OPERATION AND MAINTENANCE MANUAL BOP Control SystemsINTRODUCTION 20 3.0 40 50 60 7.0 80 13 14 18 16 17 18 19 1.24 1.22 123 DESCRIPTION SYSTEM DESCRIPTION GENERAL ACCUMULATOR UNIT MODULE Accumulator Reservoir ‘Accumulator Piping AIR PUMP ASSEMBLY ELECTRIC PUMP ASSEMBLY HYDRAULIC CONTROL MANIFOLD AIR REMOTE PANEL, AIR REMOTE CONTROL INTERFACE ASSEMBLY AIR INTERCONNECT CABLE ASSEMBLY ELECTRIC INTERCONNECT CABLE ASSEMBLY INSTALLATION DRAWINGS OPERATION MAINTENANCE FLOW METER TROUBLESHOOTING PARTS DESCRIPTION PAGE NO ROeeNNN BSSEBSB a | O06 POON NROAARHAARA Ae OO Mane an ©? 1.0 14 12 1.2.1 12.2 1.2.3 SYSTEM DESCRIPTION GENERAL A Blowout Preventer (BOP) Control System is a high pressure hydraulic power unit fitted with directional control valves to safely control Kicks and prevent blowouts during drilling operations. Windlass Engineers & Services Pvt. Lid. offers a wide variety of equipment to meet the customer's specific operational and economic criteria. The following text gives a brief description of the equipment and some of its major components. In this manual the terms ACCUMULATOR UNIT or ACCUMULATOR UNIT ASSEMBLY refer to the unitization of the air and electric pump assemblies, hydraulic control manifold and interface assembly onto the accumulator unit module. ACCUMULATOR UNIT MODULE The primary function of the accumulator unit module is to provide the atmospheric fluid supply for the pumps and storage of the high pressure operating fluid for control of the BOP stack. It includes accumulators, reservoir, accumulator piping and a master skid for mounting of the air operated pumps, electric motor driven pumps and the hydraulic control manifold ACCUMULATOR UNIT MODULE Accumulators Accumulators are ASME coded pressure vessels for storage of high pressure fluid, These accumulators are available in a variety of sizes, types, capacities and pressure ratings. The two (2) basic types are bladder and float which are available in cylindrical or ball styles. The accumulators can either be bottom or top loading. Top loading means the bladder or float can be removed from the top while it is still mounted on the accumulator unit. Bottom loading accumulators must be removed from the accumulator unit to be serviced. Bladder and bouyant float type accumulators can be repaired in the field without destroying their stamp of approval. Reservoir A rectangular reservoir is provided for storage of the atmospheric fluid supply for the high pressure pumps. It contains baffles, fill and drain ports and troubleshooting inspection ports. Accumulator Piping This piping connects the high pressure discharge lines of the pumps to the accumulators and the hydraulic manifold. Itis comprised of 1" or 1-1/2" Schedule 80 or 160 pipe, isolator valves and a 3300 PSI relief valve to protect the accumulators from being over pressured. cylindrical type accumulators are mounted on machined headers tominimize line restrictions and leaks.Beueub aa) 1.3 AIRPUMPASSEMBLY * The air pump assembly consists of one (1) & or more air operated hydraulic pumps 4 connected in parallel to the accumulator @ S piping to provide a source of high pressure : operating fluid for the BOP Control system. 7 These pumps are available in a variety of = sizes and ratios. 1.4 ELECTRIC PUMPASSEMBLY The electric pump assembly consists of a duplex 2 oF triplex reciprocating plunger type pump driven by an explosion-proof electric motor. It is e connected to the accumulator piping to provide a a source of high pressure operating fluid for the q BOP control System. It is available in a variety of . horsepower and voltage ranges. « 150° Hi Fe 5 HYDRAULIC CONTROL MANIFOLD ELSO ris PUMP ARERNBEY a The hydraulic control manifold consists of hydraulic regulators and directional control = valves to direct the flow of high pressure operating fluid to control the BOP stack. Two (2) regulators are usually provided, one (1) for the annular preventer and one(1)forthe remainder of the BOP stack functions which is called the manifold regulator. These regulators reduce the 3000 PSI accumulator pressure to a pressure compatible with the ‘operating limits of the preventers. The directional control valves are usually 1" with an 1- 1/2" size available for annular preventers requiring large volumes of control fluid. The manifold also contains gauges for monitoring the control system's operating pressures, a bleeder valve and relief valve. 299K ONGKaAa4 HYDRAULIC CONTROL MANIFOLD 6 a1.6 AIRREMOTE PANEL (S) P Air remote control panels provide partial or complete 3 control and pressure monitoring of the BOP Control gE System. this enables the accumulator unit assembly to E be placed in a safe area so thatit can remain operational B in emergency conditions. Multiple air remote control E panels can be added to a control system with minimal additional cost to enhance the safety of drilling > operations. Air remote control panels can be provided in E awide variety of sizes, styles and configurations to meet specific space and operational criteria. All air remote control panels contain a master control valve which E must be operated simultaneously with the selected 9 function to initiate operation. They all contain four-way spring centered air control valves and require a customer furnished air supply, air remote control 9 interface assembly and interconnect cable assembly. 1.7 REMOTE CONTROL INTERFACE ASSEMBLY Air remote control interface assemblies are required when an air remote control panel is included with the BOP Control > system. These sssemblies contain all of the components > that must be added to the accumulator unit assembly for air remote operation. These > components include air cylinders, fixed plate half of an 3 air junction box and all E necessary stainless steel tubing and fittings. For panels with remote regulation and pressure monitoring, these components also include the air motor operator for the regulator and a pressure transmitter assembly. L When two (2) air remote panels are included on one BOP Control System the interface assembly also includes an additional fixed plate half of an air junction box and air shuttle & valves. All Pressure Switch are mounted inside in this Interface Panel & these Pressure Switches E receives and processes pressure, transmits this data to the driller and tool pusher control panel. Alarm PLC circuit PCB, Relay and Pressure Switches are mounted in this box and > connected with electrical cable to Remote Panel for Display the due all Alarm Indicator.eect eT 1.8 AIR INTERCONNECT CABLEASSEMBLY e Air interconnect cable assemblies are used to 3 carry signals from the air operated remote ~ control panels to the air interface assemblies on = the accumulator unit. They include a customer > specified length of the flame resistant multi- 3 conductor air cable. The air cable consists of > several spirally wound 3/8" OD polyethylene air % lines in a polyvinylchloride (PVC) sheath. The e junction boxes consist of a hose end half of an air junction box on each end which mate to the J fixed plate halves mounted on the air panels and on the airinterface assemblies > a 1.9 ELECTRIC INTERCONNECT CABLE ASSEMBLY 3 a Electric interconnect cable assemblies are used to carry signals from the electric ccntrol a panels to the electric remote control interface assemblies on the accumulator unit. They © include a customer specitiod length of electric cable terminated to cable connector plugs. ~ The cable consists of 60. 16 gauge conductors encased in a arctic grade neoprene sheath 3 for operation down to- 700F temperatures. The cable connector Plugs connect to the == receptacles mounted on the electric panels and on the electric interface assemblies. They ~ are available in explosion- proof or weather-proof configurations. Cables are available to e meet NEC Article 500, Class 1, Group D. Division 1 or 2. OSIGN- © ENien oe 60 CONDUCTOR 4 CABLE = 299g 08 O08 € aone w wo ® INSTALLATION (Ssy DESCRIPTION ih Shs Re NAPAGEINGI > 20 INSTALLATION INSTRUCTIONS E a4 GENERAL ? 22 ACCUMULATOR > 2.21 Set Up Location 6 6 6 6 2.2.2. Inspect Reservoir 7 3 2.2.3. Fill Reservoir 7 |. 2.2.4 Check Accumulator Precharge 7 2.2.5 Check Air Pumps 7 8 8 8 9 9 9 9 , 22.6 — Check Electric Pumps 5 22.7 Interconnect Piping f 2.2.8 Check Valve Positions ? 2.2.9 Verify Gauges . 2.2.10 Start Pumps E 2.2.11 Check Pressure Switches , 2.242 Check Gauge Readings t 2.2.43 Connect to BOP Stack 10 L 2.2.14 Refill Reservoir 10 7, 23 AIR PANEL 1 2.3.1 Setup Location "1 2.3.2. Panel Preparation 11 ’ 2.3.3 Air Cable Connection " 5 2.34 Optional Electric Cable Connection 11 2.3.5. Panel Check Out 12 | 24 DRILL AHEAD 13 | 5 25 INSTALLATION DATA 14 [ 2.5.1 Electric Pump Assembly 14 ° 2.5.2 Air Pump Assembly 15etna INSTALLATION INSTRUCTIONS 24 2.2 GENERAL The following instructions explain how to hookup and checkout a standard Windlass Engineers & Services Pvt. Ltd. BOP Control Unit. These guidelines will ensure thiat all the equipmentis operational so that drilling operations may begin safely. Located in the Equipment Section (Section 3.0) of this manual are drawings containing information which is necessary to properly install the equipment. Also, in order to identify specific component Equipment referenced in the Operation Manual, it may be necessaryto review the assembly drawings and material lists also located in the parts Section. While reviewing the instructions, particular attention is called to all notes and cautions as these are important to ensure safety during alll phases of equipmentuse. There are two major steps that must be performed during all phases of equipment use. Wherever the following instructions are given, refer to these steps :~ 1. Stop Pumps a. Close airsupply valves. b. Tumtriplex pump motor starter to OFF position. 2. StartPuimps a. Openairsupply valves. b. Turntriplex pump motor starter to AUTO position: ACCUMULATOR: 2.21 SetUpLocation 1. The distance recommended to provide maximum protection of the accumulator unit during a blowout or other emergencies is approximately 100 TO 150 feet from the well bore. 2. Location placement should consider maintenance and service : a. Accessibility b. Illumination c. Ventilation 3. Accumulator unit SHOULD NOT be: a. Placednearoxygen storage b. Where there would be high heating effects from surrounding equipment. ea a a pa ES = el el ‘b ea! hha.2.22 INSPECTRESERVOIR 1 Open the 4” inspection/fill ports on the sides of the fluid reservoir and make sure the tank is free of any debris that could contaminate the system. Aclean reservoir reduces maintenance costs. Forreservoir cleaning see Maintenance Section 5.3.1 Make sure all reservoir connections are tightly secured. 22.3 FILLRESERVOIR 1 Fillwith a high quality WES 10 hydraulic oil to 8" from the top of the reservoir. 2.2.4 CHECK ACCUMULATOR PRECHARGE 2.2.5 CHECK AIR PUMPS (See Nitrogen Precharge Instructions in the Maintenance Section Open the manifold bleeder valve. Open the accumulator bank isolation valves. Remove the guard from the valve stern of the accumulator and attach a Charging and Gauging Assembly. ‘Screw on gauge and screw down T-handle. Gauge pressure reading should be 1000 psi +100 PSI a. Lowprecharge reading: (1) Attach the precharge line from the nitrogen bottle to the charging and gauging assembly, CAUTION DO NOT USE OXYGEN (2) Slowly open the nitrogen bottle valve until the precharge pressure reaches 1000 PSI. (3) Close the nitrogen bottle valve and verify that the gauge reading is | ‘still 1000 PSI. | b. High prechargereading: (1) Open the charging and gauging assembly bleeder valve until the precharge drops to 1000 PSI. (2) Close the bleedervalveand verify that the gauge readingis stil 4 }000 psi. NOTE: KEEP A CHARGING AND GAUGING ASSEMBLY ACCESSIBLE TO 1 2. THE ACCUMULATOR UNIT. Check that the airlubricatoris full of WES 10W lubricating oll, Close the air supply valve(s).ATION 3. Close the air pressure switch bypass valve (if so equipped). a 4. Purge a 1" airline from the main rig air supply line and connectit tothe customer __ air supply connection on the accumulator unit. For air supply requirements see > the Installation Data e NOTE: e KEEP A CHARGING AND GAUGING ASSEMBLY pili) em Con Ce Xeet Ue at = 2.2.6 CHECK ELECTRIC PUMPS © 1. Turnoffthe electrical powerat the rig main generator panel. 3 2. Tum tthe triplex pump motor starter switch to the OFF position. © 3. Ensure that the accumulator unitis grounded. S 4. Check the resistance, voltage, and current of the power lines to be connected. For electrical power requirements see the Installation Data a 5. Connect the electrical powerlines to the three-phase terminal connections inthe ~ triplex pump motor starter (See Starter Wiring Diagram located Drawing Section, ‘Similar metal conductors (copper) should be used. Ensure that a good ground connection is made. 5 6. Check that the triplex pump crankcase is full of oil (weight will vary with the = ambient temperature). For crankcase oil specifications see Maintenance. eS 7. Check that the chain guard Is filled with oil. for Chain Guard Oil Specifications _ see Maintenance e Turn on the electrical power at the rig main generator panel. © 9. Check the rotation of the motor by turning the triplex pump motor starter switch to AUTO and then OFF. Ifthe rotation is backwards from arrow indication on chain guard), swap any two-phase terminal connections to reverse the motor rotation. e 10. Use a sealing compound with a melting point of at least 200DgF and pour the © electrical conduit seat. Seat should be at least 5/8" thick, « ’ ¢ ? 2.2.7. Interconnect Piping " 1. Lay interconnect piping of sufficient size and pressure rating from the © accumulator unit to the connections on the Blowout Preventer stack. 2. Connect Swivel-joint assemblies to the 1” function outlets on the back of the accurnulator unit. DO NOT connect to BOP stack. © 2.2.8 Check Valve Positions 1 Place all four-way control valves on the hydraulic manifold in the CENTER position, 2, Place the manifold regulator bypass/internal override valve in the LOW pressure (Handle left) position. =SAE) Open the manifold bleeder valve. Open the suction valves of all pumps. Check that the air pressure switch bypass valve is closed (if so equipped) ‘Check that the accumulator bank isolation valves are open. Nogay Check that the accumulator bank bleeder valves are closed. | 229 Verify Gauges t 1. Allgauges on the hydraulic manifold should read 0 PSI. , 2. Airsupply gauge should read 125 PSI, 2.2.10 Start Pumps \ 1. With the manifold bleeder valve in the OPEN position, alternately open the air supply valve to each pump to ensure that each pump operates smoothly and } withoutleaks. Close the air supply valve to each pump. With the rig main generator power ON, place the triplex pump motor starter switch to the AUTO position. Check that the pump runs smoothly and without ! leaks. Close the manifold bleeder valve. Open allair supply valves. Setairlubricator to 6 drops per minute. Noon Pumps should continue running until accumulator pressure reaches 3000 psi. If problems occur during initial start-up, consult the Troubleshooting Section. 2.2.11 CHECK PRESSURE SWITCHES | 1. After the system pressure has reached 3000 psi and the pumps have stopped, } open the manifold bleeder valve. 2. Pumps should automatically start when accumulator pressure is 2500-2700 PSI. Iflower, the pressure switches need adjustment, (See Maintenance Section. 3. Close manifold bleeder valve and recharge the system to 3000 PSI. 2.2.12 CHECK GAUGE READINGS 1. Allaccumulator pressure gauges should read 3000 PSI. ' 2. Manifold pressure gauge should read 1500 psi i.e. the pressure setting of the | manifold regulator. To adjust the manifold regulator set ting see Operation } Section . A. Alternately decrease and increase the setting of the manifold regulator and verify the correct response on the manifold pressure gauge.2.2.13 1. 12, 13. 14. 18. MM Move the manifold bypass/internal override valve into the HIGH pressure (handle right) position and verify that the manifold pressure gauge increases to 3000PSI, Annular pressure gauge should indicate the pressure setting recommendations of the annular preventer manufacturer. To adjust the annular regulator see Operation Section. Adjust annular regulator through various operating pressures and check for correctresponse on the annular pressure gauge. CONNECT TOBOP STACK Move the manifold bypass / internal override valve into the LOW pressure (handle left) position. Stop pumps. Open manifold bleeder valve and relieve system pressure. Make sure swivel-joint and hammer union connections on function outlets are tightand secure. Start pumps. Open each four-way control valve to flush the Open function line. CAUTION PrN MARU NLM eta cls Close each four-way control valve to flush the Close function line. Return the control valves to the Center passion. Open the 4" inspection/fill ports and check the control valves for leaks. Connect but do not tighten each swivel-oint assembly to its correct inlet on the BOPstack. Operate each function to ensure correct function operation and to purge BOP stack. Make sure a joint of drill pipe is in the hole to prevent damage to rubber elementof the annular preventer. Return the control valves to the Center position. Securely tighten the swivel-joint assemblies and hammer union connections at the BOP stack. Stop pumps Open the manifold bleeder valve and relieve all system pressure. 2.2.14 REFILLRESERVOIR i 2. i a Check the fluid level of the reservoir after line flushing. Refill the reservoir to 8" from the top. heh MB 2SUE ro AIRPANEL, 2.3.1 SetUp Location 1 Install the air panels securely on firm foundation, taking into consideration the following: Operation and service accessibility. a. ; b. __ Illuminated areas. c. Unobstructed ventilation. d. Minimal heating effects from surrounding equipment. 2. The Driller's panel should be installed on the drill floor or near the Driller's position. 2.3.2 Panel Preparation 1. Fill the lubricator with SAE 10 lubricating oil. 2. Connect a 1" ID, 125 psi supply line to the air supply inlet of the panel, 2.3.3 Air Cable Connection 1. The air interconnect cable assembly connects the air remote control panel to the accumulator unit. It should be installed in a manner to avoid damage and stress at the termination fittings, normal traffic flow and other mechanical equipment. Do not hang over sharp edges or bend around sharp corners, At the panel, inspect the junction boxes and gasket for damage and/ or debris. 3. Connect the junction box on the air cable to the mating junction box on the panel } using the alignment pin as a guide and evenly tighten the mounting bolts. ) 4. Before connecting the remaining end of the junction box, hold down the panel master air valve and open and close each function. This will purge the air tubing of any debris. Then repeat steps 2 and 3 for the accumulator unit end of the air interconnect cable assembly. } 2.3.4 Optional Electric Cable Connection When ram position indicating lights are fitted to the BOP Control System, a multi- conductor electric cable connects the air operated panel's indicating lights with the pressure switches on the function outlets of the accumulator unit. fer Nuon} NEVER OPEN AN ELECTRICAL ENCLOSURE | { WHEN IT CONTAINS LIVE POWER. 1. The electrical interconnect cable should be installed, run and supported in a manner to : \ a. Avoid damage and stress at the termination fittings. b. Stay out of traffic flow. | eeCee ule en ©, Stay away from mechanical equipment. 3 Do not hang over sharp edges or bend around sharp comers. Adhere to cable bend radii to prevent tearing insulation and subsequent short- circuiting of the conductors. Electrical equipment is sensitive and should be handled carefully. 4, The electrical connection of the remote control panels to the pressure switch box assembly supplies the power to the panels and should not be unplugged while * underload. : a. Make sure power source to panels is disconnected. 4 b. Make sure interior of panel enclosure is dry of moisture. : c. Check that drain and breather plugs are open. é d. Check continuity of the cable lines with an ohmmeter. Z e. Align electrical cable connections using the guide marks. (1) Plug into the pressure switch box receptacle connector. (2) Plug into the air panel electric connector receptacle. CAUTION ase eae cia 5. Tum on power at the pressure switch box. 2.3.5 Panel Check Out 4. With the accumulator unit pumps turned off and the accumulator pressure at 0 psi, hold down the panel air master valve and operate (open and close) each function. 2. Verify that the panel valve operates the corresponding valve on the hydraulic manifold correctly. 3. Check the air panel, air cable, junction boxes and air cylinders on the hydraulic manifold for leaks. Repair if necessary. 4, Atthe accumulator unit : a, Make sure the accumulator bleeder valves are closed. b. Make sure the manifold bleeder valve is open. c. Make sure accumulator bank isolator valves are open. d. Make sure pump suction valves are open. e. Center all four-way control valves. f, Tighten the lock handle on the annular regulator. g. Start pumps. 5. When the accumulator pressure has reached 3000 psi, the Driller's panel gauges a Ee ae24 and the gauges on the hydraulic manifold should match. Gauges on the Driller's panel should read : a. Accumulator pressure - 3000 psi. b. Annular pressure- Operating pressure recommendation of the annular preventer manufacturer. ©. Manifold pressure - 1500 psi. 6. Hold down the air master valve at ht control panel and operate each function (open and close) several times. Check that the control valves on the hydraulic manifold are not interflowing. Return flow to the reservoir can be detected by viewing through the inspection fill ports on the reservoir. Check also that the appropriate indicating light illuminated as valve positions are changed. Coe) INS" pata) le Nag OA = OPERATING THE ANNULAR PREVENTER SO AS NOT A Nc aig aes apes 8 7. Using the Driller's panel annular pressure control valve, adjust the operating pressure of the annular to various pressure settings. Verify that the Driller's panel annular gauge corresponds throughout the various pressure settings. CAUTION | eee es sekel ta Neha eco ae ee ahd | } MPA Oe aaa ea Oe Neane Toi DRILL AHEAD The following list identifies the normal operating position of the shut-off valves and control valves of the BOP Control System. 1. Shutoff Valves Air pump supply valves - OPEN. Air and electric pump suction valves - OPEN. Accumulator bank bleeder valves - CLOSE. Manifold bleeder valve - CLOSE f. Air pressure switch bypass valve (If so equipped) - CLOSE. 2. Control Valves a. Annular - OPEN. b. Pipe and Blind Rams - OPEN, ©. Choke and Kill Valves - CLOSE. a b. c. Accumulator bank isolator valves - OPEN. 4. e. ee ae eaeINSTALLATION d. Manifold Regulator Bypass/Internal Override Valve - LOW PRESSURE a. (Handle left). e. Annular Regulator Lock Handle - TIGHTEN FOR REMOTE OPERATION. © 2.5 INSTALLATION DATA 4 2.5.1 Electric Pump Assembly Each electric pump assembly includes an explosion-proof electric motor starter. The __ customer must provide the power to this starter as indicated in Table 2-1. The data inthis © table is for each electric pump assembly included with the BOP Control System. e 1. Customer to furnish wiring to meet applicable codes and standards for installation. 2. Maximum allowable voltage variation is + 10%. 3. Maximum allowable frequency variation is + 5%. 4 Combined voltage and frequency variation is + 10%. (With no more than 5% « frequency variation.) ~ 5. Similar metal conductors (Copper) should be used. d Starter Full Load a Model No. | HP Connection Volts | Current (Amps) Ph | Hz e WUET10HT230| 10 | 1-1/2" FPT] 230] — 26.00 3 | 60 © WUET10HT460} 10 | 1-1/2" FPT| 460 13.00 3 | 60 = WUET15HT230| 15 | 1-1/2"FPT] 230] 42.00 3 |60 a WUET15HT460} 15 | 1-1/2" FPT| 460 21.00 3 | 60 ie WUET20HT230} 20 2" FPT | 230 48.70 3 | 60 2 WUET20HT380} 20 | 2" FPT | 380 45.00 3 150 € WUET20HT460] 20 | 2" FPT | 460 24.40 3 | 60 4 WUET25HT230} 25 FPT. 3 | 60 4 WUET25HT460| 25 | FPT. 3 | 60| © WUET30HT230] 30 FPT 3 | 60 2 WUET3OHT460] 30 FPT 3 | 60 a WUET40HT230| 40 FPT 3 | 60 “ WUET40HT460| 40 | 2" FPT | 460] 52.40 3 | 60 e WUETS50HT230} 50 2" FPT | 230 130.00 3 | 60 WUETSOHT460} 50 2" FPT | 460 65.00 3 | 60 4 WUET60HT230) 60 2" FPT | 230 154.00 3 | 60 4 WUET60HT460] 60 | 2" FPT | 460 77.00 3 | 60 & INSTALLATION DATA - ELECTRIC PUMP ASSEMBLY 5 al = eee2.5 INSTALLATION DATA (Continued) 2.5.2 Air Pump Assembly Each air pump assembly requires a customer should be supplied as indicated in Table 2-2. Customer should ensure that the alt supply 's clean and dry. Excessive moisture and other contaminants can cause operational Problems. Air supply connection to the air pump assembly is 1" FPT. furnished air supply.. This air supply woasine [S25 [Ames [ER | eke] WUA7316] 7-3/8 1 76 1.98 WUA7326| 7-3/8 = 160 3.96 WUA7336| 7-3/8 3 236 5.94 WUA8516 8-1/2 1 112 3.20 WUA8526 8-1/2 2 235 6.40 WUA8536 84/2 3 347 ie 9.60 i INSTALLATION DATA - AIR PUMP ASSEMBLY NOTE: Flow capacities are based upon a minimum air supply pressure of 90 PSI 5.3 Air Remote Control Panel Assembly (ies) 1. Connection size - 1" FPT 2. Minimum Air Supply Pressure - 100 PSIbm e © orawines : iis | BILL OF MATERIAL - BOP CONTROL SYSTEM 1” 3 4. BOP Control Unit 220 Gallons, Model WTC-220-11873 - ENAFOR ‘ = 2. Panel, interface, Alarm & Poston Indication, 8 Staion - ENAFOR, 19 © 3. Enclosure, Machined, Explosion Proof, 10°x14"x08" Aluminium, 8 Stalon- ENAFOR. 20 & 4. Ponel Ai Opraiod Model AAGPREDS-FC.- ENAFOR 2 . 5. Panel, Air Operated Model AOGPOBCE-FG, 6 Staton-ENAFOR 2 Ps 8. Schema, BOP Cont! Uni Model # WTC-220-11873 a a 1. Schema, 80P Cont Uni, Model # WTC-220-118T3 4 ad 8. Schomatic Pheumatc-Alr Operated Dilers Control Panels for BOP Control Unit 220 Gallons for ENAFOR 25 ~ 9. Schemas Pheuibatc- Ar Operated Aux. Contl Panes for BOP Control Unit 220 Gafons for ENAFOR 26 10. ‘Wing Digram for Elect Starter for 40 HP Motor ENAFOR a ‘11. Wiring Diagram for Panel, Interface, Alarm & Position Indication | 8 c 42, Wing Diagram fr Pane, Remote Alam & Poon Indication | bo s Te aayCUM aie BILL OF MATERIAL - BOP CONTROL SYSTEM SR.No,_ [OH Description Part No. [i 1 Gauge, Sight Glass 20°55 CeuGO078 2 Ia pccumeiator, Assembly, Top Loading, 11 Gallons, 3000 PSI, I-17" | aacanogy 3 4 [Machined Manifold, Bottle 1-1/4", 6 Station ANINFOOOS 4 1 [Machined Manifold, Valve, 8 Station ‘AMINFOOL4 5 7 (Valve, Ball, 1-1/2" NPT, 6000 PSI, BVLVOO10 [6 5 [Valve Relief, 3300 PSI, 3/4" ‘AVRFOOOL 7 1 [Valve Relief, 5500 PSI, 3/4” ‘AVRFOOO2 3 3 |Air Pump Assembly, 8-1/2", 60:1 ‘AAOPOO04 9 1 |Rydro-Pneumatic Pressure Switch, 3000 PSI, ‘AHPPOOOL 10 [3 [Valve, Ball, 3/4” NPT, 200 PSI, BVLVO003 it [1 [Valve, Check, 1-1/2" NPT, 5000 PSI, BVLV0026 [12 [3 Valve, Check, 172" NPT, 5000 PSI, BVLv0022 [13 | 8 |Valve, Selector, 4 Way, 3 Pos, 1" NPT 5000 PSN AVLV0083 14 1 |Valve, Bypass, 4 Way, 2 Pos, 1" NPT, 5000 PSI, ‘AVLV0045: [15 [2 Plate, Fixed, JG-24 ‘APLLOOL7 16 [9 [Cylinder Air, 3" Bore, 2 Pos, 200 PSI, ACYLOOOL 17 | 1 [Valve, Ball, 2-172" NPT, 200 PSI, BVLVO007 18] 1 [Electric Pressure Switch, Hydro-Electric, 3000 PSI, CELEOO13 19 | 2 |Gauge, Hyd. Gly. Filled 6" FC 0-6000PSI 7 KPa (Dual Scale) 17" PM | cauGooi6 20 | 1 |Gauge, Hyd. Gly. Filled 6" FC 0-10000PSI/ KPa (Dual Scale) 1/2"PM | ccucoo14 21__| 4 |Gauge, Hyd. Gly. Filled 4" FC, 0-6000PSI / KPa (Dual Scale) 1/4"PM | CGUGOO25 2 {1 [Filter Air, NPT 200 PST, 50 Micron BFLTOOO9 231 [Lubricator, Air, 1" NPT 200 PSI, BLUBOOO6: 24 {1 [Strainer, Y, 2-1/2" NPT, 20 Mesh, 250 PSI CSTROOOS 25 | 2 [Transmitter, Hydro-Pheumatic, 6000 PSI, CTMROO02 26 [5 [Breather Assembly, 3/4” BSPT BBRTOOOL 27 {1 Valve, Regulating, TR-4, Hyd, 1" 3000 PST, Manually Operated AVLROO24 28__| 1 [Valve, Regulating, TR-4, Hyd, 1” 1500 PSI, Pheumatically Operated | AVLROOIO [29 [4 [Panel, Interface, Alarm & position Indication, 8 Station (ENAFOR) ‘APNLOD4O) 30__| 1 [Valve Relief, 3300 PST, 1-1/2" CVRFOOO3: 31 1 [Transmitter, Hydro-Pneumatic, 10000 PST, ‘CTMROOO3 32 | 1 [Motor Electric, Explosion Proof, 40 HP, 230VAC /460VAC 60 Hz, wae li |Ambient Temperature 55 Deg. C, Frame Size 324T Electric Starter, 40 HP, 230/ 460VAC, 60Hz, 3 Ph, Class-I, Div-I, Exp. 3B 1 Proof With Hand/OFF/Auto Selector Switch, Reset Button & Auxiliary CESTO013 Contact. [34 1 [Triplex Pump, 1-1/8" Plunger, Model BD-60 CTRIOOO8 35 1 _|Hydro-Pneumatic Pressure Switch, 5000 PSI, AHPPOO02_ 36 i Electrical, Meter Flow Turbine with Local Display ,15-150 GPM, 24 VDC CELCO148 37 1 [Valve Relief, 3300 PST, 1-1/2" NPT AVRFO004 38 1 [Filter Hyd, 5000 PSI, 35-45 GPM, 10 Micron BFLTO004 39 i |Assembly, Canopy For B.0.P. Control Unit 220 Gallons (ENAFOR) AASLO136 40 1 [Valve Ball, 1" NPT, 5000 PSI, BVLV0038DENN) iata dou, ae Tire\ DOA er RIGHT SIDE VIEW FRONT VIEW OTTOM VIEW LEFT SIDE VIEWvom Wot a) oe Som ae Be Ce eed sour wes) rere von ane nena je ‘erene2 any mies ame ron anes @ mene TE mee — oF oa zane oo vec eee wea yaa anna cores vem B a Gy @ sum am ete OO ANNE: veces % 9% recom ere SET sve net no sien sie rose om USL. meee OC soar soe oom TB casero rso0 TEE emsen @ sn soe& DTN esddou sannnamainn outs = SN Soa at HAWS00. wae Wa |oe 20H 51 welled I masNery ee - th TON EIN TSA TSA CHA THA ZEA PEA TEA TRA TIA TIA BE yank pec ge g 88 mS G5 4 84g ig Oe Sg yy Sg By TL " 5 boop pe 3 geilgee g eg iow i § FR PEPE EER EE EG 1 sowie a a Oo one i ‘| @ = - * © ad re seats j } ‘eu mere . ats tame. ge : ae _ as ae 7 at HE a|* is ea oe ome . —* - aesOPERATION “DESCRIPTION OPERATION INSTRUCTIONS 3 GENERAL ca ACCUMULATOR UNIT MODULE ca 424 Accumulators 31 4.22 Reservoir Hn 423 ‘Accumulator Piping 32 43 AIR PUMP ASSEMBLY 32 43.1 Air Supply Manifold 32 432 Fluid Suction Manifold 33 433 Air Pumps 33 434 Air Pressure Switch 33 44 ELECTRIC PUMP ASSEMBLY 34 4a Fluid Suction Manifold 34 442 Duplex or Triplex Pump 34 4.43 Electric Motor 34 444. Drive Assembly 34 45 HYDRAULIC CONTROL MANIFOLD 35 45.1 Control Valves 35 45.2 Regulators 35 45.2.1. Manifold Regulator Assembly 35 45.2.2 Bypass/interal Override Valve Assembly 36 45.2.3 Annular Regulator Assembly 36 453 Gauges 36 454 Manifold Piping 36 46 AIR REMOTE CONTROL INTERFACE ASSEMBLY 37 464 Cylinders 37 46.2 Transmitters 37 463 Air Junction Box 37 ar AIR REMOTE CONTROL PANEL ASSEMBLY 37 474 Air Supply Manifold 38 472 Master Air Control Valve 38 473 Air Control Valve 38 Ala Bypass/Internal Override Valve 38 475 Nameplates 39 478 Gauges 39 477 Annular Pressure Control Valve 39 48 INTERCONNECT CABLE ASSEMBLIES 39 49 ACCESSORIES 40 494 Nitrogen Backup System 40 492 Rig Test Outlet 40 49.3 Alarms a 494 Optional BOP Position Indicating Lights 4 eee) aL mo Al a o oOPERATION OPERATION INSTRUCTIONS, 4.1 GENERAL The Operation Section of this manual contains functional descriptions of the subassemblies and components that comprise the Control System. Understanding the proper operation of the BOP Control System is very important for proper operation in ‘emergency situations. The BOP Control System provides the hydraulic power and controls necessary to operate the Blowout Preventers during drilling operations. It consists of the accumulator unit assembly, remote control panels and interconnect assemblies. The accumulator unit assembly consists of the accumulator unit module, air and electric pump assemblies, hydraulic control manifold and remote control interface assembly. While reviewing the instructions, particular attention is called to all NOTES and CAUTIONS, as these are important to ensure safety during all phases of equipment use. 42 ACCUMULATORUNIT MODULE The accumulator unit module provides the accumulators for storage of the high pressure control fluid, a reservoir for storage of the atmospheric fluid, supply for the air and electric. pump assemblies, accumulator piping and a master skid for all components of the accumulator unit assembly. 4.2.1 Accumulators Accumulators provide the means for storage of large volumes of high-pressure fluid necessary to control ine BOP stack. These ASME coded pressure vessels have a working pressure of 3000 psi and can be field repaired without destroying their stamp of approval. These bladder type accumulators are precharged to 1000 psi+ 100 PSlof nitrogen. r oro} Beeston nosis mer encr coll te ire When there is a demand for fluid to operate a preventer, the high-pressure fluid contained in the accumulator is forced out by the nitrogen. The port assembly contains a poppet valve, which prevents the bladder from extruding through the port as the fluid is discharged. The precharge of each accumulator should be checked during installation, see Installation Section, as a loss of precharge pressure means a loss of available operational fluid. The precharge should also be checked periodically during normal operation to ensure a proper precharge being maintained. Always keep a charging and gauging assembly readily accessible. Ifadjustments are necessary, see the Maintenance Section. 4.2.2 Reservoir A reservoir provides the means for storage of the atmospheric fluid supply for the high pressure pumps. It contains baffles, a sight glass for fluid level indication and fill and inspection ports. The reservoir should be filled with a high quality WES 10 hydraulic oil for filing procedures see Installation Section. The BOP Control System is a closed-loop system where all vented fluid is returned to the reservoir. Therafora, it is very important to inspect the preventers. Debris can clog pump suction filters and make the control system i]423 43 43.1 inoperative. For procedures to clean the reservoir or change the fluid, see the Maintenance Section. Accumulator Piping The accumulators are mounted in banks to minimize leaks and line restrictions. These banks contain isolator valves which should be open during normal operation, and bleeder valves which should be closed during normal operation. If it is known an accumulator is faulty, that bank may be isolated untilit can be serviced, CAUTION & a Smet eee eee Pam Ae NeH UU Ne) MUM Ra. cle] ac) Since the accumulators are 3000-PSI working pressure, the accumulator piping includes a 3300-PSI relief valve to protect them against higher pressures. A plug should < never be substituted for this valve. If the valve is faulty, it should be repaired and replaced or anewvalve shouldbe installed: AIRPUMPASSEMBLY The air pump assembly is one of the high-pressure power sources used to pressurize the accumulator unit, This assembly normally produces a maximum pressure of 3000 PSI but is capable of much higher pressures. It is therefore important to know how to operate this assembly, along with when and how to control the use of higher- pressure outputs. These pumps require a customer furnished air supply of sufficient pressure and volume to operate them, see Installation Section. The air pump assembly consists of air supply manifold, fluid suction manifold, air pumps, and air pressure switch, Air Supply Manifold The customer furnished air supply should be connected to the air supply manifold as indicated in the Installation Section. Included in the air supply manifold is: 4. Air Filter - This filter removes contaminants in the air supply which may damage the air pumps. This filter must be cleaned periodically to maintain maximum air flow, see Maintenance Section 2. Air Lubricator - This device impregnates the air with oil to lubricate the pumps during operation. This lubricator should also be serviced periodically to replenish the oil ,see Maintenance Section. 3, Air Supply Gauge - A 0-300 psi gauge is mounted in the air supply manifold. for monitoring of the air supply pressure at the unit. 4. Air Supply Valve - One air supply valve is provided for each pump to enable independent operation. Under normal operation, these valves. should rernain openatall times. To stop the air pumps from operation, these valves should be closed.OPERATION 4.3.2. Fluid Suction Manifold The fluid suction manifold is used to connect the high-pressure pumps to the reservoir, which contains the operating fluid. This manifold includes: 4. Suction Valve - This valve is used to isolate the pumps during servicing. t During normal operation, it should remain open at all times. 5 2. Suction Strainer - The suction strainer helps to remove impurities from the fluid, Impurities can enter the system through the preventers and return to the reservoir with the vented fluid. This strainer should be serviced periodically to prevent E clogging which could damage the pumps by running them dry, see Maintenance. Section. 4.3.3. AirPumps Air pumps are used to convert lower air pressure into higher hydraulic fluid pressures. They consist of two (2) main components: the air motor and the fluid end. They are sized by the fluid ratio of the piston area of the air motor to the area of the piston in the fluid end. The 5 standard double action pumps are 60:1 ratio. This means there is 60 times the piston area in cE the air motor as in the fluid end. Therefore, 1 psi of air will produce 60 PSI of hydraulic fluid pressure. The pumps have self-adjusting packing glands and therefore should require no 4 adjustment in normal operation. The pumps are double acting so air is exhausted on each up stroke and down stroke of the pump. As the pumps exhaust the lubricated air, itis normal > to find oil on surrounding equipment, and for the moisture in the exhausted air to cause an ice formation on the air pump. Excessive freezing may cause operational problems, See Troubleshooting Section. Before servicing the pump, bleed off the system pressure. The L pump discharge line is fitted with’a check valve to allow the system to be replenished while ? the pump is being serviced, 4.3.4 Airpressure Switch Since the air pumps are capable of producing pressures in excess of 3000 PSI, it is necessary to automatically stop the pumps when the discharge pressure reaches 3000 E PSI. The air pressure switch is adjustable in that it senses the discharge pressure and blocks the air supply to the pumps when the set pressure is reached. Normally the pressure E switch is set for 3000 PSI for accumulator units with air pumps only and 2900 PSI on accumulator units with both air and electric pumps. When the system pressure drops to 2700 PSI, the pressure switch automatically allows the air to flow to start the pumps. To adjust the pressure switch setting, see the Maintenance Section, E The line to the air pressure switch is fitted with a bypass valve to allow the pumps to produce higher fluid pressures. in normal operation this valve should be closed. If pressures in excess of 3000 psi are required, such as during testing: 5 1. Closethe electric pump isolator valve E 2. Move the manifold regulator bypass/internal override valve to the high-pressure 7 position, E 3, Open the air pressure switch bypass valve. e This will produce pressures up to 3300 PSI, whichis the setting of the manifold relief valve. hits eee© RATION = 44 ELECTRIC PUMPASSEMBLY S The electric pump assembly is a primary, or additional, high-pressure pump source usedon the accumulator unit. This assembly requires a customer furnished power supply. The __ amount of current required depends on the horsepower of the electric motor, see © Installation Section. The pump output remains constant up to the maximum pressure of __ 3000 PSI, independent of the system back pressure. This pump assembly s very important © to the overall performance of the accumulator unit. Therefore itisnecessary to understand — its function and operation. The electric pump assembly consists of fluid suction manifold, triplex pump, electric moto and drive assembly which includes chain, sprocket, chain guard and pressure switch, a 4.4.1 Fluid Suction Manifold é The fluid suction manifold connects the high-pressure pump to the reservoir, which contains the operational fluid. This manifold includes : 3 1. Suction Valve - This valve should remain open at all times in normal operation; but should be closed to isolate the pump during servicin. S 2 Suction Strainer - This strainer helps to remove impurities that have entered the system with the vented fluid from the preventers. It should be serviced periodically, see Maintenance Section to preventdamaging the pump by running itdry. a 4.4.2. TriplexPump In normal operation the pumps operate automatically, however the plunger, packing and > grankcase should be inspected periodically. For adjustments, see Maintenance Section. ‘The pump discharge line is fitted with a check valve and an isolator valve. The isolator valve remains open at all times in normal operation but is closed to isolate pumps either for servicing or to bypass the accumulators so pressures higher than 3000 psican be reached. 4.4.3, Electric Motor Alll electric motors used in the pump assemblies are of the explosion-proof design. These motors are either 60 or 60 cycle turning at speeds of 1500 and 1800 RPM respectively. = Because most pumps cannot turn at these speeds, reducing drive assemblies are usec. 4.4.4 DriveAssembly a This assembly connects the pump to the drive motor. Itconsisté of: 1. a Sprockets - The pump and motor sprockets are sized to reduce the speed of the motor to the operating limits of the pump. @ a 2. Chain complete with oil-bath-type chain guard - This assembly is used in place of belts to eliminate slippage and prolong service life. The oil level in the chain guard should be periodically inspected. For procedures and oil specifications, see © Maintenance Section, ” Motor Starter - The motor starter controls the power to the electric motor and is. housed in an explosion-proof enclosure. The starter control switch should always: be inthe AUTO position during normal operation. I » a. aOPERATION 4, Electric Pressure Switch - This switch stops the electric motor when discharge pressure reaches 3000 psi and automatically restarts the motor when discharge pressure reaches 2700 PSI. This protects the pump from over pressuring which can damage the packing or the power frame. Pressure switch settings have a tendency E to drift and require periodic calibration. This is especially true when the equipment has been moved to a different location. To adjust the pressure switch setting, see E Maintenance Section. = 5 HYDRAULIC CONTROL MANIFOLD. The control manifold directs the flow of the high-pressure fluid stored in the accumulators to E operate the preventers and gate valves. Most preventers operate at a maximum of 1500 PSI, however the accumulator pressure is 3000 PSI. Therefore, regulators are required to & reduce the operating pressure from 3000 psi to 1500 PSI. Annular (Bag Type) preventers, tequire different operating pressures from the other functions on the BOP stack, so all : control manifolds use the double manifold design. The control manifold consists of: 1) control valves, 2) cylinders, 3) regulators, 4) gauges, and 5) manifold piping which includes > asupply header, high pressure strainer, relief valve and bleeder valve. 4.5.1 Control Valves The control valves are 4", 1-1/2" are available for annular requiring large volumes of fluid), S four-way, three-position shear seal selector type valves. They have 90° handily rotation with 45° detents. There is one for each preventer and gate valve, complete with an + aluminum nameplate stating function name with OPEN and CLOSE positions marked in relation to handle position. The control valves should always be in either the OPEN or = CLOSE position. NUON} Napa RR AN Ao EO OAT Role e} BOTH THE FUNCTION PORTS OF THE CONTROL VALVE. TO OPERATE. THE VALVE FROM OPEN TO CLOSE OR FROM CLOSE TO OPEN, (ea NRA oN a1 ence Pausing will cause the valve to inter flow, thus venting some of the supply fluid and delaying function operation. The CENTER position could be used to block further pressure drop of the system if caused by regulator malfunction while operating a preventer. The control valves should be serviced perlodicaly to ensure proper operation (See Maintenance fection). Regulators The double manifold, designed to accommodate variable pressure requirements, consists of a manifold regulator assembly, a bypass valve assembly,|and an annular regulator > assembly. 4.5.2.1 Manifold Regulator Assembly The manifold regulator reduces the 3000-PSI fluid pressure from the accumulators to a Gi i58 See anSelM maximum of 1500 PSI. This regulated pressure becomes the supply to operate the ram type preventers and gate valves; pressures greater than 1500 PSI cannot be regulated. The pressure setting of this regulator must be manually adjusted; to do this: 4. Loosen the locknuton the adjustment handle and hold with one hand. 2. Rotate the regulator adjustment handle with the other hand. a. Toincrease pressure rotates clockwise. b. Todecrease pressure rotates counterclockwise. 3. Read manifold pressure gauge for the pressure setting of the regulator. Set at desired pressure. 4, Tighten the locknutof the adjustmenthandle. 4.5.2.2 Bypass/internal Override Valve Assembly To operate with pressures up to 3000 PSI, the manifold regulator assembly is fitted with a quick opening bypass/internal override valve that can shut off the supply through the manifold regulator and supply direct accumulator fluid pressure to the ram preventers and gate valves. The Regulator can be fitted with an internal override assembly that when operated will allow the full accumulator pressure supply to flow through the manifold regulator. In normal operation the bypass/ internal override valve should be in the regulated or LOW- pressure position. For pressures up to 3000 PSI, the valve must be in the HIGH pressure position Forremote operation of the bypass valve an air cylinder can be fitted to the valve. 4.523 AnnularRegulator Assembly The annular regulator controls the operating pressure settings for the annular preventer. Since the annular preventer requires different operating pressures for stripping anc well control itis necessary to consult the annular preventer manufacturer's recommendation for ‘optimum pressure settings to prolong the life of the element. Regulators are available for regulation up to3000 PSI and in 1” and 1-1/2" sizes. The regulation of the annular operating pressure is adjusted at the accumulator unit by operation of the manual adjustment handle on top of the regulator. Itis adjusted in the same manner as the manifold regulator (See Section ). Annular regulators fitted with air motor operators include two (2) quick release valves to reduce air motor "run-on". For instructions on remote regulation of the annular operating pressure. 45.3 Gauges ‘The gauges on the hydraulic manifold are 6" face, glycerin-flled, panel mount type gauges which connect to the pressure pick-up points with stainless steel tubing or mud pump type, alycerin-flled gauges which mountin-line, Three (3) gauges are provided tomonitor: 1. Accumulator Pressure 2. Manifold Pressure 3. Annular Pressure 4.5.4 Manifold Piping The manifold piping consists of a supply pressure header, a high-pressure strainer, a bleeder valve, and arelief valve.aren) i Supply Pressure Header - A 2" header provides a common pressure to the ram preventer and gate valve control valves to maximize flowand minimize leaks. 2, High Pressure Strainer -This strainerhelps to remove debris from the control fluid that could damage the regulators and control valves. It should be serviced Periodically to ensure proper operation, See Maintenance Section. 3. Manifold Bleeder Valve - This valve is used to bleed off the system pressure for servicing. In normal operation it should be in the closed position. 4, Manifold Relief Valve - This valve is set to relieve excess system pressures to Prevent component or system failure. For systems with an air pressure switch bypass valve, it is set at 5500 psi and for systems without an air pressure switch valveitis set at 3300 PSI 4.6 AIRREMOTE CONTROL INTERFACE ASSEMBLY Air remote control interface assemblies include additional components necessary on the accumulator unit to enable the BOP Control System to be remotely controlled and/or monitored from an air panel. 4.6.1 Cylinders Air oylinders are mounted on each four-way control valve on the hydraulic manifold that requires remote operation. The cylinder piston is connected to the handle of the control valve. An ait pressure signal from the air valve on the remote panel causes the cylinder piston to extend or retract. This movement causes the handle to rotate thus operating the function. The cylinders should be'serviced periodically to ensure proper operation, See Maintenance Section. 4.6.2 Transmitters Transmitters are required in the interface assembly when the BOP Control System operating pressure are tobe monitored on the air remote control panel. These bourdon tube type transmitters convert the hydraulic pressures into calibrated air pressure signals. These signals are then registered on the air receiver gauges on the air remote control panel as an equivalent hydraulic pressure reading. The transmitter air supply is obtained from the transmitter air regulator which should be set at 15 psi. Transmitters are included for: 4. Annular pressure 2. Accumulator Pressure 3. Manifold Pressure 4.6.3 Air Junction Boxes All of the signals lines included in the interface assembly terminate at the fixed-plate half of an air junction box which mates to the hose end half attached) to the interconnect cable assembly. This junction box facilitates handling of the BOP Control system equipment during rig moves or when relocating the equipment. 4.7 AIRREMOTE CONTROL PANEL ASSEMBLY. | Air operated remote control panels are used for remote control of the accumulator unit.These panels are divided into two (2) basic types : Driller's panels and auxiliary panels. Both remote control panels require a customer furnished, 125 psiair supply. 4. Driller's Panel - The Driller's panel should be located on the drill floor and provides complete remote control and operating pressure monitoring of the accumulator unit. = 2. Auxiliary Panel - The auxiliary panel should be placed in a safe area. This way if — < the Driller's panel is inoperative and the accumulator unit cannot be reached, the well can be controlled from this panel. Since itis used only in emergency situations, it does not contain monitoring of the operating pressures of the control system required during normal operation. Major components of these panels include: 1. air supply manifold, 2. master air control valve, 3. air control valves, 4. bypass/internal override valve, 5. nameplates, 6. gauges and 7. annular pressure control valve. 4.7.1 AirSupply Manifold The customer furnished air supply should be connected to the air supply manifold as ¢ indicated in the Installation Section. Included in the air supply manifold is a filter and a lubricator. The filter is used to remove contaminants in the air supply that candamage the < air valves. The lubricator is used to lubricate the valves during operation. The filter and lubricator should be serviced periodically to ensure proper operation of the air remote * control panel (See maintenance Section). 4.7.2. Master Air control Valve This valve is’a 1/4", three-way spring centered valve which must be operated to provide the < necessary air supply pressure to the remaining air valves on the remote panel. This valve must be held open to allow the air supply to flow through it while operating the other valves. When the handle is releasea, it will automatically spring center, shutting off the air supply and venting all of the down stream air pressure. This helps to prevent accidental operation ofa BOP function. 4.7.3. AirControl Valves ‘ The 1/4", four-way, spring-centered air control valves are used to remotely operate the preventer control valves on the hydraulic manifold. Operation of these valves sends a. signal (only ifthe master air valve is operated simultaneously )to the air cylinders attached > to the hydraulic control valves on the manifold. This signal extends or retracts the cylinder ¢ thus shifting the control valve. Hydraulic fluid is then directed to operate the function corresponding to the function of the panel air valve. When the air valve onthe remote panel‘ is released, the handle automatically centers. This vents the pressure on the air cylinder thus allowing the hydraulic control valve on the manifold to be manually operated if required. 4.7.4. Bypass/internal Override Valve t This 1/4" four-way spring centered valve remotely operates the manifold regulator * bypassiinternal override valve. When moved to the LOW PRESSURE position, regulated pressure is supplied to the Ram and Wing control valves. When moved to the HIGH PRESSURE position, unregulated accumulator pressure is supplied to them. Some auxiliary panels do not have this valve. hi = = amw w OPERATION 475 47.6 ATT 48 Nameplates 1. Driller's Panel- The nameplates for a standard Driller's panel are graphically shaped and arranged to represent the actual stack configuration. This helps the operator to quickly and accurately operate the required function. The function name and operation indication are formed with the cast aluminum construction to provide a long lasting function identification. 2. Auxiliary Panel- The nameplates for an auxiliary panel can be either graphic cast aluminum (Same as the Driller's panel) or anodized aluminum nametags. These nametags are used when the air control valves are arranged in a vertical, nongraphic representation of the BOP stack. Gauges Gauges are provided on the air remote control panels to monitor the supply pressure of the panel ang, if so ordered, to monitor the operating pressures of the accumulator unit. The gauge are 4-1/2" face, glycerin- filled, receiver type. 1. Driller's Panel - Four (4) gauges are provided to monitor: AirSupply Pressure Accumulator Pressure Manifold Pressure Annular Pressure poop 2. Auxiliary Panel - One (1) 2-1/2" face, 0-300 psi gauge is provided to monitor the air supply pressure to the panel. Annular Pressure control Valve The Driller's panel contains an air remote control valve for adjusting the operating pressure of the annular preventer. The air supply to this valve includes an air regulator that is preset to 90 psi. To adjust the annular operating pressure from the remote panel, the lock handle on the annular regulator on the manifold must be tightened securely. Next, the master air valve must be operated and held in position while moving the annular pressure control valve lever to either the INCREASE positions. This sends an air signal to operate the air motor attached to the adjusting screw of the annualar pressure gauge when adjusting the setting INTERCONNECT CABLEASSEMBLIES, The interconnect cable assembly connects the air remote control panel to the accumulator unit. It consists of a multi-tube bundle with a hose-end half of an air junction box on each end. These junction boxes should be attached to the mating junction boxes on the interface assembly and the air remote control panel. One interconnect cable assembly is required for each air remote control panel to the accumulator unit and the air pressure monitoring signals from the accumulator unit to the air remote control panel. The cable consists of 3/8" OD, 175 psi working pressure polyethylene tubes spirally wound and encased in 3/16" thick polyvinylchloride (PVC) outer jacket. Two (2) tubes are required for each function (OPEN and CLOSE), two (2) are required for each regulating station (INCREASE and DECREASE), and one (1) each for pressure monitoring signals.OPERATION 4.9 ACCESSORIES ao There are optional items that can be added to the BOP Control System to increase its functional capability. Accessories include : 1. nitrogen backup system, 2. rig test outet, 3. alarms, and 4. BOP position indicating lights. The following will provide functional =< descriptions and operational instructions a 4.9.1 Nitrogen Backup System a This system connects to the control manifold to provide an emergency pressure power source to close the ram type preventers and gate valves. This system should be used only as the last possible means of control. The nitrogen backup system consists of a 0 1. Shutoff valves - which are closed during normal operation and must be manually opened to begin nitrogen flow. This valve location should be familiar to operator personnel to enable quick and correct use. a a a 2. Check valves- which direct nitrogen toward control valves only and do not allow backflow to ill up the accumulators. 3. Nitrogen pressure gauge- 0-500 psi, This gauge reading should be observed = € daily. Nitrogen pressure should be maintained at 2200 psi. 4.9.1.4 Nitrogen Backup Operation- to operate the nitrogen backup system during an ‘emergency situation ; ure ate 4. Move the manifold regulator bypass/intemal override valve to HIGH pres position. Perform this operation from point of quickest access. If possible op from the remote panel before power supplies are shut down 2. Open the nitrogen system shutoff valve. This operation must be done manually at the unit. . 3. Operate the desired ram preventers or gate valves. Do not attempt to operate the annular. Nitrogen flow is not directed through this function and will only waste time and pressure. 49.2 RigTestOutlet (NotApplicable) This assembly provides a 6000 psi working pressure test outlet from the accumulator unit. The test outlet consists of : Rig test isolator valve -is open during normal operation. Rig test pressure gauge -0-10,000 psi. Rig test relief valve -6500 psi. Rig test shutoff valve -is closed during normal operation. Rig test check valve. gpene 1. Rig Test Outlet Operation - To operate the rig test outlet: (Not Applicable) 4. Connect a 600 psiline fitted with 6000 psi bleeder valve (supplied by customer) irom rig test outlet to equipment to be tested and a return line to the reservoir for vented fluiduw wwwu ~ vou uuu 4.9.3 2. Closerig testisolator valve. | 3. Openrig test shutoff valve. 4. Check that air pump suction valve is open and customer furnished bleeder valve is closed 5. Open the air supply valve for the air pump connected to the rig test outlet and then shutit when test pressure is reached, Slowly open customer furnished bleeder valve and vent fluid back to reservoir. Alarms Alarm systems of audio (horn) and visual (flashing reg light) signal can be added to the BOP Control System. These alarms require a customer supplied 120 volt AC power supply hookup at installation with cable connection of .375" to .500" diameter. The alarms include use of the lamp test/acknowledge button which deactivates the horn alarm. The flashing red light signals until the system is restored to normal operating conditions. The alarms are activated by pressure switches. 1. The low accumulator pressure alarm pressure switch is activated when the system pressure drops to 1500 psi, 2. The low fluid level alarms pressure switch is activated when the rig air supply pressure drops to 35 psi Optional BOP Position Indicating Lights Indicating lights may be added to the BOP Control System to show whether the annular and ram preventers are open or closed. Explosion-proof lights are added to the remote panel and are connected to pressure switches on the accumulator unit via a multi- conductor electric cable. Since the air valves on the remote panel are spring centered, this gives a positive indication of BOP positions. An explosion -proof box, housing pressure switches Connected to each function valve outlet, is mounted on the accumulator unit. As pressure builds in the function outlet, the pressure switches closes and send an electric signal to the appropriate indicating light on the remote panel |