run shall be performed according to the following procedure:
6.5.1 Precharge each accumulator or check its nitrogen pressure. The pressure shall be 7±0.7MPa
(1000±100psi). In case of insufficient pressure, nitrogen shall be supplemented.
20
6.5.2 Add oil to the oil tank. Oil is added from inlet on the top of reservoir or sucking oil with sucking pump.
The oil volume shall be controlled on the level of oil mark.
Attention:
When the ambient temperature is over 0℃, use YA—N32 common hydraulic oil or suitable alternate oil.
When the ambient oil is less than 0℃, use YC—N32 low temperature hydraulic oil or suitable alternate
oil.
6.5.3 Lubricate the moving parts according to the lubrication requirements specified in the manual.
6.5.4 Open the accumulator unit isolating valve and the unloading valve on the control manifold. Turn the
handle of each 3-position and 4-way rotary valve to the middle position and that of the bypass valve to
the ―Close‖ position.
6.5.5 Turn the master switch to the ―Manual‖ position. After motor startup, turn master switch to the ―Stop‖
position. When the motor is stopped slowly, observe whether its rotation direction is consistent with the
arrow indication direction above the chain protection cover; in case of inconsistency, it is needed to
change the power line phase.
6.5.6 Press the test button on the remote console, and confirm that tremblers and bulbs are in good condition.
6.6 Test run procedure:
6.6.1 Start/stop test of the electric oil pump
Turn the master switch to the ―Automatic‖ position. After the electric oil pump runs with no-load for 10min,
close the unloading valve on the control manifold so that the accumulator pressure is increased to 21Mpa (3000psi).
Here the pump shall and can be stopped automatically. If the pump cannot be stopped automatically, the master
switch on the electric control cabinet can be turned to the ―Stop‖ position so as to stop pump running.
Gradually open the unloading valve on the main pipe of the 3-positon and 4-way rotary valve so as to slowly
unload the system. When the oil pressure is decreased to around 18.9Mpa (2700psi), the electric oil pump shall and
can be started automatically.
During the above operation, check and adjust the pressure controller till the electric oil pump can be stopped
and started automatically. During boosting, observe whether each joint on the remote console is of seepage and oil
leakage etc.
6.6.2 Start/stop test of the pneumatic oil pump
21
When using the pneumatic oil pump, close the bypass valve of the liquid/air switch and open the air supply
switch valve led to the pneumatic oil pump so that the pneumatic oil pump works. When the accumulator pressure
is increased to around 21Mpa (3000psi), observe whether the liquid/air switch cuts off the air supply to stop
running of the pneumatic oil pump.
Gradually open the unloading valve on the control manifold so as to slowly unload the system. When the
system pressure is decreased to around 18.9MPa (2700psi), the pneumatic oil pump shall and can be started
automatically.
During the above operation, check and adjust the liquid/air switch till the pneumatic oil pump can be stopped
and started automatically. During boosting, observe whether each joint on the remote console is of seepage and oil
leakage etc. In case of seepage, the joint shall be repaired.
6.6.3 Adjustment of the pressure regulating valve
During the above boosting, observe whether the outlet pressure of the pressure regulating valve of the
manifold or the annular control circuit is 10.5Mpa (1500psi); in case of inconsistency, it shall be adjusted to be
10.5Mpa (1500psi).
6.6.4 Commutation test
The accumulator pressure is increased to 21MPa (3000Psi) and the by-pass valve on the control manifold is
set at the ―Close‖ position. Then change the handle direction of the 3-positin and 4-way valve on the remote
console, and observe whether the ―Open‖ and ―Close" action of the valve is consistent with the actual action of the
BOP or relief valve. Turn the button on the driller’s console for reversing of direction, and observe whether the
―Open‖ and ―Close" action of the valve is consistent with that of the controlled object. In case of inconsistency,
check whether the pipeline connection is accurate.
Attention:
During the test run, an appropriate drill pipe shall be inserted into the BOP stack so as to prevent
―Sealing None‖ from damaging the BOP (refer to the BOP Operation Manual).
6.6.5 Relief valve test
Close the accumulator isolating valve on the pipeline, turn the 3-positon and 4-way rotary valve to the
middle position, turn the master switch on the electric control cabinet to the ―Manual‖ position and start the
22
electric oil pump. The accumulator pressure is increased to around 23Mpa (3300psi). Observe whether the relief
valve at the outlet of the electric oil pump can be completely opened for overflow. After the relief valve is
completely opened for overflow, turn the master switch to the ―Stop‖ position to stop the electric oil pump. Then
the relief valve shall be completely closed when the pressure is no lower than 18.9Mpa (2700psi).
Close the accumulator unit isolating valve and then turn the bypass valve on the control manifold to the
―Open‖ position. Open the air supply switch valve and the liquid/air switch bypass valve and start the pneumatic
oil pump, so that the manifold is boosted to 34.5Mpa(4900psi). Then observe whether the relief valve on the
manifold is completely opened for overflow. After the relief valve is completely opened for overflow, close the air
supply and stop the pneumatic oil pump. Then the relief valve shall be completely closed when the pressure is no
lower than 28.5MPa (4000psi). When necessary, the overflow pressure of the relief valve shall be adjusted.
Attention:
When testing and adjusting the relief valve, the accumulator unit isolating valve must be closed to
prevent accumulator pressure increase from causing accidents.
6.6.6 Pneumatic pressure regulating test of the annular BOP
Turn downwards the handwheel of the manual relief valve of the annual BOP so that the outlet pressure of
the valve is set at 10.5Mpa (1500psi).
When the air motor type/manual relief valve is operated manually, users can complete pressure regulation of
the annular BOP stack only by pressing the pressure regulation button and the main control button on the driller's
console at the same time.
For the adjustment of the annular pressure on the remote console, users only need to adjust the pneumatic
rotary valve on the remote console and observe the pressure gauge reading of the annular BOP.
Attention:
Time lag may occur when regulating the annular pressure on the driller’s console due to long air pipeline,
so users shall operate slowly.
6.6.7 Inspection of the oil tank level height
If over much oil is leaked during the above regulation so that the oil tank level is over low, oil shall be
supplemented appropriately but shall not be supplemented excessively so as to prevent oil from overflowing out of
the oil tank when accumulator unit oil returns to the oil tank.
23
VII. Operation, Maintenance and Lubrication
The hydraulic controls system is one of important units of well control equipment; therefore, in order that the
hydraulic control system for BOPs can control well blowout effectively, reliably and quickly in an emergency,
relevant personnel must be trained technically so that they understand structure, principle, installation, operation,
maintenance and troubleshooting.
7.1 Operation instructions:
7.1.1 During normal drilling, the handle position of each rotary valve on the remote console: each BOP is at
the ―Open‖ position, relief valve at the ―Close‖ position and bypass valve at the ―Close‖ position.
7.1.2 The two-step operation mode is used for the button on the driller’s console; i.e., firstly press the main
control button and then the corresponding control button. Please loosen the button when the position
indication light is highlighted so as to ensure proper reversing of direction.
7.1.3 Vehicles shall not pass through the hydraulic line or cables connecting the control system with BOPs so
as to prevent damage.
7.1.4 The control system shall be checked completely at least weekly during normal drilling. When
approaching or entering oil and gas reservoirs, the control system shall be checked per shift. The
checking contents shall include:
 Whether the oil tank level is normal;
 Whether electrical elements and lines are safe and reliable;
 Whether oil and air pipes are leaked;
 Whether the pressure controller is started and stopped automatically, accurately and reliably;
 Whether the displayed value of each pressure gauge is in line with the requirements;
 Whether bulbs and tremblers are normal;
 Conduct opening and closing tests of BOPs according to relevant safety regulations.
7.1.5 Users are required to establish operation and maintenance records of the equipment. All documents and
records must be transferred with the equipment.
7.2 Maintenance:
7.2.1 The filter screen in each oil filter and the oil port at the top of the oil tank shall be dismantled and
checked monthly. Take out the filter screen and carefully clean it to strictly prevent dirt from blocking it.
7.2.2 The water-separating gas filter in the air source processing elements: open the water drain valve at the
24
lower end daily to discharge the sewage in the cup. Take off and clean the filtering cup and the water
storage cup once every two weeks. Clean and filter them with mineral oil such as gasoline etc. and dry
them with compressed air. Don’t use acetone and toluene solutions etc. to clean them so as to avoid
damaging them.
7.2.3 The oil fogger in the air source processing elements: check the wave surface in the cup daily and take
care to timely supplement and replace lubricating oil (N32# machine oil or other appropriate oil); if
finding unsmooth oil dropping, dismantle and clean it.
7.2.4 Periodically check the precharging nitrogen pressure in the accumulator. Check the nitrogen pressure
weekly at first. Check it monthly during subsequent normal use. When the nitrogen pressure is less than
6.3Mpa (900psi), nitrogen shall be supplemented in due time. The nitrogen pressure must be checked on
the premise that the accumulator unit is pressure released completely.
7.2.5 In case of long-distance transportation of the hydraulic control system, the nitrogen in the accumulator
shall be released till the nitrogen pressure is only around 1MPa (140psi), thus avoiding emergencies
during transportation.
7.2.6 Check the oil tank level at any time; periodically open the gate valve at the oil tank bottom to discharge
water, check whether there is mud and sand at the tank bottom and when necessary, clean the tank
bottom.
7.2.7 Periodically check the sealing packing of the electric oil pump. The packing shall not be over tight.
When the packing is damaged, it shall be replaced.
7.2.8 During pipeline dismantling, take care not to lose the ―O‖ seal ring of the quick coupler. After
dismantled, these seal rings shall be collected together and kept properly.
7.2.9 Often clean and wipe the surface of the remote console and driller's console; take care not to knock off
various label plates.
7.2.10 After completing drilling of each well, check the pressure gauge once.
7.3 Lubrication Instructions:
7.3.1 Use an oil gun to add appropriate quantity of lubricating oil and machine oil to the two nipples of the air
cylinder of the rotary valve weekly.
7.3.2 Check the lubricating oil of the oil fogger weekly; in case of insufficient lubricating oil, N32 machine oil
or other appropriate oil shall be supplemented.
7.3.3 Check the lubricating oil level of the crankcase of the electric oil pump monthly; in case of insufficient
25
lubricating oil, N32 machine oil or other appropriate oil shall be supplemented.
7.3.4 Dismantle the chain protection cover and check its lubricating oil monthly; in case of insufficient
lubricating oil, N32 machine oil or other appropriate oil shall be supplemented.
VIII. Failure and Troubleshooting
8.1 There is nose during running of the control system.
Cause: There is gas mixed in the oil of the system.
Measures: No-load running and circulation to discharge gas
Check whether the rubber bladder of the accumulator is broken or not; if yes, replace it in due time.
8.2 Motor start failure
Cause: The power parameters are not in line with the requirements.
Measures: Repair the circuit.
Cause: The electric elements in the electric control cabinet are damaged and out of order or the fuse is
burned up.
Measures: Check the electric control cabinet or replace the fuse.
Cause: An alarm due to low liquid level causes forcible motor shutdown.
Measures: Add oil into the oil tank to normal working liquid level.
8.3 After electric oil pump start, the system is not boosted or is boosted too slowly; sound is abnormal during
pump running.
Cause: The oil of reservoir is below normal level to make pump suck nothing.
Measures: Supplement oil.
Cause: The gate valve at the oil suction port is not opened or the oil filter at the oil suction port is
blocked.
Measures: Check the pipeline, open the gate valve and clean the oil filter.
Cause: The unloading valve on the control manifold is not closed.
Measures: Close the unloading valve.
Cause: The electric oil pump is out of order.
Measures: Repair the electric oil pump.
8.4 The electric oil pump cannot automatically stop running.
Cause: The tubing or joint of the pressure controller is blocked or of oil leakage.
26
Measures: Check the pipeline of the pressure controller.
Cause: The pressure controller is out of order.
Measures: Adjust or replace the pressure controller.
8.5 The outlet pressure of the relief valve is too high.
Cause: There is dirt on the sealing surface of the seal ring in the valve.
Measures: Rotate the pressure regulating handwheel to move the sealing box up and down several
times, thus making for squeezing out dirt.
When necessary, dismantle, check and repair the valve.
8.6 BOPs cannot be opened and closed on the driller’s console or corresponding action is inconsistent.
Cause: The quick hose on the solenoid valve of the remote console is connected wrongly.
Measures: Check the air hose.
Cause: The solenoid valve coil is damaged.
Measures: Replace the coil.
Cause: PLC communication error.
Measures: Make a bus connector head again or replace the bus connector.
27
Electric-pneumatic Liquid Type Remote Console
Ordering Instructions
Number and Model of Controlled Objects
Ordering Scope
Site Power Supply Type
Special Requirements
28
rdering Instructions
The control system for surface BOP stacks has complex technical parameters and multiple structural forms.
To assist customers in accurate type selection and ordering and to make well control system configuration be in
line with national standards and API codes, customers shall provide detailed technical data and application
requirements. These data and requirements include:
I. Number and Model of Controlled Objects
BOP Manufacturer: ______________________________
BOP stack configuration form:
 Annular __________ Open ____________ (L) Close ____________ (L)
 Blind ram _____ __ Open ____________ (L) Close ____________ (L)
 Semi-blind ram ____ _ Open ____________ (L) Close ____________ (L)
 Semi-blind ram ____ _ Open ____________ (L) Close ____________ (L)
 Preventer __________ Open ____________ (L) Close ____________ (L)
 Preventer __________ Open ____________ (L) Close ____________ (L)
 Spare parts
II. Ordering Scope
Customers shall explain the optional parts. These optional parts include:
 Button type driller’s console (area 1, class II /area 2, class II)
 Button type auxiliary driller’s console (area 1, class II/area 2, class II)
 Touch screen type auxiliary driller’s console (safety area /area 2, class II)
 Signal cables for the driller’s console – remote console (Profibus Fc standard cables)
 Power cables for the driller’s console – remote console (socket connector connecting/gland
connecting)
 Hydraulic lines (pipe racks, flexible lines and hoses etc.)
 Anti-lifting device
 Automatic recording system of the PN-T remote console
 Zero pressure starting system
 Others
III. Site Power Supply Type
29
 Three-phase three-wire system
 Three-phase four-wire system
 Voltage (V) ___________
 Hz ___________
IV. Special Requirements
If customers have special requirements for products or parts, they shall explain the special requirements. The
products of no special requirements will be manufactured according to relevant national standards and enterprise
standards.
 House-protecting pattern
 Painting (paint and appearance etc.)
 Connecting
 Others
Our company’s control system for surface BOPs conforms to API Spce 16D, SY/T5053.2-2001 and
enterprise standards.
30
Control System for Surface BOP Stacks
Main Hydraulic and Pneumatic Components
JYS21-25 and JYSQ21-25 Relief Valves
31
Overview
Main performance parameters:
Structure and Operating Principle
Installation, Operation and Maintenance
Failure Cause and Elimination Method
List of Wearing Parts
32
I. Overview
The crankshaft plunger pump is a triple plunger pump driven by crankshaft connecting rod and uses valve
distributing mode. Therefore, the crankshaft plunger pump has such advantages as simple structure, convenient
maintenance and strong resistance to pollution and is applicable to site operating conditions. The crankshaft
plunger pump is used for the system using hydraulic oil as medium.
II. Main performance parameters
Model QB21-80 QB21-60
Rated operating pressure MPa 21 21
Theoretical displacement (ml/r) 82 60
Motor power Kw 18.5 15
Weight Kg 200 200
III. Structure and Operating Principle
See Figure 4 for the structural drawing of the crankshaft plunger pump. Its main parts include:
1. Crankcase 12. Connecting rod nut
2. Pump head 13. Retainer ring
3. Spring 14. Crosshead shaft
4. Oil feeding and drain valve core (valve body) 15. Crosshead
5. Valve seat 16. Air ventilator
6. Packing front sleeve 17. Connecting rod
7. V-shaped sandwiched fabric seal ring assembly 18. Crankshaft
8. Packing box 19. Bush
9. Packing pressing sleeve 20. Bearing
10. Packing gland nut 21. Oil scale
11. Plunger 22. Oil seal
Crankshaft (18), connecting rod (17), crosshead (15) and crosshead shaft (14) form the crankshaft
connecting rod mechanism. When the crankshaft is rotated, crosshead shaft (14) pushes plunger (11) to move left
33
and thus to discharge high pressure oil. The crankshaft connecting rod mechanism causes the crosshead to drive
the plunger to move right via connecting rod nut (12) and retainer ring (13) and thus to suck in oil.
There are two rows of non-return valves composed of oil feeding and drain valve core (4) and valve seat (5)
in pump head (2). The three valves of the upper row are non-return valves for oil drainage, and the three valves of
the lower row are non-return valves for oil suction. When the plunger moves right, negative pressure is generated
in the pump head and the non-return valve for oil drainage is closed, so that the non-return valve for oil suction is
opened and thus sucks in oil. When the plunger moves left, the non-return valve for oil suction is closed under
pressure, and the non-return valve for oil drainage is opened to discharge high pressure oil.
出油 Z 3/4 Figure 3 Structural Drawing of the Crankshaft Plunger Pump
34
IV. Installation, Operation and Maintenance
1. The pump and the motor must be fixed on the same base using bolts so as to prevent loosening and tilting.
The pump and the motor use the sprocket drive mode.
2. During installation, all pipeline joints shall be tightened to ensure sealing and to prevent air inhalation from
causing cavitation erosion.
3. An oil filter shall be installed in the suction pipe of the pump and shall have a filtering accuracy of no less
than 100 meshes. The oil filter shall be dismantled and inspected monthly. Take out and carefully clean the
filter screen to strictly prevent dirt from blocking it.
4. The pump has bad self-suction capacity; therefore, during installation, the lowest liquid level of the oil tank
shall be over 300mm from the pump shaft center.
5. Pump rotation direction: the pump rotates anticlockwise from the pump shaft direction.
6. Both ends of the pump head (2) are fitted with oil inlet and outlet, and users can use them according to
installation position.
7. Open the air ventilation plug (16) and add 20# machine oil into the crankcase to the oil scale. During use,
often observe the liquid level height and timely supplement oil; periodically (half year in general) replace the
oil in the crankcase so as to ensure clean lubricating oil.
8. During normal operation, the oil temperature of the system shall be 20~60℃; otherwise, a cooling or heating
device shall be established in the oil tank.
9. The V-shaped sandwiched fabric seal ring in the plunger sealing device shall have moderate tightness, and
the seal ring shall not be pressed over tightly. The packing gland nut is generally regulated so that 5~10
drops of oil drop at the position.
V. Failure Cause and Troubleshooting Method
5.1 High noise, large vibration and air bubbles in oil
Cause: Triplex pump down, low oil temperature
Measures: Check whether the oil level conforms to the standard and the filter screen and the pump oil
inlet are blocked; find out the cause and eliminate it.
Cause: Low oil temperature or high viscosity
Measures: Oil tank temperature rise; substituting the hydraulic oil of appropriate grade
5.2 System pressure increase, insufficient overflow rate
35
Cause: Abrasion or sticking of sealing surface
Measures: Replace the oil feeing and drain valve core and valve seat or adjust the mutual position of
the oil feeding and drain valve core and valve seat well.
Cause: Damage of the V-shaped sandwiched fabric seal ring
Measures: Replace the seal ring.
5.3 Heating abnormity
Cause: Bearing burning-out or over tight pressing of the V-shaped sandwiched fabric seal ring
Measures: Replace the bearing or adjust the tightness of the V-shaped sandwiched fabric seal ring.
VI. List of Wearing Parts
See the following figure for the detailed list of wearing parts.
36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17
18
19
20
21
22
Drill a ? 2 hole for the pin of the two screws
26 HG4-692-67 Oil-seal PD55×75×12 1

25 Y15-09 Big chain wheel 1
24 GB297-64 Bearing 2007115 2
23 Y07-44 Crank 1
24 23
Z 34 / " 22 GB97-86 Pin 2×20 6
21 Y15-07 Small chain wheel 1
20 GB1243.1-83 Chain 10A-3×106 1
37
19 Y07-37 Bush 6
18 Y07-36 Link bonnet 3
17 Y07-35 Link nut 6
16 Y07-34 Link bolt 6
26
15 Y07-30 Link 3
14 Y07-29 Crosshead 3
13 Y07-28 Crosshead pin 3
12 GB879-86 Pin 8×45 3
11 Y07-26 Crosshead shaft 3
10 HG4-692-67 Oil-seal PD25×40×10 6
9 Y15-06 1" plunger 3
8 Y15-05 Packing gland 3
7 HG4-337-66 V pushing ring (B) 25 3

6 HG4-337-66 V sealing ring (B) 25 9
5 HG4-337-66 V bearing ring (B) 25 3
25 4 Y15-03 Packing top sleeve 3
Z 1 1/4 " 3 Y07-07-00A Seal-adapter top 3
2 Y07-09 Valve seat 6
1 Y07-08 Valve body 6
Item
No. Code Description Qty
Model QB21-80
3-cylindar crank plunger pump
Drawing No. Y15-00

Relief Valve
JYS21-25 Relief Valve
38
JYS21-25 Relief Valve
I. Overview
The relief valve in the control system for surface BOP stacks functions in reducing the high oil pressure
(21Mpa) in the accumulator to the low pressure (generally 10.5MPa) needed for controlling BOPs. In addition, this
valve also undertakes the task of automatic overflow and pressure reduction under a certain operating condition.
Therefore, the valve has two functions such as pressure reduction and overflow.
Attention:
There are 3 types of relief valves manufactured by our company. The contents of this chapter are
applicable to the airbag type pneumatic/manual relief valve and the manual relief valve.
II. Main Technical Parameters
Model: JYS21-25
Operating pressure: 21MPa
Drift diameter: 25mm
Rated flow rate: 160L/min
Pressure regulating 0～14MPa
range
Weight: 26Kg
Figure 4 Structural Drawing of the Relief Bleed Valve

III. Structure
As shown in Figure 4, the relief valve mainly consists of the following parts:
1. Handwheel 12. Bottom flange
2. Regulating screw 13. Pressure reducing sliding sleeve
3. Locking handle 14. Spring
4. Planar thrust ball bearing 15. Oil drain sliding sleeve
39
5. Spring seat 16. Spring
6. Inner spring 17. Valve seat
7. Outer spring 18. Valve body
8. Cover cylinder 19. Oil feeding flange
9. Stabilizer 20. Oil feeding valve seat
10. Pushing rod 21. Pin
11. Oil discharging flange
IV. Operating Principles
The high pressure oil P1 enters the valve chamber via the small crescent hole formed by the oil feeding
flange and the valve seat and generates pressure difference between the upper and lower end faces of the valve
core, thus making the valve core move up and down, compressing the spring and balancing the spring force. When
moving upward till the valve core closes the small crescent hole, the oil pressure in the valve chamber is not
increased any longer, and the valve core also stops rising and is balanced relatively to the spring force. Here the oil
pressure in the valve chamber is the outlet pressure P2, which can be changed by regulating the spring with the
handwheel. When the spring is adjusted loosely, the spring force is small, the pressure difference for valve core
upshifting balanced with the spring force is small, the oil pressure in the valve chamber is low and the outlet
pressure P2 is small. On the contrary, when the spring is adjusted tightly, the spring force is large, the pressure
difference for valve core upshifting balanced with the spring force is large, the oil pressure in the valve chamber is
high and the outlet pressure P2 is large.
When the outlet pressure P2 is decreased (because of opening and closing BOPs), the oil pressure in the
valve chamber is decreased and the pressure difference between the upper and lower end faces of the valve core is
decreased, so that the spring force is larger than the pressure difference. The spring force drives the valve core to
move downwards, the small crescent hole for oil feeding emerges and high pressure oil enters the valve chamber,
so that the oil pressure in the valve chamber is increased, the pressure difference is increased and the valve core is
moved upwards. Till the small crescent hole disappears, the outlet pressure is kept unchanged.
When the outlet pressure P2 is increased (when passing through a joint during a round trip), the oil
pressure in the valve chamber is increased, thus driving the valve core to move upwards (compressing the spring),
making the small crescent hole emerge at the oil spill port, starting oil spilling and reducing the oil pressure in the
40
valve chamber. The spring force drives the valve core to move downwards. Close the small crescent hole for oil
spilling and keep the outlet pressure unchanged.
Circulate as such. After setting the spring force, the outlet pressure P2 is kept unchanged all the time,
unless otherwise the inlet pressure P1 is lower than the outlet pressure P2.
Attention:
The relief valve seat uses planar sealing. After sealing surface abrasion, it can be self-compensated
depending upon spring force so as to prolong the service life of the valve.
V. Features and Operating Instructions
1. During pressure regulating of the valve, the pressure is increased in stepped mode and decreased smoothly
and stably.
2. The outlet pressure of the two relief valves provided for the pneumatic remote console is initially set at
10.5MPa. If needing a low pressure, users can rotate the handwheel anticlockwise to reduce the outlet
pressure.
3. A 1‖ oil filter is installed before the oil inlet of both relief valves in the system. Take care to clean the oil
filter so as to prevent dirt from entering the valve and thus hindering its normal operation. When the inlet oil
pressure of the valve is changed, the outlet pressure of the valve is not affected.
VI. List of Wearing Parts
41
P1
42
14 Y16-26 Oil in valve seat 1
13 Y16-22 Valve seat 1

12 GB3452 1-82 "O" seal ring 15×2.65 3
11 Y16-21 Oil release slide cover 2
10 Y16-20 4
9 GB3452 1-82 "O" seal ring 63×3.55 2
P2 8 GB3452 1-82 "O" seal ring 20×2.65 4
7 GB3452 1-82 "O" seal ring 58×3.55
6 Y02-12 Valve board 1

5 Y02-10A Handspike 1
4 Y02-26 "O" seal ring 1

3 GB3452 1-82 "O" seal ring 30×2.65 3
2 Y02-11A Centralizing sleeve 1
1 GB301-64 Bearing 8102 1
Item Qty
No. Code Description
Model JYS21-25
Manual regulator
Drawing No. Y02-00A

I. Overview
The air motor type pneumatic/manual relief valve is an important component of the control system for
surface BOP stacks for controlling annular BOP pressure. The valve reduces the high oil pressure (21MPa/3000Psi)
in the accumulator to the needed low pressure (generally 10.5MPa/1500 Psi). Driven by an air motor, the relief
valve has higher air consumption than the airbag type pneumatic/manual relief valve, but during pressure
regulation, the air motor type pneumatic/manual relief valve is very stable. The valve is suitable for the electric
hydraulic control system and the pneumatic hydraulic control system of high pressure regulation requirements.
1
2
3
Model: JYSQM 21-25 4
5
6
Operating pressure: 21MPa 7
Drift diameter: 25mm 9
剖面 A-A
10
Rated flow rate: 160L/min 11
12
Pressure regulating range 0～14MPa 13
14
15
Weight: 33Kg
16
17
18
19
27
20
28
21
22 29
23 30
31
24
25
26
Figure 5 Structural Drawing of the Relief Valve of the Air Motor
43
III. Structure
As shown in Figure 5, the relief valve mainly consists of the following parts:
1. Handwheel 17. Cover cylinder
2. Regulating screw 18. Sleeve
3. Locking rod 19. Quadrate flange
4. Locking sleeve 20. Valve seat
5. Worm wheel 21. Pressure reducing sliding sleeve
6. Bearing 22. Spring
7. Planar roller bearing 23. Oil drain sliding sleeve
8. Air motor 24. Oil feeding flange
9. Sleeve 25. Oil feeding valve seat
10. Worm shaft 26. Oil discharging flange
11. Pressure head 27. Cabinet
12. Bearing seat 28. Pushing rod
13. Worm 29. Valve plate
14. Outer spring 30. Valve body seat
15. Inner spring 31. Valve body
16. Spring seat
IV. Features and Operating Instructions
During pressure regulating of the valve, the pressure is increased and decreased very stably.
The outlet pressure of the ex-factory air motor type pneumatic/manual relief valve is set at 0.5MPa (1500
Psi). If needing a low pressure, users can rotate the handwheel anticlockwise to reduce the outlet pressure. The
valve can realize both manual pressure regulation and pneumatic pressure regulation. During manual pressure
regulation, firstly loosen the locking nut. The output pressure can be adjusted to be the setting pressure by rotating
the handwheel at the upper end of the air motor type pressure regulating valve. Turning down clockwise is to
increase the output pressure. Turning upward is to reduce the output pressure.
During pneumatic pressure regulation, firstly tighten and lock up the locking nut. For the pneumatic
hydraulic control system, air circuit commutation can be performed to realize positive and reverse rotation
44
switching of the pneumatic motor both by turning the 3-position and 4-way pneumatic rotary valve on the remote
console and by controlling the double pneumatic 3-position and 5-way valve on the remote console via the driller’s
console. The air motor drives the screw via the gear worm pair and screw pair to move up and down and thus to
release or compress the spring, thereby changing the outlet pressure (i.e., adjusting the control pressure of the
annular BOP). The pneumatic pressure regulation range is generally 1~14MPa (145~2000psi) and shall not be over
large. When pneumatic pressure regulation cannot be realized due to wrong operation, firstly recover the
electromagnetic directional valve or the double pneumatic 3-position and 5-way valve to the middle position,
loosen the locking nut, turn and rotate the handle to certain angle and then tighten and lock up the locking unit.
Then pneumatic pressure regulation can be achieved.
The oil inlet of the air motor pressure regulating valve in the system is fitted with an oil filter. Take care to
clean the oil filter so as to prevent dirt from entering the valve and thus hindering its normal operation.
Attention:
During annular pressure regulation on the driller’s console, time lag of several seconds will occur
because of large air consumption of the air motor pressure regulation valve and long transmission
distance. Therefore, when turning the 3-position and 4-way pneumatic rotary valve on the driller’s
console to regulate the annular pressure, take care to set the 3-position and 4-way pneumatic rotary valve
to the ―Middle Position‖ for 1 to 2 seconds after 1 second of ventilation each time and to observe the
reading of the pressure gauge, thus preventing time lag from resulting in improper or over high pressure.
45
Overview
46
I. Overview
The pneumatic pump is one of the main hydraulic components of the control system for surface BOP stacks.
The pneumatic pump uses compressed air as the power source. The pneumatic pump is a device converting air
pressure energy into hydraulic energy and can increase pressure up to 40MPa. During remote control, the
pneumatic pump mainly acts as auxiliary pump. When a motor doesn’t work, the pump can pressurize the whole
system.
Model: QYB40-120L
Maximum output pressure: 40MPa
Displacement per stoke: 128ml
Air supply pressure: 0.5～1.2Mpa
Compression ratio 60：1
Piston travel 97mm
Air cylinder diameter: 216mm
Hydraulic cylinder diameter: 28mm
III. Structure and Features
As shown in Figure 5, the QYB40-120 pneumatic oil pump mainly consists of the following parts:
Pump head, valve core connecting rod, air pipe assembly, valve core sleeve, pump head seat, valve core rod,
piston rod nut, piston, piston rod assembly, air cylinder, valve core rod retainer ring, spring, pedestal, plunger rod
assembly, pump body, plunger cylinder sealing assembly, plunger cylinder assembly, steel ball and seal ring etc.
Compressed air enters the upper chamber of the air cylinder from the pump head air inlet via the valve core
sleeve, the lower air inlet of the valve core, the two air inlets at the lower end of the pump head and the air inlet of
the pump head seat and drives the piston to move downwards; meanwhile, the air in the lower chamber of the air
cylinder enters the air exhaust chamber of the pump head via the air inlet of the pedestal and the air pipe assembly
and then is exhausted out of the exhaust port. The piston drives the plunger rod assembly to move downwards via
the piston rod assembly; here steel ball 1 moves upwards, steel ball 2 closes the oil suction port, and the
47
compressed oil enters the upper chamber of the plunger cylinder and then is discharged out of the oil drain port of
the pump body. After the piston moves downwards to the piston rod nut and contacts with the valve core retainer
ring, the piston continues to move downwards. The piston drives the valve core to move downwards by 1 pitch via
the valve core rod and valve core connecting rod; here the lower air inlet of the valve core is closed and its upper
air inlet is connected with the air inlet chamber of the pump head, thus realizing direction change.
At this point, the compressed air enters the lower chamber of the air cylinder from the air inlet of the pump
head via the valve core sleeve, the upper air inlet of the valve core, the air pipe and the air inlet of the pedestal and
drives the piston to move upwards; meanwhile, the air in the upper chamber of the air cylinder is discharged by the
exhaust port via the exhaust chamber of the pump head seat and pump head. In addition, the piston drives the
plunger rod assembly to move upwards with the piston rod assembly. Here steel ball 2 moves upwards, hydraulic
oil enters the lower chamber of the oil cylinder from the oil suction port, steel ball 1 is closed and the pressure in
the upper chamber of the plunger cylinder assembly is released from the oil drain port of the pump body. After the
piston moves upwards to the spring and contacts the inner hole bottom end face of the piston rod assembly, the
piston continues to move upwards. Here the piston drives the valve core to move upwards by 1 pitch via the valve
core rod and valve core connecting rod. At this point, the lower air inlet of the valve core is connected with the
lower air inlet chamber of the pump head and the compressed air enters the upper chamber of the air cylinder so as
to realize direction change. Reciprocally change the direction of air flow’s entering the air cylinder as such. Then
the piston and the piston rod assembly carry out continuous reciprocating motion up and down. Meanwhile, the
piston rod assembly is also drive to move reciprocally up and down, thus realizing the oil suction and drainage
process of the pump.
48
Figure 5 Structural Drawing of the Pneumatic Pump
49
IV. List of Wearing Parts
50
Overview
Operating Principles
51
I. Overview
The 3-position and 4-way rotary valve is one of the main hydraulic components of the control system for
surface BOP stacks. The high pressure oil in the accumulator enters each controlled object via this valve; in
addition, BOPs are opened or closed by switching this valve.
The 3-position and 4-way rotary valve can realize manual switching and also pneumatic switching by
operating the pneumatic rotary valve on the driller's console.
Model: 34ZS21-35
Operating 21MPa
pressure:
Drift diameter: 25mm
Rated flow rate: 160L/min
Valve core O型 4-Z1

4-Z1
function:
A
Weight: 12Kg A
P O
P O
B
B
中
. 中.
开关
开关
.
Figure 6 Structural Drawing of the 3-position and 4-way Rotary Valve

.
P P P
III. Structure and Features P P P
B the followingAmain components:
AB
A
AB
A
A
As shown in Figure 6, the valve consists of B B B
1. Lower valve body 2. Upper valve body 3. O
Valve core O thrust ball bearing
4. One-way O5. Axis of
O O O
rotation 6. Spring 7. Steel ball 8. Handle 9. Pin 10. Positioning plate 11. Valve seat 12.
Wavy spring, etc.

三位四通转阀
三位四通转阀
52
The valve has the following characteristics:
Both valve core (3) and valve seat (11) have been processed to enhance their surface wear resistance; in
addition, they are anticorrosive and are not easily rusted. Differential pressure sealing mode is used for the valve
core and valve seat; therefore, the higher the oil pressure, the better the sealing property. The sealing is reliable.
Wavy spring (12) functions in initial sealing and self-compensation after valve seat abrasion. Thrust bearing (4) is
installed. During valve switching, the driving kinetic moment on handle (2) is small and no greater than 30NM.
The top of the upper valve body is positioning plate (10). When the handle is turned, steel ball (7) enters a hole of
positioning plate (10) under the action of spring (6), and straight pin (9) slides in the kidney slot of the poisoning
plate to function in position restriction. Therefore, during valve switching, handle reaches an accurate position and
switching and resetting are reliable.
IV. Operating Principles
The valve has 4 oil ports including P port, A port, B port and O port. P port is pressure oil inlet. A port and B
port are pressure oil outlets and connect the two chambers of the oil cylinder of a BOP. O port is oil return port and
is connected with the oil cylinder.
During valve switching, the handle can have 3 positions: middle position (the handle is in the middle), close
position (the handle is turned right by 45°) and open position (the handle is turned left by 45°), which are
respectively described as follows:
Middle position——P, A, B and O oil ports are not connected mutually, indicating ―O‖ function;
Close position——P port is connected with B port; here pressure oil flows towards the oil chamber for
―Closing‖ BOP via B port and drives the piston of the oil cylinder to close BOP. Meanwhile, the oil on the other
side of the oil cylinder flows back to the oil cylinder via A port of the valve.
Open position——P port is connected with A port; here pressure oil flows towards the oil chamber for
―Opening‖ BOP via A port and drives the piston of the oil cylinder to open BOP. Meanwhile, the oil on the other
side of the oil cylinder flows back to the oil cylinder via B port of the valve.
It should be indicated that: during normal drilling, the handle of the 3-positon and 4-way rotary valve for
controlling the ram preventer and the annular BOP must be set at the ―Open‖ position, whereas the handle of the
3-positon and 4-way rotary valve for controlling the hydraulic relief valve must be set at the ―Close‖ position; on
the contrary, in case of well blowout, the position of the above handle is contrary; i.e., for the former, the handle is
at the ―Close‖ position, and for the latter, the handle is at the ―Open‖ position.
53
Attention:
The ―Middle‖ position of the rotary valve is not used in general. During commissioning or equipment
repair or transportation, the handle of the valve shall be set at the ―Middle‖ position so as to prevent
hydraulic oil leakage.
IV. List of Wearing Parts
54
12 Y01-12 Wavy spring
11 GB3452.1-82 O-ring 20×2.65
1
10 GB3452.1-82 O-ring 103×3.55
9 Y01-10A Valve seat
8 GB119-86 Pin D10×14
7 GB3452.1-82 O-ring 21.2×3.55
GB308-77 Steel Ball φ12
55
6
5 GB3452.1-82 O-ring 19×2.65
4 Y01-05 Spring
3 Y01-04 Transfer axes
2 GB301-64 Bearing 8113
1 Y01-03-00 Valve core
No. Code Name Qty.
Model 34ZS21-25
3 position 4 way valve
Drawing No. Y01-00A
Y25-20 Relief Valve
Y40-20 Relief Valve
QKY21-25 Liquid/Air Switch
SB21-14X2 Manual Pump
56
Y25-20 Relief Valve
57
58
Y40-20型溢流阀
Y40-20 Relief Valve

MODEL Y40-20 MANIFOLD RELIEF VALVE
标称压力
NOMINAL PRESSURE
40MPa
额定流量
RATED FLOW
40L/min
调压范围
REGULATING RANGE 5～40MPa
出厂日期出厂编号
SHIPMENT DATE SERIAL NUMBER
上海神开石油化工设备有限公司
4 JB982-77 Gasket 33 1
3 Y08-09B Valve seat 1
2 Y08-08A Valve rod 1
1 GB3452.1-82 "O" ring 20×2.65 1
No. Code Name Qty
Model Y40-20
Relief valve
Drawing No. Y09-00B

QKY21-25 Liquid/Air Switch
59
SB21-14X2 Manual Pump
60
Control System for Surface Mounted BOP Stacks
Main Electrical Components
BQD6-T Magnetic Starter
Shanghai SK Petroleum & Chemical Equipment Corporation Ltd.
61
BQD6-T Explosion-proof Electromagnetic Starter
I. General
The explosion-proof electromagnetic starter in the control system for surface mounted BOP stacks is an
important component to control the start and stop of the triplex pump motor. It is able to manually/automatically
start or stop the triplex pump motor.
Model Rated Rated Motor power Weight Remarks
voltage current
BQD6-T 600V 160A 18.5kW×2 60kg Applicable to
dual-motor, e.g.
FKDQ1280-10
BQD6-T 600V 60A 18.5kW 50 kg Applicable to
single-motor, e.g.
FKDQ640-7
III. Structure
The BQD6-T type of explosion-proof electromagnetic starter (controlling dual-motor type) is shown in Figure 14.
Operational units of the explosion-proof electromagnetic starter are as follows:
S/N Name Function
1 Power indicator light The indicator lights up after power on
2 Motor 1 overload The indicator lights up during overload (motor 1)
The indicator lights up when the triplex pump

3 Operation indicator
motor starts
Switch between automatic/manual function (motor

4 Function switch
1)
5 Start Manually start the triplex pump motor 1
6 Stop Manually stop the triplex pump motor 1
7 Start Manually start the triplex pump motor 2
8 Stop Manually stop the triplex pump motor 2
62
Switch between automatic/manual function (motor

9 Function switch
2)
10 Motor 2 overload The indicator lights up during overload (motor 2)
The indicator lights up when the triplex pump

motor starts
12 Power toggle switch Main power switch
Nameplate
Figure 14 BQD6-T Magnetic Starter
The BQD6-T type of explosion-proof electromagnetic starter (controlling single-motor type) is shown in Figure 15.
Operational units of the explosion-proof electromagnetic starter are as follows:
S/N Name Function
1 Power toggle switch Main power switch
Switch between automatic/manual

2 Function switch
function
63
Manually start the triplex pump

3 Start button
motor
Manually stop the triplex pump

4 Stop button
motor
The indicator lights up after power

5 Power indicator light
on
The indicator lights up when the

triplex pump motor starts
Figure 15 BQD6-T type of explosion-proof electromagnetic starter (controlling single-motor type)
IV. Operating Instructions
Power on: Toggle the main switch to ―ON‖ position and observe that the power indicator light
lights up.
Manual start-stop: Toggle the ―Manual/Auto‖ switch to ―Manual‖ position;
Press the start button, then the triplex pump motor starts;
Press the stop button, then the triplex pump motor stops.
64
Automatic start-stop: Toggle the ―Manual/Auto‖ switch to ―Auto‖ position;
The pressure of the energy accumulator drops to the set starting value (factory
setting is 18.9MPa), then the triplex pump motor starts;
The pressure of the energy accumulator reaches the set stopping value (factory
setting is 21MPa), then the triplex pump motor stops.
Precautions: When using the manual start-stop function, staff must be on the scene to avoid
causing damage to the motor by long-term operation.
Special note: In order to ensure normal use of the product, those other than the supplier are
not allowed to arbitrarily change internal wiring of the product!
V. Removal of Simple Troubles
Trouble description Cause Handling method
1.1 Whether the power supply is normal 1.1.1 Normal power supply
1.2 Whether the power toggle switch is 1.2.1 Toggle the power switch to ―ON‖
1. The triplex pump
toggled to the ―ON‖ position position
motor cannot start by
1.3 Whether the ―Manual/Auto‖ switch is 1.3.1 Toggle the ―Manual/Auto‖ switch to
pressing the start
toggled to ―Manual‖ position ―Manual‖ position
button
1.4 Open the box and check whether the
1.4.1 Reconnect loose wires
connection of wires is loose
2. The triplex pump 2.1 Whether the ―Manual/Auto‖ switch is 2.1.1 Toggle the ―Manual/Auto‖ switch to
motor cannot stop by toggled to ―Manual‖ position ―Manual‖ position
pressing the stop 2.2 Open the box and check whether the 2.2.1 Check the connection of wires and
button connection of wires has short circuit remove the short-circuit
3.1 Whether the power supply is normal 3.1.1 Normal power supply
3.2 Whether the power toggle switch is 3.2.1 Toggle the power switch to ―ON‖
toggled to the ―ON‖ position position

3. The triplex pump
motor cannot start
toggled to ―Manual‖ position ―Manual‖ position

65
3.5 Whether the pressure controller is 3.5.1 Adjust the pressure controller to an
normally adjusted appropriate scope
toggled to ―Auto‖ position ―Auto‖ position

4. The triplex pump
4.2 Whether the pressure controller is 4.2.1 Adjust the pressure controller to an
motor cannot stop
normally adjusted appropriate scope
automatically
4.3 Open the box and check whether the 4.3.1 Check the connection of wires and
connection of wires has short circuit remove the short-circuit
66
I. General
The integrated electric control box in the control system for surface mounted BOP stacks is an important
component to realize electric control. It is internally integrated with PLC and an integrated electric circuit.
Model Rated voltage Rated current Weight
BKX6-T 220VAC 8A 60kg
III. Structure
As shown in Figure 16, operational units of the BKX6-T explosion-proof control box are as follows:
S/N Name Function
Switch to use the standby power

1 Standby power switch
supply
Test the alarming function and

2 Test button
indicator light
Eliminate the sound of alarm bell

3 Sound damping button
and buzzer
Indicator light for low pressure of the energy Display low pressure of the energy
4
accumulator accumulator and give alarm
Display low pressure of the air

5 Indicator light for low pressure of the air source
source and give alarm
Display low level of the oil tank and

6 Indicator light for low level of the oil tank
give alarm
Display the working condition of

7 UPS alarm light
standby power supply
67
Figure 16 BKX6-T Explosion-proof Control Box
Using standby power supply: Toggle the standby power switch to ―ON‖ position and then the standby
power will automatically start when the main power supply is cut off;
Meanwhile, the UPS alarm light lights up and the buzzer bell rings to
prompt that the main power is cut off.
Display of alarm status: When the pressure of the energy accumulator is lower than 17Mpa, the
indicator light for low pressure of the energy accumulator lights up and the
buzzer bell rings;
When the pressure of the air source is lower than 0.5Mpa, the indicator
light for low pressure of the air source lights up and the buzzer bell rings;
When the level of the oil tank is lower than the limit value, the indicator
light for low level of the oil tank lights up and the buzzer bell rings;
Elimination of alarm sound: Under the alarm status, press the sound damping button to avoid normal
68
operation being interfered by the alarm sound.
(This operation does not affect the status of the alarm light. The alarm light
goes out until the alarm situation is removed)
Test: Once the test button is pressed down, all indicator lights and buzzer bells
will start work for routine inspection and maintenance.
Special note： In order to ensure normal use of the product, those other than the
supplier are not allowed to arbitrarily change internal wiring of the
product!
1.1 Whether the standby power switch is 1.1.1 Toggle the standby power switch to
toggled to ―ON‖ position ―ON‖ position
1.2.1 The standby power supply starts
1.2 Whether the power supply is normal only when the main power supply is cut
off
1. The standby power
supply cannot start 1.3.1 Reconnect loose wires
1.4 Open the box and check whether the 1.4.1 Replace the fuse protector and check
fuse protector is broken for short circuit
1.5 Whether the service cycle of standby

1.5.1 Replace the spent battery
power supply has exceeded 3 years
2.1.1 Restore normal power supply or use

2.1 Whether the power supply is normal
the standby power supply

2. No display of 2.2.1 Reconnect loose wires
alarm status
2.4 Whether PLC is under the ―RUN‖ 2.4.1 Toggle PLC switch to ―RUN‖
69
status position

3.2.1 The buzzer bell rings under alarm

3.2 Whether it is under alarm status
status
3. The buzzer bell
does not ring 3.3.1 Reconnect loose wires
3.5 Whether the buzzer bell has a failure 3.5.1 Replace faulty components

4. The sound 4.1.1 Reconnect loose wires
damping does not
work


5.2 Reconnect loose wires
5. The test cannot be connection of wires is loose
conducted 5.3 Open the box and check whether the 5.3.1 Replace the fuse protector and check
5.4 Whether part of the indicator lights or 5.4.1 Check the connection of wires of
buzzers don’t work components and replace faulty ones
70
I. General
The pressure controller is a device used to adjust the automatic start-stop pressure values of the triplex pump
motor. The controller can automatically control pressure parameters of the energy accumulator and give alarms.
II. Main Technical Parameters and Outline Drawings
Model Pressure regulating Setting error Connection Wiring interface
range interface
FBYK-165 6 MPa～36 MPa ≤±2.5% NPT 1/4‖ internal NPT 1/4‖ internal
thread thread
Figure 16 FBYK-165 Pressure Controller
III. Operating Instructions
The upper and lower limit control of controller is taken as an example. Suppose that the upper limit is 21Mpa
and the lower limit is 18.5Mpa. Operation steps are as follows:
1. Before operating the device, pipes and circuits shall be checked carefully;
2. Pressurize the controller, and if the control system does not stop when the pressure reaches 21MPa,
then adjust the adjustment rod on the right side clockwise to decrease the setting value of stop; if the
71
control system stops when the pressure does not reach 21MPa, adjust the adjustment rod on the right
side counterclockwise to increase the setting value of stop until the control system stops at around
21MPa; in this case, the point of 21MPa does not have to be very accurate;
3. Then adjust the lower limit point of 18.5MPa. When the control system stops at the point of 21MPa,
the energy accumulator starts to depressurize. If the control system does not start when the pressure
drops to 19MPa, then adjust the adjustment rod on the left side counterclockwise to increase the setting
value of start; if the control system starts before the pressure reaches 18.5MPa, adjust the adjustment
rod on the left side clockwise to decrease the setting value of start until the control system starts at
19MPa;
4. Conduct fine tuning of 19MPa and 21MPa in the same way;
5. After the adjustment of the control point, decrease the system pressure to zero and then pressurize to
conduct the final fine tuning;
Special note: In order to ensure normal use of the product, those other than the supplier are not allowed
to arbitrarily change internal wiring of the product!
IV. Descriptions of Simple Maintenance
1. In the process of disassembly and assembly of the controller, care should be taken to protect the
housing to avoid the damage and scratch;
2. When using the controller, it is strictly prohibited to disassemble accessory parts of the controller. At
the time of disassembly for repair, it is not allowed to strike or hit against the housing;
3. Before opening the front cover of the controller, the power supply should be cut off in advance;
4. Ground connection inside and outside the controller housing should be to reliable;
5. When using the controller, it should always be kept dry and clean as well as be properly maintained;
6. During the normal use of the controller, (in case the switching frequency of the contact is no more than
once per minute), generally an inspection for once every three months is appropriate. If the controller is in
normal operation with good condition and the contact is not frequently switched, the inspection period may
be extended as appropriate;
7. After long-term use of the controller, if the microswitch cannot work properly (which affect the
operational reliability) or connecting wires is aging, etc., they should be promptly repaired or replaced;
8. The pressure controller should be verified regularly. The recommended verification period is six
months.
72
I. General
The driller’s control cabinet/auxiliary driller’s control cabinet in the control system for surface mounted BOP
stacks is an important component to realize remote control of operation. It is used to remotely operate the control
system for surface mounted BOP stacks.
Model Rated voltage Rated current Weight
A7-3136-4021 24VAC 5A 30kg
III. Structure
As shown in Figure 17, operation units of the driller’s control cabinet/auxiliary driller’s control cabinet are as
follows:
S/N Name Function
Display low pressure of air source

1 Indicator light for low pressure of the air source
and give alarms
Indicator light for low pressure of the energy Display low pressure of energy
2
accumulator accumulator and give alarms
Display low level of oil tank and

3 Indicator light for low level of the oil tank
give alarms
Display the working condition of

4 Indicator light of standby power supply
standby power supply
Display the running status of triplex

5 Indicator light of operation
pump motor
Display the pressure value of

6 Annular ring pressure data display instrument
annular ring

7 Energy accumulator pressure data display instrument
energy accumulator

8 Pipeline assembly pressure data display instrument
pipeline assembly
9 Air source pressure data display instrument Display the pressure value of air
73
source
Start the operation object and

10 Illuminated pushbutton for start of operation object
display the start status
Stop the operation object and

11 Illuminated pushbutton for stop of operation object
display the stop status
12 Annular ring pressurizing button Increase the pressure of annular ring
Decrease the pressure of annular

13 Annular ring depressurizing button
ring
Eliminate the sound of alarm bell

14 Alarm acknowledge button
and buzzer
Test the alarm function and

15 Indicator light testing
indicator light
16 Main control button Two-handed second operation
17 Buzzer Indicate the alarm sound
74
Figure 17 A7-3136-4021 Driller’s Control Cabinet/Auxiliary Driller’s Control Cabinet
Start of operation object: While pressing and holding the main control button, press the illuminated
pushbutton for start of operation object;
After successful operation, the green light of corresponding illuminated button
lights up.
Stop of operation object: While pressing and holding the main control button, press the illuminated
pushbutton for stop of operation object;
After successful operation, the red light of corresponding illuminated button
lights up.
Display of alarm status: When the pressure of the energy accumulator is lower than 17Mpa, the
indicator light for low pressure of the energy accumulator lights up and the
buzzer rings;
When the pressure of the air source is lower than 0.5Mpa, the indicator light for
75
low pressure of the air source lights up and the buzzer rings;
liquid level of the oil tank is lower than the limit value, the indicator light for
low pressure of the oil tank lights up and the buzzer rings;
When using the standby power supply, the indicator light of standby power
supply lights up and the buzzer rings.
Elimination of alarm sound: Under the alarm status, press the alarm acknowledge button to avoid normal
operation being interfered by the alarm sound and eliminate the alarm sound.
(This operation does not affect the status of the alarm light. The alarm light
goes out until the alarm situation is removed)
Test: Once the test button is pressed down, all indicator lights and buzzers will start
work for routine inspection and maintenance.
Display of pressure value: The pressure value of corresponding object can be directly read on the pressure
data display instrument.
Special note: In order to ensure normal use of the product, those other than the supplier are not
allowed to arbitrarily change internal wiring of the product!

1.2.1 Pull and plug the communication

1.2 Whether the communication cable joint
cable joint and set correct communication
is correctly connected
address
1. The device cannot 1.3 Whether there is strong electromagnetic

1.3.1 The wiring should avoid strong
start interference in the area where the
electromagnetic interference
communication cable joint passes

1.5 Whether PLC is under the ―RUN‖ 1.5.1 Toggle PLC switch to ―RUN‖
status position
76

2. No display of the standby power supply
alarm status 2.2 Open the box and check whether the

3.2.1 The buzzer bell rings under alarm

3.2 Whether it is under alarm status
status
3. The buzzer does
not ring 3.3.1 Reconnect loose wires
3.5 Whether the buzzer bell has a failure 3.5.1 Replace faulty components

4. The sound 4.1.1 Reconnect loose wires
damping does not
work

5 The test cannot be 5.2 Open the box and check whether the
5.2 Reconnect loose wires
conducted connection of wires is loose
5.3 Whether individual indicator light or 5.3.1 Check the connection of wires of
buzzer doesn't work components and replace faulty ones
6.1 Whether the anode and the cathode of

6.1.1 Adjust the connection of the anode
data display instrument is inversely
6 No display on the and the cathode of data display instrument
connected
data display
6.2 Whether the current limiter is inversely 6.2.1 Adjust the connection of the anode
instrument
connected and the cathode of current limiter
6.3 Whether there is strong electromagnetic 6.3.1 The wiring should avoid strong
77
interference in the area where the electromagnetic interference
communication cable joint passes
6.4 Whether the data display instrument is 6.4.1 Replace the faulty data display
broken instrument
78
Simple Daily Maintenance Manual for Electrical Parts
1. Maintenance plan
1.1 Pilot run
a. After the pilot run of electrical parts, check electrical parts after the device stops.
b. Check fasteners and make sure they are reliable.
c. Keep proper records.
2). One-year operation (no longer than one year at most) based on operation environment and conditions.
a. After electrical parts have been operated for a year, check the electrical components and find out whether
the required spare parts are in place.
b. Keep proper maintenance records.
3). Two-year operation
a. After electrical parts have been operated for two years, check the electrical components.
b. Replace components to be updated with spare parts.
c. Keep proper maintenance records.
4). Overhaul (three years or as appropriate)
a. During the overhaul of electrical parts, test the electrical system.
b. Replace components to be updated with spare parts.
c. Keep proper maintenance records.
1.2 Maintenance items
S/N Fault phenomenon Possible cause Handling method
Cracks are found at the

1 Fasteners are not effectively tightened Retighten them
joint
Confirm that the junction box is
The junction box is not reliably sealed up
reliably sealed up
Low insulation
Bake them with low-voltage power
2 resistance Components are affected with damp
supply or heat source
(<0.1MΩ)
Components are broken (insulation is
Use spare parts
zero)
Relevant connection point of the system Confirm that the connection point is
is not closed up closed up
3 The system cannot start
Components and parts are broken Replace components and parts
79
1.3 Repair procedures
Before going through the following steps, please ensure that the distribution board is powered off.
1.3.1 Junction box
1. The cable seal joint is reliably sealed up. There is no obvious connection gap through visual inspection.
2. The housing is not broken.
1.3.2 Control cabinet
1. The housing of indicator light is not damaged.
2. The cable seal joint is reliably sealed up. There is no obvious connection gap through visual
inspection.
3. The breaking-closing actions of components and parts are flexible and reliable.
4. Connecting wires are not aged or broken.
1.4 List of common electric consumables
S/N Name Specification/Model Application position Quantity Remarks
Explosion-proof controller
1 Fuse protector RT18/3A 2
box BKX6-T
2 Fuse protector RT18/5A 2
box BKX6-T
7 Relay 24VDC 2
box BKX6-T
3 Fuse protector RT18/6A Transformer boxBBK5-T 2
4 Accumulator 24VDC 8Ah 1
box BDX5-T
Explosion-proof
5 Fuse protector RT18/3A electromagnetic starter 2
BQD6-T
Communication
6 6ES7 972-0BB12-0XA0 box BKX6-T / Driller’s 4
cable joint
control cabinet
80
The rig (its top open) with well-ventilated derrick substructure
Well-ventilated enclosed derrick (its top open)
81
Attention:
The method for dividing the hazardous areas in this manual is in accordance with SY/T 0025-95 the
Classification of Locations for Electrical Installations at Petroleum Facilities. The method is used for
user’s reference for rig floor type.
I. The rig (its top open) with well-ventilated derrick substructure
82
II. Well-ventilated enclosed derrick (its top open)
83
Connecting Method
84
Connecting Method
Siemens Profibus protocol is used for the communication of the electric-pneumatic liquid type hydraulic
control system manufactured by our company, so the PLC connecting end must connect a bus connector.
According to the default setting, the bus connector has been connected on the CPU module of the PLC, and a
segment of purple FC standard cable exposed at the tail is used for connection. Uses can connect the bus connector
according to the following figure.
Attention:
It is suggested that users should connect the bus connector with the guidance from professional
personnel.
85
T800 Tablet PC
Before You Begin
Getting the Tablet PC Running
System Recovery
Taking Care of the Tablet PC
86
T800 Tablet PC
I. Before You Begin

For complete information of the product,refer to the User Manual (in PDF format) on your Windows desktop
or Driver disc.
You can download the latest manual and drivers by accessing the Getac web link at http://www.getac.com
→Support →Download.
II. Getting the Tablet PC Running
2.1. Unpacking
NOTE: This packing list applies to standard models.

Select models may have different items.
2.2. Installing the SIM Card (Optional)

1. Locate the SIM card cover. Remove the cover by unfastening 4 screws.
87
2. Noting the orientation, slide the SIM card into place.
3. Replace the cover and secure with 4 screws.
2.3. Connecting to AC Power and Starting Up

The first time you use your Tablet PC, use the AC adapter.
1. Plug the DC cord of the AC adapter to the power connector of the Tablet PC (○
1 ).
2. Plug the female end of the AC power cord to the AC adapter and the male end to an electrical outlet (○
2 ).
3. Press the power button ( ) to start up.The Windows operating system should start.
2.4. Charging the Battery

To charge the battery, connect the AC adapter to the computer and an electrical outlet. The Battery Charge
Indicator ( ) on the Tablet PC glows amber to indicate that charging is in progress. When the battery is fully
charged, the Battery Charge Indicator glows green.
It takes approximately 3 hours to fully charge the battery pack when the power is off and approximately 3.5
hours when the power is on.
88
1 Select models have a component at this location. The component can be a serial port, microSD card slot,
RJ-45connector, or barcode reader lens.
2 Select models only.
89
III. System Recovery
Windows 8 Models
If you're having problems with your Windows8 computer, you can try one of the below
actions.
 Restore your computer to an earlier point
in time.
 Refresh your computer without affecting
your files.
 Remove everything and reinstall Windows.

For more information, see the User Manual.
Windows 7 Models
A ―System Recovery‖ tool allows you to restore the Windows 7 system to the factory state.
To run System Recovery:
1. Connect the AC adapter.
2. Turn on the Tablet PC. During system startup when the logo screen appears, tap and hold
the screen or press the Windows Logo button on your Tablet PC. This invokes a menu. Select HDI
Recovery in the menu.
Or, if a keyboard is connected, you can press Ctrl + Alt + F2 keys for four seconds instead
of tapping the screen.
3. In the screen that appears, select Recovery to start the recovery process.
4. The progress bar shows the percentage completed. When it reaches 100%, the system
turns off.
5. Turn on the computer. The Windows setup wizard starts. Follow the onscreen prompts to
continue.
6. When the system restarts, the installer screen appears. The installer will perform system
hardware detection and driver installation.
7. When completed, the system restarts and displays Windows desktop.
IV. Taking Care of the Tablet PC
4.1. Location Guidelines

 For optimal performance, use the Tablet PC where the recommended temperature is
90
between 0℃(32℉) and 50℃ (122℉).
 (Aactual operating temperature depends on product specifications.)
 Avoid placing the Tablet PC in a location subject to high humidity, extreme
temperatures, mechanical vibration, direct sunlight, or heavy dust. Using in extreme
environments for long periods can result in product deterioration and a shortened
product life.
 Operating in an environment with metallic dust is not allowed.
 Place the Tablet PC on a flat and steady surface. Do not stand the Tablet PC on its side
or store it in an upside-down position.A strong impact by dropping or hitting may
damage the Tablet PC.
 Do not cover or block any ventilation openings on the Tablet PC. For example,do not
place the Tablet PC on a bed, sofa,rug, or other similar surface. Otherwise,overheating
may occur that results in damage to the Tablet PC.
 As the Tablet PC can become very hot during operation, keep it away from objects that
are vulnerable to heat.Keep the Tablet PC at least 13 cm (5 inches) away from
electrical appliances that can generate a strong magnetic field such as a TV,
refrigerator, motor, or a large audio speaker.
 Avoid moving the Tablet PC abruptly from a cold to a warm place. A temperature
difference of more than 10℃(18℉) may cause condensation inside the unit, which
may damage the storage media.
4.2. General Guidelines

 Do not expose your skin to the Tablet PC when operating it in a very hot or cold
environment.
 Do not place heavy objects on top of the Tablet PC as this may damage the display.
91
 The screen surface is easily scratched.Avoid touching it with a sharp object such as a
pen or pencil.
 LCD image sticking occurs when a fixed pattern is displayed on the screen for a
prolonged period of time. You can avoid the problem by limiting the amount of static
content on the display. It is recommended that you use a screen saver or turn off the
display when it is not in use.
 To maximize the life of the backlight in the display, allow the backlight to automatically
turn off as a result of power management.
4.3. Cleaning Guidelines

 Never clean the Tablet PC with its power on.
 Use a soft cloth moistened with water or a non-alkaline detergent to wipe the exterior of
the Tablet PC.
 Gently wipe the display with a soft, lint free cloth.
 If water or liquid is split onto the Tablet PC,wipe it dry and clean when possible.Though
your Tablet PC is water-proof, do not leave the Tablet PC wet when you can dry it.
 If the Tablet PC gets wet where the temperature is 0℃(32℉) or below, freeze damage
may occur. Make sure to dry the wet Tablet PC.
4.4. Battery Pack Guidelines

 Recharge the battery pack when it is nearly discharged. When recharging, make sure
that the battery pack is fully charged.
 Doing so may avoid harm to the battery pack.
 The battery pack is a consumable product and the following conditions will shorten its
life:
-when frequently charging the battery pack
-when using, charging, or storing the battery in high temperature condition
 To avoid hastening the deterioration of the battery pack thereby prolonging its useful
life, minimize the number of times you charge it so as not to frequently increase its
internal temperature.
Charge the battery pack between 10℃ ~ 30℃(50℉ ~ 86℉) temperature range.
92
 A higher environment temperature will cause the battery pack’s temperature to rise.
Avoid charging the battery pack inside a closed vehicle and in hot weather condition.
Also, charging will not start if the battery pack is not within the allowed temperature
range.
 It is recommended that you do not charge the battery pack more than once a day.
 It is recommended that you charge the battery pack with the Tablet PC’s power off.
 To maintain the battery pack’s operating efficiency when removed from the Tablet PC,
store it in a cool dark place and with 30% ~ 40% charge remaining.
 Important guidelines when using the battery pack.
When installing or removing the battery pack take note of the following:
-avoid installing or removing the battery pack when the Tablet PC is in Sleep mode.
Abruptly removing the battery pack may cause loss of data or the Tablet PC may
become unstable.
-avoid touching the battery pack terminals or damage may occur, thereby causing
improper operation to it or the Tablet PC.
The Tablet PC’s input voltage and surrounding temperature will directly affect the
battery pack’s charge and discharge time:
-charging time will be prolonged when the Tablet PC is turned on.To shorten the
charging time, it is recommended that you place the Tablet PC in Sleep or hibernation
mode.
-a low temperature will prolong the charging time as well as hasten the discharge time.
 When using battery power in an extremely low temperature environment, you may
experience shortened operating time and incorrect battery level reading. This
phenomenon comes from the chemical characteristics of batteries.The appropriate
operating temperature for the battery is-10℃ ~ 50℃ (14℉ ~ 122℉).
 Do not leave the battery pack in storage for more than six months without recharging it.
4.5. Touchscreen Guidelines

 Use the finger or the included stylus on the display. Using a sharp or metallic object
other than your finger or stylus may cause scratches and damage the display, thereby
93
causing errors.
 Use a soft cloth to remove dirt on the display. The touchscreen surface has a special
protective coating that prevents dirt from sticking to it. Not using a soft cloth may
cause damage to the special protective coating on the touchscreen surface.
 Turn off the Tablet PC power when cleaning the display. Cleaning the display with the
power on may cause improper operation.
 Do not use excessive force on the display.Avoid placing objects on top of the display as
this may cause the glass to break thereby damaging the display.
 Using the touchscreen during low temperature (less than 5℃) may cause a slower
response time. This is normal. A normal response time may be restored upon returning
to room temperature.
 When there is a noticeable discrepancy in the placement of the stylus on the screen and
the indicated position of the onscreen pointer, use the calibration utility to recalibrate
the touchscreen display.
94
Wireless Remote Control Software
Overview
Installation Configuration
Basic Operations
FAQs
95
Wireless Remote Control Software for Driller's Station
I. Overview
The software is supporting software for the wireless remote control of driller’s
station, which is mainly used to realize the wireless remote monitoring of well-control
equipment.
1.1. Operating principle
Figure 1 Operating Principle

The software is operated on the mobile terminal (tablet PC) of the wireless
remote control console connected via Wi-Fi to the front PLC device (with the protocol
Modbus-TCP), so as to realize remote monitoring of well-control equipment. The
operating principle of the software is shown in Figure 1.
1.2. Main functions

1. Multi-language interface (English-Chinese)
2. Switch control
3. Indication of various monitoring status
4. Real-time display of 4 pressure values in the form of instrument panel
5. Real-time display of 4 groups of pressure curve
6. Storage of alarm log in recent 1 month
7. Storage of pressure data in recent 1 month
8. Playback of pressure curve
9. System setting
10. Giving sound alarms with the sound card of system
11. Full-screen running of software
96
12. Screen autolock
1.3. Parameter specification

Name Content
Operating system Windows 7 Chinese version (64 bits)
Development language C#
Operating framework .Net Framework 4.5.1
Local database SQLite
Data protocol Modbus-TCP
Hardware platform 8-inch tablet PC (1230x800)
II. Installation Configuration
2.1. Starting installation program

Firstly, run the installation program ―SK-WRCW Setup.exe‖ in the directory of
installation document, as shown in Figure 2.
Figure 2 Installation Program

Note that the first time of installation may take a relatively longer time, please
be patient. The main reason is that a third-party dependent package needs to be
installed. Later installation can be rapidly completed.
2.2. Installation process

The entire installation process of the software is shown in Figure 3 to Figure 8.
97
Figure 3 Installation Process
98
99
2.3. Starting main program

Double click the desktop icon (As shown in Figure 9) to start the main program.
100
Figure 9 Desktop Icon
2.4. Main interface

After the program is started normally, it enters into the main interface (as shown
in Figure 10). The entire main interface consists of six sections: Pressure Display Area,
Alarm Indication Area, Object Control Area, Curve Drawing Area, Comprehensive
Area and Status Bar.
Figure 10 Main Interface
2.5. Basic configuration

The software can be used normally without additional settings. For settings
related to specific operations, please refer to relevant paragraphs in Chapter 3.
2.6. Exit program

Click [Exit] button at the lower right corner to exit the main program.
101
III. Basic Operations
3.1. Interface language setting

Select [Settings] in the [Comprehensive Area] on the main interface, as shown in
Figure 11. The software interface supports both the Chinese and English languages.
Figure 11 Settings
If the user needs to select corresponding language options as needed, the
software will instantly and automatically switch to the language interface. The
English main interface is shown in Figure 12.
Figure 12 Main Interface
3.2. Connecting PLC device

Select [PLC Device] in the [Comprehensive Area] on the main interface, as
shown in Figure 11.
102
Figure 13 Connecting PLC Device

After the first installation of the software, the IP address of PLC device needs to
be configured based on its network conditions. The default port of PLC device is 502.
Click [Reset] button, the user can restore the IP address and port of PLC device
to the default values internally set by the program (192.168.0.10), so as to avoid
arbitrary changes of this information.
Click [Connect] button to create a connection with PLC. The connection status
will be displayed on the status bar, as shown in Figure 14. If the connection is
successful, the data and status will be updated in the refresh frequency of one group
every second, and the button will turn to [Close].
Figure 14 Connection Status Indication

After clicking the [Close] button, the software will disconnect with PLC and the
control button in the Object Control Area will be disabled.
3.3. Real-time monitoring and operation

Once the software is successfully connected with PLC device, the user can begin
with various monitoring operations (as shown in Figure 15):
1) The pressure data of Pressure Display Area and status information of Alarm
Indication Area will be regularly refreshed;
2) The control button in Object Control Area will be allowed to use;
3) Viewing alarm log (as shown in Figure 16).
4) When opening or closing the BOP, it is necessary to simultaneously press and
hold the operating button and the corresponding object. If the annular BOP
is closed, firstly press and hold the operating button, and then press the
Close button of the annular BOP. At this time, the annular close light turns
red, indicating that the turning off actions is completed.
103
Figure 15 Real-time Monitoring Interface
Figure 16 Alarm Log
3.4. Historical data inquiry

Select [Historical Data] in the [Comprehensive Area] on the main interface, as
shown in Figure 17. Note that the historical data inquiry operation is only
104
Figure 17 Historical Data

Historical data inquiry shall follow these steps:
First, the time range of data needs to be entered: Start time and End time. Note
that, taking into account the limitations of system performance, the time span shall
not be too large (maximum 4 hours by default). If the time span of data to be inquired
is too large, the user can inquire in sections.
Second, click [Load] button to start the inquiry of historical data. Data will be
drawn in the form of a curve to the [Curve Drawing Area]; and alarm logging record
will be displayed in a table in the [Alarm Log].
3.5. Viewing curve

During the process of real-time monitoring, the curve will automatically roll
forward curve based on the current value.
During the playback of historical data, the entire curve will be displayed in full
together.
3.6. Screen lock

By clicking the [Screen Lock] button at the lower right corner of the main
interface, the user can start the lock-screen function of the operating system. After the
screen is locked, successful unlock can be done only by entering the login account
and password of the operating system.
3.7. About
Select [About] in the [Integrated Zone] on the main interface, as shown in Figure
18. The subarea displays copyright information.
105
Figure 18 About
IV. FAQs
4.1. PLC device is unable to connect

Situations in which the PLC device can not be properly connected may include
the following:
1) The power supply of PLC device is not turned on or broken;
2) The power supply of radio network gateway is not turned on or broken;
3) The IP address and port of PLC set in the software are incorrect;
For Case 1 and Case 2, the user needs to check the physical line connection; for
case 3, the user needs to confirm the correct IP address and port assigned to the PLC,
and then reenter correct values in the software.
Tips: An easy way to check whether the network connection is normal is to use
the ping command:
1) Press [Alt]+R, and enter command cmd;
2) In the pop-up window, enter command: ping {IP address of PLC device}-t,
and then press [Enter], as shown in Figure 19;
3) If ―Time out‖ or ―unreachable‖ is displayed as shown in Figure 20, it means
the network is unable to connect and the physical line connection needs to
be checked.
106
Figure 19 Normal ping Command
Figure 20 Abnormal ping Command
4.2. No historical data can be inquired

Possible reasons are as follows:
1) The software will automatically clear historical data prior to January, so the
data before January cannot be inquired for certain.
2) There is indeed no record data for the specified inquiry period.
4.3. The screen is locked and the software cannot be operated

After clicking on the [Screen Lock] button at the lower right corner of the main
interface, the entire software will be locked up, making it impossible to carry out any
operation. Only after entering the correct login account and password of the operating
system, it can be successfully unlocked.
107
Technical Support
Company: Shanghai Shenkai Petroleum Instrument Co., Ltd.

Address: No. 1769, Puxing Rd., Minhang District, Shanghai
Zip code: 201114
Tel.: 86-021-64290467(Sales Dept.) 021-54332843
Fax: 86-021-64290467
E-mail: support@shenkai.com
108

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Electric-pneumatic Liquid Type Control System for Surface BOP Stacks

Electric-pneumatic Liquid Type Control System for Surface BOP Stacks

Introduction to the Use of Electric-pneumatic Liquid Type Remote Console

Main Hydraulic and Pneumatic Components

QB21-60 and QB21-80 Crankshaft Plunger Pumps

JYS21-25 and JYSQ21-25 Relief Valves

JYSQM21-25 Relief Valve

QYB 40-120L Pneumatic Pump

34ZS21-25 3-position and 4-way Rotary Valve

Illustrations of Wearing Parts of Other Hydraulic Valves

Main Electrical Components

BQD6-T Magnetic Starter

BKX6-T Explosion-proof Control Box

FBYK-165 Explosion-proof Pressure Controller

A7-3136-4021 Driller's Control Cabinet/Auxiliary Driller's Control Cabinet

Division of Hazardous Areas

Bus Connector Connecting Method

Wireless Remote Control Software for Driller's Station

Shanghai Shenkai Petroleum Equipment Co., Ltd.

Relief Valve ................................................................................................................................... 38

JYSQM21-25 Relief Valve ............................................................................................................ 43

QYB 40-120L Pneumatic Pump..................................................................................................... 46

34ZS21-25 3-position and 4-way Rotary Valve ............................................................................. 51

Illustrations of Wearing Parts of Other Hydraulic Valves ............................................................. 56

Main Electrical Components .................................................. 61

BKX6-T Explosion-proof Control Box .......................................................................................... 67

FBYK-165 Explosion-proof Pressure Controller ........................................................................... 71

A7-3136-4021 Driller's Control Cabinet/Auxiliary Driller's Control Cabinet ............................... 73

Simple Daily Maintenance Manual for Electrical Parts ................................................................. 79

Division of Hazardous Areas ......................................................................................................... 81

Bus Connector Connecting Method ............................................................................................... 84

T800 Tablet PC ........................................................................ 86

II. Getting the Tablet PC Running .................................................................................................. 87

III. System Recovery ...................................................................................................................... 90

IV. Taking Care of the Tablet PC .................................................................................................... 90

Wireless Remote Control Software ........................................ 95

II. Installation Configuration .......................................................................................................... 97

III. Basic Operations .................................................................................................................... 102

IV. FAQs ....................................................................................................................................... 106

Technical Support .................................................................. 108

Shanghai Shenkai Petroleum Equipment Co., Ltd.

Customer service hotline: +86(21)64290467 Fax: +86(21)34030004

1. Directly manually operated FK series hydraulic control system

operation manual for the anti-lifting device).

2. Pneumatic liquid type FKQ hydraulic control system

3. Electrical and pneumatic liquid type FKDQ hydraulic control system

environment area I or II can be installed as demanded by users.

device (see the operation manual for the anti-lifting device).

hydraulic control system).

II. Model designation

III. Conversion of Metering Units

1L＝0.264 US gal＝61 cu.in

1US gal=3.785L=231 cu.in

Electric-pneumatic Liquid Type Remote Console

Main Technical Parameters

Functional Configuration Table

Structure and Features

Operating Principle and Instructions

Installation and Test Run

Operation, Maintenance and Lubrication

Failure and Troubleshooting

Shanghai Shenkai Petroleum Equipment Co., Ltd.

I. Main Technical Parameters