SKID MOUNTED TEST UNIT

PAGE

 Introduction___________________________________________________ 1

 Installation____________________________________________________ 2

a) Introduction
b) Setup Location
c) Installation Preparation

 Installation Diagram____________________________________________ 5

 Installation Data Sheet___________________________________________ 6

 Operation_____________________________________________________ 7

a) Introduction
b) Description
c) Operating

 Pictorial Isometric Typical Test Unit_______________________________ 9

 Schematic Typical Test Unit______________________________________ 9

 Maintenance___________________________________________________ 10

a) Introduction
b) Maintenance Instructions

 Trouble shooting________________________________________________12

a) Introduction
b) Problems, Possible Cause, Remedy

 Equipment_____________________________________________________14

 Appendix______________________________________________________ 19

 Abbreviations__________________________________________________ 20

 Glossary of Terms______________________________________________ 21

 Conversions___________________________________________________ 25
 This manual is designed to assist on the maintenance and operating procedures of
high pressure test units brought to you by Open and Close Equipment. All test
units are designed to provide a safe and an efficient way to test the blowout
preventers.

MAXIMUM RANGES OF TEST UNITS

10,000 PSI 15,000 PSI 20,000 PSI 30,000 PSI

A majority of the units may be equipped with a chart-type recorder to provide a

recorded account of the test results.

INSTALLATION: Instructions for a proper set-up and initial preparation of

the equipment.

OPERATION: Instructions and illustrations for the proper use of the test
unit.

MAINTENANCE: Instructions on routine service points and procedures to

replace defective components.

TROUBLE SHOOTING: Instructions on how to locate and repair any operational

problem with the equipment.

EQUIPMENT: Assembly drawings and part lists of the equipment

to identify components with their location.

PARTS: List of components to help repair and replace a part.

APPENDIX: General information, i.e. glossary, legend, conversion

factors.

Please pay particular attention to all notes, cautions, and bold

print words this is important to ensure safety in all phases relating
to the equipment.

1
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EQUIPMENT, INC.
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Email: sales@bopenandclose.com

a) INTRODUCTION

It is very important to check the working pressure rates of all components to be

used during the test before beginning installation of the equipment.
Working pressure rating should be specified on all equipment. It is usually found
on the manufacturer’s plate. DO NOT use any piece of equipment if you are not
sure as to its working pressure.

b) SETUP LOCATION

The unit should be installed in a firm and leveled area with adequate air flow and
water supply.
Sufficient lighting and drainage for vented or liquid fluid. The location should not
interrupt other operations. And should be isolated in a secure area, in case of any
failure.

c) INSTALLATION PREPARATION

Before the start of any test, check the equipment thoroughly for any damage. In high
pressure testing all components must be in a perfect condition to prevent an
accident.

1. Installation Check List

1. Check that air lubricator (Item 6) is full of SAE 10W Lubricating oil.

2. Check that suction strainer (Item 9) is clean.

3. Check that rupture disk (Item 15) is installed and that opening is NOT plugged.

4. Adjust the test pressure gauge (Item 16) to zero.

5. If the unit includes test pressure recorder gauge (Item 17):

o Check that a clean chart is installed.

o Check that the ink well is full and pen operates. (Check maintenance section
if it´s not operated properly).

o Check that the clock is wound by using key provided enclosed with the
recorder.

o Check that pen sets on Zero indication. (Maintenance section if not)

2
 2) Initial Hookup

1. Close all Valves.

2. Connect water supply hose or pipe to customer water supply connection see
equipment specifications.

NOTE: For testing of self-contained units that include a reservoir, either a light
weight SAE 10W Oil or water can be used. Fill to approximately 8” from the top.

3. Connect air supply hose or pipe to customer air supply connection (item1); (see
Installation Data sheet and Equipment Specifications).

3) Test Unit Start Up

1. Open test outlet valve (Item 13) and bleeder valve (Item 14).

2. Plug high pressure test connections (Item3).

3. Open air supply valve (Item5) ONLY on low pressure pump (Item 10).

4. Purge lines with water to remove air and then close bleeder valve (Item14).

5. When pressure reaches 3,000 PSI, open air supply valve (Item 8) to high
pressure pump (Item11).

6. Adjust air regulator (Item 7) to stop pumps at desired test pressure.

a. Rotate the regulator adjustment handle:

o To increase pressure – rotate clock wise.

o To decrease pressure –rotate counterclockwise

b. Read air regulator pressure gauge for pressure setting of the regulator.
c. Set at required testing pressure.

7. Observe complete system for leaks.

8. Observe that recorder (Item 17) is tracking the same pressure as the test
pressure gauge (Item16). If adjustments are required (see maintenance section).

9. Close air supply valves (Item 5,8).

10. Open bleeder valve (Item 14).

11. Repair any leaks. If leaks are in high pressure tubing connections, (See
maintenance section).

3 2
 4) Test Hook-Up

1. Remove plug from high pressure test connections (Item 3).

2. Connect high pressure hose to high pressure test connection (Item 3) (see
equipment specifications).

3. Optional: Connect bleeder hose to bleeder line connection (Item 4) Run other end
of hose to nearest drain and safely secure.

4. Open air supply valve (Item 5 ) only to low pressure pump (Item 10).

5. Close bleeder valve (Item14).

6. Purge high pressure test hose to remove air and close air supply valve (Item 5)

7. Connect test hose to inlet of equipment to be tested.

8. Use an auxiliary water supply line to fill up cavity of equipment to be tested.

THE HIGH PRESSURE UNIT IS USED FOR HIGH PRESSURE – LOW FLOW. IT IS
NOT A VOLUME PUMP ASSEMBLY. USING IT TO FILL THE TEST CAVITY WILL
ONLY DELAY TESTING.

9. Open air supply valve (Item 5) to low pressure pump.

10. Purge entire test circuit to remove air then close air supply valve (Item 5).

11. Plug cavity connection at auxiliary water fill up line.

12. System is now ready for test.

3 4
5
RAM PREVENTER

BOP TEST HOSE

1.-WATER SUPPLY HOSE

BLEEDER
2.-AIR SUPPLY HOSE
HOSE/DRAIN

HIGH PRESSURE TEST UNIT

2
 TEST UNIT MODEL No. No. OF PUMPS Min air supply req’d
PSI CFM

OCS15RA 2 90 112
OCS10RA 2 90 112
OCS20RA 2 90 112
OCS30RA 2 90 133

Note: - You should ensure that the air supply is CLEAN and DRY.
•Excessive moister and contaminants can cause operational problems

Equipment Rated Working Pressure

1. Equipment to be tested Variable – the basis for detecting test

Pressure (see note 1)

2. Test Unit (see equipment section) Equal to or greater than test pressure

3. Water Supply Hose or Pipe 250 PSI

4. Air Supply Hose or Pipe 100 PSI

5. High Pressure Test Hose or Tubing Equal to rated working pressure of test
(see equipment section) Unit

6. Bleeder Hose(Optional) 250 PSI (see note 2)

NOTES:

1. Test pressure is the function of the rated working pressure of the

equipment being tested. Test or rated working pressure should be
specified in the test procedures provided by equipment requiring the
test.

2. Bleeder hoses are usually low pressure; however, in some cases it

may be advantageous to use a spare high pressure hose that could
also serve as a high pressure test hose should the initial hose become
3 damage.
7 2
6
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a) INTRODUCTION

High pressure hydrostatic tests must be conducted with an approved test procedure.
The test procedures should be developed by your own company or a standard accepted
test producer such as that outlined in API RP53 Section 7A can be used. All test
procedures must specify, in detail, the test criteria such as; test pressure, test duration,
acceptable test results, and a blank data sheet to record the test results.

b) DESCRIPTION

The high pressure test unit assembly uses the air supply to power the air motor of
one low and one high pressure pump to build up the high pressures for testing. The low
pressure pump (Item 10) is a double acting, 60:1 ratio pump which is capable of a
maximum 7,500 PSI output. The high pressure pump (Item 11) is a bidirectional 200:1
ratio pump. Passes through the air supply valve (Item 5), then flows through a
lubricator (Item 6) and is impregnate with 10W oil. The air supply is then routed
through an air pressure relieving regulator equipped with a pressure gauge (Item 7) The
regulator serves as the system’s test pressure controller. The air regulator contains a
diaphragm pressure side to connects to the outlet port of the regulator so that, as
pressure increases, the diaphragm compresses the adjusting spring. An equilibrium
state is maintained between the load exerted by the adjusting spring and the load from
the regulated pressure. The load exerted by the adjusting spring controls the valve
position to maintain the desired regulated pressure.

The open air supply valve (Item 5) starts up the low pressure pump and pulls the water
supply trough a strainer (Item 9) located in the low pressure pump suction line. This
fluid suction line enters the fluid end of the low pressure pump. The flow in the air
supply line to the high pressure pump is controlled by the opening of the air supply
valve (item 8). When the air supply valve is opened to start up the high pressure pump.

The fluid end pressurizes the fluid discharge from the low pressure pump. Both the
upstream and discharge lines of the high pressure pump contain check valves (Item12)
to prevent backflow of the high pressure fluid. When the backpressure fluid force
discharge by the pumps equals the regulated air pressure force into the high pressure
air motor, the pumps will stall out.

The pumps discharge line is directed through the test outlet valve (item 13) and controls
the high pressure flow through the high pressure test connection (Item 3) to the
equipment being tested. An additional vent or bleeder line is provided with a bleeder
valve (Item 14) to control the release of the system fluid and pressure. A rupture disk
(Item15) serves to protect the test unit assembly against over pressurizing. The rupture
pressure of these discs will vary according to the working pressure rated of the test
unit.
7 2
The pressure in the test line is monitored through a tube connection to a test
pressure gauge (Item 16). Units equipped with a test pressure recorder
(Item 17) connect to this tubing for indication of test pressures on the
recording chart.

Self-contained test units include a reservoir for storage of the operational

fluid. They also contain a special circuit for open and close operation of the
preventer or valve being tested. The circuit consists of a four-way control
valve, strainer, 6,000 PSI gauge and a 3,500 PSI relief valve.

NOTE: Preventer and valves that have been tested with water should be
purge with oil after testing.

c) OPERATING

All phases of installation must be completed before beginning the actual

test phase. The reference item numbers correspond to the illustration that
follow in this section.

1. Test Start-Up

o Open the air supply valve (Item 5) to the low pressure pump (Item 10).

o When test pressure reaches 3,000 PSI, open the air supply valve
(Item 8) to the high pressure pump (Item11).

o The test unit should automatically stall out at the required test
pressure as set in the installation section. If not, adjust the air regulator
(Item 8) to desired test pressure.
o After pressure stabilizes, close the air supply valves (Items 5, 8) and
test outlet valve (Item 13).

2) Test

o Follow specified duration of this hydrostatic test as stated in the

applicable test procedure.

o Observe the test pressure gauge (Item 16), or recorder chart (Item 17),
if so equipped, for any pressure losses. If there is a constant drop in
pressure, there is a leak in the test circuit.

3) Test Rig-Down

o Carefully open bleeder valve (Item 14).

o Carefully open the test outlet valve (Item 13).

o When test pressure reaches “zero”, disconnect all interconnecting

hoses.
8
 PICTORIAL ISOMETRIC
TYPICAL HIGH PRESSURE TEST UNIT
8

10
16

17

11

12

7 13
1
5 12
3
15

2
4 14
9

SCHEMATIC
TYPICAL HIGH PRESSURE TEST UNIT
Item Description

1 Air Supply Connection

2 Water Supply Connection 1

5 6
3 High pressure Test Connection

4 Bleeder Line Connection

5 Air Supply Valve (Low Pressure Valve) 7

6 Air Lubricator

7 Air Regulator With Gauge 17

8 Air Supply Valve (High Pressure Valve) 16 8

9 Suction Strainer
10
14
10 Low Pressure Pump
4 9
11 High Pressure Pump
15 13 12 12
12 Check Valves 11
2
13 Test Outlet Valve

14 Bleeder Valve
Air Supply Pressure
Regulated Air Pressure
15 Rupture Disc
Water Supply Pressure
Intermediate Pressure
16 Test Pressure Gauge
High Pressure
17 Test Pressure Recorder

9
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a) INTRODUCTION

All maintenance and troubleshooting to be performed on the test unit components,

should be done while the test unit is removed from service. Routine maintenance of the
equipment can prolong the service life and ensure optimum operational performance.
Should be performed on the equipment IMMEDIATELY after conclusion of functional
operations so that the equipment will be ready for the next test. No special tools are
required to work on the test unit. To ensure safety of maintenance personnel, workmen
should work in pairs so a backup is near in case of an emergency.

All high pressure hose lines should be double checked that pressures have been
relieved before attempting maintenance.

b) MAINTENANCE INSTRUCTIONS

The following instruction are categorized by component maintenance. The item numbers
refer to the illustrations located in the operation section.

1) Air Lubricator (Item6)

o Open the petcock of the lubricator to drain moisture that may have
accumulated.
o Fill with 10W lubricating oil.
o Check that drip setting is six drops per minute (see trouble shooting unit).

2. Strainers (Item 9)
o On a regular basis remove strainer elements and wash with warm water or
kerosene.

3) Gauge (Item 16)

o Use Zero adjustment screw to reset needle to zero setting.

4) Air Regulator With Gauge (Item 7)

o Vary the regulator pressure setting to eliminate permanent .
o “ Seating Wear” to the shear seals.
o Apply 10W oil to the regulator adjustment screw.
o Use “Zero Adjustment” screw to reset gauge needle to zero setting.
o Unscrew the bottom plug of regulator, remove the enclosed strainer screen, clean
and replace.

5) Pumps (Item 10), (Item11)

o Low pressure pumps – The pump packing is spring loaded to provide automatic
adjustment. No maintenance is required.
o High pressure pump – Periodic adjustment of the packing may be required.
Tighten only when pump is running and tighten enough to prevent dripping.
Packing should be just loose enough to lubricate rod but not tight enough to
burn up the packing. 10
 6) Rupture Disc (Item 15)

o Remove and inspect for damage. Replace if necessary.

o Do not operate test unit without rupture disc installed. Do not plug
opening. Always keep spare rupture discs on hand.

7) High Pressure Fittings

o Use a torque wrench when tightening gland nuts on high pressure fittings and
valves to stop leaks.
o Over tightening may cause seat damage. Torque requirements are:
1. Valve stem glands – 85 ft-lbs.
2. Tubing connection glands -55-ft-lbs.

8) Recorder (Item 17)

1) Pen

1. Press forefinger over end of pen box to start ink flow through pen. This
should cause pressure to build up and ink to flow through capillary.

2) Clogged Pen

o Pull pen box off of open arm and soak in water or alcohol.
o Insert a cleaner wire up the capillary hole and into the box reservoir.
o Reinstall the pen box by pushing the pen all the way on the pen arm until
the top of the pen arm touches the capillary.

3) Adjusting Time Line Tracking

o Remove the connecting link from its bearing point by rotating the retainer
clip on the end of the connecting link to allow the bearing pin to slip out of
its bearing hole on the calibration arm.

o Position the pen arm so that the pen rests on the fine line near the center of
the chart. If It:

a. Follows the line, the pen arc is correct.

b. Goes above the time arc; the pen arc is to short.
c. Goes below the time arc; the pen arc is to long.

4) Loosen the clamp screw at the upper end of the pen arm and adjust the length.

5) Tighten the clamp screws and reconnect the link to the calibration arm.

9) Reservoir

o The fluid reservoir should be checked regularly, drained and cleaned. Fill to
approximately 8” from the top with a light weight SAE 10W oil or water.

NOTE:
Never use fuel oil, kerosene or salt water in the reservoir.
11
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a) INTRODUCTION – The troubleshooting section provides a guide in locating and

remedying operational problems by identifying the problem or symptom. The
following troubleshooting charts contain information in three vertical columns.

1. The first column identifies the problem or the symptom.

2. The second column probable causes.
3. The third column describes corrective actions to be taken.

o All repairs to the unit should be performed while the unit is removed from service.

o To ensure safety the repairs should be done in pairs so there is a backup in case
of an emergency.

o All high pressure hose lines should be double checked that pressures have
been relieved before attempting maintenance.

Problems Possible Cause Remedy

A. Erratic No oil in lubricator. a) Cut off supply to test units.

pump b) Open petcock at bottom of air
Operation. lubricator.
c) Drain off any moisture or
emulsified oil.
d) Unscrew fill cap and refill with
10W motor oil.
e) DO NOT USE SYNTHETIC OR
AROMATIC TYPE OIL.
f) Turn on air supply to test unit.

B. Excessive oil Air lubricator or a) Open test outlet valve.

in pump air adjustment. b) Open air supply Valve.
exhaust. c) Open lubricator fill cap.
d) Use a thin screwdriver to adjust
lubricator to flow six drops of oil
per minute.

(1) Clockwise rotation increases

flow.
(2) Counterclockwise decreases
flow.

e) Close lubricator fill cap.

f) Close air supply valve.
g) Close test inlet Valve.
12
 Problems Possible Cause Remedy

C. No or slow 1. Low air supply a) Check air compressor for volume

pressure build pressure. and pressure output specification
up. (see installation data sheet).
b) Check and correct operational
problems with air compressor.

2. Insufficient water a) Check that water supply is

supply. connected and turned on.
b) Check for low water pressure
and/or leaks in connecting lines.

3. Clogged Strainer. a) Shut off water supply.

b) Remove (Y) strainer plug and
element.
c) Clean element with warm water or
kerosene.
d) Replace dry element and strainer
plug.
e) turn on water supply.

4. Faulty ball check a) Shut off air and water supply.

in fluid end of low
pressure pump.
b) Open test outlet and bleeder valves.
c) Remove fluid end from low pressure
pump.
d) Disassemble fluid end and install
repair kit.
e) Replace repaired fluid end.

5. Faulty inline high a) Shut off air and water supply.

pressure check b) Open test outlet and bleeder valves.
valve. c) Remove and replace faulty check
valve.
d) For torque specifications (see
maintenance section).

6. Bleeder valve a) Shut off air and water supply.

leaking. b) Open test outlet and bleeder valves.
c) Remove and replace faulty bleeder
valve.
d) Replace with new bleeder valve (see
maintenance section for torque
specifications).

D. Recorder 1. No ink or pen a) If there is no ink , fill with

pen not clogged. standard chart ink.
writing. b) If pen is clogged, (See maintenance
13 section).
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High pressure test units can be provided in working pressure ranges

from 5000 to 30,000 PSI. These units are recommended for high
pressure testing of the BOP stacks, choke and kill lines, Christmas
trees and any other type of equipment requiring high pressure static
testing. Test units are available in unit-mounted, portable, skid-
mounted and self-contained skid mounted styles. Accessories include
stand mounted chart recorders and high pressure hose assemblies.

TEST UNITS
MODEL NUMBER IDENTIFICATION SYSTEM

OC S 15 R A

Manufacture’s Name Maximum

OC OPEN AND CLOSE Pressure Pressure Readout
10 10,000 PSI G Gauge
15 15,000 PSI R Gauge and Recorder
20 20,000 PSI
30 30,000 PSI Series
A A-series
B B-Series
C C-Series
Mounting Arrangement

S Skid Mounted

14
 Approximate
Maximum Pressure Weight
MODEL
(PSI)
Lbs. kgs
OCS10RA 10,000 430 195
OCS15RA 15,000 430 195
OCS20RA 20,000 430 195
OCS30RA 30,000 445 202

15
 4

3 5

16
 Item Description Qty Item Description Qty

1 Skid 1 21 Nipple 1/2“ x 7” 20,000 PSI 1

2 Recorder 1 22 Nipple 1/2“ x 10” 20,000 PSI 1

3 Gauge 1 23 Shut Off Valve 1” LP 1

4 Low Pressure Pump 1 24 Nipple 1“ x 3“ LP 1

4.a High Pressure Pump 1 25 1”, 160 PSI, Air Filter, 1

5 Needle Valve 9/16”, 20,000 PSI, 316 SS 2 25.a 1”, 160 PSI, Air Regulator 1

6 Nipple 9/16” x 6” 20,000 PSI, 316 SS 4 25.b 1”, 160 PSI, Air Lubricator 1

7 Cross 9/16”, 20,000 PSI, 316 SS 1 26 Shot Off Valve 1/2" 3

7.a Rupture Disk 1 27 Street 90, 1” to 1”, LP 1

8 Tee 9/16”, 20,000 PSI , 316 SS 1 28 Elbow 90 1”, LP 2

8.a High Pressure Test Connector 1 29 Nipple 1” to 2 1/2”, LP 1

9 Hose Conn. 9/16” 1 30 Nipple 1” to 12”, LP 1

10 Nipple 9/16” x 4”, 20,000 PSI, 316 SS 2 31 Tee 1”, LP 1

11 Check Valve 9/16”, 20,000 PSI, 316 SS 2 32 Bushing 1” to 1/2”, LP 2

12 Tubing 1/4” 20,000PSI 316 SS 1 33 Male Conn. 9/16” 316 SS, LP 4

13 Tee 1/4“ 20,000PSI, 316 SS 1 34 Tubing 9/16”, 316 SS, LP 1

14 Needle Valve 1/4”, 20,000 PSI, 316 SS 1 35 Street Conn. 9/16” 316 SS, LP 4

15 Male Conn. 9/16” to 3/4" 1 36 Shut Off Valve 1/2”, LP 3

16 St, Elbow 1/2” to 1/2 f, 20,000 PSI 1 37 Bushing 3/4” to 1/2”, LP 1

17 Nipple 1/2“ x 2“ 20,000 PSI 1 38 Nipple 1/2” x 2”, LP 1

18 Elbow 90 1/2” 20,000 PSI 2 39 Elbow 90 1/2”, LP 1

19 Nipple 1/2“ x 5“ 20,000 PSI 1 40 Y Strainer 1/2”, LP 1

20 Union 1/2” 20,000 PSI 1 41 Nipple 1/2” x 5”, LP 1

17
18
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19
ADJ – Adjust INC/DEC – Increase/Decrease. The control
function that regulates the pressure to be applied
AMB – Ambient to the annular valve on the BOP stack

AR – As Required K – Wire Abbreviation. Relay coil; signal relay.

Constant used
ASME – American Society Of Mechanical Engineering to denote insulation resistance

ASSY – Assembly MTD – Mounted

AWG – American Wire Gage NC – Normally Closed

BOP – Blowout Preventers NO – Normally Open

BRZ – Bronze NPT – National Pipe Thread

ºC – Celsius Scale For Temperature Measurement OD – Outside Diameter

CD PL – Cadmium Plate PL – Plate. The application of one metal over

another
CFM – Cubic Feet Per Minute
PPM – Parts Per Million
CFS – Cubic Feet Per Second
PSI – Pounds Per Square Inch
CG – Center Of Gravity
RPM – Revolutions Per Minute
CHK – Check
SAE – Society of Automotive Engineers
CLN – Clean
SCH – Schedule. Pipe classifications
DR – Drain
SPM – Strokes Per Minute. Sub-plate mounted
EH – Electro Hydraulic
STD – Standard
EP – Electro Pneumatic
UNC – Unified National Coarse. An electrical
ºF – Fahrenheit Scale For Temperature Measurement standard for pipe
Threads
GPM – Gallons Per Minute
VAC – Volts Alternating Current. An electrical
HP – Horsepower. A unit for measuring the power of current that continually reverses its direction,
motors. One horse-power equals 33,000 foot-pound of giving a definite plus and minus waveform at
work per minute fixed intervals

HZ – Hertz. Preferred terminology for cycles per second, VDC – Volts Direct Current. An electrical
the frequency of an electrical wavelength current that flows in one direction only

ID – Inside Diameter WOG – Water, Oil Or Gas

20
 Ambient Temperature: The temperature of the all encompassing atmosphere within a given area.
Accumulator: A vessel containing both hydraulic fluid and gas stored under pressure as a source
of fluid power to operate opening and closing of blowout preventer rams and annular preventer
elements. Accumulators supply energy for connectors and valves remotely controlled.
Accumulator Unit: The assembly of pumps, valves, lines, accumulators, and other items necessary
to open and close the blowout preventer equipment.
Accumulator Bank Isolator Valve: The opening and closing device located upstream of the
accumulators in the accumulator piping which stops flow of fluids and pressure in the piping.
Accumulator Relief Valve: The automatic device located in the accumulator piping that opens
when the preset pressure limit has been reached so as to release the excess pressure and protect
the accumulator.
Air Breather: A device permitting air movement between the atmosphere and the component in
which it is installed.
Air Pressure Switch Bypass Valve: The opening and closing device located in the air supply line
which blocks air flow in one line to be redirected through another. In open position, air flow is not
routed through the air pressure switch for automatic shutoff thereby allowing the air pumps to
continue to run.
Air Pump Suction Valve: The opening and closing device located in the piping line that draws fluid
from the reservoir into the fluid end of the pump when the air motor is operating.
Air Regulator: The adjusting device to vary the amount of air pressure entering as to the amount
to be discharged down the piping lines.
Air Supply Valve: The opening and closing device in the connecting line of the compressed air
routed to flow into the accumulator system lines as a power source for components.
Ampere: The unit used for measuring the quantity of an electric current flow. One ampere
represents a flow of one coulomb per second.
Annular: A large valve, usually installed above the ram preventers, that forms a seal in the space
between the pipe and wellbore or on the wellbore itself. The space around a pipe in a wellbore, the
outer wall of which may be the wall of either the borehole or the casting.
Annular Regulator: The device located in the annular manifold header to enable adjustment of
pressure levels which will flow past to control the amount of closure of the annular preventer.
Blowout Preventer: The equipment installed at the wellhead to enable the driller to prevent
damage at the surface while restoring the balance between the pressure exerted by the column of
drilling fluid and formation pressure. The BOP allows the well to be sealed to confine the well fluids
and prevent the escape of pressure either in the annular space between the casting and drill pipe or
in an open hole. The blowout preventer is located beneath the rig at the land’s surface on land rigs
or at the water’s surface on jack-up or platform rigs and on the seafloor for floating offshore rigs.
BOP Stack: The assembly of well control equipment including preventers, spools, valves and
nipples connected to the top of the casing head.
Baffle: A partition plate inside the reservoir to prevent unbalancing by sudden weight shifting of the
hydraulic fluid.
Bleeder Valve: An opening and closing device for removal of pressurized fluid.
Blowout: An uncontrolled flow of gas, oil, or other well fluids into the atmosphere. A blowout, or
gusher, occurs when formation pressure exceeds the pressure applied to it by the column of drilling
fluid.
Chain guard: The metal enclosure surrounding the electric pump driving chain to protect and
contain an oil lubricate for the chain.
Check Valve: A valve that permits flow in only one direction.
Choke: A variable diameter orifice installed in a line through which high pressure well fluids can be
restricted or released at a controlled rate. Chokes also control the rate of flow of the drilling mud
out of the hole when the wells is closed in with the blowout preventer and a kick is being circulated
out of the hole.
Circuit Breaker: An electrical switching device able to carry an electrical current and automatically
break the current to interrupt the electrical circuit if adverse conditions such as shorts or overloads
occur.
Conductivity: The capability of a material to carry an electrical charge. Usually expressed as a
percentage of copper conductivity (copper being one hundred 100 percent). Conductivity is
expressed for a standard configuration of conductor.
Conductor: The substance or body capable of transmitting electricity, heat, light, or sound.
21 Contact Block: The conductor located in the electric panels which bring together the electrical
connections of the operation pushbuttons with those of the operator valves.
Continuity: The uninterrupted flow of current in a conductor.
Control Manifold: The system of valves and piping used to control the flow of pressured hydraulic
fluid to operate the various components of the blowout preventer stack.
Corrosion Inhibitor: Any substance which slows or prevents the chemical reactions of corrosion.
Cylinder: A device which converts fluid or air power into linear mechanical force and motion. It
consists of a movable element such as a piston and piston rod, plunger rod, plunger or ram,
operating within a cylindrical chamber.
Discharge Check Valve: The device located in the expelling line of a pump (air or electric) which
allows fluid to flow out only and thereby prevents a back flow of fluid into the pump.
Drain Port: The plugged openings on the lower side portions of the reservoir which can be opened to
empty or release the hydraulic fluid, and through which the reservoir can be cleaned.
Dust Cap: The screw on covering for the electric panel connector receptacles which protect the
electrical contacts from foreign matter and moisture.
Electric Pump Suction Valve: The opening and closing device located in the piping line that draws
fluid from the reservoir into the pump inlet when the motor is operating.
Element (Filter): The substance of porous nature which retains foreign particles that pass through
the containing chamber to serrate and clean the gas or liquid flow.
Fill Port: The plugged opening in the top of the fluid reservoir through which hydraulic oil is added.
Filter (Air): Apparatus used to clean air flow of dirt, moisture and other contaminants.
Filter (Hydraulic): A device whose function is the retention of insoluble contaminants from a fluid.
Filter (Air): Apparatus used to clean air flow of dirt, moisture and other contaminants.
Filter (Hydraulic): A device whose function is the retention of insoluble contaminants from a fluid.
Flow Rate: The volume, mass, or weight of a fluid passing through any conductor, such as pipe or
tubing, per unit of time.
Flow meter: A device which indicates either flow rate, total flow, or a combination of both, that
travels through a conductor such as pipe or tubing.
Fluid: A substance that flows and yields to any force tending to change its shape. Liquids and gases
are fluids. The accumulator system pressurizes fluid to be sued as a source of power to open and
closed valves and rams on the BOP stack.
Full Load Current: The amount of current used by an electrical circuit when that circuit is operating
at its designed or rated maximum capacity.
Function: The term given to the duty of operating the control valves of the accumulator system. The
action performed by the control valves when operating the ram preventers or gate valves.
Gage: A standard method of specifying the physical size of a conductor (wire) diameter based on the
circular mil system. 1 mil equals .001. The higher the number, the smaller the diameter.
Gauge: An instrument for measuring fluid pressure that usually registers the difference between
atmospheric pressure and the pressure of the fluid by indicating the effect of such pressures on a
measuring element (as a column of liquid, a bourdon tube, a weighted piston, a diaphragm, or other
pressure-sensitive devices).
Gland: The cavity of a stuffing box.
Ground: An electrical term meaning to connect to the earth, or another large conducting body to
serve as earth, thus making a complete electrical circuit. The conducting connection of a circuit to
the earth.
Hydrostatic: Relating to liquids at rest and the pressures they exert.
Indicating Light: The bulbs of the electric control panels that shine to point out which electrical
contacts have made a circuit. The electric panel bulbs make circuit contacts through pressure
switches, transducers, and solenoid valves to demonstrate activation.
Inspection Port: The plugged openings on the sides of the fluid reservoir which can be opened to
view the interior fluid level and return lines from the relief, bleeder, control valves, and regulators.
Insulation: A non-conductive material usually surrounding or separating the current-carrying parts
from each other or from the core.
Kick: The increase in pit volume caused by the entrance of formation liquids or gas in the wellbore.
Without corrective measures, this condition can result in a blowout.
Kill Line: A high-pressure fluid line connecting the mud pump and the wellhead at some point below
a blowout preventer. This line allows heavy drilling fluids to be pumped into the well or annulus with
the blowout preventer closed to control a threatened blowout.
Lubricator (Air): A device which adds controlled or metered amount of a substance into the air line of
a fluid power system to prevent or lessen friction.
Manifold Bleeder Valve: The opening and closing device in the piping that connects the manifold
header and the reservoir, and which can be opened to release the fluid pressure and vent it back into
the reservoir. 22
 Manifold Header: The piping system which serves to divide a flow through several possible
outlets. The 4-Way control valve inlets connect to the piping so that high pressure fluid is
available to pass through any or all of the valves.
Manifold Regulator: The device located in the manifold header which can vary the amount of
pressure that enters and exits its chamber. The manifold regulator controls the pressure level of
the fluid flowing through and out the 4-way control valves.
Manifold Regulator Bypass Valve: The opening and closing device which blocks flow in one line
to be redirected through another. This valve is located in the manifold piping so that in the open
position the high pressure fluid does not flow through the regulator in the manifold header,
thereby allowing higher pressure fluid to be available to the 4-way control valves.
Manifold Relief Valve: The automatic opening device located on the manifold header that opens
when the preset pressure limit has been reached so any excess pressure is released, thereby
protecting the manifold header.
Meter: An instrument, operated by an electrical signal, that indicates a measurement of pressure.
Meter Circuit Board: Printed circuit board used with the electrical meters to provide the circuits
necessary for calibration of the meter.
Micron: (A millionth of a meter or about 0.00004 inch). The measuring unit of the porosity of
filter elements.
Mil: A measurement used in determining the area of wire. The area of a circle one 1/thousandth
inch in diameter.
Motor Starter: Automatic device which starts or stops the electric motor driving the duplex or
triplex pump which works in conjunction with the automatic electrical pressure switch for
pressure limits of pump start-up and shutoff.
Needle Valve: A shutoff (2-Way) valve that incorporates a needle point to allow fine adjustment in
flow.
Ohm: A unit of electrical resistance, the resistance of a circuit in which a potential difference of
one volt produces a current of one ampere.
Ohmmeter: The measuring instrument which indicates resistance in ohms.
Petcock: The small faucet or valve used to release compression or drain moisture accumulated in
the anterior chamber of the lubricator.
Phase (3-Phase Motor): A particular stage or point of advancement in an electrical cycle. The
fractional part of the period through which the time has advanced, measured from some arbitrary
point usually expressed in electrical degrees where 360º represents one cycle.
Pipe Rack: The connecting pipelines between the control valve outlets and the BOP stack
preventers which carry the high pressure operating fluid. The lines of pipe are laid together and
are often covered with grating to create a walkway.
Potable: A liquid that is suitable for drinking.
Pressure Switch (Air): The automatic device to start and stop the air pump operation when the
preset pressure limits are reached.
Pressure Switch (Electric): An electrical switch, operated by fluid pressure, which automatically
starts and stops the electrical pump when the preset pressures are reached.
Pressure Transmitter: Device which sends a pressure signal to be converted and calibrated to
register the equal pressure reading on a gauge. The air output pressure is proportional to the
hydraulic input pressure.
Pump (Air): A device that increases the pressure on a fluid or raises it to a higher level by being
compressed in a chamber by a piston operated with an air pressure motor.
Pump (Electric): A device that increases the pressure on a fluid and moves it to a higher level
using compression force from a chamber and piston that is driven by an electric motor.
Pushbutton/Indicating Light: The control valve operates with bulbs on the electrical remote
panel which change and indicate the position of the control valves.
Ram: The closing and sealing component on a blowout preventer. One of three types blind, pipe,
or shear – may be installed in several preventers, mounted in a stack on top of the wellbore. Blind
rams, when closed, form a seal on a hole that has no drill pipe in it; pipe rams, when closed, seal
around the pipe; shear rams cut through drill pipe and then form a seal.
Recorder: An automatic device that reads and records pressure outputs continually on a revolving
chart to provide continuous evidence of pressures.
Regulator: A device that varies and controls the amount of pressure of a liquid or gas that passes
through its chambers.
Relay: An electrical device to automatically control the operation of another device in another
circuit by passing on an electric current.
Relay Socket: A device used to interconnect a relay with its circuitry and which allows quick and
23 easy removal of the relay without special tools.
Reservoir: The container for storage of liquid. The reservoir houses hydraulic fluid at atmospheric
pressure as the supply for fluid power.
Resistance: The property of an electrical circuit which determines for a given current, the rate at
which electrical energy is converted into heat and has a value such that the current squared,
multiplied by the resistance, gives the power converted.
Rupture Disk: A device whose breaking strength (the point at which it physically comes apart) works
to relieve pressure in the system. The rupture disk is contained as a safety device for the test unit
system.
Solenoid Valve: The opening/closing device which is activated by an electrical signal to control liquid
or gas pressured flow to be sent to open or close the 4-way control valves. The valve position is
controlled by an electromagnetic bar, enclosed by a coil.
Solenoid Valve Box: The explosion proof enclosure, located on the accumulator unit, which contains
the electrically powered actuators for the remote control electrical panel. The box is wired to the
electrical supply, and houses solenoid valves, pressure switches and transducers.
Span Adjustment: The control to vary the space between the electrical contact points in the electrical
pressure switch.
Strainer: A porous material which retains contaminants passing through a line along with the gas or
liquid flow.
Suction Strainer: The porous element, located in a “Y” shaped fitting of the pump suction lines, which
cleans the hydraulic fluid or air of contaminants before entering the pumps.
Surge Damper: The one quart capacity bladder accumulator used to absorb the shock and waves
caused by an initial flow of high pressure fluid. Located in the downstream line of the annular
regulator.
Swivel Joint: A connecting device, joining parts so that each can pivot freely. Swivel joints are used at
the end of the pipe rack to see connections to the control valve outlets and to the BOP stack.
Terminal Strip: Grouped electrical conductor endings where screw connections are made.
Transducer: The device located in the solenoid valve box which is actuated by hydraulic pressure and
converts the force to an electrical force for indication on a meter. The electrical output signal is in
proportion to the hydraulic input pressure.
Unit/Remote Selector: The valve located on the manifold header whose ports allow flow into the
annular regulator. The valve position determines the source of flow supply and subsequently controls
the location of operation.
Valve, Float: A device that is positioned as either open or closed, depending on the position of a lever
connected to a buoyant material sitting in the fluid to be monitored.
Valve, Manipulator: A control device having three positions, giving four direction selections for flow
which alternately pressurizes and vents the pressure outlets. The manipulator style valve vents all
pressure outlets when placed in the center position.
Valve, Selector: A control device having three positions, giving four directions selections for flow
which alternately pressurizes and vents the pressure outlets. The selector style valve blocks all
pressure points if placed in the center position.
Valve, Poppet: The opening and closing device in a line of flow which restricts flow by lowering a
piston type plunger into the valve passageway.
Valve, Precharge: The device located on the accumulator bladder ports which open and close for the
nitrogen pressure contained.
Valve, Relief: A valve that opens at a preset pressure to relieve excessive pressures within a vessel or
line whose primary function is to limit system pressure.
Valve, Shutoff: A valve which operates fully open or fully closed to control the flow through the lines.
Valve, Shuttle: A connective valve which selects one of two or more circuits because flow or pressure
changes between the circuits.
Viscosity: A measure of the internal friction or the resistance of a fluid to flow.
Volt: A unit of electromotive force.
Watt: A unit of electrical power; the power of one ampere of current pushed by one volt of
electromotive force.
Zero Adjustment: The control to move the meter gauge indicator for resetting calibration accuracy.
Control used to make the meter read 0 by applying an offset voltage to the meter to offset any positive
voltage present at the meter, even though there is no pressure at the input of the transducer.

24
 LENGTH CONVERSION AREA CONVERSIONS

To Convert To Multiply To Convert To Multiply

Unit (1) Unit (2) Unit (1) by: Unit (1) Unit (2) Unit (1) by:
cm. in. 0.3937 sq. cm. sq. in. 0.1550
cm. meters 0.01 sq. cm. sq. ft. 0.001076
in. cm. 2.540 sq. in. sq. cm. 6.452
in. yds. 0.02778 sq. in. sq. ft. 0.006944
ft. cm. 30.48 sq. ft. sq. inches 144.0
ft. meters 0.3048 sq. ft. sq. inches 0.09290
ft. miles (stat.) 0.000189 sq. ft. acres 2.296 x 10 (-5)
yd. ft. 3.0 sq. ft. sq. miles 3.587 x 10 (-8)
yd. meters 0.9144 sq. yds. sq. meters 0.8361
km mile 0.6214 sq. kms. sq. miles 0.3861
meter in. 39.37 sq. meters sq. ft. 10.76
meter ft. 3.281 sq. meters acres 0.0002471
meter yds. 1.094 sq. meters sq. miles 3.861 x 10 (-7)
meter miles (stat.) 0.000621 sq. miles sq. ft. 27.88 x 10 (6)
rod ft. 16.5 sq. miles acres 640.0
mile (stat.) ft. 5,280. sq. miles sq. kms. 2.590
mile (stat.) yd. 1,760. acre sq. ft. 43,560.0
mile (stat.) km 1,609 acre sq. miles 0.001562
furlong ft. 660.0
furlong rods 40.0
furlong ft. 6.0
furlong meters 1.828804
league miles (appx) 3.0
light years miles 5.9 x 10 (12)

TO CONVERT TO:
Celsius ºC = 5/9 (ºF - 32)
Fahrenheit ºF = 9/5 ºC + 32
Kelvin ºK = ºC + 273.15
Rankin ºR = ºF + 459.67

25
POWER AND FLOW CONVERSION PRESSURE CONVERSIONS
To Convert To Multiply To Convert To Multiply
Unit (1) Unit (2) Unit (1) by: Unit (1) Unit (2) Unit (1) by:
Hp hp. (metric) 1.014 PSI Atm. 0.06804
hp watts 745.7 PSI ft. H2O 2.307
hp ft. lbs./min. 33,000.0 PSI kgs./sq. cm. .07031
hp BTUs/min. 42.44 Atm. ft. H2O 33.90
BTU ft. lbs. 778.26 Atm. PSI 14.70
BTUs/min. hp. 0.02356 Atm. kgs./sq. cm. 1.0333
BTUs/min. watts 17.57 ft. H2O Atm. 0.02950
watt hp. .001341 ft. H2O PSI 0.4335
watt BTU/min. 0.05692 kgs./sq. cm. PSI 14.22
watt ft. lbs./min. 44.26
kw/hr. ft. lbs. 2.655x10(6)
kw/hr. BTU 3415
gpm cfm .13368
gpm liters/min. 3.7848
l/m gpm .26418
l/m cfm .035316
cfm gpm 7.48
cfm liters/min. 28.32
ft. lbs./min. hp. 3.030x10(-5)
ft. lbs./min. BTU/min. .001286

VOLUME CONVERSION WEIGHT CONVERSIONS

To Convert To Multiply To Convert To Multiply
Unit (1) Unit (2) Unit (1) by: Unit (1) Unit (2) Unit (1) by:
ozs. app.. drops (oil) 600. ozs. lbs. 0.0625
ozs. cu. in. 1.805 ozs. grains 437.5
ozs. liters 0.02957 ozs. grains 28.349527
cu. in. app.. drops (oil) 330.0 grams ozs. 0.03527
cu. in. gallons .004329 grams lbs. 0.002205
cu. in. liters 0.01639 grams/liter lbs./cu. ft. 0.062427
cu. in. cu. meter 0.02832 ft. H2O lbs./sq. ft. 62.43
cu. in. liters 28.32 lbs. ozs. 16.
cu. in. gallons 7.48052 lbs. grams 453.5924
quart liters. .9463 lbs. grains 7,000.0
gallons quart 4.0 lbs. tons (short) 0.0005
gallons cu. in. 231. lbs./in. grams/cm. 178.6
gallons cu. ft. 0.1337 lbs./ft. kgs./meter 1.488
gallons liters 3.785 lbs./cu. in. grams/cu. cm. 27.68
gal. H2O lb. H2O 8.3453 lbs./cu. ft. kgs./cu. meter 16.02
liter quart 1.057 lbs. H2O gallons 0.1198
liter gallon 0.2642 lbs. H2O cu. ft. 0.01602
liter cu. in. 61.02 kgs. lbs. 2.205
barrel gallons (oil) 42.0 kgs. tons (short) 0.001102
barrel gallons 31.5 tons (short) lbs. 2,000.0
tons (short) kgs. 907.18486
tons (short) tons (long) 0.89287
tons (long) lbs. 2,240.
tons (long) kgs. 1,016.
tons (long) tons (short) 1.12000
26