SSETPM2 Coursebook

Subsea Engineer Training Programme
Module 2
Author: Jaap Peetsold
For further information regarding ModuSpec Training, please contact the author.
Gapingseweg 1a
4353 JA Serooskerke
Tel.: +31 118 563050
Fax: +31 118 563055
Email: moduspec@moduspec.com
Website: www.moduspec.com
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2
Module 2 - Introductory chapter 1.0
Module 2 - Table of contents
Agenda .............................................................................. 6
1 Ram preventers ................................................................. 7

1 Repetition module 1 .............................................................. 9
2 Cameron type-U BOPs ......................................................... 11
3 Cameron type-U ram preventer............................................. 12
4 Cameron type U-II ram preventers ........................................ 13
5 Cameron type-T and type-TL ram preventer ........................... 14
6 18¾ inch Cameron TL-type ram BOP specifications .................. 16
7 Cameron types U and U-II ram BOPs ..................................... 17
8 Cameron Wedgelock operation.............................................. 18
9 Balance chambers for Cameron U-II ram preventers ................ 20
10 Filling the wedgelock balance chamber ................................... 21
11 Operation of the ST-Locks of the Cameron T-type preventer...... 22
12 Cameron RamLocks............................................................. 27
13 Closing ratio Cameron BOPs ................................................. 45
14 Testing the hydraulic circuits of Cameron BOPs ....................... 46
15 Testing the bore of Cameron BOPs ........................................ 47
16 Cameron variable-bore rams ................................................ 50
17 Cameron-type data VBRs and FlexPackers .............................. 51
18 Cameron shear/blind rams ................................................... 55
19 Bonnet bolts....................................................................... 57
20 Operation, care and maintenance of hydraulic bonnet studs of
the Cameron U-II BOP ......................................................... 59
21 Hydril ram-type BOPs .......................................................... 62
22 Fundamental differences between Hydril and Cameron
ram-type preventers ........................................................... 63
23 Ram blocks and fixed pipe rams ............................................ 64
24 Front packer operation......................................................... 65
25 Upper seal operation ........................................................... 68
26 Fixed pipe rams .................................................................. 69
27 Specifications Hydril ram preventers ...................................... 74
28 Cavity clearances Hydril BOPs ............................................... 75
29 Hydril variable-bore rams..................................................... 76
30 Hydril shear/blind ram operation ........................................... 81
31 Hydril 15M BOP ram bonnets ................................................ 89
32 Cylinder seals of Hydril BOP.................................................. 94
33 Hydril standard bonnet door seals ......................................... 98
34 Hydril low-torque modification .............................................100
35 Hydril 15M BOP ram cavities ................................................102
36 Ram cavity measurements ..................................................104
37 Hydril MPL automatic ram locking for conventional BOPs..........105
38 Shaffer ram-type BOPs .......................................................117
39 Ram packer pressure..........................................................122
3
40 Shaffer ram blocks and fixed pipe rams ................................ 123

41 The shaffer SLX ram .......................................................... 126
42 Shaffer elastomer operation temperature limits ..................... 129
43 The shaffer hydraulic circuit ................................................ 131
44 The NXT double-ram BOP ................................................... 133
45 The shaffer shear/blind and shear rams ................................ 134
46 Shaffer multirams (VBRs) ................................................... 138
47 Shaffer ram-locking systems ............................................... 140
48 Shaffer ultralock systems ................................................... 144
49 Table of figures ................................................................. 157
2 Annular preventers......................................................... 163

1 Hydril GL preventers .......................................................... 164
2 Shaffer spherical annular preventers .................................... 179
3 Table of figures ................................................................. 196
3 Gate valves on the BOPs ................................................. 199

1 Subsea gate valves - choke and kill valves ............................ 200
2 Fail-safe open valves ......................................................... 203
3 Balanced and unbalanced valves.......................................... 204
4 Standard and pressure assist systems .................................. 206
5 Force diagram................................................................... 208
6 Cavity liquid lock with unbalanced valves .............................. 210
7 Charts of subsea gate valves............................................... 212
8 Cameron gate valves ......................................................... 213
9 Cameron A-type and AF-type valves .................................... 214
10 Cameron type-DF valves .................................................... 217
11 Cameron MCS-type valve ................................................... 221
12 WOM gate valves .............................................................. 224
13 McEvoy valves .................................................................. 228
14 McEvoy sealant compound .................................................. 232
15 Shaffer gate valves............................................................ 235
16 Table of figures ................................................................. 239
4 Hydraulic connectors ...................................................... 241

1 Subsea wellhead and riser hydraulic connectors ..................... 242
2 The Vetco H-4 connector .................................................... 247
3 Cameron hydraulic connectors............................................. 259
4 The Cameron model 70 collet connector ............................... 259
5 The Cameron HC collet connector ........................................ 266
6 Cameron mini connectors ................................................... 268
7 Checking the proper operation of the Cameron mini connector . 270
8 Cameron connectors omparison........................................... 272
9 Cameron deepwater collet connector .................................... 279
10 Table of figures ................................................................. 283
4
5 Manifolds, chokes and valves ..........................................285

1 Layout of the choke and kill manifolds...................................286
2 Target or no target, lead plug or no lead plug? .......................288
3 Mud/gas separator .............................................................292
4 Table of figures..................................................................307
6 Hydraulic control systems ...............................................309

1 The main hydraulic supply...................................................310
2 Regulator pilot circuits ........................................................314
3 Operation of a three-position function ...................................316
4 Operation of a two-position function .....................................320
5 The operation of the straight-through function .......................323
6 Typical hydraulic pilot supply system ....................................325
7 Typical hose reel manifold function operation .........................327
8 De-activating the pod hose reel manifold after landing BOPs or
securing them on test stumps ..............................................329
9 Manipulator valves and selector valves..................................330
10 The accumulator isolator function operation ...........................333
11 Introduction to regulators ...................................................335
12 Operation of the increase/decrease function...........................341
13 Electrical operation: typical two-position function ...................343
14 Electrical operation of a typical three-position function ............344
15 Memory circuit...................................................................346
16 The pressure transducer circuit ............................................348
17 The lamp test ....................................................................349
18 Hydraulic BOP control system: general..................................350
19 Cameron valves .................................................................380
20 Table of figures..................................................................393
7 Fuzzy maths....................................................................395
1 Fuzzy maths introduction ....................................................396
2 Accumulator volume calculation for surface bottles .................397
3 Subsea accumulator bottles volume calculation ......................400
4 Calculating the poorboy degasser mud seal............................403
5 Increase of closing pressure for Ram BOPs in deep water.........405
6 Calculations for flushing times of rigid conduit lines.................406
7 Calculations for ton cycles for the riser tensioners...................407
8 Compressibility calculations .................................................408
9 Calculations riser space-outs ...............................................411
10 Exercises fuzzy maths ........................................................420
11 Table of figures..................................................................424
8 Marine riser systems .......................................................425

1 Vetco marine risers ............................................................426
2 Table of figures..................................................................460
5
Day Time Activity
Monday 08.30 Introduction

08.45 Entry Exam Module 2
12.00 Lunch break
13.00 Ram preventers level 2
14.30 Coffee break
14.45 Ram preventers Level 2
16.00 Close
Tuesday 08.30 Ram preventers Level 2

10.00 Coffee break
12.00 Lunch break
14.30 Coffee break
14.45 Annular preventers level 2
16.00 Close
Wednesday 08.30 Gate valves on the BOPs level 2

10.00 Coffee break
10.15 Choke and kill manifold level 2
12.00 Lunch break
13.00 Hydraulic connectors level 2
14.30 Coffee break
14.45 Hydraulic control systems level 2
16.00 End
Thursday 08.30 Hydraulic control systems level 2

10.00 Coffee break
10.15 Hydraulic control systems level 2
12.00 Lunch break
13.00 Fuzzy maths level 2
14.30 Coffee break
14.45 Fuzzy maths level 2
16.00 End
Friday 08.30 Marine riser systems level 2

10.00 Final exam
12.00 Lunch break
13.00 Final exam
16.00 End of the course/evaluation
6
Module 2 - 01 Ram preventers 1.0
Chapter 01
Ram preventers
1. Repetition module 1................................................................... 9

2. Cameron type-U BOPs.............................................................. 11
3. Cameron type-U ram preventer ................................................. 12
4. Cameron type U-II ram preventer.............................................. 13
5. Cameron type-T and type-TL ram preventer................................ 14
6. 18¾ inch Cameron TL-type ram BOP specifications ...................... 16
7. Cameron types U and U-II ram BOPs ......................................... 17
8. Cameron Wedgelock operation .................................................. 18
9. Balance chambers for Cameron U-II ram preventers .................... 20
10. Filling the wedgelock balance chamber ....................................... 21
11. Operation of the ST-Locks of the Cameron T-type preventer .......... 22
12. Cameron RamLocks ................................................................. 27
13. Closing ratio Cameron BOPs...................................................... 45
14. Testing the hydraulic circuits of Cameron BOPs............................ 46
15. Testing the bore of Cameron BOPs............................................. 47
16. Cameron variable-bore rams..................................................... 50
17. Cameron-type data VBRs and FlexPackers .................................. 51
18. Cameron shear/blind rams........................................................ 55
19. Bonnet bolts ........................................................................... 57
20. Operation, care and maintenance of hydraulic bonnet studs of the
Cameron U-II BOP................................................................... 59
21. Hydril ram-type BOPs .............................................................. 62
22. Fundamental differences between Hydril and Cameron ram-type
preventers ............................................................................. 63
23. Ram blocks and fixed pipe rams ................................................ 64
24. Front packer operation ............................................................. 65
25. Upper seal operation................................................................ 68
26. Fixed pipe rams ...................................................................... 69
27. Specifications Hydril ram preventers .......................................... 74
7
28. Cavity clearances Hydril BOPs....................................................75

29. Hydril variable-bore rams .........................................................76
30. Hydril shear/blind ram operation................................................81
31. Hydril 15M BOP ram bonnets .....................................................89
32. Cylinder seals of Hydril BOP ......................................................94
33. Hydril standard bonnet door seals ..............................................98
34. Hydril low-torque modification ................................................. 100
35. Hydril 15M BOP ram cavities.................................................... 102
36. Ram cavity measurements ...................................................... 104
37. Hydril MPL automatic ram locking for conventional BOPs ............. 105
38. Shaffer ram-type BOPs ........................................................... 117
39. Ram packer pressure ............................................................. 122
40. Shaffer ram blocks and fixed pipe rams .................................... 123
41. The shaffer SLX ram .............................................................. 126
42. Shaffer elastomer operation temperature limits.......................... 129
43. The shaffer hydraulic circuit .................................................... 131
44. The NXT double-ram BOP........................................................ 133
45. The shaffer shear/blind and shear rams .................................... 134
46. Shaffer multirams (VBRs) ....................................................... 138
47. Shaffer ram-locking systems ................................................... 140
48. Shaffer ultralock systems........................................................ 144
49. Table of figures ..................................................................... 157
8
1. Repetition module 1
• Ram preventers have large amounts of rubber closing around the pipe.
Small sections of rubber that are missing from the front packers will not
affect the sealing characteristics of the rams.
• Pipe rams cannot be closed to an open hole, as the anti-extrusion plates
on top and bottom of the ram packers will be damaged (unless the
closing pressure is very low, say 300 psi only).
• The internal pressures generated inside the ram elastomers can be
several million pounds per square inch. The internal pressures inside the
elastomers must ALWAYS be bigger than the wellbore pressure!
• Shear blind rams are ONLY designed to shear drill pipe and perform a
CSO. They are NOT designed to shear drill pipe tool joints, heavyweight
pipe, drill collars or casing tubulars.
• Super shear rams and some casing shear rams are designed to shear
either heavyweight pipe or casing, but cannot perform a CSO.
• Variable-bore rams are not designed to hang off the drill strings. Only a
limited weight can be hung off on a variable-bore ram. Variable-bore
rams are not rated for high-temperature operations.
• Wear at the cavity top will have a considerable effect on the low-
pressure abilities of the sealing, as the wellbore pressure assists in
maintaining a seal for the top seals.
• The wellbore pressure should always be completely bled off before the
rams are opened. The best method is to first open the gate valves on the
choke and kill line located beneath and above the ram blocks on the BOP
stack.
• The closing ratio is the minimum hydraulic operator pressure required to
close the ram BOP against the full working pressure. This is different for
each ram BOP, depending on its manufacturers. On high-pressure ram-
type BOPs this pressure can be much higher than the famous 1,500 psi
(the Cameron 15M T-type = 2,239 psi, the Shaffer 15M SL-type = 2,109
psi and the Hydril 15M type = 2,083 psi).
• The majority of the pipe rams have a stellite inlay installed in the hang-
off area on top of the ram blocks.
• The rams on subsea BOP stacks of 18¾ inch and larger should close
within 45 seconds (as per API) or within 30 seconds (as per NPD).
• Hydril and Shaffer ram-type BOPs have automatic locking systems and
are ALWAYS energized when the rams are closed. Older Cameron BOPs
have a wedgelock system, which requires extra spm valves and many
hydraulic extra hoses; they are only activated after the wedgelocks have
been PURPOSELY SELECTED BY the user. Newer Cameron BOPs either
use RamLocks or ST-Locks, which can also be used in automatic mode.
• Ram blocks and ram cavities require frequent measurements in order to
determine the clearances between the cavity and the blocks; these
clearances must be compared to a OEM-supplied maximum-allowable
wear value unique for each type of ram. Some type of rams will even
have other wear figures for one and the same BOP (for example the
Shaffer SLX pipe rams and the blind shear rams).
• Ram blocks, bonnet bolts and the ram piston hubs require frequent NDT
inspections for cracks.
9
• The tell-tale holes on the bonnets need to be open to prevent the bore
pressure from entering the hydraulic side of the bonnets. If these tell-
tale holes are blocked or if the check valves are stuck, it is possible to
put 10,000/15,000 psi on the hydraulic side of the BOP.
• Emergency ram shaft seals are NEVER used on subsea stacks. Frequent
inspections are required to ensure that the seals have not been
energized in the past. Scored piston rods can be the result of energizing
these emergency seals.
• The Spirilox ring recess can be worn at the mud seal at the ram bonnets,
preventing the lock ring from supplying adequate protection in order to
stop the mud seal from protruding from the intermediate flange (on
Cameron-type BOPs).
• Shaffer and Hydril ram-type BOPs have hydraulic lines passing through
the hinges. For this reason the rams can be operated with the bonnet
doors open, but great care should be taken not to damage the ram body
flanges. It is not recommended to operate Hydril ram-type BOPs without
the ram blocks installed.
Figure 1 - Cameron TL BOP with ST-Locks installed.
10
2. Cameron type-U BOPs

The most commonly encountered BOPs in the industry for land rigs and jack-
up rigs are the Cameron BOPs of the U-type. For subsea applications, the
Cameron types TL and U-II are used, but some older rigs still use Cameron
U-type ram BOPs.
The newer Cameron TL BOPs have either Cameron ST Locks or RamLocks
installed, which are designed for HT/HP applications and are mostly
delivered for subsea applications of 15M BOPs. Several problems have been
encountered while using Cameron automatic locking systems, which we will
discuss in detail.
All the Cameron BOPs have the same characteristics, namely:
1. A Power Ram Change (abbreviated: PCR) system. This is a hydraulic
circuit, which enables the BOP to be hydraulically opened. The control
fluid passes inside the body and is used not only for operating the rams,
but also for opening/closing the bonnets during ram changes or cavity
inspections.
2. Internal hydraulic porting. The hydraulic opening pressure first draws
the ram pistons back into the bonnet and then draws the bonnet against
the body (the rams OPEN pressures are cause the bonnets to close and
rams CLOSED pressures cause the bonnets to open).
3. Four bonnet bolts or bonnet studs per bonnet side are installed.
4. The standard locking system is constructed of a technically simple
system known as wedgelocks. This is a two-step locking system that
does not automatically operate and requires additional hoses and
function valves.
5. The ram cavities run parallel at the top and bottom.
6. Both the ram body and the bonnets are made of forged steel.
7. For Cameron BOPs there are large bore bonnets available for the shear
blind rams and for the super shear rams providing an additional shear
force (F = P x A).
8. All the Cameron ram-type BOPs have a constant contact between the
ram blocks and the ram cavities during the complete stroke of the rams.
Consequently, we have to remove the ram blocks during a low-pressure
test of the bonnet hydraulic seals. The constant friction between the top
and sides of the cavity and the ram blocks would prevent the ram
pistons from moving freely. We have to perform the hydraulic seal
integrity test of the bonnets with a pressure of no more than 300 psi.
Figure 2 - Cameron U-II with open bonnets.
11
3. Cameron type-U ram preventer
Figure 3 - Cameron type-U preventer with manual locks (which are

only used for surface BOP applications).
Specifics of the Cameron type-U ram BOPs

1. Most Cameron U-type BOPs have standard bonnet bolts connected;
these are heavy and very time-consuming to make up or break out while
using the famous Cameron “lightweight” spanners and hydraulic torque
tools.
2. Cameron U-type BOPs can be fitted with hydraulic bonnet bolts, which
require high pressures for each bonnet bolt to be pre-tensioned. The
pressure to stretch the stud is 30,000 psi. Special hydraulic pumps,
fittings and hoses are required.
3. Plastic ram shaft packings and weep holes are standard, even on subsea
BOPs. However, never use the plastic packing on subsea stacks. Ensure
that the weep holes are not blocked with debris; some BOPs have check
valves installed inside the weep holes.
4. They are all equipped with face seal-type bonnet seals. Newer Cameron
bonnets and ram bodies have stainless-steel inlays that prevent pitting
at the sealing areas.
5. The balance chamber is mounted underneath the wedgelocks.
Cameron type U specifications
Size Working Fluid open Fluid close Closing Opening

(inches) pressure (psi) (US gallons) (US gallons) ratio ratio
16-3/4 10,000 11.6 12.5 6.8: 1 2.3: 1
18-3/4 10,000 21.3 23.1 7.4: 1 3.7: 1
12
4. Cameron type U-II ram preventer
Figure 4 - The Cameron type U-II ram preventer.
Specifics of the Cameron type U-II ram BOP

1. Hydraulic bonnet studs are installed, which are pressurized from a
central connection installed at the ram body (30,000 psi is required to
pre-tension the studs).
2. The bonnet stroke is shorter than the one for the Cameron Type U,
allowing ram changes in restricted spaces.
3. Eight bonnet studs for two opposite bonnets are pre-tensioned at the
same time.
4. Subsequently, the nuts can be unscrewed manually.
5. Plastic ram shaft packing and weep holes are standard.
6. Equipped with bore-type bonnet seals.
7. The balance chamber is located underneath the wedgelocks.
8. After the hydraulic pressure on the studs has been released, a precise
tension is left on each tension bolt equal throughout all eight bonnet
bolts on both sides of the bonnets.
Cameron type U-II specifications
Size Working Fluid Open Fluid close Closing Opening

(inches) pressure (psi) (US gallons) (US gallons) ratio ratio
18-3/4 10,000 22.3 24.7 6.7: 1 2.5: 1
18-3/4 15,000 32.3 34.7 9.3: 1 3.5: 1
13
5. Cameron type-T and type-TL ram

preventer
Figure 5 - Cameron type T ram preventer with ST-Locks installed.
Specifics of the Cameron type-T ram BOPs

1. Shorter overall height, different rams packers and top seals.
2. Hydraulic bonnet studs, similar to the U-II type.
3. Replaceable wear pad fitted on the bottom of the ram blocks.
4. An ANSI 4130 annealed metallic bonnet seal (TX gasket) is installed.
5. No intermediate flange like the Cameron type-U and U-II BOPs.
6. Balance chambers are not provided for the wedgelocks.
7. The ram blocks can be removed from the side instead of from the top.
8. Most Cameron type-T preventers have automatic ST-Locks. Unlike the
wedgelock, the ST-Lock is self-locking.
Cameron Type-T specifications
Size Working Fluid open (US Fluid close (US Closing Opening
(inches) pressure gallons) gallons) ratio ratio
(psi)
18-3/4 15,000 22.2 24.2 6.7: 1 3.1: 1
14
Figure 6 - 18-3/4 inch 15M Cameron TL-type ram BOP with

RamLocks.
Specifics Cameron type-TL ram BOPs

• Most operating system seals can be replaced with the bonnet in the ram-
change position without removing the bonnets, because the operating
cylinder and ram- change cylinders fit between the bonnet and end
flange with tie-bolts holding the assembly together.
• Access caps on the ram change pistons enable easier access from the
end of the bonnet.
• The bonnet seal carrier eliminates the need for high make-up torque on
bonnet studs and nuts.
• Tandem boosters are available to shear large, extra-heavy casing.
• Super shear ram bonnets and non-sealing super shear rams are
available for shearing drill collars and heavy-wall drill pipe.
15
6. 18¾ inch Cameron TL-type ram BOP

specifications
Cameron TL BOPs with RamLocks
BOP size/ WP Closing volume Opening volume Opening

Closing ratio
(psi) (US gallons) (US gallons) ratio
18¾”/10,000 21.3 19.3 10.89: 1 3.13: 1

18¾”/15,000 25.9 22.3 7.13: 1 3.10: 1
Cameron TL BOPs with Wedgelocks
BOP size/ WP Closing volume Opening volume Closing Opening

(psi) (US gallons) (US gallons) ratio ratio
18¾”/15,000 24.6 23.4 6.7: 1 3.1: 1

Note: Wedgelock opening 5.75 US gallons.
Cameron TL BOPs with ST-Locks
Closing volume Opening volume Closing Opening

BOP size/ WP
(US gallons) (US gallons) ratio ratio
8¾”/10,000 24.6 23.4 6.7: 1 3.1: 1

8¾”/15,000 24.6 22.3 6.7: 1 3.1: 1
Note: ST-Lock locking 3.4 US gallons.

Cameron TL BOPs with ST-Locks and tandem boosters

18¾”/15,000 45.4 54.1 14.3: 1 6.9: 1
Note: ST-Lock locking US 3.4 gallons.

Cameron TL BOPs with super shear rams

18¾”/15,000 71.3 67.1 17.3: 1 8.9: 1
Figure 7 - Cameron TL blind-shear rams with wear plates suitable

for H2S.
16
7. Cameron types U and U-II ram BOPs

Inspection criteria
• The depth of the bonnet seal slot is to be measured and inspected. The
piston hub, bonnet bolts and the ram blocks require an NDT inspection
(MPI).
• Carry out cavity measurements with an internal micrometer at three
spots placed 4 inches from the bore (a 0.060-inch clearance between the
ram block and the top of the cavity is the maximum height; a 0.080-inch
clearance between the ram block and the side of the cavity is the
maximum width).
• Perform height measurements of the ram blocks on the left- and right-
hand side.
• In order to measure the clearance between the block and the cavity, it is
possible to install the ram blocks (without the top seals) inside the ram
bore and use feeler gauges to measure the gap. The ram blocks should
be installed in the cavity by hand and must not be supported by the ram
change piston rod.
• A visual inspection of the cavity must be performed, especially at the top
of the cavity. Cameron does not supply score criteria for the cavities, but
deep longitudinal scoring will affect the sealing abilities of the rams,
especially with the low-pressure sealing.
• Conduct an inspection of the Colmanoy coating of the ram pistons and
the ram change pistons.
• Inspect the bore, measure the ID and look for possible key seating. The
maximum damage allowed by Cameron is (0.188 inch + 0.031 inch) =
0.219 inch (just about ¼ inch).
• Visually inspect the ram blocks and measure the flatness on the aft side,
the maximum deformation allowed is 0.020 inch.
• Measure the flatness of the bonnet and intermediate flange; the
maximum gap in each direction should not exceed 0.015 inch.
• Measure the hardness of the bonnet (maximum 235 BHN, minimum 156
BHN).
• Measure the hardness of the intermediate flanges (maximum 235 BHN,
minimum 137 BHN).
• Measure the hardness of the ram blocks (maximum 258 BHN).
• Check the operation of the ram locking system.
Figure 8 - Cameron U-II hydraulic control system.
17
8. Cameron Wedgelock operation
Closing the wedgelocks

1. Close the rams with a closing pressure of minimum 1,500 psi.
2. As soon as the rams are fully closed, close the wedgelocks with a closing
pressure of 1,500 psi.
3. After the wedgelocks are fully closed, the closing pressure of the rams
can be bled off.
4. The rams are now locked in the closed position and cannot be opened
before the wedgelocks are opened, allowing the ram piston to travel.
5. The rams should hold the full wellbore pressure assisted by the
wedgelocks only and with the closing pressure of the rams completely
bled off.
Opening the wedgelocks

1. First the closing pressure to the ram must be applied. When the rams
are put in ‘block’, the pistons have a tendency to ‘relax’ slightly.
However, the wedgelocks will prevent this. There will be contact with the
ram piston tail rod and the wedgelock cone. If ram-closing pressure is
not applied and opening pressure is applied to the wedgelock piston, the
wedgelock will not open; damage to the wedge and the tail rod of the
rams can be the result.
2. Only after the ram closing pressure of 1,500 psi is reached, the opening
pressure of the wedgelocks can be applied.
3. After taking ample time for the wedgelocks to be fully opened, the rams
can be opened. Be patient and allow at least one full minute.
4. Balance chambers with diaphragms are installed to the close side of the
wedgelocks in order to equalize the hydrostatic.
Figure 9 - Severely damaged tail-rod by the wedgelock caused by

human error!
18
Figure 10 -
Wedgelock
components.
Figure 11 -
Wedgelock
open.
Figure 12 -
Wedgelocks
closed.
Figure 13 -
Wedgelock
and tail rod in
the open
position.
19
9. Balance chambers for Cameron U-II

ram preventers
(Source: Cameron Equipment Bulletins Nos. 533D and 575D)

The wedgelock pressure balance system prevents the risk that the
unbalanced hydrostatic head pressure of the operating fluid might unlock the
wedgelocks. This phenomenon occurs in water depths exceeding 150 feet!
All the Cameron U-type BOPs and the Cameron U-II BOPs wedgelocks are
fitted with pressure balance chambers. With this system the wedgelock
housing is filled with lubricant (pure soluble oil), which is then connected
with a volume of the same lubricant within the diaphragm of the pressure
balance chamber.
Since seawater comes in direct contact with the outer side of this
diaphragm, the fluid of the wedgelock housing has the same pressure as the
surrounding seawater, which balances the hydrostatic head of the operating
fluid on the opening side of the wedgelock piston. This ensures that the
wedgelock will not unlock unless wedgelock unlock pressure is
applied from the surface.
Figure 14 - A tail rod showing severe damage after a collision with

the wedgelock.
20
10. Filling the wedgelock balance chamber
Figure 15 - Cameron U-II preventer installed with a wedgelock

installed.
Filling instructions for the wedgelock pressure balance unit.

Step 1: Fully unlock the wedgelocks; then fully open the rams.
Step 2: Remove the plug from the air bleed fitting port ‘Y’ located at the top
of the balance chamber.
Step 3: Fill the system with soluble-oil fluid through port ‘X’ on top of the
lock side of the wedgelock housing until the lubricant begins to flow out of
port ‘Y’. Continue to fill port ‘X’ until the wedgelock housing is completely
full.
Step 4: When the wedgelock housing is full, reinstall the ½-inch pipe plug in
port ‘X’ and check the system for leaks by first closing the rams, then
locking the wedgelocks, followed by unlocking the wedgelock and finally
opening the ram preventer. Check for possible leaks at the fitting and the
seawater entrance holes.
Note: Ensure that you give the rams enough time to build up pressure and
that you give the wedgelocks at least one minute to either open or close.
Patience is the keyword here!
21
11. Operation of the ST-Locks of the

Cameron T-type preventer
ST-Locks form the locking mechanism on the T-type preventer and are
different from the normal wedgelock system. The lock features a short
wedge piston with a larger taper angle. Unlike the wedgelock, the ST-Lock is
not self-locking.
The ST-Lock’s wedge piston is held in place against the end of the tail rod by
means of an overhauling nut, a stem and a one-way clutch arrangement.
When independent lock pressure is applied, the locking stem moves into
position against the end of the tail rod. The overhauling nut and brake hub
assembly rotates in order to accommodate this movement, as the clutch
teeth have a buttress thread profile. The clutch teeth are held in the
engaged position by means of springs located in the brake ring.
The ST-Lock’s unlocking feature is integral with the ram's hydraulic opening
system in such a way that the ram opening and the ST-Lock’s unlocking
feature are sequenced as the same function (i.e. automatic unlock). The
opening pressure is piped into both sides of the wedge piston and into the
unlock piston port. The unlock piston moves the brake ring out of
engagement with the brake hub, thus permitting the wedge and stem
assembly to move to the unlock position.
The original T-type preventers had type-T locks installed. A retrofit is
available in order to change the type-T locks into type ST-type locks. The
retrofitted ST-type locks are compatible with fixed pipe rams, variable-bore
and shear blind rams and are suitable for hang-off or stripping purposes with
the type-T preventers.
Figure 16 - ST-Lock ram is closed but the wedge is not locked yet.
22
Figure 17 - The ST-Locks in the ram-closed and the ram-open

position.
23
BOPs equipped with the ST-Lock locking mechanism can be functioned in

two ways:
1. Fully automatic mode
In this mode the BOP will be automatically locked after initiating the CLOSE
cycle of the BOP. ST-Locks will work concurrent with the normal OPEN and
CLOSE function of the BOP. The ST-Lock hydraulics is supplied via hosing or
tubing that is fed directly from the BOP-operating piston chambers.
After initiating the CLOSE sequence, the main piston will stroke forward.
Control fluid will be staged at the lower sequence valve, waiting for the main
piston to trigger its flow to the ST-Lock. Only after closing the main piston is
the ST-Lock allowed to engage.
Initiating the OPEN sequence will cause control fluid to be initially directed to
the UNLOCK and OPEN ports of the ST-Lock. Control fluid will be staged at
the end cap sequence valve waiting for the trigger that indicates that the
ST-Lock is fully open.
After triggering the end cap sequence valve, control fluid is directed to the
OPEN side of the main piston, causing the BOP to open.
For this operating mode, control valves and hydraulic hoses measuring ¾
inch, 1 inch and 1-1/2 inch are normally used. Closing times of the BOP are
directly affected by the sizes of these function valves and supply hoses. Flow
rates of 60 gpm or more are required to accomplish a closure in the API-
required 30 seconds for surface BOPs or 45 seconds for subsea BOPs.
Figure 18 - ST-Lock in detail, before locking the ram.
24
2. Semi-automatic mode (manual lock): automatic unlock and open

In this mode the operator can choose whether or not to create a lock after
initiating the CLOSE function of the BOP. The automatic lock function of the
ST-Lock is isolated from the hydraulic supply of the close function (by means
of a pipe plug installed in the cylinder head). A separate function is then
supplied from the control system directly to the LOCK port of the operator.
Experience has shown that for an efficient operation of the ST-Lock a
minimum of a ½ inch valve and supply hose should be used. This will
eliminate the need for any quick-dump valve associated with the use of
smaller control valve, which invariably causes unwanted backpressure within
the system during operation, potentially causing damage to the BOP-
operating system components. Flow rates for the independent LOCK lines
should be 20 gpm or more to reach a LOCK in 5 to 7 seconds.
For shear ram and or emergency disconnect systems the LOCK function may
be automatically initiated through the control system software using a time-
out function.
If the lower sequence valve that controls the automatic LOCK function is in
place, a time-out may not be necessary, as control fluid from the separate
LOCK function will be staged at this valve and allowed to lock after the lower
sequence valve has been triggered.
Figure 19 - ST-Lock in detail, before locking the ram.
25
Figure 20 - Locking rings of the ST-Lock in detail.
Figure 21 - ST-Lock sequence valve.
26
12. Cameron RamLocks

(Source: Cameron Equipment Bulletin No. 870)
BOPs equipped with the Cameron RamLock locking mechanism may be
operated in a number of ways. Currently there are three systems available:
Manual: CLOSE/LOCK/UNLOCK/OPEN
Semi-Automatic: CLOSE and LOCK/OPEN
Automatic: CLOSE and UNLOCK and OPEN
The RamLock mechanism is a friction-locking mechanism in compliance with
the original Wedgelock mechanism. When closing the main piston, the
UNLOCK piston must be hydraulically restrained by either the continuous
supply of pressure, or by blocking or checking the UNLOCK volume within
the internal chamber of the main operating piston by use of a sequence
valve.
1.0 Manual mode
When controlled manually, the BOP requires OPEN and CLOSE valves and
related hoses, similar to the ST-Lock. The OPEN and CLOSE valves should be
¾ inch, 1 inch or 1½ inch valves and must be suitably coupled with
equivalent-sized hoses or plumbing.
The LOCK/UNLOCK function is driven by a single control valve as opposed to
the original Wedgelock system, which required two valves for the
LOCK/UNLOCK functions. The LOCK function of the RamLock is reached by
the same CLOSE function hydraulic supply as the main BOP piston. In order
to effect a LOCK, the hydraulic supply to the UNLOCK chamber must be
vented or released. This will allow the LOCK to engage, as it is driven by tye
CLOSE function hydraulic supply.
Obviously, a LOCK should not be attempted until the BOP has completed its
closure, as simultaneous closing and locking will reduce closing force and
may not fully compress the ram packers. Secondary to this, the
simultaneous closing and locking may gall or damage the internal
components of the RamLock.
Figure 22 - Cameron RamLock.
27
After closing and locking, and prior to opening the BOP, the RamLock must
first be unlocked. This is achieved by supplying hydraulic fluid and applying
pressure to the UNLOCK side of the Locking piston. This valve should again
measure at least ½ inch. However, a ¾- or 1-inch valve would be desirable,
as this would ultimately improve the efficiency of the RamLocks.
When unlocking, the UNLOCK piston reacts better to increased flow and
volume, as a so-called water hammer effect is obtained. This effect
considerably reduces the amount of pressure required to effect an UNLOCK.
Also, the time required to lock is considerably reduced and the need for a
quick-dump circuit is avoided. Overall, the BOP CLOSE and OPEN functions
should receive at least 60 gpm and the LOCK/UNLOCK circuit 30 to 60 gpm.
2.0 Semi-automatic mode

When set up for semi-automatic operation, the CLOSE/LOCK function is
controlled by the same sequence valve as is employed by the ST-Lock. The
exception is that it is not staging pressure to affect the LOCK, but it is
checking the fluid in the UNLOCK chamber prior to being triggered and
allowing the chamber to vent. The same rules apply to the UNLOCK/OPEN
function as for the manual mode.
3.0 Fully automatic mode

For a fully automatic operation of the RamLocks, the functions may be
controlled either by the control system software (using time-outs) or by
employing the use of pilot-operated check valves (POCVs). The time-outs
should be finalized at the integration of the BOP and the control system, but
as a rule of thumb 25 seconds should be taken for a closure and 10 seconds
for a lock. A time-out of 30 seconds should be used after unlocking the
RamLock, and prior to applying opening pressure.
POCVs should be plumbed in such a manner as to allow quick venting of the
pilot pressure, as this may slow down the sequence of the next function and
cause erratic operation of the RamLock bonnet assembly.
Note 1:
Where POCVs are employed it is recommended that sequence valves be
utilized on all bonnet assemblies for both surface and subsea stacks.
Note 2:
EDS functions can be simplified by the use of sequence valves on shear ram
cavities.
Note 3:
Acoustic functions or auto shear packages require sequence valves in most
cases.
28
Figure 23 - RamLock stage 1: Opening pressure is still applied and

unlocked.
29
Figure 24 - RamLock stage 2: Closing pressure is applied, opening the

fluid vents; the main piston reaches the end of its stroke, and is
still unlocked.
30
Figure 25 - RamLock stage 3: Ram is CLOSED; the whistle pistons and

secondary piston are moving and starting to LOCK.
31
Figure 26 - RamLock stage 4: Secondary piston is bottoming out; the ram

is CLOSED and fully LOCKED by the whistle pistons and LOCK
components.
32
Figure 27 - RamLock stage 5: The RamLock UNLOCK pressure is applied

and the closing fluid is venting; the ram is still CLOSED but starting to
UNLOCK.
33
Figure 28 - RamLock stage 6: Secondary piston at the end of stroke; the

whistle pistons are now free from the LOCKING component. The
ram is still CLOSED but is now fully UNLOCKED.
34
Figure 29 - RamLock stage 7: Fully UNLOCKED; the OPENING pressure is

applied, the CLOSING fluid is venting, the main piston is
moving, and the ram is OPENING.
35
Figure 30 - RamLock stage 8: The OPENING pressure is applied; rams are

now completely OPEN and UNLOCKED.
36
Figure 31 - RamLock in automatic mode. Stage 1: OPENING pressure is

applied.
37
Figure 32 - RamLock in automatic mode. Stage 2: CLOSING pressure is

applied, the fluid vents are OPENED and the main piston is
moving to CLOSE.
38
Figure 33 - RamLock in automatic mode. Stage 3: The ram is CLOSED

but not yet LOCKED; the secondary piston is moving to start
LOCKING and the fluid is vented through the sequence valve.
39

and fully LOCKED.
40
Figure 35 - RamLock in automatic mode. Stage 5: RamLock UNLOCK

pressure is applied, the CLOSING fluid starts to vent; the ram
is still CLOSED.
41
Figure 36 - RamLock in automatic mode. Stage 6: The secondary piston

at the end of its stroke and the whistle pistons are now free
from the LOCKING components. The ram is still CLOSED but
fully UNLOCKED.
42
Figure 37 - RamLock in automatic mode. Stage 7: The ram is fully

UNLOCKED; the OPENING pressure is applied, the CLOSING
fluid is venting, the main piston is moving, and the ram is
OPENING.
43
Figure 38 - RamLock in automatic mode. Stage 8: The OPENING

pressure is applied; the ram is now completely UNLOCKED and
OPEN.
44
13. Closing ratio Cameron BOPs
2239 psi
15,000 psi
2239 psi
Figure 39 - Cameron 15M BOP showing forces for the closing ratio
calculation.
The closing ratio of the BOP is the relation between the bore pressure
multiplied by the piston rod area, divided by the minimum closing pressure
multiplied by the area to which the hydraulic pressure of the bonnets is
applied.
15,000 x area piston rod = The closing ratio

Minimum pressure x (area piston - area tail rod)
The closing ratio for the Cameron T-type BOP is 6.7: 1, which means that
the area of the piston minus the area of the tail rod is 6.7 times as large as
the area of the piston shaft.
For instance, the closing ratio of the Cameron 15M type-T BOP is 6.7: 1. This
means that the minimum hydraulic pressure applied to the bonnets to
hold the full working pressure is 15,000: 6.7 = 2,239 psi.
Question:
How much can this Cameron T-type BOP theoretically hold if a closing
pressure of only 1,500 psi closing pressure is applied?
Note: With this calculation we only look at pressures and dimensions. We do
not take the wellbore assist forces or the top seal friction losses in
consideration.
45
14. Testing the hydraulic circuits of

Cameron BOPs
Figure 40 - Cameron T-type BOP hydraulic circuit.
Testing the hydraulic circuit of the Cameron rams

1. Remove one of the hydraulic control hoses from the shuttle valve.
2. Install the test hose straight on the shuttle valve with a hose from the
test pump that has a pressure chart recorder and a pressure gauge
installed.
3. Ensure that the HPU accumulator bottles are isolated.
4. Pressure-test the hydraulic control system to 300 psi for 5 minutes and
to 3,000 psi for 10 minutes. These pressures are allowed to drop only
slightly and should stabilize rapidly after the test pump has been
stopped and isolated.
5. When leaks are encountered, install a JIC plug on the opposite side of
the shuttle valve to ensure that it is the ram bonnet that is leaking and
not the shuttle valve.
6. When there is any doubt, remove the shuttle valve(s).
7. Check the weep holes and make sure that they are not plugged; check
whether the check valves (if installed) are not frozen.
8. Ensure that the plastic shaft packing is not energized, as most subsea
ram-type BOPs are no longer fitted with emergency packers.
9. Ensure that the pressure charts are to be incorporated into the history
files.
10. Each ram has to be tested to a pressure of 3,000 psi OPEN and CLOSE.
This can be done with the bonnet in the OPEN position. It is not required
to tighten the bonnet bolts, unless the test is performed in extremely
cold conditions, for instance in the Arctic.
When the bonnets are opened and any kind of maintenance is performed,
remove the pod hose junctions from the pod hose reels. This will make it
impossible to accidentally close a ram or a bonnet from the remote-control
panels.
When available, install the aluminium covers over the ram change pistons to
prevent the bonnets from closing. If no aluminium covers are present, tie
logs of wood against the ram change pistons during PM operations.
46
15. Testing the bore of Cameron BOPs
Prerequisites
The BOP is to be filled with water and all bonnet bolts are to be made fully
up. Each ram is to be tested up to 250 psi for low pressure, and up to its full
working pressure for 10 to 15 minutes.
The pipe rams

The rams are to be tested against a drill pipe of the same size as the rams.
Ensure that the test pipe can withstand the external pressures. The rams are
to be closed with a minimum of their closing ratio closing pressure. While
maintaining closing pressure, the ram wedgelock system has to be energized
and locked. Upon completion of the locks engaged, the operating pressure at
the close side of the rams is to be reduced to zero psi.
Subsequently, the bore pressure is to be brought up to 250 psi. If for any
reason the pressure increases too quickly and let’s say 1,000 psi is reached
spontaneously, the low-pressure test cannot be achieved by simply bleeding
off the test pressure to 250 psi. In this case the pressure has to be bled off
to zero psi and again be brought up to 250 psi again (this is an API
regulation).
We have to realize that the low-pressure test is providing vital information
regarding the condition of the top seals and the condition of the cavity.
Higher pressures will disguise the possible flaws due to the strong forces
from the wellbore assist.
After a straight line has been achieved for five minutes, the pressure can be
increased up to the working pressure of the BOP. During the first test it is
good practice to increase the pressure in increments of 1,000 psi and stop
every 1,000-psi step for one minute in order to check for leaks. As small
leaks during high-pressure testing can cause damage to the equipment, it is
preferable to detect the leaks at lower pressures, especially at the AX or VX
wellhead sealing areas.
When the maximum working pressure is reached, the pressure is to be held
for at least 10 minutes. If the pressure is dropping slightly but seems to
stabilize, it can be brought up a few times. Such a pressure drop could be
caused by air. Air in the system will eventually migrate and become
compressed and will NEVER cause a repetitive leak at the same leaking rate.
Air in the system will eventually ALWAYS level out.
After the bore test the wellbore pressure is bled off to zero psi. Ensure that
an adequate amount of fluid is coming back. This fluid is needed because the
pressure has expanded the BOP (!) and we can slightly compress the test
fluids with very high pressures.
If an insufficient quantity of fluid is coming back, it is possible that the test
hose is plugged. When it is not possible to unplug the test hose, try to open
the choke and kill valves to bleed off the pressure.
NEVER VENT TRAPPED BORE PRESSURE BY OPENING THE RAM
PREVENTERS.
47
The force of a 10,000-psi bore pressure in a 18¾ inch BOP is (according to

F = P x A)
10,000 psi x (0.25 x ∏ x 18.75) = 2,761,165.418 lbs. In other words: a
force of more than 2.7 million lbs!
If these forces are applied, it is easy to understand the damage that will
occur on the piston hubs and the ram blocks when the rams are opened with
any bore pressure beneath.
After a successful bore test, the rams require to first receive a minimum of
1,500-psi closing pressure before unlocking the wedgelocks. After the BOP
has been pressure-tested, function the rams again and inspect whether the
rams operate fully by using approximately 500 to 700 psi of operating
pressure.
Figure 41 - Damaged piston hub on a Cameron ram.
Even with low pressures underneath the rams, it is still possible to crack the
piston hubs of the rams. Consequently, we must be 100% certain that all
the pressure is bled off after the completion of the ram testing. The only
reliable manner to ensure that there is no trapped pressure present
underneath the rams is to first open the choke and kill gate valves below
and above the ram, and then open the rams.
Especially when operating in deeper water, the test pressure might be
conveniently vented at the cement unit. As the BOP itself is located a very
long way from the cement unit and subsea, there might be still pressure
present!
48
Question:
What are the forces created by a mere 200-psi pressure on the ram blocks
and piston hubs for a 18¾ inch BOP?
During pressure testing of the Cameron type-U or U-II BOPs, drops are often
coming from the intermediate flanges immediately after we bring up the
pressure. After a while, the dripping stops. Most of the time this is trapped
seawater, which is allowed to vent due to the slight deformation of the BOP
components during testing.
If we want to prove (in order to satisfy a head mong or a surveyor) that
these drippings are NOT coming from the bore, we can use dye to colour the
water in the bore to prove that this water does not come from the bore.
49
16. Cameron variable-bore rams
The variable-bore rams (VBRs) are to be tested in a similar fashion to the

pipe rams, by using the locking system and bleeding off the closing
operating pressure. The variable-bore rams need to be tested first with the
normal drill pipe, which will be 5-inch drill pipe on most rigs. The smallest
drill pipe that the rig will use during the well needs to be tested during the
second test. This is normally a 3½-inch or 2⅞-inch drill pipe.
The top seals of the Cameron variable-bore blocks are different from the top
seals of the pipe rams and should be ordered separately. The ram blocks of
the variable-bore rams are different from the pipe rams. The ram packers
are expensive but will last a long time if they are used in the proper manner.
The variable-bore packers are absolutely NOT suitable for stripping purposes
and only have limited hang-off capacities compared to the pipe rams.
Figure 42 - Cameron T variable-bore rams.
50
17. Cameron-type data VBRs and

FlexPackers
(Source: Cameron Equipment Bulleting No. 859D)
Hang-off with VBRs
Should it become necessary or in the event of an emergency, drill pipe may
be hung on closed and locked rams. Before hanging the pipe, the rams
should be closed with the maximum-available hydraulic pressure up to 3,000
psi, and then “locked in” with the appropriate locking device as determined
by the BOP configuration.
NOTE: Cameron does NOT recommend hanging off pipe in the lower end of
the range of a VBR, FlexPacker, or FlexPacker NR. During the hang-off of
smaller pipe sizes, the load is supported by the packer, not by the ram
block. This way of loading can damage the packer and lead to premature
failure.
Rams manufactured from 1986 onwards have the upper corner of the pipe
cut-out hardened in order to increase their hang-off capacity. Table 4, Table
5 and Table 6 show the documented test results, along with estimates of
hang-off capacity for other sizes and capacities for the VBR, FlexPacker and
FlexPacker NR ram bodies.
Table 4: Available Cameron VBR packers
Type BOP Working pressure Available sizes
(psi)
18¾ inch type U 10,000 3½ inch to 7⅝ inch

18¾ inch type U-II 10,000 2⅞ inch inch to 5 inch
18¾ inch type U-II 10,000 3½ inch” to 7⅝ inch
18¾ inch type U-II 15,000 3½ inch” to 5 inch
18¾ inch type U-II 15,000 3½ inch” to 7⅝ inch”
18¾ inch type TL 10,000 3½ inch” to 7⅝ inch”
18¾ inch type T/TL 15,000 3½ inch” to 5 inch”
18¾ inch type T/TL 15,000 3½ inch” to 5½ inch
18¾ inch type T/TL 15,000 3½ inch” to 6⅝ inch
18¾ inch type T/TL 15,000 3½ inch to 7⅝ inch
Note: The VBRs require special ram blocks; they will not fit into the
standard pipe ram blocks.
Figure 43 -
VBR packer.
51
Figure 44 -
FlexPacker NR.
The FlexPacker type NR

The FlexPacker NR (abbreviation of “narrow range”) ram body was
developed to increase the operational service range of standard BOP pipe
rams. The Flexpacker NR enables a standard BOP pipe ram to seal on
several different pipe diameters.
The rubber in the ram front packers is supported against extrusion by a
single set of steel plates, which adjust to the different pipe sizes and reduce
the extrusion gaps. For 15,000-psi service the Flexpacker NR has anti-
extrusion plates both on the top and on the bottom of the packer. These
metal anti-extrusion plates are sized to the smallest pipe size of the
FlexPacker range, whereas the upper retainer plate is sized to the largest
pipe size. Since an extrusion gap exists between the plate ends during
closure on intermediate size pipes, sealing on intermediate sizes can reduce
the overall packer life. Utilizing this packer with either the lower or the upper
pipe size increases the service life of the packer, but the packer can also
provide satisfactory service when used on intermediate pipe sizes.
The mechanism of closure of the FlexPacker NR is different from that of
standard pipe ram packers. The packers extend forward of the ram body.
Since the packers are moulded with the packer bore sized to the smallest
pipe size, the anti-extrusion plates usually contact the pipe first during
closing. As the rams are closed, the anti-extrusion plates are pushed into the
packer to adjust to the pipe size. Once the packers are “sized” to the pipe,
additional movement of the rams causes the packer faces to become loaded.
52
Table 5: Available Cameron FlexPackers
Type BOP Working pressure Available Ram blocks to be

(psi) sizes used
18¾” Type U 10,000 2⅞” to 5” NR VBR
18¾” Type TL 10,000 2⅞” to 5” 5” pipe ram blocks
18¾” Type TL 10,000 3½” to 5½” 5½” pipe ram blocks
18¾” Type TL 10,000 5” to 7” 7” casing ram blocks
Note: With the exception of the 18-3/4 inch 10M type-U 2-7/8 inch to 5
inch units, the FlexPacker is used with standard pipe rams.
Table 6: Cameron FlexPacker NR (Narrow Range)
Working Ram blocks to be

Type BOP Available sizes
Pressure (psi) used
18¾” Type U 10,000 3½” to 5” 5” pipe ram blocks
18¾” Type U 10,000 5” to 6⅝” 6⅝” pipe ram blocks
18¾” Type U-II 10/15,000 3½” to 5” 5” pipe ram blocks
18¾” Type U-II 10/15,000 5” to 6⅝” 6⅝” pipe ram blocks
18¾” Type T/TL 15,000 5” to 5½” 5½” pipe ram blocks
18¾” Type T/TL 15,000 5” to 6⅝” 6⅝” x 5” FlexPackers
Note: With the exception of the 18-3/4 inch 15M T/TL 6-5/8 inch to 5 inch,
the FlexPacker NR is used with standard pipe rams.
Table 7: Cameron VBRs hang-off capacity
18¾” BOP Range Drill pipe tool joint hang-off capacity in lbs
Type Max. Min. 2⅞” 3½” 4½ 5” 5½” 6⅝” 7⅝”

U 7⅝” 3½” X 200,000 240,000 350,000 350,000 375,000 450,000
U-II 10M 5” 2⅞” 120,000 300,000 350,000 450,000 X X X
U-II 10M 7⅝” 3½” X 200,000 240,000 350,000 350,000 375,000 450,000
U-II 15M 5” 3½” X 140,000 300,000 450,000 X X X
U-II 15M 7⅝” 3½” X 140,000 240,000 350,000 350,000 350,000 350,000
T/TL 10M 7⅝” 3½” X 60,000 175,000 225,000 275,000 350,000 450,000
TL 15M 5” 3½” X 140,000 240,000 450,000 X X X
TL 15M 5½” 3½” X 140,000 240,000 450,000 450,000 X X
TL 15M 6⅝” 3½” X 140,000 240,000 350,000 350,000 600,000 X
(tested) (tested)
TL 15M 7⅝” 3½” X 140,000 240,000 350,000 350,00 375,000 450,000
Note: The hang-off capacity of the 18¾ inch 15M type TL VBR size 3½ inch to 6⅝ inch with 5 inch
pipe and 6⅝ inch pipe are actual test results; all the other figures are calculated values.
53
Table 8: Cameron FlexPacker NR Hang-Off Capacity
18¾” Range Drill pipe tool joint hang-off capacity in lbs

BOP
Type Max. Min. 2⅞” 3½” 4½” 5” 5½” 6⅝”
U 5” 3½” X 150,000 200,000 450,000 X X
U 6⅝” 5” X X X 190,000 240,000 450,000
U-II 5” 3½” X 250,000 350,000 450,000 X X
10M/15M
U-II 6⅝” 5” X X X 250,000 350,000 450,000
10M/15M
T/TL 15M 5” 5½” X X X 450,000 450,000 X
T/TL 15M 6⅝” 5” X X X 250,000 350,000 450,000
Table 9: Cameron FlexPacker Hang-Off Capacity
18¾” Range Drill pipe tool joint hang off capacity in lbs
BOP
Type Max. Min. 2⅞” 3½” 4½” 5” 5½” 6⅝” 7”
U 2⅞” 5” 30,000 30,000 150,000 450,000 X X X
TL 10M 2⅞” 5” 120,000 140,000 220,000 450,000 X X X
TL 10M 3½” 5½” X 140,000 220,000 450,000 450,000 X X
TL 10M 5” 7” X X X 150,000 150,000 250,000 450,000
54
18. Cameron shear/blind rams

We never perform a shear ram test by actually shearing a drill pipe, unless
this is explicitly required by the client and agreed on by the rig
superintendent. If a shear test is ever performed, the shear ram blocks
require a visual inspection and an NDT inspection straight after the shearing
procedure at the first possible opportunity. If you have to perform shearing
operations, ensure that the drill string has been hung off first.
This must be done for following reasons:
• In order to be 100% certain of the exact location of the tool joint, as the
standard shear/blind rams cannot shear tool joints.
• In order to be 100% sure that there is no movement of the drill pipe at
the time of the shearing operation. Any movement will cause the blades
of the shear rams to break off.
• Hanging off rams will centralize and “straighten” the drill pipe prior to
shearing.
• After the string is hung off, we can apply a 10,000-lbs overpull force on
the drill string, which will increase the chance of a successful shearing
operation.
• Last but not least, we do not drop the drill string in the well so that we
do not have to “fish” for the drill string first. The drill string allows us to
circulate bottom-up in the event of the presence of gas prior to opening
the rams.
Ensure that the distance between the tool joint and the bottom of the
shear/blind or the shear rams is wide enough to be sure that the tool joint
cannot be touched by the bottom of the shear/blind or shear rams.
It is good drilling practice to reduce the operating pressure of the
shear/blind rams to 500 psi when the shear/blind rams are used to perform
a CSO during the testing of the BOPs. This is done to ensure that the blocks
do not close at a high speed, which could result in packer damage when the
blocks and packers are smashed together.
It is important to realize that the blade seals of the shear/blind rams do not
have the same, large rubber quantity as the pipe ram rubbers. The shear
rams, like the super shear rams or casing shear rams, do not have a blade
seal and cannot be tested. Do not make a fool of yourself in trying!
Figure 45 - Cameron U-II type DSV shear rams.
55
The side packers of the shear rams are not moulded in a symmetric manner,
which is why there is a LEFT-HAND and a RIGHT-HAND packer present. So,
check your stock items to be sure that there is a left-hand and a right-hand
packer available. This information is written on the packers (see Figure 46).
The asymmetric design of these packers makes it impossible to install the
RIGHT-HAND packer in the left-hand slot.
The top seals of Cameron shear/blind rams have a part number that is
different from the pipe rams and should be ordered separately.
Figure 46 - Shear/blind rams with a stellite enforcement on the

blade.
56
19. Bonnet bolts
The bonnet bolts of each individual BOP require different torque values. The
torque value of a particular bonnet bolt is related to the expected stretch of
the bolt, depending on its size and the maximum working pressure of the
BOP.
To pre-load the bolts, which is done by stretching them further than they
would under maximum working pressure conditions, a seal is maintained for
when the bolts are pressured up to their maximum working pressure.
When the friction coefficient of the grease is unknown, it will not be possible
to determine the torque values to be applied to the bolts. The friction
coefficient s normally used for subsea applications is 0.067 to 0.069
(Sweeny Molylube, etc.)
Bonnet bolts require frequent NDT inspections. The internal and external
threads must be inspected with a thread gauge. To ensure that the bolts are
sufficiently stretched, a thread lubricant is necessary to reduce the friction of
the threads during the pre-loading (torquing) of the bonnet bolts. The
friction factor of the used grease can reduce the torque by a factor 3 or 4
(see Figure 48). The stretching of the bonnet bolts on the Cameron U-II, the
type T and the type TL BOP makes it possible to remove and install the nuts
with little effort.
Figure 47 - Hydraulic stud of Cameron U-II BOP (old style).
57
Figure 48 - Torque table with different grease coefficients.
58
20. Operation, care and maintenance of

hydraulic bonnet studs of the Cameron
U-II BOP
(Source: Cameron Engineering Bulletin No. 797D)

Description
The hydraulically tensioned bonnet studs are built into the Cameron U-II and
T/TL BOPs so that the four studs on each end of the BOP are tensioned
simultaneously through their respective ports.
Operation and testing of the BOP
A. Safety precautions
1. Keep away from high-pressure oil leaks. Jets of liquid escaping from
high- pressure equipment have sufficient power to penetrate the
skin, which may cause blood poisoning. In case of such accidents,
immediate medical attention must be obtained, regardless of how
superficial the wound may appear.
2. The operating pressure for the hydraulic studs is 30,000 psi. This
pressure must never be exceeded during tensioning. Ensure that
the pressure gauge on the hydraulic pump is regularly calibrated by
a competent and qualified calibration technician.
B. Tensioning of hydraulic bonnet studs

1. Slowly close the bonnets of the U-II BOP, using approximately 500
psi on the OPEN port. When the bonnets are closed, increase the
pressure up to 1,500 to 3,000 psi.
Note: Hold the OPEN pressure to the BOP-operating system to ensure that
the bonnet will be pressed tightly against the BOP body. This ensures that
the bonnet makes proper contact with the BOP body. If a gap still exists,
check for the presence of foreign material between the bonnet and the BOP
body and ensure that the bonnet seals are properly seated. It may be
necessary to increasing the OPEN pressure to 3,000 psi.
2. Lightly grease the stud ends with a moly type grease or equivalent
with a friction coefficient of 0.067 to 0.069, and install the hydraulic
bonnet stud nuts onto the studs. Screw the studs in up to the point
where the studs are flush with the bonnet.
3. Connect the high-pressure hose to the tensioning port on the side of
the ram body and the hydraulic pump. Ensure that all male and
female fittings are spotless; remove grime and mud if present.
Caution: The high-pressure hose must be fitted to the tensioning port

and the pump with the fluid valve in the OPEN position to avoid a
hydraulic lock in the system. Bleed off the air from the system by using
the bleed-off port placed directly opposite the tensioning port (see Figure
49. Use rope slings and tighten the end sections of the hydraulic hose for
extra security.
59
4. Apply a pressure of 30,000 psi to the hydraulically tensioned studs

through the tensioning port. This will stretch the bonnet studs and
supply a gap between the ram body and the bonnet flange. Do not
stand directly above the pressured hose.
5. After having maintained the 30,000-psi pressure for a minimum of 5
minutes, rotate the nuts clockwise. The nuts must be tight against
the bonnet flange before releasing the pressure. A wrench with a
maximum length of 1 to 2 feet may be used to seat the nuts. Do not
use a hammer on the wrench to tighten the nuts; just hand-tight is
sufficient.
6. SLOWLY open the fluid valve of the pump by gradually releasing the
hydraulic pressure. When you are working with these extremely high
pressures, the gradual build-up and release of the pressure will
prevent shock loads to the material involved. Once the fluid valve is
fully opened, wait an additional three minutes before disconnecting
the hose.
Note: Should any problems arise when achieving a zero gap between
the bonnet and the ram body, a second tensioning sequence must be
performed (i.e. step 3 through 6).
Caution: Hydraulic pressures must be always released SLOWLY and

GRADUALLY to avoid irreparable damage to the pressure gauge. Such
damage will lead to inaccurate pressure readings to avoid ‘sucking’ the
tensioning seals.
7. Release the BOP OPEN pressure.
Figure 49 - Cross-section of the Cameron U-II tensioning system.
60
C. Untensioning the hydraulic bonnet studs

Note: Apply 1,500- to 3,000-psi OPEN pressure on the BOP-operating
system in order to keep the bonnet tight against the ram body.
1. Connect the high-pressure hose to the tensioning port on the side of

the ram body and the hydraulic pump. Ensure that all male and
female fittings are spotless; remove grime and mud if present.
Caution: The high-pressure hose must be fitted to the tensioning port

and the pump with the fluid valve in the OPEN position to avoid a
hydraulic lock in the system. Bleedoff the air from the system by using
the bleed-off port placed directly opposite the tensioning port (see
Figure 49). Use rope slings and tighten the end hose sections of the
hydraulic hose for extra security.
2. Apply a 30,000-psi pressure to the tensioning port. This is necessary
to create a gap between the nuts and the bonnet flange. Do not
stand straight above the pressured hose. This pressure may be
increased up to a maximum of 32,000 psi.
3. Rotate the nuts counterclockwise with a minimum of two turns or
with a gap of at least 1 inch while the pressure is applied and the
studs remain stretched.
4. Slowly open the fluid valve on the pump by gradually releasing the
hydraulic operating pressure.
Caution: Release the hydraulic pressure to prevent shock loads on the
material and to protect the pressure gauge on the hydraulic pump.
5. Disconnect the high-pressure hose from the tensioning port.
6. Unscrew the bonnet studs in the normal manner and store the studs
on their side to avoid damage on the face of the nuts. Make sure
that no debris can enter the threads of the nuts.
7. Release the ram BOP OPEN pressure.
D. Testing the Cameron U-II BOPs

1. Verification of leaks: when the BOP to be tested has recently been
subsea, there may be a problem of a leak through which trapped
water is escaping. During pressure testing, a gap will open between
the BOP body and the bonnet. Seawater then is trapped inside
various voids in the bonnet face. The water will then drip out of the
gap, which occurs when the surface or stump test is performed.
There are two ways to alleviate this problem:
• Leave the test pressure applied for a sufficient period of time to allow all
the trapped water to escape. This may take several hours. The pressure-
recording device (chart recorder) should not show any loss of pressure if
it is only trapped water leaking out.
• Add dye before filling up the BOP bore and mix it with the water; if leaks
are present it can be determined whether or not water comes from the
bore. Remember that small leaks will not show on the pressure chart
recorder.
2. Re-tensioning the studs: the studs should be checked for proper

tension after the tests are completed by performing, once again, the
tensioning procedure, especially when a full bore pressure has been
performed (body test).
61
21. Hydril ram-type BOPs
The majority of the Hydril subsea ram-type BOPs are 18¾-inch preventers
rated at 10M and 15M. The 10M Hydril BOPs are equipped with a 14¼
inchOD operator piston. Hydril recommends a minimum closing pressure of
1,050 psi for operating the fixed-bore and variable-bore pipe rams. Hydril
also recommends a minimum closing pressure of 3,000 psi for operating the
blind/shear rams in the shear ram mode.
The 15M Hydril BOPs are equipped with a 15¼-inch operator piston. Hydril
recommends a minimum closing pressure of 2,200 psi for operating the
fixed-bore and the variable-bore rams. Furthermore, Hydril recommends a
minimum of 3,000 psi closing pressure for operating the blind/shear rams in
shear ram mode.
Both the 10M and the 15M blind/shear rams should be closed with reduced
pressure when the rams are used as blind rams in order to prevent wear at
the ram packers and the ram blocks. A closing pressure of 500 psi should be
applied; after the read-back pressure has indicated that the rams are closed,
the pressure can be raised.
Figure 50 - Hydril 15M BOPs with MPL.
62
22. Fundamental differences between

Hydril and Cameron ram-type
preventers
1. Hydril BOPs have fluid hinges and a large number of bonnet bolts.
2. Hydril BOP bonnets are hinged open and have no hydraulic circuit to
open the bonnets.
3. Hydril bonnet bolts are tightened with high-torque tools. There are
no hydraulic bonnet bolts present.
4. Hydril has a bore seat seal installed at the top of the ram cavities.
5. Hydril ram blocks only touch and seal at the very end of the stroke
inside the cavity.
6. Hydril has a modification by which wear pads are installed in the
bottom of the cavity.
7. The Hydril Multiple Position Lock (MPL) system is integral to the ram
bodies and does not require an additional hydraulic function.
8. Hydril has developed a low-torque modification to use new bonnet
door seals; these require approximately 25% of the previous torque.
9. The Hydril high-temperature ram blocks require a machinery
adaptation in order to accommodate the packer studs going straight
through the ram blocks.
10. Hydril has developed a so-called limited-height and low-weight 15M
BOP.
11. Hydril's cavity clearances between the ram blocks and the cavity are
larger than those of Cameron BOPs.
Figure 51 - Hydril's new, compact design of the 15M BOP.
63
23. Ram blocks and fixed pipe rams
Figure 52 - Brand new Hydril ram-type BOP 5-inch block.
Hydril ram blocks are shaped slightly differently from the Cameron ram
blocks. However, in principle the anti-extrusion plates are the same as with
the Cameron rams. Furthermore, Hydril ram blocks have a separate top seal
and a front packer. The front packer should stick out approximately ⅜ inch
beyond the face of the ram when it is in its proper position. For all Hydril
blocks it applies that the blind/shear rams, the fixed pipe rams and variable-
bore rams use the same top seals. This is in contrast with Cameron ram
BOPs that use a different top seal for each ram type.
The Hydril ram is manufactured from one-piece low-alloy steel casting
designed to combine strength with the most effective seal assembly. The
ram upper surface is recessed to prevent seal seat wear while opening and
closing the rams and to prevent scoring of the seal seat from a damaged
ram.
A unique technique of energizing the upper seal creates contact with the
upper seal seat only during the final seal-off portion of the ram stroke.
64
24. Front packer operation
Figure 53 - A new front packer closing on a drill pipe.
A new front packer contains a large volume of feedable rubber. When seal-
off is obtained a large clearance arises between the ram and the pipe. The
front packer has a large volume of feedable rubber bonded to heavy anti-
extrusion plates.
As the plates meet face to face, the crowns of rubber of the front packer's
face cause a pressure in the rubber to initiate the seal-off. Further
movement of the rams causes the anti-extrusion plates of the opposing front
packers to come together in order to control the flow of rubber into the
sealing area.
65
Figure 54 - A moderately worn front packer closing on a drill pipe.
Wear generated at the face of the front packer due to rotation or

reciprocation of the drill pipe during seal-off is compensated for by the large
feedable rubber volume at the rear of the front packer. This rubber is fed to
the wear area as the ram blocks move closer to the drill pipe.
The worn packer depicted in Figure 55 contains a large but reduced volume
of feedable rubber. The clearance between the ram and the drill pipe is
reduced at the seal-off position.
66
Figure 55 - An extensively worn front packer closing on a drill pipe.
The extensively worn front packer has used almost all of its feedable rubber
volume, but it is still able to realize a full-rated seal-off. The clearance
between the ram and the drill pipe is now approaching zero, indicating
completion of the useful life of the front packer.
For subsea BOP applications, the packers should be never allowed to wear
up to this level.
Nevertheless, packers require replacement, as the duration of the drilling
programme can never be accurately predicted prior to drilling the well. Most
deep-water operations demand to have the packers in as-new condition as
the cost to renew the packers are peanuts compared to a change-out during
the well by pulling the BOPs!
67
25. Upper seal operation
Figure 56 - Location of the upper ram block seal and upper seal seat
at the bore with the rams in the fully closed position.
The upper seal is an independently replaceable seal with a large volume of

feedable rubber bonded to heavy anti-extrusion plates. The energizing
technique of the upper seals retains the seal inside the ram and prevents
seal wear during the ram travel in the cavity.
The upper seal of the ram blocks is energized by the closure of the rams; in
other words, the seal is not energized until a final seal-off is achieved. This
will make this type of ram less vulnerable for swarf from milling operations
or other discrepancies in the mud, as there is no contact between the top
of the cavity and the ram blocks during most of the travel of the ram blocks.
The design of the upper interior surfaces of the seal seat of the BOP body
prevents the upper seal from dragging across these surfaces prior to the
final seal-off of the body. This provides a reliable service life.
68
26. Fixed pipe rams
Figure 57 - Hydril fixed pipe rams (standard-temperature

applications).
Ram seals replacement (standard-temperature applications)

1. Remove the upper seal by prying upward between the front packer
and the upper seal.
2. Remove the front packer by prying with two heavy-duty screwdrivers
on each side.
3. Clean the blocks and lightly oil them with hydraulic oil (SAE 10W).
4. Insert the front packer into the ram block until it is correctly seated.
At the packer the word Top indicates the correct side up.
5. Insert the upper seal by pointing the pins down; then fit the seals
into the ram block groove. The groove should be coated with
hydraulic oil.
Notes
1) Do not put grease into the slot of the upper seal, as the top seal might
stick out too much, causing excessive wear.
2) After all packers have been installed, it is a good practice to cover the
side and the top rubber sections with a light coat of multi-purpose
grease. This applies to the ram cavity.
69
Ram seals replacement (high-temperature applications)

The high-temperature elastomers and sealing systems for high-temperature
and high-pressure applications were developed in the early 1990s. The high-
temperature applications are mostly used with the 15M BOPs.
To be able to use high-temperature elastomers, the ram blocks require a
modification. The ram packers are tightened with bolts at the end of the
packer going through the ram block in the horizontal plane. The studs that
are used to tighten the high-temperature ram packers can only be used once
and are to be replaced when a packer change is performed.
The high-temperature elastomers are rated at 350oF continuous operating
temperature with a 380oF peak temperature at 15M. Top seals, piston rod
mud seals and the bonnet seals are rated to 350oF continuous operating
temperature for this 15M ram preventer.
Newer Hydril ram blocks have replaceable inserts installed called MP35N.
Hang-off area enforced

with replaceable
MP35N hanging insert.
Figure 58 - Hydril fixed pipe ram (no packer has been installed).
70
Figure 59 - High-temperature application on Hydril

ram blocks.
71
Figure 60 - Closing/opening ratio with 5 inch pipe rams installed

(Source: Hydril Operator’s Manual).
72
Figure 61 - Torque table for Hydril 15M compact rams.
73
27. Specifications Hydril ram preventers
Figure 62 - Hang-off capacities and dimensions of Hydril ram BOPs

(source: Hydril Operator’s Manual 2003).
74
28. Cavity clearances Hydril BOPs
Figure 63 - Clearances cavity-ram block for Hydril 10/15M ram

BOPs.
A MINIMUM B MAXIMUM C MAXIMUM NEW C MAXIMUM WORN
10.742” 10.793” 0.051” 0.113”
A MINIMUM = Maximum ram height (new)

B MAXIMUM = Maximum ram compartment height (new)
C MAXIMUM NEW = Maximum gap between ram block bearing surface
and seat sealing surface (new)
C MAXIMUM WORN = Maximum allowable gap between ram block and
seal seat (worn)
75
29. Hydril variable-bore rams
The Hydril variable-bore rams (VBRs) have a range from 3½ to 5 inch. The
front packers are expensive, but can last quite a long time in normal drilling
conditions. VBRs are not designed for stripping operations. They are not
available for high-temperature applications.
The Hydril VBR packer has interlocking I-beam inserts moulded into the
rubber. These inserts confine the rubber within the packer and against the
pipe, thus preventing extrusion of the sealing element. During the seal-off
on a small-diameter pipe, the inserts move radially inwards towards the
pipe. During the seal-off on a pipe with a large diameter the inserts are
displaced into the front packer.
Application with load by the BOP operator squeezes the sealing element
within the confines of the inserts and the pipe outside diameter. This action
establishes a steel-contained sealing element. A key feature is the
automatic adaptation to the pipe size as the ram closes and seals off. VBRs
can be used with standard MPL systems. VBR packers are vulnerable for
heavy brines such as zinc bromide and for some aggressive mud additives.
Figure 64 - The Hydril VBR block.
76
Figure 65 - New-style Hydril VBR front

packer secured with studs.
77
Figure 66 - VBR 4-1/2 to 7 inch closing/opening ratio graphs

(Source: Hydril).
78
Figure 67 - VBR 3-1/2 to 5-1/2 inch closing/opening ratio graphs

(Source: Hydril).
79
Figure 68 - Old-style Hydril VBR packers.
80
30. Hydril shear/blind ram operation
The shear/blind ram assembly is designed to shear drill pipe and seal off the
wellbore. The shear/blind rams can be used as blind rams to close on open
hole, creating a complete shut-off (CSO). If the Hydril shear/blind rams are
to be used as blind rams, it is recommended to reduce the operating
pressure to 500 psi in order to reduce the closing speed and thus prevent
damage inside the blade seal.
The dual V-blade arrangement with sharp rake angles concentrates the
deforming forces, so that the drill pipe is crimped only on the shear plane.
Once shearing has been initiated, the blades' rake angles impose an
additional tensile load to add in the separation of the drill pipe. The sheared
‘lower fish’ is left with an opening large enough to allow pumping of drilling
fluid down the drill pipe to the bit in order to circulate “bottoms up” to check
for trip gas.
Following a pipe-shearing operation, a seal against the wellbore pressure is
obtained in a similar manner as in the operation of blind rams. The T-seal
seals on the horizontal plane, rather than on the vertical plane.
The cap screws on the upper blade are torqued to 1,600 ft-lbs; this means
that a torque multiplier should be available, as well as heavy-duty six-point
sockets. It is important to use Hydril thread lubricant or a similar kind of
grease with a friction coefficient of 0.069 or less. The lower blade cap screws
require a torque of 800 ft-lbs.
Figure 69 - Old-style shear/blind ram blocks.
81
Figure 70 - Old-style Hydril upper and lower shear ram blocks.
The anti-extrusion blocks are located behind the shear ram lower blade.
Should you forget to install these blocks, the shear rams will not hold
pressure! Normally this is only done when the lower blade is renewed.
Figure 71 - New-style Hydril shear/blind and casing shear ram

torque tables.
82
Figure 72 - Shearing procedure for 15M Hydril ram-type BOP.
83
Figure 73 - New-style Figure 74 - New-style blind /

blind/shear ram lower blade shear ram upper blade carrier.
carrier.
Note: The difference between the old-type and the new-type blind/shear
rams is easily noted when counting the Allen-headed cap screws: the
new-style blocks have six cap screws installed in the upper blade,
whereas the old-type blind/shear rams only have four caps crews
installed in the upper blade.
84
Figure 75 - New-style casing Figure 76 - New-style casing

shear ram lower blade. shear ram upper blade.
Note: The casing shear rams have no blade seal; consequently will it not be
possible to perform a CSO with these shear rams. These rams are
normally installed with large bore bonnets with 22-inch pistons.
Special maintenance instructions need to be followed to perform in-
between-well preventive maintenance with these large bore bonnets.
85
Figure 77 - Closing/opening ratio of shear rams with different-sized

operator pistons.
86
Figure 78 - Hydril new-style casing shear rams.
Figure 79 - Samples of sheared casing and drill pipe sections using

casing shear rams.
87
Figure 80 - Shearing table from Hydril (Source: Hydril Operating

Manual 2003).
88
31. Hydril 15M BOP ram bonnets
Figure 81 - Hydril ram bonnet (old style).
The Hydril ram BOP bonnet hinges can swing 52 degrees for the purpose of
changing the rams or for servicing. An opening and closing line is required to
operate each set of rams. The operator's hydraulic chambers and seals are
rated for a 3,000-psi continuous operation, although normal operation
pressures are 1,500 psi. Hydraulic operating pressures from 80 to 200 psi
against a zero well pressure indicate a satisfactory operation of the MPL
systems.
89
Figure 82 - Conventional ram BOP operation.
The hydraulic pressure applied to the closing port initiates a fluid flow in
drilled passages inside the BOP body. The fluid flows from the body to the
fluid hinge, through the fluid hinge sub and into the bonnet hinge. From
there it flows through a drilled passage in the bonnet and remains between
the cylinder and the cylinder liner.
The fluid then presses on the backside of the operating piston and moves
the piston towards the wellbore. This closes the rams. As the assembly
piston moves towards the wellbore, the hydraulic fluid in the opening
chamber flows out of the opening port of the bonnet.
The closing time of the preventer is determined by the rate at which the
hydraulic pressure closing fluid volume can be supplied to the operating
cylinders. The rate of the displaced fluid volume can vent to sea through the
open hydraulic system of the BOP control system. The minimal closing time
will be achieved by using short, large-bore hydraulic control lines in
combination with large accumulator volumes.
During in-between-well preventive maintenance a so-called signature test
must be performed to check and record the minimum pressure that the rams
require to open. This test will supply vital information on the condition of the
MPL bearings and the friction plates. Normally, the minimum pressure
should be below 100 psi; if it exceeds 200 psi the MPL system requires a
visual inspection. It is important to record the minimum opening pressures
in the history files in order to spot trends.
90
Figure 83 - New-style Hydril bonnet, showing its metallurgic

composition.
The new Hydril bonnets are different from the old design. The open side of
the piston is connected to the internal ports by means of the MPL transfer
ring. We will discuss this when we look at the MPL system in detail.
Figure 84 - New-style Hydril bonnet. Clearly visible is the port inside

the bonnet going to the transfer ring of the MPL.
91
Figure 85 - Fluid ports going through the fluid hinges.
Figure 86 - Hydraulic circuit on Hydril BOP. Note: This is a surface

BOP with manual locks.
92
Four fluid lines are passing through the hinges of the Hydril BOP. The fluid
hinges and bonnet hinges contain all the seals that are involved in the
transfer of hydraulic fluid from the body to the bonnet and from the bonnet
to the body.
Figure 87 - Schematic view of Hydril ram BOP fluid hinge.
93
32. Cylinder seals of Hydril BOP
Figure 88 - Bonnet flange of Hydril 15M BOP (not converted to low-

torque application).
a. The bonnet-to-piston rod seal

The bonnet-to-piston rod seal prevents leakage of the hydraulic opening
fluid from the cylinder-opening chamber. This seal is moulded lip-type
packing.
Replacement of the bonnet-to-piston rod seal requires removal of the
cylinder assembly and the fitting of a new seal in the groove, with the
sealing groove installed with the sealing lips towards the operating cylinder.
94
Figure 89 - Exploded view of the old-style Hydril bonnet.
b. The cylinder liner-to-bonnet seal

The cylinder liner-to-bonnet seal is an O-ring located at the end of the
cylinder liner nearest the wellbore. There are two back-up rings: one on
either side of the O-ring associated with this seal. The O-ring prevents
closing pressure from entering the opening side of the cylinder liner and the
opening pressure from entering the closing side.
95
Inspect the groove and sealing surfaces for any nicks, scratches and burrs,
and repair as required. Do not use knifes, only fine emery cloth. Always
change the O-ring and back-up ring as one set, and use silicone grease on
the seals. The entire area should be spotless.
Figure 90 - Cross-section of bonnet bore and piston rod.
c. The bonnet-to-piston mud seal

The bonnet-to-piston seal prevents leakage of hydraulic fluid from the
cylinder's opening chamber. This seal is a moulded lip-type packing. The
opening-chamber pressure will push the lip outwards, thus improving the lip
seal's sealing capacity.
If this seal is installed the other way around it will not seal properly. For this
reason it is important to ascertain where the pressure is coming from; you
have to double-check that the face of the lip seal is aligned in the right
direction.
If this seal is leaking, hydraulic fluid will escape from the weep hole. Some
rigs are fitted with check valves in the weep holes; ensure that these are not
frozen because of debris and rust.
d. The piston rod mud seal

The piston rod mud seal is a lip-type seal located in the bonnet on the
wellbore side. Its purpose is to prevent wellbore fluids from escaping into
the environment. The seal lips have to face outwards toward the wellbore.
This seal has direct contact with the wellbore fluids and (sometimes) with
very aggressive fluids such as zinc bromide, brines or certain mud additives,
which will cause this seal to rapidly deteriorate (read: turning rubber into
snot!).
When this happens the piston rod looses its support; scoring of the bonnet
flange of the piston rods will be the result. The repair cost of one bonnet
comes to a minimum of 150,000 US dollars. Always inspect the piston rod
mud seal; it should not bent outwards caused by a worn recess in the
bonnet. Remember that a severely worn seal can cause failure of the
complete bonnet.
96
Figure 91 - Hydril ram bonnet piston seals.
e. The piston seal

The piston seal is a three-piece two-directional seal fitted into a groove in
the piston. This seal is flanged by two composite wear rings. The wear ring
seals may be placed in hot water to ease the installation, as they are very
stiff in the North Sea temperatures.
The piston groove, piston outer diameter and cylinder inner diameter should
all be spotless and inspection is required for nicks, scratches and scores. The
piston and cylinder must be repaired or replaced when necessary. Lubricate
the piston seals with silicone grease prior to assembling them.
f. The cylinder head seal

The cylinder head seal is an O-ring located on the pilot diameter of the
cylinder head. This seal prevents the closing hydraulic-fluid pressure from
leaking to the marine environment. Inspect to make sure that the groove is
free from any nicks, scratches and burrs. The O-ring needs to be greased
with silicone grease when it is installed new.
g. The cylinder head seal

The cylinder head seal is an O-ring located on the inside face of the cylinder
head. This seal prevents dirt or seawater from entering the cylinder. The O-
ring needs to be greased with silicone grease when it is installed new.
h. The lock-out stem seal

The lock-out stem seal is an O-ring with one back-up ring located in a
groove on the lock-out system. Replacement of the O-ring and the backup
ring should be performed as one set. The O-ring needs to be greased with
silicone grease when it is installed new.
97
33. Hydril standard bonnet door seals
Figure 92 - Hydril ram body (without low-torque upgrade) showing

the seal characteristics when made up and pressurized.
The standard bonnet seal is a special seal designed to seal between the
bonnet and the BOP body. It fits into a groove in the front face. This seal
prevents wellbore fluids from escaping between the body and the bonnet to
the marine environment. During subsea applications it also prevents
seawater from entering the BOP body.
The bonnet seal's integrity is as important as the ram seals. The bonnet
seals are deformed after the bonnets have been torqued and during
pressure tests; for this reason it is common practice to always replace this
type of bonnet seal after the doors have been opened (if the BOP is used for
subsea applications).
The proper torque is important to retain contact between the bonnet and the
body and it provides evenly distributed bonnet bolt loads during pressure
operations. The 18¾ inch 15M Hydril bonnet bolts require 10,800 ft-lbs of
make-up torque.
The bonnets are normally tightened in two cycles. First the bonnet bolt in
the middle on the opposite side of the hinge is to be tightened; secondly the
bolt in the middle of the hinge must be tightened. Finally all the other bolts
are tightened diagonally opposed, as shown in the figure below.
98
Figure 93 - Order of tightening the bonnet bolts on Hydril BOPs.
First the bonnet bolts should be tightened by hand. Do not use any air tools
before at least three full turns of threads are engaged, otherwise either the
bonnet bolts or the threaded hole inside the ram body could be damaged.
The torque of the bonnet bolts is always related to the type of bonnet seal.
The high-temperature bonnet door seals require a 20% higher torque than
the standard bonnet seals. Hydril has developed a low-torque modification
for the bonnets. Such a modification can only be performed in the Hydril
factory and will be discussed in the next chapter.
99
34. Hydril low-torque modification
The new high-pressure bonnet seal design overcomes any bonnet gap
problems caused by high pressures (see Figure 94).
Figure 94 - The (first) upgraded bonnet seal assembly in three

different conditions.
Minimizing these seal gaps requires the use of very high torque values for
these BOP bonnet bolts, i.e. more than 10,000 ft-lbs on BOPs of 10 and
15,000-psi WP (15M). This high torque requires the use of heavy equipment,
which is time-consuming to operate.
Seal gap problems become more severe in cold-water and high-temperature
applications. Standard high-pressure seals tend to loose their preload
without internal pressure in the BOP. This sometimes causes sealing
difficulties during low-pressure tests, especially in low-temperature
conditions.
The seal ring carrier, which is equipped with a special compound O-ring,
avoids high bolt torque values. This device seals low pressures (as shown in
the centre drawing of Figure 94) and high pressures (as shown in the right-
hand drawing of Figure 94) with make-up torque values on bolts of 1,000 to
2,000 ft-lbs.
Tests show that the new seal is particularly effective at high pressures, as
shown in the right-hand drawing of Figure 94. It was first used at pressures
of 30,000 psi during an API Spec 16A qualification test, and to 350°F and
20,000 psi during high-temperature tests with Hydril 20M 11-inch ram BOPs.
The seal ring carrier deflects under differential pressures to close seal gaps
to almost zero pressure.
After having worked with these seals for a few years, an unexpected
phenomenon happened with a rig operating in deep water. Due to lost
circulation the pressure in the BOP was much lower than the hydrostatic
pressure of the seawater. This caused this seal assembly to fail and Hydril
came up with several other seal carrier modifications, which will be
discussed in Module 4.
100
Figure 95 - Seal ring carrier installed in the Hydril bonnet (old style).
Pressure differentials in the axial direction of the bonnet bolt forces the seal
ring carrier against the BOP body face as the bolts stretch under load. This
will result in a zero-pressure gap between the seal carrier and the BOP body,
even with large bolt deflections.
Similarly, pressure differentials in the radial direction close the gaps between
the seal ring carrier and the bonnet at pressures above 5,000 psi. The radial
loads are low enough to allow seals to slide as the bonnet bolts stretch
under pressure loads.
The floating seal ring carrier reduces the bolt torques of 10,000 to 15,000 ft-
lbs down to 1,000 to 2000 ft-lbs. This will speed up the opening and closing
of the Hydril rams while improving their seal integrity. Smaller bonnet bolt
preloads increase the risk of bolt fatigue.
Annual NDT inspections (MPI) of the bonnet bolts will overcome potential
problems from low-cycle fatigue when using seal ring carriers. The old-style
bolts had to be NDT-inspected every four yearly. The seal O-rings are to be
glued into the carrier; therefore, the subsea engineer should have an ample
supply of superglue in stock to replace the O-rings on the seal carrier.
101
35. Hydril 15M BOP ram cavities
Figure 96 - Hydril ram cavity with wear plate modification and seal
seat.
The Hydril BOPs had a unique design in which the replaceable metal seat is
located above the ram compartment inside the preventer body. It provides
the sealing surface for the upper seal of the ram cavity.
Figure 97 - Hydril seal seat assembly.
102
Figure 98 - Replaceable seal seat assembly of an 18-3/4 inch 15M

BOP.
The seal seat is held in place by a lock ring expanded into a groove inside
the BOP body. The lock ring is expanded by sixteen specially coated socket
head cap screws. The seal seat contains the seat to the body’s upper and
lower seals and lower back-up ring.
When replacing the seal seat, the seat to the body upper and lower seal
back-up ring should be replaced. The sixteen socket head cap screws are
made of stainless steel and cannot be cut out with a cutting torch. During
removal special care is required to avoid damage to the BOP body.
The worn seal seat contributes to the increase of the height of the cavity.
When this is out of specifications, a new seal seat must be installed.
103
36. Ram cavity measurements
Figure 99 - Wear limit on Hydril 15M ram BOPs.

Note:
• The wear at the cavity should be measured at frequent intervals (six-
monthly).
• The height of the cavity can be measured with an internal micrometer
and the ram blocks can be measured with a vernier caliper.
• The clearance between the ram block and the top of the cavity has a
minimum limit of 0.051 inch when new; the maximum allowed gap is
0.113 inch for an 18¾ inch 15M BOP.
When the gap between the ram block and the ram cavity becomes too large,
the low-pressure sealing capacity of the BOP is reduced. Remember that
the low-pressure sealing capability is very important, as all kicks
start with a low pressure!
Another modification is the installation of wear plates at the bottom of the
cavities. These plates must be replaced when the cavity in the ram block
clearance becomes too high. This modification can only be performed in an
authorized Hydril machine shop. The wear plates can be replaced on the rig,
which is a huge advantage compared to sending the complete bonnet ashore
for overhaul.
Figure 100 - Ram cavity wear plate of the Hydril BOP.
104
37. Hydril MPL automatic ram locking for

conventional BOPs
Figure 101 - Conventional Hydril BOP bonnet with MPL.
Hydril ram-type BOPs have automatic multiple-position locking (MPL)

systems installed. The MPL system allows the ram to seal off with the
optimum seal squeeze at every closure. The system automatically locks
the ram and keeps it closed with the optimum rubber pressure required
for sealing off in the front packer and the upper seal.
The front packer rubber wear requires different ram-locking positions with
each closure to ensure an effective seal-off. The MPL also works with VBRs
and does not require any other adjustments or different bonnets like the
Shaffer ram-type BOPs. The MPL is required to ensure retention of the seal-
off position. A mechanical lock is automatically set each time the ram is
closed.
Ram closure is accomplished by applying hydraulic pressure to the closing
chamber, which then moves the ram to a seal-off position. The locking-
system pressure is maintained after releasing the closure pressure. The ram
is opened only by the application of opening pressure, which
automatically releases the locking system and opens the ram at the same
time. The MPL system is available on all Hydril BOPs.
105
Figure 102 - The ram is held closed and sealed only with the MPL.
How does the Hydril MPL system work?

Figure 102 shows the ram in the closed position; it is sealed off by the MPL
only. Hydraulic pressure has been released on the closed side. The MPL
system maintains the required rubber pressure in the front packer and upper
seal to ensure a seal-off at rated working pressure.
The MPL system will preserve the seal-off without closing pressure and can
withstand the opening forces created by hanging off the drill string on the
ram blocks.
106
Figure 103 - MPL mechanism in operation.
Locking and unlocking the MPL mechanism is controlled by a one-directional

clutch mechanism and a locknut. The one-directional clutch mechanism
keeps the nut and ram in a locked position until the clutch is disengaged by
the application of a control system pressure to open the ram.
The hydraulic opening pressure disengages the front and rear clutch plates
in order to rotate the locknut and to open the ram. As the ram and piston
move towards the open position, the locknut and front clutch plate are
allowed to rotate freely.
107
Figure 104 - The locknut position.
The motion of the piston and tail rod during the closing or opening of the
ram causes the locknut to rotate. The fast lead (six-path helical thread)
rotates the nut three turns per foot of travel.
Notes:
• The ram-opening motion is caused by the application of hydraulic
opening pressure. The hydraulic opening pressure activates the cylinder
liner in order to release the locking mechanism.
• The cylinder liner is moved back against the transfer ring.
• The ring bears against the rear clutch plate to disengage the rear clutch
plate from the front clutch plate and keeps them separated for as long as
the opening pressure is maintained.
• Continuous application of the opening pressure moves the ram to the
open position, as the locknut and the front clutch plate rotate without
restriction.
• The closing pressure moves the cylinder liner forward, allowing the
springs of the rear clutch plate to engage the two clutch plates.
108
Figure 105 - Complete MPL assembly in motion.
Figure 106 - MPL clutch plates. Figure 107 - MPL clutch assembly.
109
The front clutch plate is bolted to the locknut. There are four rectangular
keys in the rear clutch plate, which slide into slots in the retainer plate. The
keys offer linear movement of the clutch plate, but prevent rotational
movement. The springs are captured between the rear clutch plate and the
retainer plate.
Forces on the piston rod that attempt to open the ram are held back by the
locknut. This force creates torque inside the locknut. The torque is
transmitted through the front clutch plate teeth to the engaged teeth of the
rear clutch plate. The rear clutch plate is keyed to the retainer plate, which
is pinned to the cylinder head and thus locked in position. The locked clutch
mechanism prevents the ram from opening.
Figure 108 - Hydril MPL components.
Figure 109 - Exploded view of the clutch assembly.
Component parts of the MPL

A one-directional clutch mechanism permits the piston to move freely in the
ram's closing position. The piston is mechanically locked and prevented from
moving towards the ram-opening position by the clutch mechanism and the
locknut. Application of control system opening pressure disengages the
clutch mechanism and permits the piston to move backwards to open the
ram.
110
The tail rod of the piston assembly contains two types of thread. One end is
threaded with standard left-hand ACME thread. This thread is used to
mate the tail rod to a standard mechanical lock-type piston. The other end is
threaded with a fast lead six-path helical thread. This thread makes only
three turns per foot.
Maximum strength is obtained by using independent threads (rather than
the normal single-start thread). Six independent thread starts can be seen
at the end of the tail rod (six-start thread). A mating nut is fitted onto the
tail rod. The nut is restrained by the thrust bearings, which permit the nut to
rotate whilst preventing linear travel of the nut.
The linear motion of the threaded tail rod creates torque inside the locknut
and, consequently, rotary motion of the locknut. The fast lead of the tail rod
threads (six-start thread) causes rapid rotation of the tail rod, which causes
the nut to rotate as the piston moves to either close or open the ram.
Figure 110 - MPL clutch mechanism.
111
Figure 111 - MPL without its cover.
Figure 112 - Schematic of operation of the MPL ratchet.
112
Figure 113 - Liner locked. Figure 114 - Liner locked.
The lock test

The MPL system offers possibilities for testing the lock mechanism. Each MPL
system is equipped with two lock-out devices, one on either side of each
MPL cylinder. These lock-out devices are manually operated and require
either a ⅜-inch square drive or a 5/16-inch twelve-point socket wrench.
A visual indication of the lock-out device position is provided. When the
square end of the lock-out system is approximately flush with or extends
beyond the lock-out gland up to 3/32 inch, the lock-out device is engaged
(see Figure 113).
When the square end of the lock-out stem is below the lock-out gland by ⅛
to ¼ inch, the lock-out device is disengaged and the MPL system falls into
its normal operating mode (see Figure 114).
Prior to running the BOP stack subsea, verification should be made that each
lock-out device is disengaged. This verification is made by turning the lock-
out stem counterclockwise for approximately seven turns until it
bottoms. Be aware not to overtorque the device.
113
The procedure to test the MPL mechanism of the 18¾ inch 15M
Hydril BOP
1. Install the operator hydraulic circuits.

2. Ensure that a test mandrel of the appropriate diameter is installed in
the BOP for pipe rams and that there is no test mandrel when
testing the shear/blind ram MPL system.
3. Close the rams by using a 2,200-psi closing pressure, and visually
check for leaks.
4. Reduce the closing pressure to 100 psi maximum.
5. Visually inspect the freedom of movement of the lock-out devices by
turning the stem alternately clockwise and counterclockwise with
seven turns.
6. Engage the lock-out devices by rotating the stems clockwise with
circa seven turns on both sides of the MPL system on each ram
bonnet.
7. Hand-tighten the lock-out devices until they are snug and use the
correct-sized wrench.
8. Bleed off the closing pressure to zero psi.
9. Apply the opening pressure from zero psi up to 1,500 psi in 500-psi
increments.
10. Hold the pressure for three minutes and check for leaks.
11. Visually observe the rams for any movement. Only no movement
whatsoever is permitted.
12. Bleed off the opening pressure from 1,500 psi to zero psi.
13. Disengage the two lock-out devices on both sides of the MPL bonnets
by rotating the stems counterclockwise with about seven turns.
Hand-tighten until they are snug.
14. Gradually increase the opening pressure from zero psi until the rams
open.
15. After the rams are open, perform a number of cycles to ensure that
the rams are operating satisfactorily.
Maintenance tips for Hydril BOPs and the MPL system

1. Never use or operate the rams without the ram guide pins and the
bonnets in the open position, as the MPL system has a tendency to
twist the ram piston rod; then the ram block will not fit inside the
cavity. Torque the ram guide pins 75 ft-lbs, which need to be
checked frequently. For the same reason, never operate the rams
without the ram blocks installed.
2. If the ram piston rods are twisted by mistake, the only method of
turning the pistons is trying to turn them while the ram is in motion
and the bonnets are opened fully. Use a spanner on the ram piston
hub. This activity requires a careful approach and must be done
gradually. Do not try to use a chain tong on the ram piston rod end,
as damage of the coating will result. Reducing the fluid flow with a
needle valve will help slowing down the speed of the ram.
114
3. Never move the rams when either one of the doors are fully opened
(52 degrees or more) or when the bonnet bolts are tightened; if not,
serious damage can occur on the ram piston rods (bent piston rods
and deep scoring on the ram body sealing area).
4. The condition of the bearings remains fit for service when the rams
can be operated with only 80 to 200 psi. If the pressure to operate
(close) the rams increases, the bearings require replacement. Use
the Hydril signature testing procedure for this purpose. Watch for
trends, record pressures in the history files.
5. If the ram piston rod requires replacement, Hydril will supply the
ram lock screw separately from the piston. The torque required for
the lock screw is 4,000 ft-lbs! Not to worry! The assembly can be
tightened by hand, after which the MPL movement will apply the
correct torque when the ram is operated with 3,000 psi and the ram
blocks are inside the cavity. The lock screw has left-hand threads
capable of mating with the piston!
6. As a result of this it will only be possible to break the lock screw
when the piston is installed through the bonnet, the bonnet swung
open, the ram block hung, the piston retracted and the bonnet
closed and snugged. The ram block will isolate the piston rotation
and permit the removal of the lock screw with a large torque
wrench.
7. Hydril has renewed the MPL locknut and the bearings with a new
material, but this proved not to be very successful. For this reason
Hydril went back to their original design.
8. Figure 115 and Figure 116 provide images of a completely sheared
locknut, which failed when the BOP was subsea! It was made of the
newly designed material mentioned in point 7.
115
Figure 115 - Failure of the MPL locknut.
Figure 116 - Failure of the MPL locknut.
116
38. Shaffer ram-type BOPs
Figure 117 - Shaffer 15M 18¾-inch NXT BOP stack.
117
Figure 118 - Shaffer SL ram-type BOP with PosLocks installed.
Shaffer manufactures various models for land rigs and jack-ups.
118
Shaffer ram BOP proprietary nomenclature
Code Application/design Use

SL Lightweight and slim line Surface and subsea
BOPs
LWS Lightweight Surface and subsea
BOPs
LWP Lightweight for production and workover Surface BOPs
Sentinel Lightweight and compact, low-pressure Surface BOPs
BOPs
NXT Lightweight, slim line, boltless bonnet Surface and subsea
doors BOPs
LXT Lightweight, slim line, boltless bonnet Surface BOPs
doors
SLX Lightweight, slim line, low-torque bonnet Surface and subsea
studs BOPs
All the Shaffer ram-type BOPs basically have the same characteristics:
• Cast-iron body and bonnet doors (new Shaffer BOPs are also made of
forged steel).
• Hinged doors using a fluid pin.
• Ram cavity is tapered to a reduced height when the ram blocks reach
the closed position. There is only contact between ram block top seals
and cavity at the last section of the stroke of the ram piston.
• Manual or PosLock locking system; MultiLock and UltraLock locking
systems are required when VBRs are installed in the ram cavity.
• No separate top seals and front packer, but one integrated top seal/front
packer.
• Some newer Shaffer block designs also have independent top seal and
front packers.
119
Figure 119 - New Shaffer BOP suitable for subsea ram change-out.
The concept shown in Figure 119 is the Shaffer subsea ram change system.
Yellow ram block carousels are fitted within the confines of the BOP frame to
accommodate a change-out of different ram block configurations while
subsea.
The Shaffer model-SL ram-type BOP

The Shaffer BOP used subsea and on most land rigs is the model SL. Its
main features are the following:
• Cast-iron body and bonnet door.
• Hinged door using a fluid hinged pin.
• Ram cavity tapers of a reduced height when ram block is reaching the
bore at the closed position.
• PosLock system for fixed pipe rams.
• MultiLock and UltraLock systems when using VBRs.
Figure 120 - Shaffer SL ram preventer with PosLocks installed.
120
The fundamental differences between Shaffer and Cameron BOPs
• Shaffer BOPs have fluid hinges and a large number of bonnet bolts on
each bonnet door.
• Some Shaffer BOPs (NxT) have boltless bonnet doors that are opened up
with hydraulic power.
• Shaffer BOP bonnets are hinged open without using a hydraulic circuit.
• Standard Shaffer and Hydril bonnet bolts are tightened with high-torque
tools. There are no hydraulic bonnet bolts present.
• Several Shaffer BOPs have a bore seat seal installed at the top of the
ram cavities.
• Shaffer has a modification with wear pads installed in the cavity.
• The Shaffer PosLock and UltraLock systems work automatically and do
not require an additional hydraulic functions or hoses.
• Shaffer has developed a low-torque modification to use new bonnet door
seals, which require approximately 25% of the previous torque.
• Shaffer has developed a limited-height and low-weight 15M BOP.
• Shaffer cavity clearances between the ram blocks and the cavity are
larger than those of Cameron BOPs.
• Shaffer has different cavity clearances for shear/blind rams and for fixed
pipe rams.
• Most Shaffer ram blocks have one integrated packing element instead of
a top seal and separate front packer.
Shaffer PosLocks need to be adjusted for different ram sizes and cannot be
used with variable-bore packers.
Figure 121 - Interior of the body of a Shaffer ram-type BOP.
121
39. Ram packer pressure
Figure 122 - Ram packer internal forces.
Packer pressure is the internal elastomer compressive force generated

inside the ram packers when the closing hydraulic pressure drives the
ram assemblies into contact which each other. For the ram assembly to
contain wellbore pressure, the packer pressure must be higher than the
wellbore pressure that will be trying to get past the rubbers. Typically, the
closing hydraulic pressure generates several thousands of psi elastomer
pressure inside the ram packers.
This is sufficient to internally contain wellbore pressure. As the wellbore
pressure rises, the packer inserts pressure rises as well due to the
closing effect that the wellbore pressure has upon the ram blocks (wellbore
assist). With this mechanism, packer pressure is maintained above the
wellbore pressure.
When we have a worn-out ram cavity or worn ram rubbers, the closing
operating pressure is not able to generate the required packer pressure,
resulting in a leak. Especially a low bore pressure might leak; when little
wellbore pressure is available to assist support to the ram blocks, the top
seals are not sufficiently energized to form a proper seal.
122
40. Shaffer ram blocks and fixed pipe rams
Figure 123 - Shaffer pipe ram blocks: top seals/front packer

segment in one piece.
The Shaffer ram blocks are differently shaped different compared to Hydril
and Cameron ram blocks in that the integrated packer top seal and front
packer form one item. The disadvantage here is that when the top seals are
worn, the complete packer needs to be changed out. Normally the
vulnerable top packer is wearing at an accelerated rate compared to the
front packer.
Shaffer ram blocks are only sealing at the recess of the bore at the very end
of the stroke of the ram pistons. Several Shaffer BOPs have a kind of seal
seat similar to Hydril BOPs, protecting the top of the cavity at the bore.
Shaffer SL rams are designated for regular duty. They do not have the hard
inlay around the pipe bore and will not support drill pipe on the 18-degree
tool joint taper.
Shaffer SL-D ram preventers will support a 600,000-lb drill string load when
a tool joint is lowered onto the closed rams. There is a hard inlay welded
around the pipe bore to support the 18-degree taper on the bottom of the
tool joint and to support the drill string. The remainder of the block is made
of alloy steel with a hardness below Rc 22.
Shaffer no-weld cavity in ram BOPs

The new Shaffer SLX ram preventer has several wear plates installed in the
cavities.
This allows the ram BOP to be upgraded to an as-new condition by changing
out the seal seats, the side pads and the bottom skid plate. These items are
all field-replaceable.
123
Figure 124 - Shaffer cavity with replaceable parts.
Shaffer SL/SLX pipe rams

Shaffer ram blocks have extrusion plates extending vertically to support the
sides of the ram rubber (shown in Figure 125). This securely anchors the
rubbers next to the ram block and reduces the wear at this point. Wide
vertical faces provide extra ram rubber strength.
Figure 125 - Shaffer fixed pipe ram blocks for 10,000 psi and higher.
124
Most Shaffer pipe ram assemblies consist of three major elements:

• The ram block
• The ram rubber
• The ram holder
Some sizes have a separate top seal. In most Shaffer rams, two retracting
(shoulder) screws secure the ram holder to the ram block, but they permit
the block to move (slightly) inside the holder to ensure positive alignment of
the rubber faces as sealing contact occurs.
The ram rubber is mechanically secured to the block/holder assembly to
keep the rubber in place under extreme pressures. The design permits the
block to move slightly inside the holder, allowing controlled extrusion of the
rubber to create a tighter and more reliable seal.
The ram rubber is secured to the ram block by two retaining screws, which
fit into trunnion nuts. The trunnion nuts extend through holes in the two
steel extrusion plates moulded into the rubber to control the extrusion of the
rubber.
Figure 126 - Shaffer ram element.

Floating rubber ensures a positive seal at low and high pressures, even with
a (moderate) worn cavity. As the ram closes, the following sequence of
events occurs:
1. The rubber faces contact each other and the pipe.
2. The blocks move slightly to achieve alignment.
3. Further closing movement causes the rubber faces to seal around the
drill pipe and against each other. Simultaneously, the ram holder pushes
against the semicircular top seal and extrudes it upward to seal against
the seat of the BOP body. This creates the initial seal.
4. As the well pressure increases, the block moves up and closes the
clearance below the seat.
Self-centring of pipe is accomplished by angular guides protruding on the
top and bottom of ram blocks, which designed to close around a single string
of pipe. This self-centring feature automatically aligns the pipe string with
the ram bore, even if the string hangs off centre. Continuous-moulded ram
rubber has no separation between the semicircular top seal and the
horizontal face seal in most sizes.
125
41. The shaffer SLX ram

Floating ram blocks
Ram blocks are mechanically energized against the upper body seat area,
but only after the rams are completely closed. There is no abrasive
interference while the rams are cycled closed or open. The floating ram
blocks ensure a low-pressure sealing, as the seals are energized even
without wellbore pressure. The floating ram blocks enhance the sealing
ability while reducing wear or damage to the upper body seat, except in the
instance of oversized ram cavities.
Figure 127 - Seal seat installed. Figure 128 - New seal seat ready
to be installed.
Pressure-energized door sealing

The advantages of this specially designed bonnet door sealing are the
following:
• It contains fewer bonnet bolts.
• A much lower torque is required for the bonnet bolts.
• The radial seal is tolerant of corrosion in the seal seat area.
Figure 129 - Bonnet door Figure 130 - Details of bonnet door

seal. seal.
The initial low-pressure seal is created by the BOP door forcing the seal
carrier against the BOP body.
126
Figure 131 - Pressure build-up at bonnet door seal.
Figure 132 - Energized door seal while wellbore pressure is present.
127
Hinges on Shaffer BOPs

Shaffer BOPs have hinges installed that can be used to open the bonnets
“easily”. Usually a chain hoist or air tugger is required to open the bonnets
completely. Hydraulic lines are fed through the hinges to the open and
close circuit of the ram pistons. Sometimes a hydraulic leakage occurs at
these hinges.
The maximum wear at the pin is 0.004 inch. The wear at the hinge bracket
bore is maximally 0.006 inch, according to Shaffer specifications. The
hydraulic circuits are tested to 3,000 psi during in-between-well
maintenance.
A visual inspection is required during these tests, as drips are often
observed at the hinges. The hinges are to be greased regularly. This should
be done every time the BOP is on the surface. The hinge pins and seals of
the Shaffer rams can be changed when the bonnets are in place. Support for
the bonnets during this replacement is required to ensure that the seals and
pins are not damaged (large imposed bending moments with bonnets open).
Figure 133 - Shaffer hinge door assembly.
Due to the new bearing hinge assembly, the forces to open the doors are
reduced by 50%. Nevertheless, we still need to open the door with the help
of a tugger. Only in instruction movies these doors are opened up so easily!
Changing the bearings on Shaffer doors is much easier than on Hydril BOPs.
In order to operate the rams safely, the doors need to be opened at
a 57-degree angle.
128
42. Shaffer elastomer operation

temperature limits
Expiration
Type of component Type of elastomer Sell date (1)
date (2)
BOP ram block rubbers Nitrile 4 years 6 years
Hydrogenated
BOP ram block rubbers 4 years 7 years
Nitrile
BOP door seals Nitrile 3 years 5 years
Hydrogenated
BOP door seals 4 years 6 years
Nitrile
The sell date is the maximum Shaffer storage life.

Expiration date is the maximum total storage life.
Type of component Temperature in ºF Temperature in ºC

Standard ram rubber packers (pipe
-10ºF to +200ºF -23ºC to +93ºC
and shear)
T-SL (T70 or T75) ram rubber
-10ºF to +250ºF -23ºC to +121ºC
packers drill stem testing (pipe)
CS (critical service) ram rubbers
-10ºF to +350ºF -23ºC to +177ºC
drill stem testing (pipe)
Ultra-temperature ram rubber
+20ºF to +350ºF -7ºC to +177ºC
packers (pipe and shear)
Multi-ram rubbers +30ºF to +180ºF -1ºC to +82ºC
Bonnet door seals -10ºF to +350ºF -23ºC to +177ºC
Operator seals -10ºF to +225 ºF -23ºC to +107ºC
Ram shaft seals -10ºF to +350ºF -23ºC to +177ºC
Note: With intermitted exposure to +30ºF and above these operating

ranges should not create a problem, but Shaffer will not guarantee
that the sealing compounds be fully functional at elevated
temperatures.
129
Figure 134 - Test graph of Shaffer testing high-temperature seals.
Storage conditions for elastomers

Light, heat, ozone and stress are the four factors that have a detrimental
effect on any elastomer’s storage life. In addition, elastomers should not be
stored in water or grease and should not be hung from pegs.
Ideal conditions: less than +70ºF (+21ºC), in complete darkness (opaque
package), special package to protect from ozone, and stored in separate
compartments instead of stacks.
Good conditions: between +70 and +100ºF (+21 and +38ºC), indoors,
away from ozone-generating devices (i.e. printers, photocopiers, electric
motors, arc welders, etc.) or in low stacks. Any deviation from the ideal
conditions degrades the storage condition.
Poor conditions: more than +100 ºF (+38ºC) or below +40ºF (+4ºC), in
direct sunlight, in daylight, close to ozone-generating devices, or in high
stacks. Any one of these factors deviating from the ideal condition degrades
the storage condition. A combination of any of these factors will decrease
storage time even further.
Shaffer-recommended shelf life for elastomers
Type of part Ideal condition Good condition Poor condition

Ram rubbers 60 months 42 months 30 months
General rubber goods 60 months 42 months 30 months
Annular preventer
60 months 36 months 24 months
rubber
130
43. The shaffer hydraulic circuit
Figure 135 - Shaffer BOP hydraulic circuit going through the fluid
hinges.
Figure 136 - SL-type rams mount Figure 137 - SL-type rams

horizontally on preventers rated mount vertically on preventers
for working pressures of 10,000 rated for working pressures of
psi and lower, with the exception 15,000 psi and on the 7-1/16
of the 7-1/16 inch 10,000-psi inch 10,000-psi type.
type.
131
Closing ratios of shaffer SL and NXT ram BOPs
Minimum Recommended
Wellbore
SL Shaft Cylinder Closing pressure closing closing
sizes diameter diameter ratio pressure pressure
(psi)
(psi) (psi)
13⅝”
4¼” 10” 5.54 5,000 903 1,500
16¾”
13⅝”
5,000 461 1,500
16¾” 4¼” 14” 10.85
15,000 1,382 1,500
18¾”
13⅝”
5,000 703 1,500
16¾”
5¼” 14” 7.11 10,000 1,406 1,500
18¾”
15,000 2,109 2,200
21¼”
NXT 3¾” 14” 13.94 15,000 1,076 1,500
18¾” 4¼” 14” 10.85 15,000 1,382 1,500
Closing ratio = Piston area

Ram shaft area
This is not taken for any hydrostatic force of the mud column we might have
to overcome in deep water. The advantage of these relative low closing ratio
pressures is that Shaffer 15M ram BOPs require far less accumulator volume
to reach the closing ratio pressures when we compare this with the Cameron
TL (2,238 psi minimum closing pressure) or the Hydril (2,083 psi minimum
closing pressure) units.
Figure 138 - Schematic calculation of the closing ratio on Shaffer

rams.
132
44. The NXT double-ram BOP
Figure 139 - Shaffer NXT ram BOP.
The Shaffer NXT BOP is a recent design from Shaffer, which has the
following benefits:
• It has boltless BOP doors. The new NXT BOP door-locking system has
enabled hydraulic opening and closing of the doors, which will reduce the
ram change time from 4 hours to approximately 40 minutes.
• Hydraulic passages drilled through the body eliminate the need for
external pipes between the hinges. Each set of rams requires only one
opening and one closing line.
• There are two opening and two closing hydraulic ports, which are clearly
marked on the backside of the BOP. These extra hydraulic ports facilitate
connecting the control system to the preventer.
• A standard hydraulic accumulator system can provide sufficient pressure
and fluid to close any NXT ram preventer with the rated working
pressure in the wellbore.
• The boltless-door assembly is mechanized by using hydraulics for
locking, unlocking, opening and closing the door. The lock and unlock
process is done with hydraulic cylinders mounted on the doors that are
used to engage and disengage a locking-bar system. These load-bearing
lockbars are housed in the door grooves and energize the door and body
together.
• It is very important that the slots and eccentric mechanism of the doors
stay in spotless condition; mud and debris will jeopardize the operation
of the automatic doors.
In Module 4 we will explain the Shaffer NXT ram preventer in detail.
133
45. The shaffer shear/blind and shear

rams
Figure 140 - Shaffer shear/blind rams in operation.
Shaffer type-72 shear/blind rams

These rams shear pipe and seal wellbore in one operation. They also
function as blind rams to perform a complete shut-off (CSO) of the well in
order to secure the annulus should there be no pipe in the hole. To ensure
adequate shearing force, 14-inch or larger pistons should be used. These
pistons are standard in all BOPs rated to 10,000 psi and higher. Sometimes,
14-inch pistons are used to increase the shearing force when high-grade drill
pipe is used. When shearing a pipe subsea, a 3,000-psi closing pressure is
required.
When shearing, the lower blade passes below the upper ram block’s sharp
lower edge and shears the pipe. The lower section of the cut pipe is
accommodated in the space between the lower blade and the upper holder.
The upper section of the cut pipe is accommodated in the recess in the top
of the lower ram block.
134
The closing motion of the rams continues until the ram block ends meet.
Continued closing of the holders squeezes the semicircular seals upward into
sealing contact with the seat in the BOP body and energizes the horizontal
seal. The closing motion of the upper holder pushes the horizontal seal
forward and downward on top of the lower blade, resulting in a tight sealing
contact. The horizontal seal has a moulded-in support plate, which holds it in
place when the rams are open.
The hydraulic closing pressure normally required to shear drill pipe is below
1,500 psi with 14-inch pistons. However, this varies depending on the size,
weight and grade of the drill pipe. When shearing pipe in a subsea BOP
stack, a 3,000-psi closing pressure should be used. Try to shear the pipe the
first time, so give them “SHIT!”
Figure 141 - Shear/blind Figure 142 - Figure 143 -

rams in motion. Shear/blind rams Shear/blind rams
showing a bottom view. performing a CSO.
Figure 144 - Shaffer V-type shear rams.
Shaffer V-type shear rams

The Shaffer V-type shear ram enhances the features of the Shaffer T-72 ram
by increasing the range of pipe that can be sheared without modifications to
the BOPs. The type-V shear rams are capable of shearing at 20% lower
pressures than the standard shears. The type-V shear rams are capable of
shearing 6⅝-inch grade S-135 drill pipe at less than 2,700 psi operating
pressure (according to Shaffer figures). This typically allows the shear ram
to be put in any ram cavity on the BOP stack without the addition of booster
cylinders or control system upgrades.
135
Shaffer CV shear rams

The CV shear rams use the V-shear technology to reduce shear-operating
pressures while obtaining a reliable seal afterwards. The CV blocks shear and
seal in the 18¾-inch standard NXT BOPs.
Shafer casing shear rams

The Shaffer casing shear ram has extended capabilities to cut casing tubular
up to 13⅜ inch in an 18¾-inch bore BOP. The casing shear rams cannot
perform a CSO, as there is no blade seal installed.
Figure 145 - Shaffer casing shear rams.
V-type shear ram capacity

The larger opening in the lower sheared “fish”:
• Allows a better circulation down the remaining drill string
• Allows an easier entry when required to snub coiled tubing into the drill
string
• Requires less milling operations to land the overshot over the tool joint
when hung off in the BOP stack. Remember that V-type shear rams are
NOT blind rams.
Figure 146 - V-shear rams operating pressures compared to

standard shear/blind rams.
136
Figure 147 - Pipe after shearing by V-shear rams (enough to allow

circulation).
137
46. Shaffer multirams (VBRs)
Shaffer MultiRams are used when tapered strings are used. The MultiRams
are interchangeable with standard rams and blind/shear rams. The
MultiRams use the same holder and retracting screws as the other ram
assemblies. The only new parts are the ram block, top seal and special
packing assembly. When the MultiRam closes on a drill string, there are steel
segments moulded into the ram rubbers that move radially inward,
decreasing the bore size.
We have to be certain that the MultiRams are installed inside the bonnets
that have MultiLocks or UltraLocks installed. The PosLock bonnets can
only lock the rams in one position.
Figure 148 - Shaffer MultiRams closing on 5-1/2 inch (right-hand

upper blocks) and on 3-1/2 inch pipe (lower set of
blocks).
It is important to operate new variable-bore ram-packers prior to pressure

testing at least seven times in order to remove the coating applied to
remove the rubber elements from their moulds. It is possible for several
models of Shaffer MultiRam blocks to be improperly installed. Due to their
geometry, they can even be installed upside down!!
138
If the ram assembly is improperly installed, the ram block and BOP cavity
can be damaged when the ram is cycled. The ram assembly must be
installed with the top seal on top or damage will be the result. For the 18¾-
inch 10M and 15M BOPs, this means that the centring ear must be on the
bottom of the block.
Figure 149 - Proper installation of MultiRams on 18¾-

inch ram BOPs.
VBR sizes available for Shaffer ram BOPs
Ram type and working pressure (psi) VBR size (inches)

18¾” 10M SL / SLX / NXT 3½ to 5
18¾” 10M SL / SLX / NXT 5 to 7
18¾” 10M SL / SLX / NXT 5 to 6⅝
18¾” 15M SL / NXT 3½ to 5
18¾” 15M SL / SLX / NXT 3½ to 5½
18¾” 15M SL / NXT 5 to 7
139
47. Shaffer ram-locking systems
Shaffer PosLock system

The Shaffer PosLock system automatically locks the rams when they are
hydraulically moved into the closed position. When hydraulic pressure is
applied on the open side of the operating pistons, the rams are automatically
unlocked. The hydraulics required to operate the PosLocks are provided via
the opening and closing ports. Operating the PosLocks requires no additional
hydraulic functions or hoses.
Figure 150 -The Shaffer PosLock system.
The PosLock system in operation

When the closing hydraulic pressure is applied, the entire piston assembly
moves inward and pushes the rams into the wellbore. As the piston reaches
its fully closed position, the locking segments slide forward to the piston's
outer diameter (OD) and over the locking shoulder; the locking cone is then
pushed inward by the closing hydraulic pressure driving the locking
segments securely inside the recesses of the locking shoulder.
140
The locking cone holds the locking segments in position and is prevented by
a spring from vibrating outward should the hydraulic pressure be removed or
lost. The locking cone can be regarded as a second piston inside the main
piston.
The locking piston is forced inward by the closing hydraulic pressure and
outward by the opening hydraulic pressure. When opening hydraulic
pressure is applied, the locking cone moves outward and the locking
segments slide towards the piston's inner diameter (ID) along the tapered
locking shoulder. The piston is then free to move outward and to open the
rams.
A PosLock can only secure a fixed pipe ram and as the PosLock’s use is
complicated when the rams fitted with PosLocks are configured with VBRs.
Variable-bore rams are best fitted with MultiLocks or UltraLocks. The
operating pressure of the PosLocks is an indication of their setting. These
values must be recorded in the equipment history files for future reference.
Shear/blind UPR 3,5" pipe MPR 5" pipe LPR VBR on LPR VBR on
rams rams rams 5" pipe 3.5" pipe
1,300-1,400 1,000-1,200 1,000-1,200 1,350-1,450 1,000-1,700
Figure 151 - PosLock measurements (in psi) of a Shaffer 18 ¾ inch

10M LW BOP.
Figure 152 - PosLock components moving to close, but not yet

locked.
As for the locking piston and spring assembly (see Figure 152), the spring is
to keep the locking piston from creeping back in case of closing pressure
being lost.
141
Figure 153 - PosLock with the locking dogs being pushed into the
locking shoulder area and held there by the locking
piston.
Figure 154 - The yellow-coloured lock plate is visible at the aft of the
main piston.
Look at the locking plate mounted in the center of the back of the piston.
This plate keeps the piston from turning on the ram shaft when operating.
The plate also has to be removed once it is determined that the locking
pressure has to be increased or decreased, as the adjustment is made by
turning out the piston (increases the locking pressure) or turning in the
piston on the ram shaft threads (decreases he locking pressure). There are
two Allen screws that hold this plate in place; these screws must always be
properly reinstalled before installing the end cap.
142
The Shaffer PosLock system can be tested and calibrated in the

following way:
1. Set up a simple system as shown in Figure 155.
2. Slowly close the rams; when the pressure reaches 1,000 to 1,200 psi, a
small but rapid pressure will increase, as noted on the test gauge. This
pressure spike on the gauge is the closing and ‘bottoming-out’ of the
PosLock inner piston caused by the PosLocks. The pressure at which
the spike is observed is critical and should be recorded.
3. The same pressure spike can be seen when the rams are opened.
The closing pressure of fixed pipe ram PosLocks lies between 1,000 and
1,200 psi. The closing pressure for the shear/blind rams PosLocks lies
between 1,300 and 1,400 psi.
0 ~ 3,000
SHEAR
psi gauge /BLIND
Needle
valve
RAMS
5,000 psi
from aux.
charging
panel Close port Open port
Figure 155 - Rig-up for calibration (PosLocks).
143
48. Shaffer ultralock systems
The following UltraLock systems have been developed by Shaffer:

• UltraLock I Uses four locking rods with teeth on the lock rods and
dogs.
• UltraLock II Locking rods and wedges, friction/sliding contact
design.
• UltraLock II-A UltraLock II with button head lock rod.
• UltraLock II-B Major revisions to reduce stresses in the locking
components.
Figure 156 - The UltraLock I system.
The UltraLock I system features:

• Different-sized ram assemblies can be freely interchanged with no
adjustment required.
• The UltraLock I operator locks at any closing pressure with no preset
pressure range to ensure a lock.
• Operators lock on any pipe within the range of MultiRams.
• Four lock rods with machined teeth use the ratch-latch method to hold
the rams closed. (These were replaced in the UltraLock II system.)
144
Figure 157 - UltraLock I locking segment and dog.
UltraLock closing function features:

• The closing hydraulic pressure moves the locking piston into the closed
position.
• The load springs push the lock segments against the lock rods.
• The lock segment teeth are free to ratchet forward over the lock rod
teeth. This design would ‘follow’ or allow the locks to move forward
during a wellbore test. Wellbore assist ram blocks travel to allow the
extrusion plates to linearly increase packer pressure.
• A lock is achieved by the engagement of the teeth between the lock
segments and the lock rods.
• The engaged tooth design prevents wellbore forces from opening the
rams.
• Only two out of the four locking rods are engaged at the same time with
the locking dogs.
145
UltraLock I opening function
Locking rod Locking segment

Figure 158 - UltraLock I opening function.
Features:
• Hydraulic pressure is applied to the OPEN port, causing the unlock
piston to move away from the wellbore, thus lifting and separating the
locking segments from the lock rods.
• The unlock piston holds the locking segments clear of the teeth on the
locking rod as the main piston opens the rams.
146
UltraLock I Operation
Figure 159 - UltraLock I rods.
The UltraLock I rods are designed with the teeth on the alternate rods
located 0.060 inch offset to the opposite rod. The result is they lock every
0.060 inch of travel, but only two opposing rods provide locking at any
one time.
147
Shaffer UltraLock II System

The UltraLock II system was intended to replace the UltraLock I and utilizes
an entirely different design. The original UltraLock II was revised and
became the UltraLock IIA. Another major revision followed and it became
the UltraLock IIB. Shaffer recommends UltraLock IIB for deep-water use.
Figure 160 - The UltraLock IIA in the OPEN position.
148
UltraLock IIA operation
Figure 161 - UltraLock IIA system installed in a Shaffer double-ram

BOP.
149
Figure 162 - UltraLock IIA going into the close position.
Trapped hydraulic pressure must keep the lock piston stationary, while the
main piston is traveling into the closed position.
Figure 163 - UltraLock IIA at the end of the stroke.
150
The UltraLock IIB system
Figure 164 - UltraLock IIB system.
When the main piston has completed its stroke, the poppets vent pressure
from the lock chamber and allow the lock piston to move into the engaged
position, forcing the lock segments radially outward where they wedge
against the locking rods. The UltraLock IIB system is operationally identical
to the Ultralock IIA version, but the modified components are stronger and
can withstand increased operating pressure.
Rev A
Figure 165 - UltraLock IIA version.
151
Figure 166 - UltraLock IIB version.
Differences between UltraLock II A and UltraLock IIB systems:

1. The operating piston was reduced in length to allow strengthening of
the retainer plate.
2. Retainer plate inserts were eliminated, again to allow strengthening of
the retainer plate.
3. The lock/unlock piston was lengthened in order to provide better
coverage for the locking segments.
4. The cylinder head was made thicker, with a deeper recess to
accommodate the longer lock/unlock piston.
5. The IIB can be operated at 3,000 psi.
152
Figure 167 - UltraLock IIB in fully open/unlocked position (only one

of two poppets are depicted here).
In Figure 167 the following is demonstrated:

• The operating piston and lock/unlock piston are in the unlock/open
position.
• The poppet traps pressure in the lock chamber, preventing lock/unlock
piston movement.
• The locking wedges are not in contact with the locking surfaces.
Figure 168 - UltraLock IIB system in mid-stroke position, with the

poppets just making contact.

• The operating piston has moved until the poppets are touching the door.
• The lock/unlock piston is still held in the unlock/open position by the
fluid trapped in the lock chamber.
• The locking wedges are still not in contact with the locking surfaces.
153
Figure 169 - UltraLock IIB in the fully closed/locked position.

• The operating piston is in the fully closed and locked position.
• The poppets have been opened, venting the fluid and the lock/unlock
piston has moved to the lock position.
• The locking wedges are now locked between the lock piston and the
locking rods.
154
Questions Ram Preventers
1. What are the differences between the standard Cameron wedgelocks and
the ST Locks? Which type of Cameron rams have ST Locks?
2. Explain the operation of the ST Locks.
3. Explain why standard wedgelocks require a balance chamber.
4. Explain the procedure on how to fill the wedgelock balance chamber.
5. What are the differences between Cameron U and U-II BOPs?
6. Calculate the force on the 18¾-inch ram blocks with the bore pressure
of 15,000 psi (disregard the mud weight column on top of the rams).
7. Explain how to measure the Cameron ram cavity height. What are the
maximum vertical and horizontal clearances of the Cameron ram blocks
in their cavities?
8. What is the maximum allowable wear at the bore of Cameron rams?
9. Can you close another set of rams after the wedgelocks are closed?
Explain your answer.
10. Why should you isolate the hydraulics when performing maintenance on
a Cameron BOP? Explain how to isolate the hydraulics adequately.
11. Explain the advantage and the disadvantage of the Hydril Ram BOP seal
seat.
12. How can a twisted ram piston of the Hydril BOP be turned into its proper
position? What could cause the piston to twist?
13. How do we have to upgrade Hydril ram blocks for high temperatures?
14. How can you repair the hang-off area of the new Hydril ram blocks?
15. What is the torque setting of the Hydril shear ram upper blades, and
what tool is required to achieve this torque?
16. Following a pipe-shearing event, what is the advantage of non-fully
closed-off crimped pipe at the top of the fish?
17. When the weep hole of the Hydril ram is showing an escape of fluid while
there is no wellbore pressure applied, what could be the cause?
18. Explain the difference between the Cameron and the Hydril piston seals.
19. How much is the torque reduction of the Hydril conversion from standard
bonnets to low-torque bonnets?
20. Does the lowering of the torque of the bonnets have an effect of the
inspection interval of the Hydril bonnet bolts?
21. Mention 5 differences between Shaffer and Cameron BOPs.
22. What is the disadvantage of having integrated top seals and front
packers with Shaffer ram blocks?
23. Explain the advantage of the recently developed bonnet seals of the
bonnets of Shaffer ram-type BOPs.
24. What is the minimum angular opening of Shaffer bonnets to operate the
rams safely? What can happen if this is ignored?
25. Explain the ideal storage conditions of the BOP elastomers.
26. What is the minimum closing pressure of the 18¾-inch Shaffer SL ram?
27. What are the major benefits of the Shaffer NXT rams?
155
28. Why can Shaffer V-type shear rams not perform a CSO?
29. What happens if you install a Shaffer MultiRam upside down?
30. Explain step by step how the PosLock system works.
31. Explain why it is not desirable to use VBRs in bonnets fitted with
PosLocks.
32. Explain the operation of the MultiLocks.
33. How many UltraLock rods are actually securing the rams?
34. At what distance intervals of the travel can a ‘lock’ be provided?
35. Explain the design features of the upgrade of UltraLock IIB over the
UltraLock II system.
156
49. Table of figures

Figure 1 - Cameron TL BOP with ST-Locks installed................................ 10
Figure 2 - Cameron U-II with open bonnets. ......................................... 11
Figure 3 - Cameron type-U preventer with manual locks (which are
only used for surface BOP applications). .............................. 12
Figure 4 - The Cameron type U-II ram preventer................................... 13
Figure 5 - Cameron type T ram preventer with ST-Locks installed. ........... 14
Figure 6 - 18-3/4 inch 15M Cameron TL-type ram BOP with RamLocks. .... 15
Figure 7 - Cameron TL blind-shear rams with wear plates suitable for
H2S. ............................................................................... 16
Figure 8 - Cameron U-II hydraulic control system.................................. 17
Figure 9 - Severely damaged tail-rod by the wedgelock caused by
human error! ................................................................... 18
Figure 10 - Wedgelock components. .................................................... 19
Figure 11 - Wedgelock open. .............................................................. 19
Figure 12 - Wedgelocks closed. ........................................................... 19
Figure 13 - Wedgelock and tail rod in the open position. ......................... 19
Figure 14 - A tail rod showing severe damage after a collision with the
wedgelock. ...................................................................... 20
Figure 15 - Cameron U-II preventer installed with a wedgelock
installed. ......................................................................... 21
Figure 16 - ST-Lock ram is closed but the wedge is not locked yet. .......... 22
Figure 17 - The ST-Locks in the ram-closed and the ram-open position..... 23
Figure 18 - ST-Lock in detail, before locking the ram.............................. 24
Figure 19 - ST-Lock in detail, before locking the ram.............................. 25
Figure 20 - Locking rings of the ST-Lock in detail................................... 26
Figure 21 - ST-Lock sequence valve..................................................... 26
Figure 22 - Cameron RamLock............................................................ 27
Figure 23 - RamLock stage 1: Opening pressure is still applied and
unlocked. ........................................................................ 29
Figure 24 - RamLock stage 2: Closing pressure is applied, opening the
fluid vents; the main piston reaches the end of its stroke,
and is still unlocked. ......................................................... 30
Figure 25 - RamLock stage 3: Ram is CLOSED; the whistle pistons and
secondary piston are moving and starting to LOCK. ............... 31
Figure 26 - RamLock stage 4: Secondary piston is bottoming out; the
ram is CLOSED and fully LOCKED by the whistle pistons
and LOCK components. ..................................................... 32
Figure 27 - RamLock stage 5: The RamLock UNLOCK pressure is
applied and the closing fluid is venting; the ram is still
CLOSED but starting to UNLOCK. ........................................ 33
Figure 28 - RamLock stage 6: Secondary piston at the end of stroke;
the whistle pistons are now free from the LOCKING
component. The ram is still CLOSED but is now fully
UNLOCKED. ..................................................................... 34
Figure 29 - RamLock stage 7: Fully UNLOCKED; the OPENING pressure
is applied, the CLOSING fluid is venting, the main piston is
moving, and the ram is OPENING........................................ 35
Figure 30 - RamLock stage 8: The OPENING pressure is applied; rams
are now completely OPEN and UNLOCKED............................ 36
Figure 31 - RamLock in automatic mode. Stage 1: OPENING pressure
is applied. ....................................................................... 37
157
Figure 32 - RamLock in automatic mode. Stage 2: CLOSING pressure

is applied, the fluid vents are OPENED and the main piston
is moving to CLOSE...........................................................38
but not yet LOCKED; the secondary piston is moving to
start LOCKING and the fluid is vented through the
sequence valve.................................................................39
and fully LOCKED..............................................................40
Figure 35 - RamLock in automatic mode. Stage 5: RamLock UNLOCK
pressure is applied, the CLOSING fluid starts to vent; the
ram is still CLOSED. ..........................................................41
Figure 36 - RamLock in automatic mode. Stage 6: The secondary
piston at the end of its stroke and the whistle pistons are
now free from the LOCKING components. The ram is still
CLOSED but fully UNLOCKED. .............................................42
Figure 37 - RamLock in automatic mode. Stage 7: The ram is fully
UNLOCKED; the OPENING pressure is applied, the
CLOSING fluid is venting, the main piston is moving, and
the ram is OPENING. .........................................................43
Figure 38 - RamLock in automatic mode. Stage 8: The OPENING
pressure is applied; the ram is now completely UNLOCKED
and OPEN. .......................................................................44
Figure 39 - Cameron 15M BOP showing forces for the closing ratio
calculation. ......................................................................45
Figure 40 - Cameron T-type BOP hydraulic circuit. .................................46
Figure 41 - Damaged piston hub on a Cameron ram...............................48
Figure 42 - Cameron T variable-bore rams. ...........................................50
Figure 43 - VBR packer. .....................................................................51
Figure 44 - FlexPacker NR. .................................................................52
Figure 45 - Cameron U-II type DSV shear rams. ....................................55
Figure 46 - Shear/blind rams with a stellite enforcement on the blade. .....56
Figure 47 - Hydraulic stud of Cameron U-II BOP (old style). ....................57
Figure 48 - Torque table with different grease coefficients. ......................58
Figure 49 - Cross-section of the Cameron U-II tensioning system.............60
Figure 50 - Hydril 15M BOPs with MPL. .................................................62
Figure 51 - Hydril's new, compact design of the 15M BOP. ......................63
Figure 52 - Brand new Hydril ram-type BOP 5-inch block. .......................64
Figure 53 - A new front packer closing on a drill pipe..............................65
Figure 54 - A moderately worn front packer closing on a drill pipe. ...........66
Figure 55 - An extensively worn front packer closing on a drill pipe. .........67
Figure 56 - Location of the upper ram block seal and upper seal seat at
the bore with the rams in the fully closed position. ................68
Figure 57 - Hydril fixed pipe rams (standard-temperature
applications). ...................................................................69
Figure 58 - Hydril fixed pipe ram (no packer has been installed). .............70
Figure 59 - High-temperature application on Hydril ram blocks. ...............71
Figure 60 - Closing/opening ratio with 5 inch pipe rams installed
(Source: Hydril Operator’s Manual)......................................72
Figure 61 - Torque table for Hydril 15M compact rams............................73
Figure 62 - Hang-off capacities and dimensions of Hydril ram BOPs
(source: Hydril Operator’s Manual 2003). .............................74
Figure 63 - Clearances cavity-ram block for Hydril 10/15M ram BOPs. ......75
Figure 64 - The Hydril VBR block. ........................................................76
Figure 65 - New-style Hydril VBR front packer secured with studs. ...........77
Figure 66 - VBR 4-1/2 to 7 inch closing/opening ratio graphs (Source:
Hydril).............................................................................78
158
Figure 67 - VBR 3-1/2 to 5-1/2 inch closing/opening ratio graphs

(Source: Hydril). .............................................................. 79
Figure 68 - Old-style Hydril VBR packers. ............................................. 80
Figure 69 - Old-style shear/blind ram blocks. ........................................ 81
Figure 70 - Old-style Hydril upper and lower shear ram blocks. ............... 82
Figure 71 - New-style Hydril shear/blind and casing shear ram torque
tables. ............................................................................ 82
Figure 72 - Shearing procedure for 15M Hydril ram-type BOP.................. 83
Figure 73 - New-style blind/shear ram lower blade carrier. ..................... 84
Figure 74 - New-style blind / shear ram upper blade carrier. ................... 84
Figure 75 - New-style casing shear ram lower blade............................... 85
Figure 76 - New-style casing shear ram upper blade. ............................. 85
Figure 77 - Closing/opening ratio of shear rams with different-sized
operator pistons. .............................................................. 86
Figure 78 - Hydril new-style casing shear rams. .................................... 87
Figure 79 - Samples of sheared casing and drill pipe sections using
casing shear rams. ........................................................... 87
Figure 80 - Shearing table from Hydril (Source: Hydril Operating
Manual 2003)................................................................... 88
Figure 81 - Hydril ram bonnet (old style).............................................. 89
Figure 82 - Conventional ram BOP operation......................................... 90
Figure 83 - New-style Hydril bonnet, showing its metallurgic
composition. .................................................................... 91
Figure 84 - New-style Hydril bonnet. Clearly visible is the port inside
the bonnet going to the transfer ring of the MPL. .................. 91
Figure 85 - Fluid ports going through the fluid hinges............................. 92
Figure 86 - Hydraulic circuit on Hydril BOP. Note: This is a surface BOP
with manual locks............................................................. 92
Figure 87 - Schematic view of Hydril ram BOP fluid hinge. ...................... 93
Figure 88 - Bonnet flange of Hydril 15M BOP (not converted to low-
torque application). .......................................................... 94
Figure 89 - Exploded view of the old-style Hydril bonnet......................... 95
Figure 90 - Cross-section of bonnet bore and piston rod. ........................ 96
Figure 91 - Hydril ram bonnet piston seals. .......................................... 97
Figure 92 - Hydril ram body (without low-torque upgrade) showing the
seal characteristics when made up and pressurized. .............. 98
Figure 93 - Order of tightening the bonnet bolts on Hydril BOPs. ............. 99
Figure 94 - The (first) upgraded bonnet seal assembly in three
different conditions. ........................................................ 100
Figure 95 - Seal ring carrier installed in the Hydril bonnet (old style)...... 101
Figure 96 - Hydril ram cavity with wear plate modification and seal
seat.............................................................................. 102
Figure 97 - Hydril seal seat assembly................................................. 102
Figure 98 - Replaceable seal seat assembly of an 18-3/4 inch 15M
BOP.............................................................................. 103
Figure 99 - Wear limit on Hydril 15M ram BOPs. .................................. 104
Figure 100 - Ram cavity wear plate of the Hydril BOP........................... 104
Figure 101 - Conventional Hydril BOP bonnet with MPL......................... 105
Figure 102 - The ram is held closed and sealed only with the MPL. ......... 106
Figure 103 - MPL mechanism in operation. ......................................... 107
Figure 104 - The locknut position. ..................................................... 108
Figure 105 - Complete MPL assembly in motion................................... 109
Figure 106 - MPL clutch plates. ......................................................... 109
Figure 107 - MPL clutch assembly. .................................................... 109
Figure 108 - Hydril MPL components.................................................. 110
Figure 109 - Exploded view of the clutch assembly. ............................. 110
Figure 110 - MPL clutch mechanism................................................... 111
159
Figure 111 - MPL without its cover. .................................................... 112

Figure 112 - Schematic of operation of the MPL ratchet. ....................... 112
Figure 113 - Liner locked.................................................................. 113
Figure 114 - Liner locked.................................................................. 113
Figure 115 - Failure of the MPL locknut............................................... 116
Figure 116 - Failure of the MPL locknut............................................... 116
Figure 117 - Shaffer 15M 18¾-inch NXT BOP stack. ............................. 117
Figure 118 - Shaffer SL ram-type BOP with PosLocks installed. .............. 118
Figure 119 - New Shaffer BOP suitable for subsea ram change-out. ........ 120
Figure 120 - Shaffer SL ram preventer with PosLocks installed............... 120
Figure 121 - Interior of the body of a Shaffer ram-type BOP. ................. 121
Figure 122 - Ram packer internal forces. ............................................ 122
Figure 123 - Shaffer pipe ram blocks: top seals/front packer segment
in one piece. .................................................................. 123
Figure 124 - Shaffer cavity with replaceable parts. ............................... 124
Figure 125 - Shaffer fixed pipe ram blocks for 10,000 psi and higher. ..... 124
Figure 126 - Shaffer ram element. ..................................................... 125
Figure 127 - Seal seat installed. ........................................................ 126
Figure 128 - New seal seat ready to be installed. ................................. 126
Figure 129 - Bonnet door seal. .......................................................... 126
Figure 130 - Details of bonnet door seal. ............................................ 126
Figure 131 - Pressure build-up at bonnet door seal. ............................. 127
Figure 132 - Energized door seal while wellbore pressure is present. ...... 127
Figure 133 - Shaffer hinge door assembly. .......................................... 128
Figure 134 - Test graph of Shaffer testing high-temperature seals.......... 130
Figure 135 - Shaffer BOP hydraulic circuit going through the fluid
hinges. .......................................................................... 131
Figure 136 - SL-type rams mount horizontally on preventers rated for
working pressures of 10,000 psi and lower, with the
exception of the 7-1/16 inch 10,000-psi type. ..................... 131
Figure 137 - SL-type rams mount vertically on preventers rated for
working pressures of 15,000 psi and on the 7-1/16 inch
10,000-psi type. ............................................................. 131
Figure 138 - Schematic calculation of the closing ratio on Shaffer rams. .. 132
Figure 139 - Shaffer NXT ram BOP..................................................... 133
Figure 140 - Shaffer shear/blind rams in operation............................... 134
Figure 141 - Shear/blind rams in motion............................................. 135
Figure 142 - Shear/blind rams showing a bottom view.......................... 135
Figure 143 - Shear/blind rams performing a CSO. ................................ 135
Figure 144 - Shaffer V-type shear rams.............................................. 135
Figure 145 - Shaffer casing shear rams. ............................................. 136
Figure 146 - V-shear rams operating pressures compared to standard
shear/blind rams............................................................. 136
Figure 147 - Pipe after shearing by V-shear rams (enough to allow
circulation)..................................................................... 137
Figure 148 - Shaffer MultiRams closing on 5-1/2 inch (right-hand
upper blocks) and on 3-1/2 inch pipe (lower set of blocks).... 138
Figure 149 - Proper installation of MultiRams on 18¾-inch ram BOPs...... 139
Figure 150 -The Shaffer PosLock system............................................. 140
Figure 151 - PosLock measurements (in psi) of a Shaffer 18 ¾ inch
10M LW BOP. ................................................................. 141
Figure 152 - PosLock components moving to close, but not yet locked. ... 141
Figure 153 - PosLock with the locking dogs being pushed into the
locking shoulder area and held there by the locking piston. ... 142
Figure 154 - The yellow-coloured lock plate is visible at the aft of the
main piston.................................................................... 142
Figure 155 - Rig-up for calibration (PosLocks). .................................... 143
160
Figure 156 - The UltraLock I system. ................................................. 144

Figure 157 - UltraLock I locking segment and dog. .............................. 145
Figure 158 - UltraLock I opening function. .......................................... 146
Figure 159 - UltraLock I rods. ........................................................... 147
Figure 160 - The UltraLock IIA in the OPEN position. ............................ 148
Figure 161 - UltraLock IIA system installed in a Shaffer double-ram
BOP.............................................................................. 149
Figure 162 - UltraLock IIA going into the close position. ....................... 150
Figure 163 - UltraLock IIA at the end of the stroke. ............................. 150
Figure 164 - UltraLock IIB system. .................................................... 151
Figure 165 - UltraLock IIA version. .................................................... 151
Figure 166 - UltraLock IIB version. .................................................... 152
Figure 167 - UltraLock IIB in fully open/unlocked position (only one of
two poppets are depicted here). ....................................... 153
Figure 168 - UltraLock IIB system in mid-stroke position, with the
poppets just making contact. ........................................... 153
Figure 169 - UltraLock IIB in the fully closed/locked position. ................ 154
161
162
Module 02 - 02 Annual preventer 1.0
Chapter 02
Annular preventers
1 Hydril GL preventers .............................................................. 164

2 Shaffer spherical annular preventers ........................................ 179
3 Table of figures ..................................................................... 196
163
1 Hydril GL preventers
Figure 1 - Hydril GL annular preventer.
The Hydril GL annular preventer has a unique design that is not found on
any other annular preventers. This type of preventer has a secondary
chamber installed, which can be connected with either the open or the close
side.
The first part of the section on annular preventers deals with the optional
hook-up for surface operations, which uses a closed hydraulic system. It is
included in this course material because there is a new trend to use BOP
control systems subsea that have a full recovery system to surface; they are
therefore closed hydraulic systems. Hydril is momentarily considering these
old surface system arrangements for subsea adaptation, in which the
hydraulic returns are brought back to the surface.
164
Surface Operation Hydril GL: the standard surface hook-up

With this hook-up the secondary chamber is connected to the opening
chamber, which has the following advantages:
a) This hook-up requires the least amount of control fluid and has the
fastest closing time.
b) The control pressure to the closing chamber raises the piston and closes
the packing unit, thus creating the seal-off.
c) The return flow from the opening chamber splits to fill the secondary
chamber and balance flows to the system control reservoir (closed HPU
system).
Figure 2 - Hydril GL standard surface hook-up.
165
Surface operation: the optional surface hook-up

The secondary chamber is connected to the closing chamber, which has the
following advantages:
a) This hook up requires the least amount of closing pressure for an
optimum closing force.
b) The control pressure to the closing chamber and the secondary chamber
raises the piston, closing the packing unit to create a seal off.
c) Return flow from the opening chamber flow to the control reservoir
(closed HPU system).
Figure 3 - Hydril GL optional surface hook-up.
166
Stripping operation at the surface BOPs
Figure 4 - Stripping operation of Figure 5 - Stripping operation of

standard surface hook- optional surface hook-
up. up.
The stripping operations during the standard and the optional hook-up are
similar; however, because of the larger closing volume in the optional
surface hook-up, the pressure surges are lower than those at the standard
surface hook-up.
The stripping procedures provide the following:
1. There will be a full seal-off while rotating or stripping drill pipe and tool
joints.
2. Slight leakage prolongs the packing unit life by providing lubrication.
3. Slow tool joint stripping speeds reduce the surge pressure.
4. It is a good practice to grease the tool joints during stripping-in.
5. The surge absorber accumulator (an 11-gallon accumulator is the
minimum capacity) is installed for faster closing-pressure response and
to reduce the pressure peaks when the tool joints are passing through
the closed preventer element.
6. The precharge pressure of the stripping bottle should be low
(approximately 500 to 700 psi).
167
The following graphs clearly show that the optional hook-up results in lower
closing pressures.
STANDARD HOOK-UP
HYDRIL Reduced Closing Pressures for Generic Casing Sizes GL 18¾ inch 5M
MD Packing Unit Closing Pressure
Figure 6 - Standard hook-up surface closing-pressure chart for drill

pipe and casing.
OPTIONAL HOOK-UP
HYDRIL Reduced Closing Pressures for Generic Casing Sizes GL 18¾ inch 5M
MD Packing Unit Closing Pressure
Figure 7 - Optional hook-up surface closing-pressure chart for drill

pipe and casing.
168
Subsea operation of the Hydril GL annular BOP
Figure 8 - Three different set-ups for the Hydril GL preventer in

subsea operations.
The hydrostatic pressure of the drilling fluid column exerts an opening force
on the BOP piston because of unbalanced areas. The hydrostatic pressure of
control fluid column has no effect on opening and closing chambers, because
they have equal areas.
The three hook-up techniques shown here achieve a means to compensate
for the effects of the drilling fluid on the BOP annular piston. These three
hook-ups are:
1. The standard hook-up: the secondary chamber is connected to the
opening chamber.
2. The optional hook-up: the secondary seal is connected to the closing
chamber.
3. The counterbalance hook-up: the secondary chamber is connected with
the mud column of the marine riser through a separating accumulator.
169
Subsea operation of the Hydril GL annular BOP

When operating any annular BOP subsea the hydrostatic pressure of the
drilling fluid column in the marine riser exerts an opening force on the
annular BOP. Therefore, the closing pressures required are equal to the
surface installation closing pressures plus a compensating pressure (ΔP) to
account for the opening force exerted by the weight of the drilling-fluid
column.
The GL annular BOP’s secondary chamber should be hooked up using one of
the three techniques to realize the full benefits of the GL-type annular
preventer. The opening and closing chamber areas are equal and therefore
the hydrostatic pressure of the control fluid has no effect.
Two of the hook-up techniques require adjustment of the closing pressure by
adding pressure (ΔP) to compensate for the drilling fluid column hydrostatic
pressure in the marine riser (a function of water depth and drilling-fluid
density).
A counterbalance hook-up technique automatically compensates for the
effects of subsea operations. The area of the secondary chamber is equal to
the area acted on by the hydrostatic pressure of the drilling-fluid column.
Thus, when the secondary chamber is connected to the marine riser, the
opening force exerted by the drilling-fluid column is automatically
counterbalanced.
CLOSING PRESSURE COMPARISON (in psi)

SUBSEA HOOK-UP
(18¾-inch 5M Hydril GL 5,000-psi well pressure with 16 lbs/gallons
of drilling fluid)
Water STANDARD OPTIONAL COUNTER BALANCE
depth
(feet) Secondary chamber Secondary chamber Secondary chamber
to OPENING to CLOSING to MARINE RISER
chamber chamber
500 1,140 785 1,050
1,000 1,225 845 1,050
1,500 1,310 905 1,050
2,000 1,400 965 1,050
2,500 1,485 1,025 1,050
3,000 1,570 1,085 1,050
3,500 1,660 1,145 1,050
4,000 1,745 1,205 1,050
4,500 1,835 1,275 1,050
5,000 1,920 1,325 1,050
=Recommended hook-up
170
Figure 9 - Closing pressure secondary chamber connected to opening

chamber; relation between wellbore pressure and drill
pipe size.
Figure 10 - Closing pressure secondary chamber connected to

opening chamber; required pressure adjustment due to
water depth and mud weight.
171

closing chamber; relation between wellbore pressure and
drill pipe size.

closing chamber; required adjustment due to water
depth and mud weight.
172

marine riser; relation between wellbore pressure and
drill pipe size.
Figure 14 - Precharge graph standard hook-up. Calculation: 0.8 x

(surface closing pressure + 0.41 x water depth).
173
Figure 15 - Precharge graph optional hook-up. Calculation: 0.8 x

(surface closing pressure + 0.41 x water depth).
Figure 16 - Precharge graph counterbalance hook-up. Calculation:

0.8 x (surface closing pressure + 0.41 x water depth).
Note: The 0.41-psi/ft gradient used in the equations of the previous page is
calculated as follows: 0.41 psi/ft is the pressure gradient for the
control fluid (water and water/soluble oil) using a specific gravity of
the mixture = 0.95 and 0.433 psi/ft pressure gradient for the
freshwater.
174
Subsea stripping operations

Drill pipe is sometimes rotated and tool joints need to be stripped through a
closed subsea Hydril GL annular BOP packing unit, while a seal-off on the
pipe needs to be maintained. To ensure a long packing life we have to adjust
the closing chamber pressure to the low level that is still maintaining a seal
on the drill pipe, but also allowing a slight amount of drilling fluid to pass
through the packing unit in order to cool and lubricate the element.
The annular preventer regulator should be set to maintain the proper closing
chamber pressure. In subsea applications, a surge bottle of approximately
10 US gallons should be connected to the closing chamber. This surge
absorber prevents excessive high-pressure surges when stripping tool joints
through a closed packing unit. Slow tool joint stripping speeds are reducing
the surge pressures, and therefore prolong the packing element’s lifespan.
The closing chamber absorber should be precharged to 80% of the sum of
the closing pressure for drill pipe being used: a zero wellbore pressure plus
the hydrostatic pressure of the control fluid.
The Hydril GL sometimes has an opening chamber surge bottle installed.
This is done when the blow-out control system does not permit a free,
bidirectional control fluid flow from the opening chamber during stripping
operations. This surge bottle is normally precharged to 80% of the seawater
bottom pressure (0.445 x water depth).
For shallow-water operations or when a strip drill is planned it makes sense
to file off tong marks from the tool joints and add grease (NO DIPE DOPE!)
to the tool joints. It does not make sense to do this in deep-water operations
if there is no drill, as there will be many tool joints passing through the
annular BOP, which were already located in the marine riser.
Engineering data of the Hydril GL 18¾-inch 5M annular BOP:
• Volume close chamber: 44 US gallons
• Volume open chamber: 44 US gallons
• Volume secondary chamber: 20 US gallons
• Piston stroke: 10 inch
• Port size: 1-1/2 inch NPT
• Weight: 34,160 lbs
• Torque jaw-operating screw: 400 ft-lbs
175
Figure 17 - Pull-down assembly of the Hydril GL annular preventer.
176
Counterbalance hook-up for water depths of more than 1,200 ft
Figure 18 - Counterbalance hook-up of Hydril GL annular preventer.
In this set-up the secondary chamber is connected with the marine riser.
The counterbalance technique automatically compensates for the effects of
subsea operations. The area of the secondary chamber is equal to the area
acted on by the hydrostatic pressure of the drilling-fluid column. Thus, when
the secondary chamber is connected to the marine riser, the opening force
exerted by the drilling-fluid column is automatically counterbalanced.
The closing pressure will be the same as the standard surface hook-up,
regardless of the water depth and drilling-fluid density, and thus eliminating
calculations and control decisions at the time of the closure. The control
pressures used in the table in figure 19 can be used for the standard hook-
up. The Hydril accumulator is specifically designed for this application.
The connection of the marine riser must be located above the uppermost
blowout preventer. If the marine riser connection is located in the LMRP, the
drilling-fluid connection can be made through a stab similar to the choke and
kill stabs.
The table in Figure 19 presents the average closing pressures to establish a
seal-off in the Hydril GL BOPs for standard surface installation (secondary
chamber to opening chamber).
Hydril GL annular preventer

Pipe OD 13-5/8" 5M 18-3/4" 5M
Pipe OD Well pressure (psi) Well pressure (psi)
2,000 3,500 5,000 2,000 3,500 5,000
7 inch 900 950 1,100 700 825 950
5 inch 900 1,000 1,100 1,000 1,050 1,100
3½ inch 1,200 1,500 1,500 1,050 1,000 1,100
Full closure 1,400 1,500 1,500 1,500 1,500 1,500
Figure 19 - Closing pressure chart of Hydril GL-type annular BOP.
177
For the optional surface hook-up (secondary chamber to closing chamber),

multiply the pressure of the table shown above with Γ, which is the ratio of
the closing chamber area to the sum of the closing chamber plus the
secondary chamber areas. This factor is used to adjust the closing pressures
for the secondary chamber to the closing chamber hook-up.
GL 5M 13-5/8 inch 18-3/4 inch

Γ 0.71 0.69
Dynamic Seals Static Seals

Figure 20 - Different types of seals.
The dynamic seals are installed on the piston, the body sleeve and on the
adapter ring. Ensure that the bottom internal ring on the adapter ring is
facing down. The bottom internal ring on the annular cap should be facing
up. Static seals are installed on the outer adapter ring and on the annular
head.
All the hydraulic internal seals must to be changed at least every three
years, regardless their condition (OEM recommendation).
178
2 Shaffer spherical annular preventers
Lower housing
Upper housing
Adaptering
Piston
Element
Figure 21 - Exploded view of Shaffer 5M Spherical wedgecover

annular BOP.
Shaffer offers two types of annular preventers: the wedgecover and the
bolted-cover type. In most subsea BOPs the wedgecover model is used.
Most Shaffer annular preventers used for subsea applications have a hubbed
connection.
Shaffer annular preventers are wellbore-assisted, meaning the wellbore
pressure will maintain a pressure on the piston to maintain a seal. That does
not mean that only the wellbore pressure will keep the annular preventer
closed.
Shaffer manufactures special lightweight models for airlifting operations (on
land rigs in mountainous regions) and provides special arctic models for
extremely low-temperature service.
179
Figure 22 - Shaffer sealing element with steel reinforcing segments.
The element of the Shaffer annular preventer is steel-reinforced. The

element should seal in three places:
a) Around the pipe closing off the annulus
b) At the top, sealing off at the annular upper housing area
c) At the bottom, sealing off at the piston area
The steel segments moulded into the element partially close over the rubber
to prevent excessive extrusion when sealing under high pressures. The
segments always move out of the wellbore when the element returns to the
OPEN position.
180
Mud column
Wellbore
pressure
Figure 23 - Shaffer annular preventer closed on drill pipe.
The wellbore pressure will assist the annular preventer. However, the weight
of the mud column above the annular preventer in the marine riser acts as
an opening force. The Shaffer annular preventer requires 1,500-psi closing
pressure when closing on 5-inch drill pipe.
The following table shows the recommended MAXIMUM closing pressures of

the Shaffer 5M 18¾-inch annular BOP with two different type of annular
elements installed.
181
STANDARD ELEMENT CASING ELEMENT (*3)

WP (*1) (in Close (*2) WP (*1) Close (in
Tubular size
psi) (in psi) (in psi) psi)
5-inch drill pipe 5,000 1,500 2,000 1,500
6½-inch drill collar 5,000 1,500 5,000 1,500
7-inch casing 5,000 1,500 5,000 1,500
9⅝-inch casing 5,000 1,000 (min.) 5,000 1,500
13⅜-inch casing 2,000 600 (min.) 5,000 1,500
16-inch casing N/A N/A 5,000 1,500
(*1) This is the maximum pressure and must be observed to prevent

collapse of the tubular.
(*2) Damage to the tubular may be caused by the element's segment
contact.
(*3) Shaffer casing elements are not recognized by API Spec 16A.
Note: Once the element's segments contact the tubular, additional closing
pressure may not affect a tighter seal.
Shaffer 5M Hydrostatic effects

1600
1400
Closing chamber pressure
1200
1000
800
600
400
200
0
0 500 1000 1500 2000 2500 3000 3500
Simulated riser pressure in psi
Figure 24 - Influence of riser annulus hydrostatic pressure versus

closing pressure for a Shaffer 5M annular BOP.
182
Figure 25 - Closing pressure adjustment due to mud weight water

depth for a Shaffer 5M annular BOP.

depth for a Shaffer 10M annular BOP.
183
Recommended closing Pressures Shaffer 18-3/4-5M on Large Pipe
18
16
14
Pipe size in inches
12
10
0
0 200 400 600 800 1000 1200 1400 160
Closing pressure in psi
Figure 27 - Reduction of the closing pressure on large pipe.
For casing, the closing pressure must be reduced according the table shown
below. This table should be displayed on the driller's BOP panel in the
driller’s control room. When the Shaffer annular preventer is closed on a
13⅜-inch casing string, there is a risk that the top of the steel fingers will
make indents in the casing. Some drilling contractors grind off the top of the
steel fingers of the element. However, Shaffer supplies a special casing
element for this purpose.
Pipe size Recommended closing pressure Shaffer

18-3/4" 5M BOP
5 inch and smaller 1,500 psi
7 inch 1,400 psi
8⅝ inch 1,180 psi
9⅝ inch 960 psi
10¾ inch 780 psi
11¾ inch 640 psi
13⅝ inch 480 psi (check with toolpusher first)
Figure 28 - Graph showing the recommended closing pressures on
large tubulars for the Shaffer 5M Spherical BOP.
184
IBW inspection of the Shaffer annular preventers
Upper housing bore area
Sphere surface
Weep hole
Figure 29 - Visual inspection points of Shaffer annular preventer.
When the Shaffer annular preventer is on the surface, an internal inspection

is required to look for possible key seating and to check the condition of the
element. During pressure testing of the hydraulic side of the annular
preventer the weep hole can supply vital information about the condition of
the static seals. While testing the operator chambers it is very important to
look inside the bore for leaks.
185
Shaffer 5M spherical annular preventer
Wearbands
2
A
Figure 30 - Layout of Shaffer 5M 18¾-inch annular preventer seals.
The hydraulic pressure seals are the seals with the numbers 1 up to and
including 5. The wellbore pressure seals are the seals referred to as A, B and
C.
186
Jackscrew
Lock ring
Locking segments
Figure 31 - Removal of the locking ring.
In order to remove the upper housing or annular preventer cap, the

jackscrews that will have to lift the lock ring are to be tightened. These
jackscrews are specially made by Shaffer and are made of very hard steel.
It is most unlikely that ordinary studs will work, as the forces to lift this ring
are considerable.
Ensure that you use the original Shaffer jacking screws. If you don’t have
them, order them. Try to break one side and go around the circumference of
the annular preventer; then apply tightening torque to all the jackscrews.
After the lock ring has been removed, the segments can be taken out and
the annular upper housing can then be lifted. Ensure that the correctly
certified and rated lifting eyes are used.
Be aware of the following: sometimes, when the annular preventer cap is
lifted, the annular element can stick onto the annular cap; as soon as you lift
the cap, the element may drop out of the cap. The weight of the element is
enough to kill a person!
The locking segments and their recesses should be thoroughly greased to
prevent them from “freezing” when the annular preventer has to be opened
next time.
187
Testing the wellbore pressure seals

The wellbore pressure test is a means to test the spherical BOP sealing
element and the piston ID of upper seals A, B and C.
Figure 32 - Testing the wellbore seals.

The wellbore pressure test is to be performed in the following manner:
1. Fill the annular bore with clean water.
2. Install a test pipe (a 5-inch drill pipe) inside the annular preventer, and
fill the pipe with water. Do not use a donut!
3. Operate the annular preventer three times with 1,500-psi open and close
pressure to ensure that all air is vented from the hydraulic system.
4. Close the annular preventer.
5. Due to the large amount of compressed rubber, a continuous movement
of the rubber will take place, even after the closing pressure reaches
1,500 psi. Wait at least 5 minutes for the pressure to stabilize (packer
creep).
6. Apply low pressure and full wellbore pressure and monitor for leaks.
7. A leak at this stage can occur in the following areas:
• Around the wellhead or riser connector seal ring (shown as leaks coming
from below the connector)
• Around the seals of the test pipe (shown as fluid coming out of the drill
pipe)
• Around the element (shown as a rise of fluid above the annular BOP in
the bore)
• Coming from seal A while maintaining 1,500-psi closing pressure on the
annular preventer; the hydraulic regulator situated in the control pod will
continue to vent
• Seals B and C can only be tested if the annular preventer is in the OPEN
position. If the element is in the closed position, it will seal off the area
where the seals are located from the wellbore pressure. Testing the seals
B and C can only be done when the bore is isolated above the element
by an upper annular BOP or a blind flange. In this case, the bore
pressure will vent again through the opening port to the regulator,
should seal B leak. If seal C leaks it will come out of the weep hole.
188
Hydraulic system pressure test
Figure 33 - Hydraulic pressure seals of the Shaffer Spherical annular

BOP.
Closing hydraulic pressure test
1. Install a 5-inch drill pipe inside the preventer and ensure that there is no
fluid in the bore.
2. Operate the annular preventer at least three times to vent the air from
the hydraulic system.
3. Install a test hose to the close side with a pressure chart recorder.
4. Close the annular preventer (1,500 psi), allowing ample time to ensure
that the creep movement of the rubber of the element has stopped (at
least for 5 minutes).
5. Isolate the closing pressure and monitor the pressure gauge and chart
recorder.
6. If there is no pressure drop, seals No. 1 and No. 2 are holding. A leak of
seal No. 1 will show fluid venting from the annular preventer’s hydraulic
circuit of the annular OPEN SPM inside the control pod that is connected
by the position of the annular preventer opening shuttle valve. When in
doubt, remove the opening shuttle valve for clarification.
7. A leak of seal No .2 will show inside the bore, which can only be seen if
you have the opportunity to look underneath the BOP, as the element is
closed. Basically, if there is a leak and no venting caused by seal No. 1,
most likely seal No. 2 is leaking. If it is impossible to visually examine
beneath the annular preventer, after opening up there will be hydraulic
fluid at the bottom of the preventer.
8. Sometimes there are air bubbles inside the hydraulic fluid that could
cause small pressure drops. In this case it is perfectly legitimate to
increase the pressure a few times, but at the final test the pressure will
have to level out to a straight-like line and not an unacceptable negative
gradient. Air will eventually level out and the line will become straight
after a while. Remember that leaks will never be indicated by
straight lines.
189
Figure 34 - Opening hydraulic test.
Opening hydraulic pressure test

1. Ensure that the bore of the annular preventer is empty.
2. Install a drill pipe and function-test the annular BOP three times to vent
the air from the hydraulic circuit.
3. Install a hot line and the test unit to the opening side of the annular
BOP.
4. Apply a 1,500-psi opening pressure.
5. If there are no leaks, seal Nos. 3, 4 and 5 are holding pressure.
6. A leak in seal No. 3 will be indicated by fluid venting from the annular
preventer hydraulic circuit at the SPM of the annular CLOSE inside the
control pod, which is connected by the position of the annular preventer
closing shuttle valve.
7. A leak in seal No. 4 will be visible by hydraulic fluid going inside the
wellbore.
8. A leak in seal No. 5 will be indicated by hydraulic fluid seeping through
the weep hole.
9. Sometimes there are air bubbles inside the hydraulic fluid that could
cause small pressure drops. In this case it is perfectly legitimate to
increase the pressure a few times, but at the final test the pressure will
have to level out to a straight-like line and not an unacceptable negative
gradient. Air will eventually level out and the line will become straight
after a while. Remember that leaks will never be indicated by
straight lines.
190
Location Type Shape Elastomer
Adapter OD O-ring Nitrile
Nitrile seal with

Adapter Top Lip seal
hardback
Adapter ID Upper
Wiper Nitrile
Piston ID Upper
Adapter ID lower
PolYurethane with
Piston ID lower Polypak
Nitrile O-ring expander
Piston OD
The seals of the annular preventer must be kept lying horizontal and NOT
hung onto a nail on the wall. They are to be covered with non-transparent
plastic bags and stored in a cool environment in order to preserve their
proper condition.
The seals of the Shaffer annular preventers are to be replaced every three
years regardless of their condition or the presence of leakage. A complete
set of seals and at least one spare element should be present on the rig at
all times (API RP 53).
191
Wear bands on the Shaffer Spherical BOPs

The wear bands are located on the outside of the annular preventer piston
on the upper and lower side. These wear bands are identical. On the lower
body a wider wear band is installed. The wear bands are normally glued in
place.
0.003 to 0.008 inch
Figure 35 - Wear band protrusion dimensions.
It is important that the wear bands are not sticking out too much. The best
approach is to install the wear bands in three different pieces, leaving one
inch of free space between the sections. This will provide sufficient room for
the wear bands to expand.
Sometimes will it be difficult to lower the piston again after installing the
wear bands. The use of an H-beam connected to the annular BOP lifting eyes
and hydraulic jacks may be necessary to gradually jack the piston
downwards, while constantly monitoring that the piston still travels straight
and remains level by means of a tape measure.
Note: It is important to remove all old glue residues and clean the wear ring
slots before applying new glue.
192
Examples of wear and tear on Shaffer annular preventers
Normal
wear: still
Sealing area:
critical
Figure 36 - The top of a used Shaffer 5M element that appears to be

in order.
Figure 37 - The bottom of the same element, but now severely

cracked and with a large piece missing, most likely
caused by using a running tool.
193
Figure 38 - Close-up of cracks at the bottom of the Shaffer annular

preventer element.
Figure 39 - Severe key seating in the annular preventer cap (looking

from the top).
194
Questions Annular Preventers
1. Describe the hook-up used for a Hydril GL annular preventer at a water

depth of 1,000 feet.
2. Explain the difference between the standard and the optional hook-up
for the Hydril GL annular preventer.
3. What is the closing pressure of the Hydril GL 18¾-inch 5M annular
preventer at a water depth of 5,200 feet?
4. Explain the factor Γ for the Hydril GL BOPs.
5. What is the average closing pressure for the Hydril GL annular BOP at
the standard hook-up?
6. What is the average closing pressure for the Hydril GL annular BOP at
the optional hook-up?
7. How much volume is required for the three different chambers of the
18¾-inch Hydril GL?
8. Explain the operation of the Hydril GL counterbalance hook-up.
9. Calculate the precharge pressure of the Hydril GL in 2000 feet of water
using the three different hook-ups.
10. What is the purpose of the surge bottle on a Shaffer annular preventer?
To what side is the surge bottle connected?
11. Calculate the precharge pressure of the surge bottle in 4,130 feet of
water for a Shaffer annular preventer.
12. Why are Shaffer annular preventers not tested on the stump with a test
donut?
13. What are the risks involved of closing a Shaffer annular preventer on a
casing string? What is the maximum operating pressure of the Shaffer
annular preventer closing on a 13⅜-inch casing string?
14. What is the maximum stick-up of the wear bands of the Shaffer annular
preventer and why? How do you prevent the wear band from sticking
out too much?
15. How do you solve the problem when the Shaffer annular piston has
difficulties to be reinstalled?
16. When there is fluid coming out of the weep hole of the Shaffer annular
preventer during pressure testing, what seals might be leaking?
17. Why do we use special studs to lift the Shaffer lock ring?
18. Explain the need of the adapter ring update of the Shaffer annular
preventers.
19. How much should you reduce the closing pressure of the Shaffer annular
BOP closing on a 9⅝-inch casing string?
20. When we test the lower annular preventer and during low-pressure
testing, the pressure goes up. What could be the problem?
21. What is the most common cause of key seating with annular preventers?
195
3 Table of figures
Figure 1 -
Hydril GL annular preventer. .............................................. 164
Figure 2 -
Hydril GL standard surface hook-up..................................... 165
Figure 3 -
Hydril GL optional surface hook-up. ..................................... 166
Figure 4 -
Stripping operation of standard surface hook-up. .................. 167
Figure 5 -
Stripping operation of optional surface hook-up..................... 167
Figure 6 -
Standard hook-up surface closing-pressure chart for drill
pipe and casing. ............................................................. 168
Figure 7 - Optional hook-up surface closing-pressure chart for drill pipe
and casing. .................................................................... 168
Figure 8 - Three different set-ups for the Hydril GL preventer in subsea
operations. .................................................................... 169
chamber; relation between wellbore pressure and drill pipe
size............................................................................... 171
chamber; required pressure adjustment due to water
depth and mud weight. .................................................... 171
Figure 11 - Closing pressure secondary chamber connected to closing
chamber; relation between wellbore pressure and drill pipe
size............................................................................... 172
Figure 12 - Closing pressure secondary chamber connected to closing
chamber; required adjustment due to water depth and
mud weight.................................................................... 172
Figure 13 - Closing pressure secondary chamber connected to marine
riser; relation between wellbore pressure and drill pipe
size............................................................................... 173
Figure 14 - Precharge graph standard hook-up. Calculation: 0.8 x
(surface closing pressure + 0.41 x water depth).................. 173
Figure 15 - Precharge graph optional hook-up. Calculation: 0.8 x
(surface closing pressure + 0.41 x water depth).................. 174
Figure 16 - Precharge graph counterbalance hook-up. Calculation: 0.8
x (surface closing pressure + 0.41 x water depth). .............. 174
Figure 17 - Pull-down assembly of the Hydril GL annular preventer......... 176
Figure 18 - Counterbalance hook-up of Hydril GL annular preventer. ...... 177
Figure 19 - Closing pressure chart of Hydril GL-type annular BOP. .......... 177
Figure 20 - Different types of seals. ................................................... 178
Figure 21 - Exploded view of Shaffer 5M Spherical wedgecover annular
BOP. ............................................................................. 179
Figure 22 - Shaffer sealing element with steel reinforcing segments. ...... 180
Figure 23 - Shaffer annular preventer closed on drill pipe...................... 181
Figure 24 - Influence of riser annulus hydrostatic pressure versus
closing pressure for a Shaffer 5M annular BOP. ................... 182
depth for a Shaffer 5M annular BOP................................... 183
depth for a Shaffer 10M annular BOP. ................................ 183
Figure 27 - Reduction of the closing pressure on large pipe. .................. 184
Figure 28 - Graph showing the recommended closing pressures on
large tubulars for the Shaffer 5M Spherical BOP. ................. 184
Figure 29 - Visual inspection points of Shaffer annular preventer............ 185
Figure 30 - Layout of Shaffer 5M 18¾-inch annular preventer seals........ 186
Figure 31 - Removal of the locking ring. ............................................. 187
Figure 32 - Testing the wellbore seals. ............................................... 188
196
Figure 33 - Hydraulic pressure seals of the Shaffer Spherical annular

BOP.............................................................................. 189
Figure 34 - Opening hydraulic test..................................................... 190
Figure 35 - Wear band protrusion dimensions. .................................... 192
Figure 36 - The top of a used Shaffer 5M element that appears to be in
order. ........................................................................... 193
Figure 37 - The bottom of the same element, but now severely cracked
and with a large piece missing, most likely caused by using
a running tool. ............................................................... 193
Figure 38 - Close-up of cracks at the bottom of the Shaffer annular
preventer element. ......................................................... 194
Figure 39 - Severe key seating in the annular preventer cap (looking
from the top). ................................................................ 194
197
198
Module 02 - 03 Gate valves on the BOPs 1.0
Chapter 03
Gate valves on the BOPs
1 Subsea gate valves - choke and kill valves ................................ 200

2 Fail-safe open valves ............................................................. 203
3 Balanced and unbalanced valves.............................................. 204
4 Standard and pressure assist systems ...................................... 206
5 Force diagram....................................................................... 208
6 Cavity liquid lock with unbalanced valves .................................. 210
7 Charts of subsea gate valves................................................... 212
8 Cameron gate valves ............................................................. 213
9 Cameron A-type and AF-type valves ........................................ 214
10 Cameron type-DF valves ........................................................ 217
11 Cameron MCS-type valve ....................................................... 221
12 WOM gate valves .................................................................. 224
13 McEvoy valves ...................................................................... 228
14 McEvoy sealant compound...................................................... 232
15 Shaffer gate valves................................................................ 235
16 Table of figures ..................................................................... 239
199
1 Subsea gate valves - choke and kill

valves
1.1 General
Choke and kill valves required on subsea BOPs must be hydraulically
operated. There are always two valves in each choke and kill line. Depending
on the layout of the BOP, there is at least one choke and kill line, but often
there are two choke lines and two kill lines, each containing two valves. The
outer valves are target valves and the inside valves are straight valves.
The layout of certain valves makes it vital that the valves are installed in the
right way in the upstream or downstream position with respect to well
control procedures, and it offers the optimum flexibility of flow paths to
circulate out a well influx. The valves must be installed as close as possible
to the stack.
Always keep in mind that there must be one valve installed directly to the
stack before the fluid flow path makes a turn, thus minimizing the risk of
sand cutting and erosion in the inner valve.
Choke and kill valves used on the subsea stacks differ from manufacturer to
manufacturer, not only for the gates and the fluid flow sealing design, but
also the operator design. The selection of a particular valve/operator
combination will depend on peculiarities of the installation, for instance
geometry, water depth, capability and other considerations, including:
• Cost
• Working pressure
• Maintenance cost
• Repair and spare parts availability
• Closing pressure requirements
• Water depth of operations
200
The basic components are illustrated as below (also see Module 1 of this
course):
Open port
Piston
Spring(s)
Close port
Stem
U-seal
Gate
Body Bushing
Balance Stem
U-seal
Figure 1 - Cameron MCK subsea choke and kill valve.
When opening the gate valve, the movement of the gate causes a hole in
the gate to line up with the flow passage through the valve body. The flow
passage through the gate is located near the stem end for fail-close valves.
Retraction of the gate towards the operator causes the valve to close. The
gate seals against the downstream seat assembly with a metal-to-metal
seal. Most choke and kill valves are bidirectional, i.e. they will hold pressure
from both directions.
201
Figure 2 - Cameron slab-style gate valve.
The stem connects the valve gate to the valve operator. Most subsea valves
have a balance stem on the bottom of the gate, which will balance the forces
across the gate.
The seawater hydrostatic pressure of the exposed end area of the lower
stem will transform into a force to close the valve, thus offsetting the force
to open the valve.
When forces across the gate are balanced by a lower stem, the valve is
virtually insensitive to water depth. The valve is then known as a balanced
valve.
202
2 Fail-safe open valves
It is possible to obtain special gates with the flow passage in the lower
portion of the gate. Most of the time these gates are used on the choke and
kill isolation valves on the lower marine riser package (abbreviated LMRP).
It should be noted that these valves are NOT part of the well control
equipment. They are used to test the choke and kill lines on the marine
risers when the LMRP is to be run without the BOP stack (for repairs or
disconnection because of bad weather).
The “isolation” or “test” valves have their gates installed in a reversed
position to make these valves “fail-safe-open”.
LMRP Receiver Plate
Figure 3 - Choke isolation valve on the LMRP (fail-safe-open).
203
3 Balanced and unbalanced valves
actuator actuator
well bore well bore

pressure pressure
balance stem
Gate valve Gate valve

standard balanced
Figure 4 - Standard and balanced gate valves. Figure 5 - Cameron type-

F valve with AF operator,
and an unbalanced stem
at the bottom.
The operators or actuators characteristically use combinations of:

• Spring forces
• Hydrostatic forces due to the column of control fluid and seawater
hydrostatic pressure actuating on the open side of the operator
• Seawater hydrostatic or control fluid hydrostatic acting on the close side
of the operator.
Some operators have a single opening fluid inlet. When this type of operator
is used, the force to close the valve is generated by a spring or a spring
cartridge in the operator and the seawater hydrostatic pressure acting on
the actuator.
Pressure inside the valve (in-line pressure) is used to assist in closing
several unbalanced valves. An example is the Cameron type-F gate valve
with the AF fail-safe operator (see Figure 5). It is important that the valve is
installed with its vent line facing the BOP and not the other way around.
Remember that these valves are not permitted for deep-water
operations.
204
Figure 6 - Assist circuit valve control (open).
205
4 Standard and pressure assist systems
All operators for deep-water applications have a pressure assist close port.
Many valves use a pressure assist circuit on the close port to extend the
water depth rating of the valve. Examples of pressure assist control circuits
are given in Figure 7 and Figure 8.
Figure 7 - Assist circuit valve control (close).
The circuits shown in these figures are part of a fourth-generation Shaffer

MUX BOP control system. Some rigs have enough pilot hoses and hydraulic
functions to obtain a conventional control of the gate valve, having an SPM
valve function for the open and close function.
206
Shuttle Valve
Yellow Pod Blue Pod
Power
Close Close
Shuttle Valve Open

Open
Vent
Close
Figure 8 - Conventional valve controls (valve closed).
The preferred option is the one having conventional valve controls. The
disadvantage of the fail-safe assist close system is that it places check
valves, accumulators, etc. downstream the retrievable control pod. A failure
of one component may lead to the retrieval of the BOP. This once happened
and following appreciable downtime the system was disconnected and
dismantled.
Another factor to consider is that deep-water applications on the working
pressure of the accumulator may increase the working pressure on the
accumulator when the BOP is retrieved, unless the accumulator can be bled
off subsea prior to pulling the BOP. This can be achieved by cycling the
valves during retrieval of the BOP stack from deep water.
207
5 Force diagram
Po PcAc
PcAc
Fp
Fs PcAc Pc Fs
Fp
Pv
μΔPvAv
μΔPvAv
Ac = Area, close side operating piston

Ao = Area, open side operating piston
As = Area, stem.
Av = Area valve gate (sealing)
PvAs Fp = Force packing piston PvAs
PvAs Fs = Force springs PvAs

Pc = Pressure hydraulic close assist
Ph = Pressure seawater hydrostatic PcAc
To open To close
Po = Pressure hydraulic open
Pv = Pressure line
ΔP = Pressure differential across gate
μ = Coefficient friction gate and seat
Figure 9 - Force diagram of Cameron AF 3-inch 10M valve and

operator.
208
Error! Reference source not found. Depicts the operator force diagram.
We want to determine the maximum pressure that can be placed on the
opening side of the operator when the valve is in the following condition:
Line pressure (Pv)= 0 psi
Water depth= 1,575 ft
Bladder operator with single opening line
Cameron AF valve and operator force diagram
Ac = 30.87 inch²
Ao = 35.78 inch²
As = 4.91 inch²
Av = area of the valve gate at the sealing area
Fp = 0 - 50 lbs/ft, assume 0 ft/lbs
Fs = 2,500 ft/lbs
Pc = seawater density (8.56 ppg) x constant (0.052) x WD (1,575
feet)
Ph = pressure hydrostatic of sea water
Po = pressure hydraulic to open valve
Pv = 0 psi
ΔP = pressure differential across the gate
μ = coefficient of friction between the gate and the seat
(Po.Ao) = (Fs – Fp) + (Pc.Ac) + (Pv.Av) - (μ.ΔPv.Av)
(Po x 35.78) = (2 500 – 0) + [(8.56 x 0.052 x 1575) x 30.87] + (0 x ?) –
(? x 0 x ?)
Transposing for Po: Po = 674.73 psi
Question marks indicate unknown values. However, this is of no
consequence since zero multiplied by any positive integer equals zero.
The hydrostatic head of the control fluid at the opening line is:
1,575 ft x 0.445 psi/ft = 700 psi
This means that the valve will not necessarily be in the close position at this
water depth. Therefore, a close assist pressure will be required to ensure
that this valve remains closed subsea.
209
6 Cavity liquid lock with unbalanced

valves
Valve A Valve B
Stem
Stem
Seal
Upstream Downstream
Seal
Cavity Pressure
Figure 10 - Cavity-liquid-lock of tandem, non-balanced bidirectional

gate valves.
Note: When Valve A begins to open (direction: see the blue arrow), liquid in
the cavities (the ‘shaded’ section in Figure 10) cannot exhaust. This will
cause a pressure lock.
Valves can cavity-pressure-lock when the operator piston pushes the
unbalanced stem into a bidirectional sealing gate valve body cavity to
open the valve. A cavity pressure lock occurs because the volume of the
liquid below the stem is displaced as the stem enters the body cavity. The
resulting pressure increase in the valve body must be incorporated in the
valve so that no volumetric fluid change occurs in the body cavity as the
stem and gate move to open or close.
210
A cavity liquid lock can occur on balanced stem bidirectional split gate
sealing valves (such as the McEvoy EDU valve) during high-pressure testing.
When the gate is closed and the BOP pressure-tested, the high pressure can
force the gate to seat against the downstream seat. Fluid within the valve
cavity is also under high pressure. After the test pressure is rapidly bled off,
fluid can be trapped within the valve as the upstream seal energizes causing
the split gate to simultaneously seal on both the upstream and the
downstream seats. High friction forces between the gate and the gate seat
increase the pressure on the operator required to open the valve.
Another consideration when selecting valves is that two unbalanced stem
gate valves installed very close together on the same line are subject to
liquid locking between the two valves. Normally gate valves will hold a
pressure differential across the gate from either direction. A so-called “line
liquid lock” may occur when a valve is opened by piston movement into a
closed and constant volume of nearly incompressible fluid (see Figure 10).
The line liquid lock problem arises because it is possible to build up pressure
between an adjacent pair of valves while functioning. When either valve
stem begins to move (prior to the gate opening), the liquid displaced by the
retracting stem may exhaust to the pressure cavity between the two valves.
When this occurs, the high pressure can increase the gate/seat friction,
causing the operator opening pressure to increase.
Liquid locking can be avoided by taking the following precautions:
1. Install flow control valves in the one of the two valves to provide a time
delay of a few seconds to close the adjacent valve.
2. Vent the valve body cavities. When the valve bodies are vented, the
upstream valves must be vented upstream and the downstream valves
must be vented downstream.
3. Use the unbalanced stem design (which is not suitable for deep-water
operations).
4. Make sure that the upstream valve only seals in one direction. (Note that
this is not an option for subsea operations.)
5. Place the valves far away from each other. (Again, this is not an option
for subsea operations.)
211
7 Charts of subsea gate valves

Operator
Valve
Type Lower stem closing control
cavity
line
Cameron Type A F or FC None No
Cameron Type AF F or FC Ported to in-line bore No
Cameron Type DF F or FC Ported to seawater Yes
Cameron Type MCS FC Ported to seawater Yes
McEvoy Type EU --- Ported to in-line bore Yes
McEvoy Type EDU --- Ported to seawater and in-line bore Yes
McEvoy Type DS --- Ported to closing operator closing chamber Yes
Shaffer HB Type Short
--- Ported to closing operator closing chamber Yes
Sea Chest
Shaffer HB Type Long Ported to closing operator closing chamber
--- No
Sea Chest (seawater hydrostatic)
Vetco Type VS --- None ---
Flow Control Inc. Type
--- Ported to seawater Yes
DW
Figure 11 - Chart I: gate valves.
Figure 12 - Chart II: gate valves.
Figure 13 - Chart III: gate valves.
212
8 Cameron gate valves
In 1988 Cameron purchased McEvoy and in 1990 WKM. So, at this moment
Cameron markets all the subsea valves built by themselves and by McEvoy
and WKM. Cameron valves are the most commonly used choke and kill
valves in the industry on floating drilling rigs. Four basic Cameron valves can
be found for subsea applications today. Charts I, II and III summarize the
characteristics of these valves.
Prior to 1977, Cameron produced their gate valves with a ratchet device to
rotate a seat on the valve gate. Rotation of the seat each time the valve
functioned was thought to distribute the wear on the valve seats, thus
extending the valve life. Between 1977 and 1980 the rotating seats were
phased out because the ratcheting seat often broke off and caused the seat
to lose its pressure integrity.
In 1989 Cameron introduced the FLS-type gate and seat design for the FC
body cavity design valves for 10M- and 15M-service (see Figure 16). This
design offers an improvement compared to the previous FC and FL designs
for gate/seat wear, low-pressure sealing and resistance to contaminants
such as heavy mud and sand. The FLS design also featured a change in
geometry of the stem size in order to reduce the weakness of the FL design.
Cameron recommends the FLS gate and seat design for new installations.
Cameron manufactures both standard (sweet-service) and H2S (sour-
service) valve cavity equipment. For example, standard service gates can be
chrome-plated, which is not acceptable for sour service. Cameron uses
hard-faced gates and stellite gate seats in H2S service.
213
9 Cameron A-type and AF-type valves
Type-A valves are the oldest design, dating back to 1957. Today they are
hardly ever encountered on floating rigs. The type-A valves were made
obsolete by the AF design. The use of type-A valves is not recommended for
subsea applications. The type-A valve has a non-balanced stem and gate
assembly installed. Early type-A valves utilized the F-type valve body cavity
and some had check valves in the gate (in the valve's close position) to
assist in the prevention of a cavity pressure lock in the cavity.
The check valve in the gate proved unreliable when drilling with mud and
was eliminated in the beginning of 1964. In order to prevent line liquid lock
of closely spaced tandem type-A valves, the upstream valve can be fitted
with unidirectional seals utilizing a special upstream gate seat.
The F-type valve cavity design and manufacturing process was questionable
for the use of sour service. Due to this problem, the type-FC valve cavity
was recommended for the type-A valves in 1975 (see Figure 14).
Some of the F-type valve body cavities were converted into the FC-type
valve body design during their lifespan. Cameron recommends upgrading
from type-FC to type-FCS (designed in 1987) by changing the seats (body
bushings) into the new spring-loaded lip seal in order to eliminate washouts
and to improve low-pressure sealing. The new seals will also prevent the
build-up of solidified mud behind the body bushings that cause washouts at
high pressures.
The type-A valves were originally rated to a 1,000-foot water depth by
Cameron. The type-A valves used the same fail-safe operator that is used on
the type-AF valve.
Figure 14 - Cameron type-AF gate valve.
214
Cameron type-AF valve

The type-AF valve appeared on the market at the end of the 1960s. The
valve body is forged. The AF-type valve design incorporates a lower stem
with a vent port in the lower body cavity to prevent a valve cavity pressure
lock and line liquid locking.
Figure 15 - Layout of two AF valves with the proper pressure ports.
The internal pressure to the valve (through the vent) will act on the stem to
assist with closing the valve. The valve is non-balanced since the lower stem
is not exposed to seawater hydrostatic pressure. When using multiple AF
valves, it is important that the direction of the vent (upstream or
downstream) is considered because the volume is displaced upstream to the
valve internal diameter as it functions (see Figure 15).
Standard to the type-AF subsea gate valve is the A-type fail-safe operator,
which has a pressure-open line only. Opening forces include surface
pressure and control-fluid hydrostatic pressure acting on the open side of
the operator. The closing force is provided by operator's spring force, the in-
line pressure acting on the valve stem and the seawater hydrostatic
pressure. The seawater hydrostatic pressure generates a closing force
because of the valve design that allows seawater hydrostatic pressure on the
closing side of the operator.
The original design of the bladder used a clamp similar to an automobile
radiator clamp to secure the bladder. This clamp design was prone to
leakage and very sensitive of the volume of oil inside the operator and
bladder. Around 1977 a bolted design was introduced that improved the
securing of the bladder. Also, the oil volume inside the bladder was
increased in the new design. The increased oil capacity required a larger
operator housing outside diameter, which was unique for the new design.
Cameron Engineering Bulletin 531G provides the method on how to upgrade
the old bladders to the new design.
Nowadays many users remove the bladder and the outer sleeve altogether
and convert the operator to pressure assist closure. The pressure assist
215
closure's working pressure is limited to 1,500 psi and the closing side is
limited to 3,000 psi.
The use of in-line pressure as a pressure source for closure makes the
valves sensitive to the water depth. When the in-line pressure drops below
the hydrostatic pressure of the seawater, the valve's closing force is
diminished and can cause the valve to open.
Cameron advertised that the valve could be used in water depths up to
2,000 feet. However, with a zero-psi internal valve pressure the valve
will fail to close in water depths that are much smaller. For instance,
the calculated maximum water depth for a 3-inch 10M Cameron AF-type
valve with a standard operator, which will close with zero in-line pressure, is
about 1,100 feet.
The water depth closing rate can be increased by the addition of a pressure
assist feature to the closing side of the operator. The AF-type valve is not
recommended for use in more than 1,000 feet of water depth without
converting the operator to pressure assist closure. For details, see the
force diagram in Figure 9.
216
10 Cameron type-DF valves
The DF valves were introduced in 1975 and have a lower stem installed to
make the valve pressure balanced. The end area of the lower stem is
exposed to seawater hydrostatic pressure and the valve is almost insensitive
to water depth. The valve body is made of forged steel. The valve balance
stem also supplies an indication of the position of the valve, which is
impossible to see with the Cameron type-AF valves.
The DF-type valve is balanced in that the closing force from the seawater
hydrostatic pressure acting on the lower stem is combined with closing
force from the hydrostatic pressure of control fluid acting on the close
control line balance the opening force from the hydrostatic of the control
fluid acting on the opening control line. The force of the operator springs
keeps the valve in the closed position. Since in-line pressure does not assist
the closing with this valve, unplanned valve opening will not occur when in-
line pressure drops below the seawater hydrostatic pressure.
Due to the balance concept, there is no fluid displacement in the valve body
during its functioning, which could cause the cavity pressure lock within the
valve or between the valves. This feature also permits bidirectional sealing
of the gate.
Early DF valves were manufactured with the type-F valve body design. In
the early 1980s the valve was built with the FC-type valve cavity body
design. Some of the F-type valve cavity body designs were converted into
the FC-type valve cavity body design during their lifetime. This was done
because of the problems with the F-type valve body design during sour
service.
Cameron recommends upgrading their 1989 FCS design by changing the
seats to the new spring-loaded lip seals, in order to eliminate washouts and
to improve low-pressure sealing.
The operator of the DF valve is unique. It has an opening and closing port
and the normal operating cylinder pressure is 1,500 psi, although the valve
is designed for 3,000 psi. The DF valve and actuator are available for 10M
and 15M pressure ratings. Cameron rated this valve and actuator to a
6,000-foot water depth. The DF valve relies on the operator's spring force
and the closing control line for closure.
According to Cameron, the spring alone lacks sufficient force to cause a
complete closure when closing on a high-pressure flowing stream. In this
case a closing pressure on the operator (in addition to control fluid
hydrostatic) is required to ensure a complete closure of the valve.
217
Figure 16 - Cameron type-DF gate valve (target type).
218
Figure 17 - Exploded view of the Cameron DF-type valve.
219
Figure 18 - Cameron FC-type components.
220
11 Cameron MCS-type valve
The MCS valve was introduced in 1984 as a premium subsea valve and
operator, especially designed for high pressures. It was designed to
eliminate the gate, seat and body washouts seen in 15M applications, and to
reduce maintenance and cost. The valve is similar to the DF-type valve in
that it is balanced and has a forged body. The valve uses the FC valve cavity
body design.
At the introduction of the valve, special FCM gate and seat assemblies were
used and the valve was called MCK. In 1985 the FCS gate and seat
components were incorporated into the MCK valve and the complete valve
assembly was renamed the MCS valve. All MCK valves had been upgraded to
MCS by 1990. The MCS valve is similar to the DF type in that is relies on the
operator's spring force and closing control line pressure for closure.
The actuator of the MCK valve can be removed from the valve without
disturbing any of the pressure-containing components seals. The stem
packing can be changed without removing any of the other line pressure-
containing components. The operator is detached by removing eight cap
screws located at the valve end of the actuator, extending the actuator stem
by applying pressure to the top of the piston and then sliding the actuator
off sideways.
It is important that the actuator is supported properly before removing the
caps crews, as the actuator weighs approximately 300 pounds. The space
required for removing the MCK detachable actuator adapter flange, which
connects the valve to the actuator and the stroke, can be adjusted by means
of the adjusting screw in the top of the actuator.
Care must be taken to assure that the adjusting screw is properly set for the
stroke length before closing the actuator with control system pressure.
Failure to properly adjust the stroke length may result in the valve stem
stopping on the back seat and pressure force generating by the piston,
causing failure in the stem shoe or valve stem.
The actuator stem is threaded into the piston with a left-hand thread and
fastened with high-strength adhesive (Threadlock). Remember not to
attempt to remove the piston without a spring press. The spring assembly
has stored pre-load energy, which must only be released by following the
proper procedure and by using the right equipment.
The gate is reversible and assembled either on normally open or normally
closed as controlled by the assembly number and procedures. The gate is a
metal sealing slab design that helps to prevent upstream sealing and
reduces the likelihood of trapping pressure in the cavity, when compared
with the two-piece gates.
221
Figure 19 - Cameron FCM gate valve components.
222
The FCS cavity components

This FCS design was introduced in 1987 as an improvement of the FCM
design. The wedging of the seats in the FCM design eliminated washouts,
but reduced the ability to seal at low pressures (200 psi). The FCS design
utilizes two (very delicate) spring-loaded lip seals behind each seat in order
to eliminate washouts and to provide low-pressure sealing.
Due to the use of high-density mud when drilling HP/HT wells, the
accumulation of barite behind the body bushings became a problem. This
barite caused the body bushings to leak, resulting in a valve body washout
at the body bushing sealing area.
Figure 20 - Cameron FCS cavity components.
223
12 WOM gate valves
The WOM Magnum gate valve has the following advantages:

1. Through conduit seal.
2. Bidirectional upstream seal.
3. No loss of grease in the fully open or closed position.
4. Lower torque because of floating gate action, centralization of lift
threads, good surface finishes on gate, seat and Magnaseal.
5. Long-lasting gate and seats because of little exposure at the critical
moment of opening and closing with less loss of lubricant.
6. Primary seal upstream.
7. Secondary seal downstream.
8. Two seals to improve sealing conditions.
9. Gate is floating continuously:
• Close: floating ¼ inch turn off the bottom of the valve body
• Open: stops on the -T-nut and not on the bonnet
10. It is possible to flush the grease or body contaminants in full open or
close position.
11. In the full open position, the stem will be lubricated through the
threads.
12. After backing off the bearing cap, you can backseat the stem in the full
closed position by power closing and relieving any trapped pressure.
13. In the event of a stem packing leak, the O-rings that are installed
protect the bearings and provide continuous protection to the bearings.
14. The O-ring on the bonnet protects the threads against seawater.
224
Figure 21 - WOM Magnum manual gate valve.
Figure 22 - The Magnum Figure 23 - The Magnum

Sure-Seal valve. floating gate.
225
Magnum Sure-Seal valve

The heart of this bidirectional valve is the Magnum Sure-Seal. This simple
gate/seat assembly eliminates gate guides, seat skirts and springs. Line
pressure expands the seat assembly against the floating gate and forms an
upstream seal.
In the open and close position, the seal prevents lubrication loss and
reduces the build-up of contamination in the body cavity. Lower torque can
be maintained over a long period of time. The solid gate is connected to a
separate stem nut, which can withstand extreme pressures without
deflecting. Hard-faced coatings of nickel, cobalt or other exotic materials
improve the seal under highly corrosive, erosive or other abrasive
conditions.
Magnum floating gate

This design features significant low-torque values; the break-out torque for a
2-9/16” 15M Magnum valve averages between 30 and 40 ft-lbs. This is a
direct result of several interrelated factors:
1. An independent stem nut, which allows the gate to float, maintaining
contact with the seats without binding them.
2. Mating gate and seats have final surface finish of 1 to 2 RMS, which
substantially reduces friction.
3. Good retention of lubricant in the body reduces the build-up of
contaminants, which can increase torque.
4. The forces between the gates and seats are balanced and nullify the
effect on the valve operation.
5. The Magna-Seal lubricant has special additives, which reduces friction
further.
Figure 24 - Pinching during closing of the gate.
226
Critical pinching position

The protection against harmful content (particles, contaminants or
destructive by-products) will lengthen a valve's service life. All WOM
components are resistant to harsh CO2 and H2S service conditions. The
lower torque makes the operation quicker, greatly reducing the pinching
time when the gate and seats are exposed to highly destructive flow
velocities.
Hard facing on both the gates and the seats increases their resistance to
abrasive, erosive and corrosive forces. Good retention of lubrication
minimizes the contamination of the body cavity. The bearings are isolated
from any possible stem-packing leak, which may include highly embrittling
H2S-contaminated fluids.
WOM valve HP/HT service

Seat sealing is accomplished by a high-temperature-rated elastomer, fitted
with PEEK backup rings. For this HP/HT application, different seat seal
grooves are also required. Standard service elastomers are rated for 250oF
continuous and 350oF for one hour.
Pressure testing on the surface

Prior to pressure testing on the surface, remove the test screw (see the
valve in Figure 21 item 27 for location). Monitor the port test screw for
leakage during the wellbore testing to ensure that the valve is achieving an
upstream seal.
Caution: Magnum valves are sealing upstream and downstream. Therefore,

when the valve is in the fully open or fully closed position, the body cavity
remains pressurized for a period of time depending on the pressure when
the valve was cycled last time. Hence, a fully open valve does not mean that
body cavity pressure is zero. When the line pressure is to be bled off, the
valve must be cycled to relieve the body cavity pressure. It is also a
good practice to cycle the valve before greasing the valve.
227
13 McEvoy valves
13.1 McEvoy Type-EDU Valve

The McEvoy type-EDU subsea valves originate from the mid-1970s and
incorporate a split-gate bidirectional seal. The valve has a detached
balancing stem, which allows in-line pressure to act on the valve assisting to
keep the valve closed. The valve has a cast-iron body and uses a metal to
metal sealing of the gate.
The EDU valve is a balanced valve. The area of the operator piston on the
close side upon which the control fluid acts and the area of the balancing
stem upon which the sea water acts equals the area of the operator piston
on the opening side upon which the control fluid acts. This leaves spring
force to fail-safe-close the valve.
Since the lower stem is not attached to the gate, it will be an exceptional
event that the in-line pressure exceeds the seawater hydrostatic pressure.
In this event, the in-line pressure will act on the stem and add to the closing
force to the valve.
According to Exxon documentation, the maximum water depth that this
valve will fail-safe-close is approximately 5,600 feet. According to the same
source the control line pressure to open the valve decreases with increased
water depth and increases with increased differential pressure. This valve
uses an automatic injection system in order to apply sealing compound to
the seat face. Remember that this is a sealant and no grease!
In some instances booster cylinders were added to the operator, effectively
doubling the opening force on the valve stem. This caused an additional
problem, namely the large forces involved in overcoming the cavity pressure
lock and overloaded the gate/stem assembly when reaching the bottom of
the stroke. In some cases the gates actually experienced warpage (torsion).
This same problem can occur when opening pressures more than 2,400 psi
are applied to the operator. To eliminate this kind of damage to the gates,
McEvoy now installs a circular stem stop at the base of the operator to
prevent the gate from bottoming out. Valve operators without this feature
can be upgraded at the McEvoy (Cameron) shops.
To perform field maintenance the following special tools are required:
• A special spanner to release and preload the springs of the actuator
• A fit-for-purpose hydraulic jack (run by a handpump on most rigs) to
press in the valve seats into the body seat housings
The internal piston rod packing is difficult to replace and care must be taken
not to rotate the cylinder, as a 180-degree rotation will reverse the open and
the close ports of the valve.
228
Figure 25 - McEvoy type-EDU valve.
229
Figure 26 - McEvoy valve with extra sealant reservoir.
230
Figure 27 - Typical McEvoy spilt-gate design.
McEvoy EDU-type valve

The phenomenon known as cavity liquid lock has occurred with this type of
valve due to the split-gate design. A cavity liquid lock with this valve can
occur in shallow water depths after the BOP has been tested to 10,000 psi.
When the wellbore test pressure is rapidly bled off from the inside of the
BOP stack, the wellbore test pressure is trapped between and under the split
gate. This causes the gate to exert a force against the upstream and the
downstream seats.
When hydraulic opening pressure is applied, the trapped liquid cannot flow
or be readily compressed. An opening pressure of more than 1,500 psi will
be required to overcome the cavity liquid lock. The operator is designed for a
3,000-psi working pressure. The lock can also be broken by reapplying
pressure and then by slowly bleeding down the pressure.
231
14 McEvoy sealant compound
The McEvoy gate valves have a special feature that is unique for this type of
valve. It uses a sealant compound, which replaces the seals on the body
bushing.
The valve has the following features (see Figure 28):
1. It has a free-floating piston which transmits the pressure in the valve
housing to the sealing compound in the reservoir (B).
2. The reservoir holds the McEvoy sealing compound at a level sufficient
for an outstanding number of valve operations in severe service.
3. The sealing compound passes from the reservoir to the sealing groove
(D) in face of the seat.
4. The sealing groove between the gate and seat receives sealing
compound from reservoir (B) through jumper (C), but only when the
valve is closed.
5. The groove for the sealing compound between the body and seat
positively prevents ‘back-of-seat’ leakage.
6. There is a passageway for the sealing compound to flow from exterior
points of injection into the reservoirs.
7. There is a jumper in the gate face. When the valve is closed, the
jumper completes the circuit, allowing the sealing compound to flow
from the reservoir to the sealing groove (D).
Notice that the jumper brakes the circuit and prevents any waste of sealing
compound when the gate moves from the closed position.
Note: For high-temperature applications a special high-temperature sealant
is to be used.
14.1 Construction features of McEvoy valves
McEvoy valves contain the following construction features:

1. Bearing grease seal - seals in grease - seals out dirt and moisture.
2. Roller trust bearings with large rollers.
3. Bearing protection seals retain bearing lubricant and prevent
contamination.
4. Vented cap allows possible packing seepage to bypass directly to the
atmosphere without going through the bearings.
5. Spherical bleeder valve for checking stem back sealing.
6. Replaceable stem guide and back seat bushing.
7. Stem thread and lifting-nut design.
8. Field-replaceable seats.
9. Sealing groove in V-contour.
10. Full-skirted seats extend above and below the conduit protecting faces of
both seats and gates at all times (continuously in wiping contact).
232
11. Trash ring between gates keeps foreign material out of the valve body
and retains body filler.
12. Gates resiliently held against both seats at all times for excellent wiping
and self-cleaning action.
13. Connection allows body filler to be injected at any time the valve is at
least partly open.
14. Check valve that is buried deep in the body for safety reasons.
14.2 Chapter 2.3.14.3 The McEvoy Automatic Sealing
The McEvoy automatic sealing operates in three steps:

1. When the gate is moving toward the closed position.
A turbulent line flow washes the sealing compound off the sealing surfaces
and partially from the sealing groove. The sealing groove is disconnected
from the sealing compound reservoir when the gate is not in the closed
position, which prevents loss of sealing compound from the reservoir.
2. When the valve is in closed position.
The jumper now connects the reservoir with the sealing groove. The two
washed surfaces may not hold pressure and a leak may occur. This leaks
sets up unbalanced pressures in the downstream sealing system. Full line
pressure is then exerted into the piston and the reservoir forces new sealing
compound to refill the sealing groove.
3. The sealing system in the McEvoy valve has now automatically
stopped the leak. Pressures in the system are again in balance,
tightness is established and no additional compound is used until it is
again needed.
Figure 28 - Automatic grease sequence McEvoy valve (in three

steps).
233
It should be obvious that the McEvoy valves are to be filled regularly and
that the special designed McEvoy sealant cannot be replaced by
multipurpose grease or even with the special sticky gate valve grease.
The following tables supplies information about the compound required for
the different-sized McEvoy type-C valves.
Weight of compound to fill

Bore size Recommended practice
reservoir
Strokes per side 0.1 Per side (in Per valve (in
In inches
inch3/stroke ounces) ounces)
1-13/16 15 1.1 2.2
2- 1/16 18 1.5 3.0
2- 9/16 20 1.6 3.2
3- 1/16 35 3.3 6.6
4- 1/16 50 4.5 9.0
6- 1/8 225 21.7 43.4
7- 1/8 280 26.7 53.4
8- 1/8 280 26.7 53.4
The amount of grease that needs to be pumped inside each valve for the
body filler is stated in the following table.
Valve bore (in inches) Body filler (in lbs)

1-13/16 1.5
2- 1/16 2.0
2- 9/16 2.5
3- 1/16 3.0
4- 1/16 5.0
6 10.0
234
15 Shaffer gate valves
15.1 Shaffer HB-Type Valve

The Shaffer HB-type valve is rated from 5,000- to 15,000-psi WP M for
bidirectional sealing. All the HB valves have a lower stem and the valve is
manufactured either with a short or a long sea chest.
The short sea chest requires both an opening and a closing operator line,
whereas the long sea chest version requires only an opening line. The 15M
HB valve is manufactured with a short sea chest only. The manufacturer
claims that the water depth has no effect on the hydraulic operating
pressure of all the HB valves.
The primary difference between the CB-type and the HB-type valve is that
the latter design incorporates a port or vent through the valve body from the
close side of the operator to the bottom of the lower balancing stem. The
CB-type valve makes use of an external line to the valve body jumper line
from the operator balancing stem.
For the short sea chest valves, the end area of the lower stem is exposed to
closing pressure plus control line fluid hydrostatics when closing or in the
closed position. When opening or in the open position, the lower stem is
exposed to seawater hydrostatics, as the close hydraulic line is vented into
seawater at the control pod.
Long sea chest valves incorporate an oil-filled bladder at the bottom of the
valve. The bladder transfers seawater hydrostatic pressure to the end area
of the lower stem and to the port through the valve body. The port going
through the valve body allows the transfer of seawater hydrostatic pressure
to the closing side of the operator.
The lower stem of a long sea chest valve is ¼ inch smaller in diameter than
the stem, so that in-line pressure acting on the larger area of the stem
pushes the stem upwards to assist in closing the valve. The closing force is
the total spring force plus the limited in-line pressure assist.
The long sea chest valve is balanced only when in-line pressure equals
seawater hydrostatics. As the in-line pressure decreases below the seawater
hydrostatics, the in-line pressure-assist closing pressure becomes smaller.
The Shaffer HB-type gate valve with the long sea chest is not recommended
to be used in water depths of more than 1,000 feet.
We will explain Shaffer HB gate valves in more detail in Module 4.
235
Figure 29 - Shaffer HB valve Figure 30 - Shaffer HB valve

with short sea chest. with long sea chest.
236
Figure 31 - Double Shaffer HB-type valve with short sea chest.
237
Questions Subsea Gate Valves
1. Explain the difference between a balanced and an unbalanced gate

valve.
2. Explain why there are fail-safe-open gate valves installed on the BOP.
3. Draw the schematic of the fail-safe-close circuit and explain briefly its
operation.
4. How does the seawater hydrostatic pressure help to close the gate
valves?
5. When a new gate valve is installed, what is of utmost importance?
6. How do you prevent the body bushings from falling into the bore when
you lower a gate into the valve body?
7. Why is the Cameron type-F valve still considered fail-safe?
8. Explain the cavity liquid lock with unbalanced valves.
9. How can we avoid liquid locking?
10. What is the danger while performing maintenance on WOM valves?
11. Explain the difference of standard valve grease and McEvoy sealant.
12. What must be done to make McEvoy valves suitable for HT application?
13. Explain why it takes much longer to open fail-safe valves than to close
them when a fail-safe-close system is used.
14. Explain why we cannot use a long sea chest for Shaffer valves during
deep-water operations.
15. What is the main difference between Cameron gates and McEvoy gates?
16. Explain the proper procedure to fill up the McEvoy sealant reservoirs.
238
16 Table of figures
Figure 1 -
Cameron MCK subsea choke and kill valve. .......................... 201
Figure 2 -
Cameron slab-style gate valve............................................ 202
Figure 3 -
Choke isolation valve on the LMRP (fail-safe-open)................ 203
Figure 4 -
Standard and balanced gate valves. .................................... 204
Figure 5 -
Cameron type-F valve with AF operator, and an unbalanced
stem at the bottom......................................................... 204
Figure 6 - Assist circuit valve control (open). ...................................... 205
Figure 7 - Assist circuit valve control (close). ...................................... 206
Figure 8 - Conventional valve controls (valve closed). .......................... 207
Figure 9 - Force diagram of Cameron AF 3-inch 10M valve and
operator........................................................................ 208
Figure 10 - Cavity-liquid-lock of tandem, non-balanced bidirectional
gate valves.................................................................... 210
Figure 11 - Chart I: gate valves. ....................................................... 212
Figure 12 - Chart II: gate valves. ...................................................... 212
Figure 13 - Chart III: gate valves...................................................... 212
Figure 14 - Cameron type-AF gate valve. ........................................... 214
Figure 15 - Layout of two AF valves with the proper pressure ports. ....... 215
Figure 16 - Cameron type-DF gate valve (target type). ........................ 218
Figure 17 - Exploded view of the Cameron DF-type valve. .................... 219
Figure 18 - Cameron FC-type components. ......................................... 220
Figure 19 - Cameron FCM gate valve components................................ 222
Figure 20 - Cameron FCS cavity components. ..................................... 223
Figure 21 - WOM Magnum manual gate valve. .................................... 225
Figure 22 - The Magnum Sure-Seal valve. .......................................... 225
Figure 23 - The Magnum floating gate................................................ 225
Figure 24 - Pinching during closing of the gate. ................................... 226
Figure 25 - McEvoy type-EDU valve. .................................................. 229
Figure 26 - McEvoy valve with extra sealant reservoir. ......................... 230
Figure 27 - Typical McEvoy spilt-gate design. ...................................... 231
Figure 28 - Automatic grease sequence McEvoy valve (in three steps). ... 233
Figure 29 - Shaffer HB valve with short sea chest. ............................... 236
Figure 30 - Shaffer HB valve with long sea chest. ................................ 236
Figure 31 - Double Shaffer HB-type valve with short sea chest. ............. 237
239
240
Module 02 - 04 Hydraulic connectors 1.0
Chapter 04
Hydraulic connectors
1 Subsea wellhead and riser hydraulic connectors......................... 242

2 The Vetco H-4 connector ........................................................ 247
3 Cameron hydraulic connectors ................................................ 259
4 The Cameron model 70 collet connector ................................... 259
5 The Cameron HC collet connector ............................................ 266
6 Cameron mini connectors ....................................................... 268
7 Checking the proper operation of the Cameron mini connector..... 270
8 Cameron connectors omparison............................................... 272
9 Cameron deepwater collet connector........................................ 279
10 Table of figures ..................................................................... 283
241
1 Subsea wellhead and riser hydraulic

connectors
As discussed in Module 1, there are connectors that are used to connect the
BOP stack to the high-pressure wellhead and the LMRP to the BOP stack.
The BOP stack connector

The BOP stack connector always has the same working pressure as the
rams. To keep selected control functions live while running or retrieving the
BOP stack, hydraulic controls are installed on the conventional hydraulic
systems (pod hose reel). These controls normally include such functions as
the stack and riser connector latch and unlatch, and the pod latch. Power
fluid from the surface HPU (hydraulic power unit) is transferred to the hose
reels through a swivel and provides control fluid to the functions during the
operation of the reel.
The reels have their own manual regulator and isolation valve to
complement the hydraulic circuit. The pod manual regulator reduces the
3,000-psi supply to a set pressure, normally 1,500 psi, which is the working
pressure for the stack functions that are controlled from the live pod reel.
The hydraulic pilot signal quick junction plates (RBQ plates) are
disconnected at the reels while running and pulling the stack. It is good
practice to remove the valve handles of the connectors, i.e. the stack
connector and the LMRP connector from the pod hose reel manifolds on both
reels to prevent inadvertent operation of these functions.
Losing the closing pressure to the wellhead connectors, which is probably
due to vibrations during normal drilling operations, has resulted in several
instances of the lower connector unlocking on the high-pressure wellhead.
To prevent the lower connector disconnect problem (and sometimes also the
riser connector), it is a common practice to install a POCV (pilot-operated
check valve) in the closing-side power fluid line of the connector. The
connector can only be unlatched when this check valve is activated, allowing
the closing pressure and its hydraulic fluid to be vented subsea when
opening pressure is applied.
To open the check valve, fluid from the connector's primary or secondary
unlock power fluid line is routed to the valves opening side, where it pushes
against a piston that unseats the check valve seat (see Figure 1).
The POCV is not without potential malfunction problems, but this is mainly
caused by a lack of proper maintenance by the subsea engineer. In the
event that the POCV fails to operate properly, the power fluid line (hose) can
be either cut with a cutting manipulator tool on a ROV, or, if a bypass valve
is installed in the line, this valve can be opened allowing pressure to vent. A
schematic is shown inFigure 2.
242
Rubber
seat
Supply
Pilot
Figure 1 - Cameron pilot-operated check valve.
Cameron POCVs are mostly used in the industry. The tricky element is the
rubber seat. If the valve is used numerous times, the piston tends to
damage the rubber seat. Next, small particles of rubber can block the pilot
line causing the valve to malfunction. Regular (six-monthly) inspections of
the rubber seat are therefore required.
243
Figure 2 - ROV diagram for a wellhead connector.
The angle between the connector body and the connector mandrel can be a
problem during latching or unlatching the connector. Generally, the required
force to unlatch the connectors is substantially greater than the force
required to latch. Most difficulties are encountered while unlatching the
connectors. This has led to the development of locking dog retraction fingers
and secondary unlocking piston systems.
The primary and secondary hydraulic unlocking systems should never be
connected together. The primary and secondary locks are virtually always
connected together.
On several deep-water wells, hydrates have formed between the BOP stack
and the wellhead (caused by gas seepage outside the 20-inch casing). In
addition, ice deposition will have prevented the unlatching of the BOP stack
from the wellhead due to ice formation in the connector voids and even in
the BOP hydraulic circuits inside the connector.
244
The connector functions properly when it is hydraulically unlatched, but the

hydrates bond the connector to the wellhead, which overall can prevent the
BOP stack retrieval to surface. For this reason an O-ring lip seal has been
installed inside the wellhead connector sleeve to prevent the hydrates from
settling between the connector fingers. This seal is called a hydrate
prevention seal. Ensure that you have a witness like the senior toolpusher
after installing this seal, as frequently this seal is lost after pulling the BOP.
A mud mat can be run as a part of the wellhead system in deep-water wells;
it may serve to deflect the gas seepage away from the wellhead and the BOP
stack, as the gas bubbles ascend from the mud line.
Hydrate
seals
Figure 3 - Elastomer hydrate seal.
245
30" housing
Hydrate seals
Figure 4 - Mud mat hydrate seal.
246
2 The Vetco H-4 connector
The most commonly found connector for floating rigs is the ABB Vetco Gray
Figure 5).
Test
stump Number Wellhead
System size H-4 Seal H4 OD
mandrel of mandrel
and rated WP types ring (inch)
or pistons OD (inch)
wellhead
13-5/8 inch /
C C AX 6 20.50 36.00
5M
13-5/8 inch /
C CxD VX 8 20.50 41.63
10M
13-5/8 inch /
C CxE VX 10 20.50 46.88
15M
16¾ inch / 5M D D AX 8 25.75 41.63
16¾ inch / 10M D DxE VX 10 25.75 46.88
16¾ inch / 15M D DxE VX 10 25.75 51.50
18¾ inch / 10M E E VX 10 27.00 46.88
18¾ ich / 15M E ExF VX 12 27.00 51.50
18¾ inch / 15M E HD VX 10 27.00 62.00
21¼ inch / 10M F F VX 12 30.00 66.00
Figure 5 - Table of H-4 connectors.
The Vetco H-4 connector is operated by several hydraulically operated

actuator pistons, which are capable of driving a cam ring upwards and
downwards (see Figure 6). A shallow taper on the ID of the cam ring in turn
drives a segmented ring of dogs radially inwards into a grooved profile on
the wellhead housing. This radial constricting movement provides a large
axial locking force that energizes the ring gasket and preloads the connector
to the wellhead.
The hydraulic system configuration features a primary and secondary lock
system in which parts of the cylinders are ported to the primary lock port
with the balance of the cylinders being ported to the secondary lock. The
same arrangement is included on the unlock side of the cylinders. When
hydraulic fluid is applied to either of the lock ports, fluid enters the operating
cylinders (rod side) from above. The pistons pull the cam ring downward,
driving the dogs radially inward (lock position).
Prior to 1981, the pistons of the secondary system were not connected to
the cam ring and were therefore unable to pull the cam ring downwards
(into the lock position). These pistons were only capable of pushing the cam
ring upwards (into the unlock position). This meant that the secondary
pistons provided no locking force, but were only able to contribute to the
unlocking force.
Since 1981 all the pistons have been connected to the cam ring after a
larger ring was introduced that is capable of supplying a greater locking
force and therefore a larger connector preload. Nowadays the primary and
secondary ports are still connected separately inside the connector (except
for the HD H-4 type) and are usually externally connected to prevent
contamination.
247
The primary and secondary ports should be connected to separate control

lines, which will provide redundancy to unlock a connector if one function
would fail during service. All the control lines have a recommended working
pressure of 3,000 psi and a 5,000-psi test pressure. Tests with more than
3,000 psi should be carried out at the machine shop only! The unlock area of
the pistons is the complete piston area, whereas the lock area of is the
piston area minus the area of the piston rod.
When pressure is applied to the unlock ports, fluid enters the cylinders below
the pistons. The pistons and the cam ring are forced upwards, thus allowing
the dog segment to move radially outwards through the action of the springs
located between the dog segments. When the connector is picked up, the
dog segments are forced radially outward by this taper.
When pressure is applied to either the primary or the secondary unlock
ports, both the primary and the secondary lock port must be vented before
the connector can release. The primary and secondary unlock ports must be
vented while locking the connector.
The connector is equipped with an indicator rod, which makes it possible to
monitor the locking and the releasing function on the surface or subsea with
the aid of an underwater camera. The stroke of the H-4 type indicator, E x F
is 4-inch and the indicator rod stick-up is ⅝ inch in the locked position and
4⅝ inch in the open position.
Under NO conditions should we accept to work underneath the connector
with the BOP hanging in the overhead crane or the drawworks. Sufficient
spacers must be present on which to rest the BOP until you approach the
connector sealing area. In 1998 a terrible fatality happened in Brazil where a
subsea engineer was caught between the test stump and the BOP when an
overhead crane brake failed. Other similar fatalities have occurred since
1998.
The sealing area of the VX-rings must be inspected by the subsea engineer.
The sealing area is to be cleaned with very fine emery paper or, even better,
with a scouring sponge (scotch-brite) as used in the kitchen. These sponges
are made of artificial abrasive fibers and are very suitable to clean these
sealing areas. Never use a knife or wire brushes to clean the VX sealing
areas.
The VX sealing areas as well as the VX rings are connected without the
application of any grease or oil. They are completely dry. The VX rings are
used only once. After the BOP has been retrieved the old ring must be
removed and discarded. After cleaning the sealing area the BOP connector is
to be tested with a new ring.
On some rigs you will find the practice to use the old ring for testing the BOP
after retrieval. The old ring is used and afterwards a new ring is put in after
a successful test on the stump prior to running the BOP. This ring is the
client’s account.
When the BOP is retrieved, all the debris of mud and corrosion from the riser
is passing through the BOP, the VX-ring is virtually hanging in the gasket
ring retainers creating a small stand-off void around the VX sealing area for
debris to settle.
The risk of having contamination underneath the old VX-ring, which can
cause a washed-out connector when pressure testing the BOPs, is
significantly justifiable to use a new VX-ring for testing the BOP on the test
stump. A washed-out connector can result in a very large amount of
downtime and a very angry rig owner and client. In addition to this, it will
create a lot of unnecessary extra work for the subsea engineer.
248
There are four types of seal ring retainer screws:

1. The solid type
2. The spring latch type
3. The hydraulic retractable type
4. The orienting two-piece type
In all cases the retainers should be completely backed out before returning
the connector to the test stump, the mandrel or the wellhead housing in
order to install a new VX-ring. If the gasket ring retainers are not completely
retracted, the seal ring retainers may suffer bending damage or shear off
and the seal ring and sealing profiles will be damaged, causing certain
subsequent damage to the wellhead, test stump or connector.
Before 1981 a secondary seal, called the trash seal, was only available on
request. Since 1981 all H-4 connectors have had their secondary seal groove
machined in the top adapter. The trash seal has two functions:
• It provides back-up for the ring.
• It isolates the ring gasket from the environment.
The groove is located just below the ring gasket. The O-ring seals the
wellhead housing OD to the connected ID area. The secondary seal has a
10,000-psi working pressure. A port may be connected to the area between
the ring gasket and the secondary seal to provide a means of detecting a
leak across the gasket.
If a monitoring line is used, testing should be limited to 1,000 psi unless the
bore of the connector is under a pressure that is equal to the secondary seal
test pressure. This prevents temporary de-energizing of the ring gasket and
the wellhead seal surface washout.
Formerly, cadmium-plated carbon-steel or stainless-steel ring gaskets could
be used in 10,000-psi applications with temperatures not exceeding 250°F.
Only stainless-steel (302/316) ring gaskets should be used for a 15,000-psi
service and a temperature of 250°F and more. Recently, cadmium-plated
rings have been taken out of service in some regions because of the
recognition that cadmium is highly toxic, both to humans and to the marine
environment.
The maximum temperature limit of 250°F has been imposed after detailed
finite element analyses and testing of these gaskets. This value is due to the
reduction in material strength at elevated temperatures and the difference
between the linear coefficient of thermal expansion of stainless steel and
carbon steel (source: ABB Service Bulletin No. EBA-950001, dated 5 July
1995). The available H-4 connector styles are summarized in the tables in
Figure 8 and Figure 9 hereafter.
The designations in style (with exception of the HD and the HAR) are based
on the size of the wellhead. When two letters are used to identify the H-4
connector, the first letter applies to the wellhead size and second letter
denotes the hydraulic section of the connector. For example: the 18¾” 15M
connector is referred to as type E x F.
The HD-H4 connector is a heavy-duty, high-preload connector suitable for
high bending loads at a 15,000-psi operating pressure. The HAR-H4 is a
high-angle release connector primarily used on LMRPs. The riser connector
has a reduced swallow dimension over the mandrel and still allows a release
when the rig-to-wellhead coordinates are offset. In general, the higher the
service applications, the more cylinders are required.
249
Vetco recommends that a locking pressure of 1,500 psi has to be maintained

on all LMRP connectors at all times (while running and during routine
operations). This is a contingency since a loss of pressure would not allow
the connector to release in normal circumstances.
Generally, BOPs are landed on the subsea wellhead with a 1,500-psi
pressure on the unlock port of the connector to ensure the connector is
completely open. After landing the stack, the unlock ports are vented and
the locking pressure is applied to the primary and the secondary lock ports.
After locking with the required pressure, the locking pressure might be
reduced to 1,500 psi and kept at that level during normal drilling operations.
Vetco recommends locking pressures for various connectors and these are
shown in the tables given in Figure 8 and Figure 9. The recommended
locking pressure depends on an effective riser bottom tension and wellhead
angle.
Upper body
VX gasket
Retainer
screw
Figure 6 - Vetco H-4 connector.
250
Secondary release
Secondary lock
Position indicator
Primary lock
Primary release
Figure 7 - Hydraulic connections on the H-4 connector looking from

above.
Figure 8 - Operating guidelines for the Vetco Gray 10M type-E

connector (Source: Graphics Vetco Gray H-4 Procedure No.
335).
251
Figure 9 - Operating guidelines for Vetco Gray 10M type-E connector

(Source: Graphics Vetco Gray H-4 Procedure No. 335).
There are VX-rings that have been developed for the event that the wellhead
or the connector sealing areas are damaged. The ring gaskets are fitted with
so-called Hycar inserts. The bonded resilient inlays can either be installed on
one side of the VX-ring (single resilient) or on both sides (double resilient).
There are also double Hycar gasket rings available. Some DP (dynamic
positioning) rigs use Hycar gaskets on their LMRP connector to ensure that
the ring seals again after the re-entry following a (controlled or non-
controlled) drive-off and disconnection of the LMRP.
It is a bad practice to use a Hycar gasket to perform a stump BOP tests,
as the Hycar can disguise the discrepancies of the connector sealing area.
Should a plain ring be used after running the BOPs, this could result in a
leak subsea!
The risk of damaging the sealing area of the connector due to a damaged
Hycar gasket ring (causing a washed wellhead sealing area) are considerably
larger than when a plain VX-ring is used. Therefore, as a standard plain
rings should be utilized.
Greasing the Vetco H-4 connector and inspection procedures

There are two large grease ports located underneath the connector in the
vicinity of the cylinder heads. Greasing of the Vetco H-4 connector is an
absolute necessity to ensure the proper operation of the connector. Greasing
is to be carried out as soon as the BOPs are on the surface. The old grease
has to be replaced with new grease to make sure that the dogs are fully
retracting when the connector is put in the open position. Most of the time
‘stuck’ dogs are encountered on the surface and not subsea. The minimum
quantity of grease to be used is between 15 and 25 lbs.
The grease operations MUST be performed with the H-4 connector REMOVED
from the test stump. Failure to do so may cause a hydraulic lock on the
connector. This means that the connector will not unlock and stripping of the
connector will be the only solution!
252
After the greasing has been completed (using the two grease ports), the
connector is to be cycled at least 15 to 20 times to ensure that the excess
grease can be displaced. Again, this cycling can only be performed when the
connector is not connected to the test stump.
When the connector is in the locked position, the excess grease that has
been pushed out between the dogs must be removed. If not, it may
seriously impair the proper operation of the cam ring and dog segments.
It sometimes happens that the grease escapes with some force. So, when
the dogs are moving do not stick your head inside unless you love to eat
grease.
The following grease types are recommended by Vetco Gray:
• Jet-Lube AP-5 or equivalent for the assembly of hydraulic components
• Pyroshield 5180 Grade O for routine maintenance, greasing of the dogs
and cam rings, etc. on all the connectors, with the exception of HD-H4
connectors
• Jet-Lube Kopr-Kote for routine maintenance, greasing of dogs and cam
rings, etc. on all HD-H4 connectors
• Never-Seize or Jet-Lube Kopr-Kote for all bolting requirements
(Source: Graphics Vetco Gray H-4 Procedure No. 335.)
There are four undesirable operational characteristics of the H-4 connectors
that indicate that the connector has not been properly lubricated:
1. An increase in the unlocking pressure

The key components of the H-4 connector, i.e. the cam ring and the dogs,
are sliding bearing surfaces that interact during the locking and unlocking
operations. The lack of proper lubrication and maintenance of the main
components will cause abnormally high friction loads between the sliding
bearing surfaces, resulting in an increased hydraulic pressure requirement to
unlock the connector. In addition, cycling of an improperly lubricated
connector will cause mechanical damage to cam ring/dog bearing surfaces,
reducing the ability of any lubricant to minimize high friction loads. A further
increase in frictional loads will be the result, leading to an even greater
increase of hydraulic pressure to unlock the connector.
2. A kick in the locking pressure and corresponding noises during

cycling
When not properly lubricated, the dogs tend to rock rather than slide into
position. This rocking motion aggravates the locking sequence in that the
cam ring must kick the dogs into place. This kick (which is sometimes
audible) can cause scoring and wear on the cam ring and dogs. The
occurrence of the kick phenomenon results in the indicator rod moving
sporadically during the first half of travel when the connector is being
locked.
3. Irregular wear on the test stump or mandrel tooth profile, dog

segments and wear rings
The kicking action discussed above can also cause damage and/or wear on
the surfaces of the tooth profile of the test stump or mandrel. This damage
and/or wear can cause the dogs to stick to the test stump or mandrel even
when the indicator rod indicates the connector is unlocked.
253
4. Dogs sticking in the inward or locked position

This condition usually occurs when attempting to release the connector
under low separation forces, for instance from a test stump that is not
secured to the deck. This may be the result of lack of lubrication or damage
to connector parts, as discussed earlier.
The following procedure is provided for evaluating the operational
characteristics of a H-4 connector caused directly by improper lubrication.
1. Inspect the test stump and the riser connector mandrel.

Thoroughly clean and inspect the tooth profile for ridges. Dress the ridges
with a fine tooth file. Apply an anti-seize water-resistant compound such as
Never-Seez or Kopr-Kote on the tooth profile of the test stump or mandrel
where the H-4 connector dogs engage.
2. Closely monitor the lock pressure.

Operate the H-4 connector locking system, making note of the pressure
required to initially move the cam ring, i.e. the pressure at which the
indicator rod starts moving downwards. Monitor ands record the lock
pressure during the complete travel of the ram ring and make sure that the
complete travel is a smooth motion without kicks in the pressure and/or
corresponding noises. The indicator rod should travel past mid-stroke (a 2-
inch travel) before the pressure builds up. If a kick is present, inspection of
the connector is required.
3. Closely monitor the initial "unlock" pressure.

Operate the H-4 connector unlock system, making note of the pressure
required to initially move the cam ring, i.e. the pressure at which the
indicator rod begins to move upwards. The pressure will increase until the
preload between the cam ring and the dogs is released; subsequently, the
pressure should drop sharply during the upward movement of the ring. The
unlock cycle should be performed after the connector has remained locked
to the test stump or mandrel for at least 4 to 8 hours.
The following is a troubleshooting guide based on the initial hydraulic
pressure required to unlock the connector:
Unlock pressure Action required

1. 200 to 700 psi: Normal operation rate; continue normal PM.
2. 700 to 1,500 psi: Greasing operation required.
3. 1,500 to 3,000 psi: Connector dogs to be removed and cleaned.
4. Over 3,000 psi: Possible damage on the dogs, cam ring and wear
rings. Inspection of these parts should be
performed immediately and damaged parts are to
be replaced.
254
Figure 10 - Graph of Vetco Grey H-4 unlock requirements.
255
Figure 11 - Measuring clearance between the dogs segments and the

upper wear ring.
Measuring the clearances between the dog segments and the upper
wear ring.
The following procedure must be followed:
1. The clearance between the individual dog segments and the upper wear
ring should be taken and recorded in the table (see Figure 12).
2. When these clearances have been taken, the feeler gauge should be
moved in a swaying motion from left to right to ensure that the whole of
the top surface is measured.
3. We measure the dog clearance with the connector in the unlatch
position.
Dog No. Clearance Comments Dog No. Clearance Comments

1 7
2 8
3 9
4 10
5 11
6 12
Figure 12 - Dog measurements table.
256
Checking the dog clearances on the Vetco H-4 connector.
The following procedure must be followed:

1. Stud bolt connectors must be made up to the BOP prior to taking the
clearance readings.
2. Function the connector through three complete cycles.
3. Confirm that the connector is fully latched, measure the travel on the
indicator rod and check the correct volume.
4. Leave the connector in the unlatch position.
5. Ensure that the dog area is clean.
6. Take a reading in the unlatched position.
7. Record all the readings in a table as shown in Figure 12.
At the initial manufacture, the 10-15M studded connectors have a clearance
ranging from 0.007 inch minimum to 0.030 inch maximum.
Field experience and computer analyses have shown that this clearance can
decrease by 0.019 inch on the 10M type-E connector and increase to 0.006
inch on the 15M type-ExF connector, when the connector is assembled to
the BOP stack or the LMRP and the studded top, when using torque and
thread lubricant as recommended by API Spec 6A.
Depending on the actual initial clearance, this deflection could result in the
locking dogs being jammed, particularly if the clearance is not checked after
the assembly of the BOP or LMRP (Source: Vetco EB No. H022 dated 17
February 1992).
Minimum clearance Maximum clearance

Type of H-4 Connector
(inch) (inch)
E, 10M 0.005 0.030
ExF, 15M 0.011 0.036
Studded-Top E, 10M 0.020 0.045
Figure 13 - Table of allowable distances of gaps between the dog
segments and the upper wear band.
Note: The studded-type gap is prior to make-up.

The most accurate and preferred procedure is to remove the segments and
measure the dog window and the segments, and then subtract the two
measurements. Both the segment window and the dog segments are
nominally six inches in size. Removing the dog ring periodically (yearly) is
necessary for removing corrosion from the segments and the window.
Dog segments should be removed and the clearances calculated in the
following instances:
• When the dog to wear ring clearances are approaching Vetco's maximum
allowable measures
• When corrosion is observed in the dog to wear ring area
• When problems have been experienced while separating the connector
257
Figure 14 - Measurement of the H-4 dog segment.
Figure 15 - Internal of the H-4 type E x F connector with the dogs

removed.
The hydrate seal is only partly left inside the seal groove after the BOP was
pulled. Sometimes the hydrate seal disappears completely when the stack is
pulled. To prove that the hydrate seal was installed prior to running the BOP,
it is advisable to have a senior staff member witness the installation of the
hydrate seal and record this installation in the IADC report (see Figure 15).
This will prevent discussions with the operator in case downtimes occurs due
to ice forming on the connector despite the installation of the hydrate seal.
258
3 Cameron hydraulic connectors

In this chapter we will discuss the following connectors:
1. The Cameron Model 70 Collet Connector
2. The Cameron HC Connector
3. The Cameron Mini-Connectors
4 The Cameron model 70 collet connector

The original Cameron Collet 70 Connector design was developed in the early
1960s. It has been refined through the years, but it has always retained the
basic Collet finger self-locking taper design.
The Collet 70 design approach provides many useful advantages for a
wellhead or riser connector:
a) Large preloads are possible because of the mechanical strength built into
the design.
b) High strength and stiffness with a very direct load path through the
connector.
c) Short swallow and large Collet 70 finger opening permits locking and
unlocking, despite large angular misalignments between the well
coordinates and the RKB.
d) Inherent self-locking characteristics.
As the Cameron Collet 70 connector achieves large preloads during locking,
it must utilize a self-locking taper design. This is achieved through the
design of a very steep angle between the actuator ring ID and the OD of the
assembly of the fingers (see Figure 16).
Figure 16 - 18¾-inch 10M Model-70 Collet Connector.
259
The self-locking behaviour of the 18¾-inch 10M Model 70 connector

indicates a minimum coefficient of friction (μ) of 0.1225 (source: Cameron
EB No. 601). Figure 17 shows schematically the forces that act on the
actuator ring, ignoring the seal drag and the gravity force that both could
also keep the connector in the locked position without any operating
pressure applied to the connector.
There are therefore only two forces on this ring:
a) A normal or perpendicular force: Fn
b) A frictional force: Ff
Fn and Ff are directly related by the coefficient friction (μ) in the equation
Ff = μ . Fn
Ff Fn
Figure 17 - Force diagram of actuator ring.
260
The downward force on the actuator ring Fn (Fnet down) that keeps it locked
is simply the difference between the axial components of the two forces Fn
and Ff.
For example, for an angle of 4°:
Fnet down = (Ff . cos 4°) - (Fn . sin 4°)
Substituting for Ff
Fnet down = ([μ . Fn] . cos 4°) - (Fn . sin 4°)
Factoring Fn
Fnet down = Fn (μ . cos 4° - sin 4°)
Since cos 4° = 0.998; and sin 4° = 0.07
Fnet down = Fn (μ x 0.998 - 0.07)
and μ = 0.1225
Fnet down = Fn ([0.1225 x 0.998] - 0.07)
Fnet down = Fn (0.052)
For example, if Fn = 8 x 1,000,000 lbs (typical for a 18¾-inch 10M HC
connector)
Fnet down = 416,000 lbs
The value for 416,000 lbs illustrates that under given conditions an upward
force of 416,000 lbs would have to act directly upon the actuator ring in
order to reach a force equilibrium condition.
261
Figure 18 - Cameron Collet 70 Connector finger layout.
The 18¾-inch Cameron Collet 70 connector rated at 10M has nine Miller
cylinders installed, which are protected by the skirt. Six hydraulic cylinders
are connected to the primary lock and unlock port. Three hydraulic cylinders
are connected to the primary lock and the secondary unlock port. The
cylinders are rated to a 3,000-psi working pressure, but normally a pressure
of 1,500 psi is used for lock/unlock or secondary unlock the connector.
Some newer types have steel piping installed instead of the hydraulic hoses.
This modification was aimed at improving the reliability of the hydraulic
circuitry against single-point failure. Removing this skirt to access the
hydraulic circuitry is very labour-intensive. Due to the water-hammer effect
in deep-water operations made it necessary to change the steel piping again
for hydraulic hoses; this completes the circle!
262
Figure 19 - Typical hose schematic for the Cameron Collet Model 70.
The AX ring is used to provide the gasket between the connector and the
wellhead, or between the riser connector on the LMRP and the BOP stack
hub. The AX gasket is held in place with AX retainer pins. These pins are
spring-loaded for the extend function and pressure-retracted.
Ensure that the operating pressure for the AX release port is 1,000 psi for
older connectors, and no more than 1,500 psi for newer units. The port of
the AX release should not be plugged when not in use. Either a vented port
should be available, or no plug at all. Most operators install an ROV hot stab
but this stab must be fitted with a vented connection plug.
263
Figure 20 - The AX Gasket Ring Retainer Assembly of the Cameron

connectors.
/ WP
Cylinders
cylinders
of
Amount
Volume of fluid to
Stroke operate Hydraulic operating
(inch) pressure (in psi)
(in US gallon)
Primary Sec. Primary Sec. Gasket

Close Close
open open open open retainer
5
inch 9 9¾ 4.973 2.486 6.265 1,500 3,000 1,500 1,500
/ 3M
Figure 21 - Table of operating data: 18¾-inch 10M Collet 70
connector.
Visual inspection of the Cameron Collet Connector

Collet fingers
The dogs of the Cameron connectors do not receive grease like the Vetco H-
4 connector. However, the fingers should be protected from corrosion.
Lubrication with Mystic Blue, Mystic JT-6 or an equivalent should be used
during the IBW preventive maintenance.
Gasket retainer
The AX release dogs should always be inspected as they often have bent
stems. The Spirilox retainer rings need to be firmly in place. The retainer
ring sometimes ‘rolls’ itself outwards from its recess or is distorted. Verify
that the pins stroke out completely when the retracting pressure is released.
Gasket ring groove

Ensure that only a gasket with an AX profile is used in the connector. The
finish of the stainless steel ring groove should be 32 RMS or better. AX
resilient gaskets have the following temperature ratings:
a) With a Nitrile insert 250°F
b) With a CAMLAST insert 350°F
264
Function test
Function-test the connector for full stroke of the cam ring; the indicator rods
travels nine inches. The off-stump stroke should be at least 0.188 inch more
than the on-stump stroke (source: Cameron EB No. 831M).
Unlocking test
The required unlocking pressure of more than 900 psi calls for cleaning and
possible rework of the connector when locking the connector with a 1,500-
psi pressure. Locking with 3,000 psi will require locking pressures twice the
ones experienced at 1,500 psi, and using the secondary unlocking chamber
on its own will also require pressures twice that of the primary unlock.
Figure 22 - 16¾-inch Cameron 10M Collet 70 Connector assembly.
265
5 The Cameron HC collet connector
The HC Collet connector is actuated by an annular hydraulic cylinder and

locks to the mating hub by means of pivoted locking segments shaped like
tapered fingers. These segments form a funnel to guide the connector into
position and clamp the mating hub to secure the connection. When
unlocking pressure is applied, the segments swivel about the approximate
midpoint into the fully open position prior to being released from the mating
hub to allow disconnection at angles up to 30 degrees (according to
Cameron).
The annular hydraulic design provides higher preloads than those available
with piston-type actuators. The HC Collet connector is locked to the mating
hub by pivoted lockdown segments, which are shaped like tapered fingers.
All HC connectors have stainless-steel linings on the AX/CX sealing surfaces.
AX gasket rings are available with and without bonded resilient rings.
All Cameron Collet connectors have a milled orientation slot in the bore,
which is used to locate production tubing hangers and components.
Therefore, the same connector may be used on both drilling and production
operations.
The travel of the ring is 3-13/16 inch. The stick-up of the indicator rod of the
15M HC connector is 3¼ inch in the locked position and 8-1/16 inch in the
open position. The swallow of the 18¾ inch 15M HC connector is 12½ inch.
The primary piston is connected to the actuator and travels vertically. The
secondary piston can provide an extra boost to unlatch the primary actuator.
In order to use the secondary open piston, the primary piston should be in
the vent position (see Figure 24).
266
Secondary opening port

Indicator rod
Closing port
AX release port
Indicator rod
Primary opening port
Figure 23 - 18¾ inch 15M HC Collet Connector hydraulic

connections.
Figure 24 - 18¾-inch 15M Cameron HC Collet connector.
267
6 Cameron mini connectors
The Cameron Mini Connector is virtually identical to the HC connector. The

only difference is that it is sized 3⅛ inch and that it is used in the choke and
kill line on the LMRP to connect the LMRP choke and kill lines with the BOP
stack choke and kill lines.
The AX rings are connected with Allen bolts and no gasket release
mechanism is present. The Mini Connector is equipped with a mechanical
override system that will unlatch the connector in case the hydraulic system
fails. It is important that only stainless-steel and plain AX rings are used in
Mini Connectors.
The hose connections on top of the Mini Connectors should be designed in
such a manner that they allow the travel of the ring without shearing the
hose fittings. Straight hydraulic fittings should be installed here, but no 90-
degree elbows.
The lining of the Mini Connectors is not very strong and over the past decade
frequent re-chroming has been required with the earlier revisions of the
equipment. Testing the connectors to 3,000 psi open and close is required to
ascertain the condition of the seals inside the hydraulic circuit of the Mini
Connectors. The Mini Connectors do not have a secondary open port, but
merely an open and close port.
Figure 25 - Cameron 3⅛-inch 15M Mini Connector.
268
Detail A-A
Figure 26 - Cameron Mini Connector in locked position.
Allen-headed set-screw
Locking dogs
AX-gasket (3⅛ inch)
Figure 27 - Detail of A-A cross-section of the Mini Connector.
269
7 Checking the proper operation of the

Cameron mini connector
The following steps have to be taken:

Before disconnecting the LMRP from the BOP stack, the distance from the
stop ring to the top of the cage should be ⅜ inch to ensure that the rubber
springs are in compression and force the connector down onto the mating
spacer spool on the BOP stack.
If the shear pins are sheared, the stop ring has moved or is no longer
present. This indicates that the connector has had to unlock mechanically,
most probably due to a failure of the hydraulic system to unlock the
connector.
When unlatching hydraulically during the stump function test, investigate the
proper operation of the manual unlatching rod.
After the Mini Connector is unlatched and the LMRP is lifted from the stack,
the body should drop approximately ⅜ inch (as mentioned in item 1) and
the stop ring should rest on the mounting cage. The rubber springs should
be slightly compressed after the unlatching.
Figure 28 - Cameron Mini Connector in the open position.
270
Figure 29 - Cameron Mini Connector in the closed position.
271
8 Cameron connectors omparison
Figure 30 - Cover of the Cameron prospectus.
272
Figure 31 - Cameron connector features.
273
Figure 32 - Comparison between Collet Connector types.
274
Figure 33 - Hub interchangeability.
275
Figure 34 - Load paths and performance data.
276
Figure 35 - Load capacities graphs.
277
Figure 36 - Volume and weight specifications.
278
9 Cameron deepwater collet connector
Figure 37 - Cameron Deepwater Connector type DWHC.
279
Figure 38 - Cameron Deepwater Collet DWHC Connector: technical

data.
280
Figure 39 - Dimensions of Collet Connector hub types.
281
Questions Hydraulic Connectors

1. Explain the reason for the presence of POCVs in hydraulic connectors.
When do we NOT use POCVs on hydraulic connectors and why?
2. Why are POCVs wearing out much faster when connected to a Vetco
connector than to a Cameron connector?
3. What is the most common cause for a Cameron POCV pilot line getting
plugged?
4. What can cause an override in case the POCV is blocked?
5. Why should we not connect the primary and the secondary unlatch of
connectors?
6. How do we protect the wellhead connectors from hydrates?
7. Explain why the unlocking force is always greater than the locking force
when the same pressures are being applied.
8. What is the allowable wear range of the Vetco type-EXF connector
dog/wear ring gap? Sum up the procedure how to measure this gap.
9. What is the difference between the secondary unlatch function of a
piston-type connector (Cameron Collet 70) and an annular-type
connector (Cameron HC)?
10. When do we use T-bars on the Vetco H-4 connector?
11. What is the minimum unlocking pressure of the Vetco H-4 connector and
what has to be done if this pressure is exceeded?
12. Where do we use unbalanced shuttle valves in the connector and why?
13. Why is the swallow of the riser connector shorter than that the wellhead
connector?
14. How do we measure the backdrive of a connector and what is the
consequence if the backdrive measurement is beyond the allowable
dimension?
15. Why do we discourage the use of a standard, a Hycar or a resilient seal
ring? What could be the exception?
16. Why is the correct grease for the H-4 connector so important? Mention
some of the recommended greases for this connector.
17. Mention the four indicators that an H-4 is not properly lubricated.
18. Mention the recommended lubricators of the Cameron Collet Connector.
19. Above what pressures on Cameron connectors is extra maintenance or
cleaning required?
20. If the Cameron Mini Connector fails to open hydraulically during an EDS,
what will be the outcome?
21. What is the most vulnerable part of the Cameron Mini Connector?
22. How are the seal rings in the Mini Connector bore installed?
23. What is the tension capacity for the Cameron DWHC Collet Connector?
24. Mention the amount of fluid to close the 10M Model 70 and the HC
connector.
25. How much volume does the secondary unlock needs to have for the
secondary unlock on the Collet Model 70 Connector?
26. What is the weight of the 10M Cameron Model 70 and the HC connector?
27. What is the weight of the 15M Cameron DWHC connector?
282
10 Table of figures
Figure 1 -
Cameron pilot-operated check valve.................................... 243
Figure 2 -
ROV diagram for a wellhead connector. ............................... 244
Figure 3 -
Elastomer hydrate seal...................................................... 245
Figure 4 -
Mud mat hydrate seal. ...................................................... 246
Figure 5 -
Table of H-4 connectors. ................................................... 247
Figure 6 -
Vetco H-4 connector. ........................................................ 250
Figure 7 -
Hydraulic connections on the H-4 connector looking from
above. .......................................................................... 251
Figure 8 - Operating guidelines for the Vetco Gray 10M type-E
connector (Source: Graphics Vetco Gray H-4 Procedure No.
335). ............................................................................ 251
Figure 9 - Operating guidelines for Vetco Gray 10M type-E connector
(Source: Graphics Vetco Gray H-4 Procedure No. 335)......... 252
Figure 10 - Graph of Vetco Grey H-4 unlock requirements. ................... 255
Figure 11 - Measuring clearance between the dogs segments and the
upper wear ring.............................................................. 256
Figure 12 - Dog measurements table. ................................................ 256
Figure 13 - Table of allowable distances of gaps between the dog
segments and the upper wear band................................... 257
Figure 14 - Measurement of the H-4 dog segment. .............................. 258
Figure 15 - Internal of the H-4 type E x F connector with the dogs
removed. ...................................................................... 258
Figure 16 - 18¾-inch 10M Model-70 Collet Connector. ......................... 259
Figure 17 - Force diagram of actuator ring.......................................... 260
Figure 18 - Cameron Collet 70 Connector finger layout......................... 262
Figure 19 - Typical hose schematic for the Cameron Collet Model 70. ..... 263
Figure 20 - The AX Gasket Ring Retainer Assembly of the Cameron
connectors..................................................................... 264
Figure 21 - Table of operating data: 18¾-inch 10M Collet 70
connector. ..................................................................... 264
Figure 22 - 16¾-inch Cameron 10M Collet 70 Connector assembly......... 265
Figure 23 - 18¾ inch 15M HC Collet Connector hydraulic connections..... 267
Figure 24 - 18¾-inch 15M Cameron HC Collet connector. ..................... 267
Figure 25 - Cameron 3⅛-inch 15M Mini Connector............................... 268
Figure 26 - Cameron Mini Connector in locked position. ........................ 269
Figure 27 - Detail of A-A cross-section of the Mini Connector................. 269
Figure 28 - Cameron Mini Connector in the open position...................... 270
Figure 29 - Cameron Mini Connector in the closed position.................... 271
Figure 30 - Cover of the Cameron prospectus. .................................... 272
Figure 31 - Cameron connector features............................................. 273
Figure 32 - Comparison between Collet Connector types....................... 274
Figure 33 - Hub interchangeability..................................................... 275
Figure 34 - Load paths and performance data. .................................... 276
Figure 35 - Load capacities graphs. ................................................... 277
Figure 36 - Volume and weight specifications. ..................................... 278
Figure 37 - Cameron Deepwater Connector type DWHC........................ 279
Figure 38 - Cameron Deepwater Collet DWHC Connector: technical
data. ............................................................................ 280
Figure 39 - Dimensions of Collet Connector hub types. ......................... 281
283
284
Module 02 - 05 Choke and kill manifold 1.0
Chapter 05
Choke and kill manifold
1 Layout of the choke and kill manifolds ...................................... 286

2 Target or no target, lead plug or no lead plug? .......................... 288
3 Mud/gas separator ................................................................ 292
4 Table of figures ..................................................................... 307
285
1 Layout of the choke and kill manifolds
to poor-boy Buffer tank

degasser
16 17 18
15A 15B
to cement hose
19 20
test
line
from cement unit
manual remote remote

sensor choke choke choke sensor
10 11 12 13 14
9 8 7 6 5
3 4
1 2
Kill line Choke line
Figure 1 - Choke and kill manifold of the drilling rig Atwood Eagle.
Fill in the test sheet for the manifold on the Atwood Eagle:
Test No. Valve numbers Pressure applied (psi)

1
2
3
4
5
6
7
8
9
10
286
to overboard to delution ditch
Poor-boy 23
degasser 22
20
19
pressure gauge
18 buffer tank buffer tank 21
17 16 15 14
2" hose
(Bleed off line) manual remote manual targeted remote
choke choke elbow choke
choke
28 10 11 12 13
blind flange 9 2 5 6 8
blind flange
(Chiksan adapter plug)
(Chiksan adapter plug)
4
1 26 7
3 check
valve
check
valve LT LT
chiksan
connection
Kill line
J-2 Choke line
Sensor
10M 10M
from Cement unit from Stand Manifold
pipe
10M line 5M line
Figure 2 - Choke and kill manifold of the drilling rig Explorer III.
Fill in the test sheet for the manifold on the Explorer III:
Test No. Valve numbers Pressure applied (psi)

1
2
3
4
5
6
7
8
9
10
287
2 Target or no target, lead plug or no lead

plug?
Legislation states that targets must be installed in 90-degree elbows in

choke and kill lines, regardless if they are in the high-pressure section,
upstream the chokes or the low-pressure section, or downstream the
chokes.
The API rule is that the radius of the pipe bend must be greater than 10
times the nominal diameter of the piping. If not, a target block installation is
required. Standard 90-degree elbows have a radius of only 1.5 times the
diameter of the pipe. Heavy-wall elbows are no exception of this rule!
A target is required for all choke and kill manifold piping where:
R < 10d
d = The nominal diameter of the pipe
R = Radius of the pipe bend measured at the centre line
It is important that the targets are positioned according to the flow
direction; some systems require targets at either side of the 90-degree
change in direction, as a flow can occur from both directions.
It is good oilfield practice not to install lead plugs in the targets in the
vertical plane; when they come loose from the target housing under the
influence of gravity, this can lead to blocked or partially blocked pipework
inside the manifold.
Figure 3 - Sketch depicting limits for target requirement.
288
Figure 4 - Blind target flange with lead plug.
It is a good practice to drill ¼-inch pressure-equalizing holes into the

supplied replaceable lead plugs that will be installed in target flanges, in
order to prevent the lead plug from being ‘pumped out’ by differential
pressure, which can occur if system fluids migrate to the rear of the plug.
Another practice is to remove the lead plugs all the way and use the target
blocks more or less like “fluid targets” where the extra recess should reduce
the speed of the mud, thus preventing a pressure increase and excessive
cavitation erosion. It is still too early to tell whether this approach will
survive a serious well control situation. The lead plug is not installed due to
sacrificial part but rather to absorb the imploding bubbles that are causing
the cavitation erosion.
Figure 5 - Lead plug showing normal Figure 6 - The lead plug has been
wear as a result of cavitation removed and the target block is used
erosion. as a fluid target.
289
Figure 7 - Used and new lead

plug on target flanges.
Figure 8 - A 90-degree heavy-

wall elbow; the radius is only
1.5 times the diameter of the
pipe. This is allowed neither
upstream nor downstream the
chokes on the choke and kill
manifold (R > 10d).
Figure 9 - Not only erosion on

the inside but also corrosion
on the outside will affect the
safe operation of the choke
and kill lines (maximum wear
12.5% of the original wall
thickness). What do you think
about this radius?
290
Figure 10 - Obsolete
Cameron gate valve. The
square edges on the slot
are very vulnerable for
H2S. The condition of the
seal rings is very poor;
new rings are required
and the retainer plates
must be thoroughly
cleaned. The gate needs
to be renewed as well.
Figure 11 - More recent

design of valve that has a
round slot. It is being
inspected for wear and
tear around the body
bushing sealing area.
Figure 12 - It is very
important that the gate is
installed EXACTLY
opposite the inlet and
outlet lines of the valves.
If not, the complete
gate/seat assembly is
washed out in no time!
291
3 Mud/gas separator
The mud/gas separator is used to control gas when circulating through the
choke manifold or during kick situations. The mud/gas separator is an
essential item of the well control equipment and is required on floating rigs.
The mud/gas separator is installed downstream the choke manifold in order
to separate gas from drilling fluids returning from the well.
This equipment provides a method for safely venting gas and returning
usable liquid mud into the active mud system. Small amounts of entrained
gas can then be handled by a vacuum degasser located near the mud pits.
There are three types of mud/gas separators:
1. Open-bottom separators
2. Closed-bottom separators
3. Float-type separators
Open-bottom separator
The open-bottom separator, also termed the poorboy separator, is mounted
directly with its open bottom submerged in either a mud tank or a trip tank.
The mud leg (fluid level) is controlled by adjusting the level in the mud tank
or by repositioning the separator vertically. There is a restriction of the
maximum mud leg height with this type of separator due to the level in the
mud tank; the system may become plugged because of solidified mud
deposits.
Figure 13 - Open-bottom mud/gas separator.
292
Closed-bottom separator
The closed-bottom separator has, as its name implies, a closed bottom and
a mud outlet in the form of a U-shaped bend that effectively controls the
fluid level. The U-shaped configuration of this pipework also constitutes a
mud seal that assures that gas can never return to the active mud system,
even at calculated peak volume and velocity of the fluid gas mixture at the
inlet.
Figure 14 - Closed-bottom mud-gas separator.
Float-type separator
The fluid level (mud leg) in a float-type mud/gas separator is maintained by
a float valve configuration as shown in Figure 15 Valves can be operated by
means of a mechanical linkage system, which is manually operated and
connected from the float to the valve. Alternatively, the valve can be air-
operated with rig air. The mud leg height is controlled by adjusting the float
assembly.
293
Figure 15 - Float-type mud/gas separator.
Some problems have occurred with these units, caused by both loss of rig
air and failure of the mechanical linkage. For these reasons, the closed-
bottom mud/gas separator is nowadays the preferred unit.
General observations
During well control operations the main purpose of mud/gas separators is to
vent out the gas and save the drilling mud. This is important as it minimizes
the risk of circulating out a gas kick without having to shut down the
operations in order to mix additional mud volumes. In some situations the
amount of lost mud can be critical when the surface volume is marginal and
the on-site mud supplies are limited in offshore conditions.
When a gas kick is properly shut in and circulated out, the mud/gas
separator should be capable of salvaging the majority of the mud. Peak gas
flow rates should theoretically be experienced when gas initially reaches the
separator.
The basic design of a mud/gas separator that operates by gravity or
hydrostatic pressure should have the following design features checked:
a) The height and diameter of the separator.
b) The internal baffle arrangement that invokes gas coming out of the
solution.
c) The diameter and length of the gas outlet.
d) An impingement plate to minimize erosion where the inlet mud/gas
mixture contacts the inner wall of the separator and a method of
inspecting the plate for wear.
294
e) A U-tube arrangement properly sized to maintain a fluid seal in the

separator; the resistance caused by the height and weight of the mud
column is called the mud seal of the poorboy degasser. The U-tube
height provides a higher mud column than the poorboy degasser vessel
only.
There are a number of design features that affect the volume of gas and
fluid that the separator can safely handle. For production operations
mud/gas separators can be sized and internally designed to efficiently
separate gas from the fluid. This is possible because the fluid and gas
characteristics are known and design flow rates can be readily established.
Poorboy degassers for drilling rigs cannot be designed on the same basis,
because the properties of the circulated fluid from gas kicks are
unpredictable and a wide range of mixing conditions occur downhole. In
addition, theoretical mud properties vary and have a strong effect on gas
entrainment. Recent well site disasters have led to an increased emphasis on
properly sized mud/gas separators that have adequate dimensioning and
volumetric capacity to handle the most dramatic of exploration well influxes.
A mud/gas separator-sizing worksheet is included at the end of this chapter
as an aide to determine whether a gas flow rate will exceed the capacity the
installed separator. The height and the diameter of a mud/gas separator are
critical and considered fundamental criteria in the designed sizing of the unit
(rig-specific data).
As the mud/gas mixture enters the separator, the opening pressure consists
of the atmospheric pressure plus the pressure due to the friction in the gas
line. The vertical distance from the inlet to the static-fluid level allows time
for an additional gas breakout and makes it possible for the fluid to rise
somewhat during the operation on order to overcome friction loss in the mud
outlet lines.
As shown in Figure 20 the gas/fluid inlet should be located approximately at
midpoint of the vertical height. This turns the top half into a gas chamber
and makes the bottom half suitable for gas separation and fluid retention
(storage). The 30-inch diameter and 12- to 16-foot minimum height
requirements have been developed through experience and have proven
adequate in past well control operations.
The separator inlet should have at least the same ID as the largest line on
the choke and kill manifold, which means a nominal diameter of at least 3
inches. Some separators use a tangential inlet, which produces a small
centrifugal effect on the gas/fluid mixture (see Figure 20).
Other separators use an inlet that is perpendicular to the separator and that
directs the flow at a flat steel plate perpendicular to the flow (see Figure 13,
Figure 14, and Figure 15).
This so-called impingement plate minimizes the erosive wear to the internal
walls of the separator and assists the mud/gas separation. A method to
inspect and replace the impingement plate should be incorporated in the
mud/gas separator design. The internals of all mud/gas separators must be
field-repairable.
The baffle system causes the mud to flow in thin sheets, which assists the
separation process. There are numerous arrangements and shapes of baffles
used. It is important that each plate be securely welded to the body of the
separator with angle braces. The perforated inner sleeve is not a
requirement and may not be found in existing separators. This device helps
prevent debris and some fluid from escaping with the vented gas and is
recommended in new installations.
295
An 8-inch (HSE 11/90) minimum gas outlet internal diameter is

recommended for allowing a large volume of low-pressure gas to be released
from the separator with little restriction and few friction losses. Care should
be taken to minimize the backpressure in the vent line. Many new rigs are
fitted with lines having an ID of no less than 10 inch in the derrick to reduce
the backpressure even more.
The vent line should be routed into the derrick and should extend above the
crown block platform. The vent should not be placed any lower due to the
potential fire hazard created by the gas blowing across the derrick. The
outlet of the poorboy degasser is considered a Zone 1 hazardous area. The
operating pressure within the separator is equal to the friction pressure of
free gas venting through the vent line.
Fluid is maintained at a specific level by the liquid leg at all times. If the
friction pressure of the gas venting through the vent line exceeds the liquid
hydrostatic pressure within the separator, the hazardous situation of blowing
the liquid from the bottom of the separator and discharging the gas through
the liquid leg to the mud ditch will occur. The mud outlet downstream of the
U-tube should be designed to maintain a minimum vessel fluid level of
approximately 4.5 feet in a 16-foot-high separator.
Assuming a 12-ppg mud weight and an U-tube height of 8 feet, the liquid
seal would have a hydrostatic pressure equal to 5 psi only! This again
highlights the importance of providing a large-diameter gas vent line that
contains the fewest possible bends and diametrical restrictions to minimize
line friction losses and is less prone to erosion cavitation.
The mud/gas separator should be equipped with a low-pressure gauge to
monitor the vessel pressure during a kick circulation and compare the
available mud leg seal hydrostatic pressure. This gauge should have a range
from 0 to 20 psi and should either be visible from the driller's doghouse, or
be remotely installed. The pressure gauge makes it possible to determine
the impending gas flow through the mud leg to the mud ditch and to take
appropriate action, such as reducing the mud pump rate or opening the
bypass valve around the mud/gas separator. Vessel pressure data could also
be used to verify line friction losses calculated with the mud/gas separator
sizing worksheet.
The mud outlet line must be designed to handle viscous and contaminated
mud returns. An 8-inch ID line or larger is recommended to minimize friction
losses (see Figure 19). This line normally discharges into the mud ditch in
such a manner that clean mud can be directed over the shakers and the
untreatable mud contents will be routed overboard. The end of the line
should be visible to allow a constant observation of the flow.
Under no circumstances should the line be extended below the
mud/fluid levels in the tanks. This could allow mud to be siphoned from
the mud system, thus upsetting the gas/mud interface in the separator. A
method to drain, clean out and wash this line and the separator are also
important, as they may become plugged or freeze up.
Most floating rigs have the shale shakers enclosed either in special room on
the top deck or within the structure of the rig. For floating rigs with this
arrangement a valve has been installed in the mud outlet line that allows
mud to be pumped into the lower section during operation, in order to
minimize the risk of gumbo settling out and partially or fully blocking the
mud outlet. Also, this line is frequently used to clean the interior of the
vessel following a well control event.
296
Figure 16 - Poorboy degasser with a good U-tube creating a high

mud seal. The siphon breaker on the U-tube should be connected to
the vent line high up in the derrick (monkeyboard level).
Should the fluid seal in the separator be lost in a gas-handling occurrence,

the mud outlet valve can be closed to prevent gas from venting into the
shaker house. To prevent overpressuring the poorboy degasser, it is
important to discontinue the use of the poorboy degasser as soon as
possible if the mud outlet valve is closed.
Some drilling contractors install open-bottom atmospheric separators in the
shaker mud tank. This type of installation can be hazardous and is not
recommended.
Experience has proven that cuttings and debris can plug the bottom of the
separator and cause serious operational problems. In addition, separators
should not be installed on top of the mud tanks, since this can create
hazardous working conditions around the shaker area.
Separators should be firmly anchored on a separate platform with the gas
line outlet directed away from the rig floor and the mud system. All
separators must be built in compliance with the ASME (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code (Sec. VIII, Div. 1)
with all material requirements laid out in the NACE (National Association of
Corrosion Engineers) Standard MR01-75-84 (1980). All welding on the
vessel must meet the ASME requirements. Due to lower temperatures
caused by expanding gases, the steel used for the poorboy degasser must
be able to withstand lower temperatures, as normal steel becomes brittle as
it cools off.
297
Due to the large mud volume stored in the deep-water marine drilling riser,
several deep-water drilling rigs have recently added a second mud/gas
separator, which provides the option of simultaneously circulating the well
by means of the rig's primary mud/gas separator while circulating the
marine riser with the second mud/gas separator.
Large separators and lines are required, since the riser and diverter systems
are low- pressure systems. The system should be used for circulating gas
units out of the mud in the riser only. If substantial flow is encountered
while circulating out the riser, the mud and gas should be diverted directly
overboard.
In recent years there have been several serious accidents caused by
mud/gas separator failures during well control situations. Primarily, these
were the result of an inadequate design and poor training standards for
personnel to handle high-pressure gas kicks for deeper drilling operations. It
is important that the drilling staff fully understand the limitations of all well
control equipment and that they are trained to take remedial actions before
pressure capacity limitations occur.
The key initial decision that must be made is the mud pump rate at which
the kick will be circulated out. Large influx, high-pressure gas kicks should
be pumped out at low rates (normally at 1 barrel per minute or less) in
order to minimize the gas release rate at the surface where a rapid
expansion occurs. Circulating out at slow rate reduces the surface pressure
and provides additional reaction time.
Mud/Gas Separator Sizing Worksheet

(Reference: MacDougall, G.R., Mud/Gas Separator Sizing and Evaluation,
SPE Drilling Engineering, December 1991)
This worksheet can be used to determine whether a mud/gas separator can
safely handle the peak gas flow rate of a kick. The kick can be an actual
kick; alternatively, the separator sizing can be checked before the spud with
a typical kick. The typical kick should be based upon previous, offset well
data and should be a realistic worse-case scenario gas kick. For a well data
example, see Figure 19.
The maximum surface pressure of the kick (Pc) and the volume of the kick
upstream the choke can be calculated by means of the KIK computer
program or other programs that use the so-called Drillers Method to
circulate out a kick.
The time to vent the peak gas at the flow rate (T) can be calculated as
follows:
Kick volume (in bbls)
T =
Kill rate (in bbls/min.)
75.9 bbls
T =
3 bbls/min.
T = 25.3 minutes
V is the gas volume downstream the choke (neglecting the gas
compressibility and temperature) and can be calculated by means of Boyle's
gas law as follows:
Pc (in psi) x Kick volume (in bbls)
V =
14.7 (in psi)
298
1,750 psi x 75.9 bbls

V =
14.7 psi
V = 9,036 bbls
The peak flow rate Qmax (expressed in bbls/min.) can be calculated as
follows:
V in bbls
Qmax =
T in min.
9,036 bbls
Qmax =
25.3 min.
Qmax = 357.2 bbls/min.
The conversion factor from bbls/min. to cubic feet/day is 8,085:
Qmax = 357.2 bbls/min. x 8,085 = 2,887,971 cubic feet/day
The vent line friction pressure can be calculated when you know the total
length of the vent line plus the equivalent length of various bends, corners,
etc. Equivalent lengths for these vent line geometry changes are shown in
Figure 18.
For example, when the vent consists of 200 feet of 7-inch-ID pipe with three
right-hand sharp bends, the effective length (Le) can be calculated as
follows:
Le = 200 ft + (3 x 70 ft) = 410 ft
The vent line friction (Pf) can be calculated as follows:
Pf = (5.0 x 10-12) x (Qmax)2 (expressed in cubic feet/day) : the vent line ID5
Where 5.0 x 10-12 is derived from the Atkinson-modified Darcy-Weisbach
equation, which uses an empirical friction factor for smooth, straight steel
pipe.
Pf = (5.0 x 10-12) x 410 x (2,887,806)2 : 75 = 1.0 psi
The mud leg requires that the U-tube pressure exceed the vent line friction
pressure to prevent a separator blow-through condition. Assuming a 6-foot
mud leg filled with 8.65 ppg (0.45 psi/feet) salt water, we get:
Pressure mud leg (Pml) = mud leg length (in feet) x mud leg gradient
(psi/feet)
Pml = 6 x 0.45 = 2.7 psi
Since the mud leg U-tube pressure exceeds the vent line friction drop, a
blow-through condition does not exist at peak gas flow rate.
A small-ID separator can cause a blow-through condition if a gas/liquid
mixture is not given sufficient time to develop inside the separator. An
estimate of minimum separator ID that will allow ample time in the
separator can be calculated as follows:
IDmin = 15,56 x circulation rate¹/² (in bbls/min.), in which 15.56 is a
constant factor.
IDmin = 15,56 x 3.0¹/² = 27 inches
299
So, in this example the mud/gas separator is sufficiently sized and should be
able to properly handle the worst-case scenario kick. If the separator had
been too small in ID, the kill rate can be reduced to increase the mud/gas
retention time on the separator and thereby improve the efficiency of
mud/gas separation.
In cases where the vent line pressure drop exceeds the mud leg height,
options to improve the separator are:
a) To increase the height of the mud leg
b) To reduce the vent line bends (changes in direction)
c) To increase the vent line ID
d) To install a second vent line
The picture below shows a formal mud/gas separator sizing worksheet.
300
Figure 17 - Mud/gas separator sizing worksheet.
301
SIDPP= 520 psi

SICP = 640 psi
5" DP
WD= 500 ft
Mudline
MW= 15.2 p.p.g.
9-5/8@ 12.200 ft
Pit= 16.6 ppg EMW
8-1/2" hole
TD= 14,400 ft
Kick
Pit gain = 24 bbls
Slow pump rate: 790 psi @33 SPM (3 BPM)
From WCSIM
Maximum surface pressure of kick= 1750 psi
Kick Volume upstream of choke = 75.9 bbls
Figure 18 - Sample of the wellbore conditions for the example

worked out above.
302
Source Sketch Equiv. Length (ft)
Bend-acute 3
Round
Bend-acute 150
Sharp
Bend-right 1
Round
Bend-right 70
Sharp
Bend-obuse 1
Round
Bend-obuse
Sharp 15
Contradiction
Gradual 1
Contradiction 10
Abrupt
Expansion
Gradual 1
Expansion 20
Abrupt
Figure 19 - Equivalent lengths for the separator vent line geometry
changes.
303
Gas Outlet
8-inch Minimum
Pressure gauge 0-20 psi

Approx 1/2 of Height
7-5/8-inch
Inner Sleeve
3/4-1 inch Holes on 3" Centers

16-ft Minimum Height
Inspection
Cover 30-inch OD
4" ID inlet ( Tangential= optional)

to Shell from Choke manifold
Half Circle Baffles

Brace arranged in "Spiral"
Configuration To Shaker
Ditch
4.5 ft
8-ft approx
10ft mud seal
2" Drain
or Flush Line
4-inch Clean-out Plug 8-inch Nominal U-tube
Figure 20 - Schematic of a mud/gas separator.
304
4-inch ID Inlet Tangential

Steel Target Plate to Shell from Choke manifold
Inspection cover
Figure 21 - Top view of a mud/gas separator with a tangential inlet.
Figure 22 - A mud/gas separator with a valve assembly, which often

causes problems with the valve assembly. The valves used must be
full-bore to prevent friction build-up and reduce erosion problems.
305
Questions Manifolds, Chokes and Valves

1. Are chokes periodically pressure tested? Explain your answer.
2. Explain the difference between the Cameron AX choke and the Swaco
Superchoke.
3. Which packer seals are to be changed if the gate valves are to operate in
high-temperature conditions?
4. Why is the buffer tank divided into two sections?
5. What is the minimum radius of the elbows and bends in the choke and
kill lines?
6. What is the optimum closing time of the remote choke?
7. Why are there sometimes three low-pressure gauges in three pressure
ranges installed on the remote choke panel?
8. Why should you still need to have an emergency air back-up even when
there is a hydraulic handpump available at the remote choke panel?
9. How do we adjust the position indication of the Cameron remote choke?
10. What are the colour indications of the desiccant of the Cameron remote
choke air supply system?
11. What is the ratio of the Cameron remote choke panel gauges for the
casing and drill pipe pressure gauges?
12. Why is it impossible to pressure-test the positive chokes?
13. How can you change the flow in a positive choke?
14. How can we prevent lead plugs in targets from migrating into the system
stream?
15. Where do we install thermometers in the choke and kill system if the rig
is upgraded to HT/HP?
16. How are the thermometers installed on the system?
17. Calculate at what pressure the mud seal in the mud/gas separator is lost
when the height of the mud seal is 12 feet and the mud weight is 12.4
ppg.
18. Describe some alternative methods to install emergency air for the
remote choke panel.
19. Explain how to control the speed of the choke using a Cameron remote
choke unit? How is this done with a Swaco choke?
20. Why do we have to make the mud/gas separator vessel from special
steel?
21. If we use an acute sharp bend in the vent lines, what will be the friction
increase in relation to the piping used?
22. Why is it not smart to install a 0-100-psi pressure gauge on a poorboy
degasser?
23. Why does the poorboy degasser require special steel?
24. What is the maximum bend radius of the piping going to the poorboy
degasser?
25. Why is the pressure rating of the poorboy degasser much higher than
the normally expected pressures in the poorboy degasser?
26. What is the required inspection interval according to API 520 section
6.4? What inspection methods can be used?
306
4 Table of figures
Figure 1 -
Choke and kill manifold of the drilling rig Atwood Eagle.......... 286
Figure 2 -
Choke and kill manifold of the drilling rig Explorer III............. 287
Figure 3 -
Sketch depicting limits for target requirement. ..................... 288
Figure 4 -
Blind target flange with lead plug........................................ 289
Figure 5 -
Lead plug showing normal wear as a result of cavitation
erosion. ........................................................................ 289
Figure 6 - The lead plug has been removed and the target block is
used as a fluid target. ..................................................... 289
Figure 7 - Used and new lead plug on target flanges. ........................... 290
Figure 8 - A 90-degree heavy-wall elbow; the radius is only 1.5 times
the diameter of the pipe. This is allowed neither upstream
nor downstream the chokes on the choke and kill manifold
(R > 10d)...................................................................... 290
Figure 9 - Not only erosion on the inside but also corrosion on the
outside will affect the safe operation of the choke and kill
lines (maximum wear 12.5% of the original wall
thickness). What do you think about this radius?................. 290
Figure 10 - Obsolete Cameron gate valve. The square edges on the
slot are very vulnerable for H2S. The condition of the seal
rings is very poor; new rings are required and the retainer
plates must be thoroughly cleaned. The gate needs to be
renewed as well. ............................................................ 291
Figure 11 - More recent design of valve that has a round slot. It is
being inspected for wear and tear around the body bushing
sealing area. .................................................................. 291
Figure 12 - It is very important that the gate is installed EXACTLY
opposite the inlet and outlet lines of the valves. If not, the
complete gate/seat assembly is washed out in no time! ....... 291
Figure 13 - Open-bottom mud/gas separator. ..................................... 292
Figure 14 - Closed-bottom mud-gas separator. ................................... 293
Figure 15 - Float-type mud/gas separator. ......................................... 294
Figure 16 - Poorboy degasser with a good U-tube creating a high mud
seal. The siphon breaker on the U-tube should be
connected to the vent line high up in the derrick
(monkeyboard level). ...................................................... 297
Figure 17 - Mud/gas separator sizing worksheet. ................................. 301
Figure 18 - Sample of the wellbore conditions for the example worked
out above...................................................................... 302
Figure 19 - Equivalent lengths for the separator vent line geometry
changes. ....................................................................... 303
Figure 20 - Schematic of a mud/gas separator. ................................... 304
Figure 21 - Top view of a mud/gas separator with a tangential inlet. ...... 305
Figure 22 - A mud/gas separator with a valve assembly, which often
causes problems with the valve assembly. The valves used
must be full-bore to prevent friction build-up and reduce
erosion problems. ........................................................... 305
307
308
Module 02 - 06 Hydraulic control system 1.0
Chapter 06
Hydraulic control system
1 The main hydraulic supply ...................................................... 310

2 Regulator pilot circuits ........................................................... 314
3 Operation of a three-position function ...................................... 316
4 Operation of a two-position function......................................... 320
5 The operation of the straight-through function........................... 323
6 Typical hydraulic pilot supply system........................................ 325
7 Typical hose reel manifold function operation ............................ 327
8 De-activating the pod hose reel manifold after landing BOPs or
securing them on test stumps ................................................. 329
9 Manipulator valves and selector valves ..................................... 330
10 The accumulator isolator function operation .............................. 333
11 Introduction to regulators....................................................... 335
12 Operation of the increase/decrease function .............................. 341
13 Electrical operation: typical two-position function ....................... 343
14 Electrical operation of a typical three-position function................ 344
15 Memory circuit ...................................................................... 346
16 The pressure transducer circuit ............................................... 348
17 The lamp test ....................................................................... 349
18 Hydraulic BOP control system: general ..................................... 350
19 Cameron valves .................................................................... 380
20 Table of figures ..................................................................... 393
309
1 The main hydraulic supply
Hydraulic fluid made up by the automatic mixing system (see Module 1) is

achieved by combining potable water and soluble oil. Only potable (drinking)
water may be used. The water must be soft and containing low levels of
calcium; no chlorides must be present, as these solidify and cause silting on
the shear plates of the control valves.
Several manufacturers are marketing suitable soluble oil. The dilution rate
should be kept to 2% minimum, despite the recommended 1% level by the
soluble-oil manufacturers. Do not increase the soluble-oil level above 5%
when automatic locking systems like Hydril MPL, Shaffer UltraLock or
Cameron CAMLocks are used; these locking systems rely on friction and a
too-rich concentration of soluble oil will reducing this friction too much.
If the percentage concentration of soluble oil dips below the 1% level, the
corrosion effect increases dramatically, which has a devastating adverse
effect on all the control valves, actuators and pistons in the BOP hydraulic
systems. In the long run it is more economic to maintain high concentration
levels than to economize on soluble oil, which can result in costly repairs and
downtime of the major BOP components.
The triplex pumps and/or air pumps charge the hydraulic fluid to 3,000 or
5,000 psi. The suction filters of the pumps are normally fitted with a 40-
micron cartridge. The discharge filters have a larger retention: 10 to 20
microns. The pumps discharge to a number of surface accumulators racks,
which are normally precharged with nitrogen to 1,000 psi for a 3,000-psi
hydraulic system or to 1,500 psi of nitrogen for a 5,000-psi hydraulic
system. The hydraulic fluid is routed through a flow meter in the hydraulic
power unit (HPU) before it enters the accumulator bottles.
An accumulator pressure gauge is located on the main HPU panel, together
with the manifold and annular preventer pilot and readback pressure
gauges. Pressure transmitters send their signals to the electrical pressure
meters located on the driller's panel and the toolpusher's panel. A low-
accumulator-pressure alarm is installed in the system and has a set point of
2,200 psi, decreasing the system pressure with visual and audio activation
on both remote-control stations.
The main supply line of the hydraulic fluid goes via a 1-inch check valve to a
1-inch selector valve, which directs the main hydraulic supply (MHS) either
to the blue or the yellow control pod. The pod which receives the MHS is
called the active pod. The pod selector valve is located on the front panel of
the HPU and can be operated manually.
Remote control of this valve is provided from the driller's and the
toolpusher's panels. When the MHS flows from the pod selector valve to
either of the pods, the fluid pressure activates a pressure switch in the
output line and operates the appropriate pod indicator light on the remote-
control panel, which sets off the remote indication of the active pod.
The hydraulic communication from the pod selector valve and the selected
control pod goes via a 1-inch high-pressure hydraulic hose located at the
centre of the blue-pod and yellow-pod hose bundles. The MHS line enters
the pod through the 1-inch connection on the pod’s RBQ plate located on top
or on the side of the control pods. Finally, the hydraulic supply is distributed
within the pod body to two or three 1-1/2 inch subsea regulators, also
known as HKRs (Hydraulic Koomey Regulators).
310
Figure 1 - HPU control panel manufactured by Cameron-Payne.
311
Open Block Close
Drillers panel
Surface accumulator bottles
Pilot pressure Read back pressure Direct current 110Volt
air 110V=
motor
1500 1500
psi psi
pipe ram 1/4" Panel
TR regulator
Mixture tank close valve
Minimum 1% solution
PV
Hydraulic pump
shuttle valve PT Rig air 120 psi
3000 psi S
AC
Air cylinder
S Solonoid valve(open)
3000 psi
PSV pilot 1500 psi Pressure PT
pilot 1500 psi Transmitter 3000 psi
Pod selector Rig air 120 psi
0 psi Valve pilot lines
yellow and blue pod
Figure 2 - Typical main hydraulic system.

Hydraulic Hydraulic
Regulator Regulator
Located in located in
HKR Yellow Pod HKR Blue Pod
shuttle valve 3000
0 psi 0 psi 0 psi psi 1500 psi

SPM
in Yellow SPM SPM SPM in

Pod Blue Pod
pilot line
3000 psi
Subsea Operating
Accumulators
Pressure
1500 psi
Operating pressure
0 psi
312
Ram preventer
Figure 3 - Schematic of typical MHS going to the control pod.
In Figure 2 we see the MHS supply being activated from the pod selector
valve to the supply of the HKR 3,000-psi accumulator pressure. Both the
surface and subsea accumulators are connected to this circuit. Activation will
occur as soon as the pod selector valve is shifted on the HPU panel; only the
active pod will receive MHS.
313
2 Regulator pilot circuits

The HKRs located inside the BOP control pods subsea require a plot signal to
produce the output pressure. The regulators are designed to have an input
signal to output supply ratio of 1:1. For example, a hydraulic pilot signal of
1,500 psi will regulate the HKR to have an output pressure of exactly
1,500 psi.
The pilot signal of the subsea regulators is provided by dedicated regulators
installed in the HPU. In the past these regulators installed in the HPU were
the so-called AKRs (air Koomey regulators), but most systems are now
equipped with the failsafe Koomey TR-type regulators. These “True-Reading”
regulators in the HPU apply a pilot pressure via 3/16-inch pilot lines, through
the pod hoses, and to the subsea manifold and annular HKRs located inside
the control pods. The regulated pilot pressure is also fed to gauges on the
main HPU panel, which has pressure transmitters installed that send the
signal to the electric pressure meters located on the driller's panel and the
toolpusher's panel.
The read-back signal from the HKR output has to pass through a 3/16-inch
pilot hose coming back to the surface. So, when the pressure is altered, BE
PATIENT! Use small increments and wait until the subsea regulator reacts
and sends a read-back signal back to the HPU. On most rigs these
signals, which have to go up and down, have to travel approximate
10,000 feet through 3/16-inch pilot hoses. This readback pressure
signal is additionally connected to pressure transmitters that convert the
signal into an electrical signal, which is sent to the driller’s panel and the
toolpusher’s panel.
The output of the manifold subsea HKR goes to the supply of all the SPM
valves connected to the manifold system: the rams, the gate valves, the
wellhead and the riser connector circuits. The output of the annular
preventer HKR goes to the supply of the annular preventer’s SPM valves.
A ¼-inch shuttle valve is located on the input to each gauge on the HPU
main panel and pressure transducer, separating the read-back signal lines
coming from the yellow and the blue pod. When this shuttle valve is faulty
you will see in most cases that the read-back pressure indication is exactly
50% of the pilot pressure. Only the active pod supplies the read-back
pressure through the shuttle valve to the gauge and the pressure
transmitter.
Figure 4 - Driller’s panel with pilot and read-back gauges.
314
Figure 5 - Schematic of manifold and annular regulator pilot and

read-back circuits.
In Figure 5 the MKRs and the annular regulator receive their pilot signal;
both regulators send out their output pressure to the supply of all the SPMs
connected to their system. All SPMs are still closed by the spring force
of their actuators, so that no fluid is passing through them in this
stage. The read-back pressures from the regulators are sent back through
the pilot hoses inside the pod hoses to the read-back gauges and pressure
transmitters in the HPU.
315
3 Operation of a three-position function
The pilot pressure required to operate a function begins at the main HPU
where the 3000-psi hydraulic fluid supplies the pilot circuit. The pilot circuit
has two 11-gallon accumulator bottles installed and operates at 3,000 psi for
the Shaffer/Koomey system. The pilot system is separated from the main
system by means of a check valve. Even when the main accumulator circuit
pressure is going down, the pilot pressure remains constant at 3,000 psi.
The pressure in the pilot system is monitored by a pressure gauge situated
on the main HPU panel; pressure transducers supply the indication of the
electric pressure meters on the drill floor and the toolpusher’s office. The
pilot pressure is fed to all the ¼-inch manipulator valves installed on the
front of the HPU panel.
Figure 6 - Cameron panel valve with three-position/four-way

manipulator valve.
The panel valves receive their input from the pilot circuit. Each outlet is
connected to the pilot hoses of the yellow and the blue pod hose. The vent
of the valves is connected to the mixture tank. If this valve is put in the
block or vent position, the pressures from both the open and close outlets
are simultaneously vented back to the mixture tank.
316
Figure 7 - Schematic for a single function using a three-position

manipulator valve.
Now, the dedicated SPM 29 and SPM 35 are actuated by annular preventer
OPEN or CLOSE functions, either of which receives a pilot pressure coming
from the three-position/four-way valve, in Figure 7 called the Hydril. Both
SPMs in the active and non-active pods receive their pilot signals and both
SPMs open, but only the active pod SPM receives main flow.
317
The pilot line for the annular OPEN function is line No. 29 and the pilot line
for annular CLOSE function is line No. 35. The pilot lines exit the manipulator
valve, connect the pressure switches, and are then directed from the
manifold, through the pod hoses, and finally to the yellow and the blue pod.
Once inside the control pod, the pilot lines are connected to their respective
SPM valve. The dedicated 1-1/2 inch annular preventer SPM valve located in
the active pod supplies hydraulic pressure to either the OPEN or the CLOSE
side of the annular preventer. The SPM in the non-active pods opens but
does not receive any fluid, as the regulator in the non-active pods supplies
no output.
When the function is operated, the pilot pressure is directed through the ¼-
inch manipulator valve, through the pilot lines, and simultaneously activates
the associated pressure switch, which converts this pressure into an
electrical signal and turns on the indicator light on the remote-control
panels.
The illumination on the panels will only supply the information that
the control valve in the HPU has shifted. In order to verify that the SPM
has fired, we have to watch the read-back gauge to monitor a rapid pressure
spike in the specific read-back circuit. If the pilot line should be ruptured
close to the BOP, the friction losses in the 3/16-inch pilot line would allow a
build-up of pressure at the HPU while no pilot signal reaches the pods!
The pilot pressure is transmitted to both the yellow and the blue pod
hose bundles and continues subsea through the kidney plates mounted on
the subsea pods. The pilot signals finally arrive at the appropriate SPM
valves inside the control pods. The pilot pressure (more than 900 psi is
required) opens the appropriate SPM valves against the spring force. This
allows a usable hydraulic volume to flow from the active pod subsea annular
HKR to the open port inside the SPM, and into the annular preventer.
The opposite pilot lines are vented through the manipulator valve to release
the pressure in the redundant line. When the pilot pressure is released from
the opposite SPM valves, they return to the closed position by spring action
and vent the displaced fluid from the opposite side of the annular function,
in this case CLOSE.
Note that although both pod SPM valves receive pilot pressure
simultaneously, only the selected pod will actually supply the operating fluid
to function the preventer. This is the pod that receives the MHS pressure
from the pod selector valve. When the manipulator valves on the main HPU
are positioned in the block centre position, then both pilot lines of both pods
are vented. This results in both the OPEN and the CLOSE side SPMs
returning to the CLOSE position on both pods, so that the hydraulic pressure
in vented from both the OPEN and the CLOSE operating side of the particular
function.
318
Figure 8 - Schematic of hydraulic system of a typical three-position

function.
Figure 8 shows a Koomey circuit that uses three solenoids for the
OPEN/CLOSE and block functions. Be aware of the old-fashioned Shaffer
circuits, which only use two solenoids: one for OPEN and one for CLOSE. If
one of these solenoids in the Shaffer circuit is faulty, an undesired
operation might occur when this function is put into the block position from
the driller’s panel or the toolpusher’s remote-control panel.
319
4 Operation of a two-position function
A two-position function differs from a three-position function because of the

presence of only one pilot line. There are only the two positions: either OPEN
or CLOSE, also known as PRESSURE or VENT. These functions are used for
items such as subsea failsafe gate valves, which must be pumped into the
open position or vented to allow them to close under the influence of their
own spring. Also, the secondary unlatch functions of the hydraulic
connectors do not have a latch function, so they only require one pilot line
and a VENT.
Hydraulic power for these pilot lines is delivered from the pilot system
originating from the pilot accumulator bottles. The manipulator valves
located on the main HPU have one of the two outlets plugged; the other
outlet is feeding the function. The pilot pressure from the single line from
the manipulator valve is connected to a pressure switch; both pods through
the hose bundles are passing the RBQ plates on the hose reels and the
kidney plates on the control pods subsea. Inside the pods the pilot line is
connected to the appropriate SPM valve.
To open a subsea failsafe gate valve, hydraulic pressure acts against the
piston of a linear actuator and compresses a spring installed on the other
side of the piston. To initiate this, the ¼-inch manipulator valve on the HPU
is put into the OPEN position. This supplies pressure to the pressure
transducer in the pilot line, which energizes the valve position indicator light
on both remote-control panels.
The pilot pressure also fires the appropriate SPM valves in both pods. The
pilot pressure opens each SPM, again against spring pressure. The SPM on
the selected pod receives hydraulic usable volume; the hydraulic fluid flows
from the HKR through the SPM valve to the failsafe gate valve-opening
chamber.
When the failsafe gate valve is closed, the ¼-inch manipulator valve on the
HPU is placed in the centre or into the CLOSE/VENT position. Either position
of the manipulator valve will vent off all the pilot pressure to the SPM valve
and the pressure switch. The pressure switch energizes the appropriate
indicator light on the remote-control panels.
As soon as the pilot pressure is removed from the SPM valve, it returns by
spring force to the CLOSE position and also vents pressure from the opening
chamber of the subsea failsafe gate valve. With no hydraulic pressure to
hold the fail-safe gate valve in the OPEN position, the failsafe valve closes
because of the operator spring force. The fluid from the OPEN side is vented
through the SPM in the pod.
It is important to mention here that these PRESSURE/VENT-functioned gate
valves can only be found on shallow-water MODUs, since it is now a
legislative regulation that all BOP-mounted failsafe valves fitted on deep-
water BOP stacks must have an OPEN and a CLOSE hydraulic function or a
common failsafe assist system installed. The hydraulic actuator spring
however remains a component.
320
Figure 9 - Hydraulic schematic of a typical two-position function.
In Figure 9 there is only one pilot line connected to the SPM No. 15 outer
choke valve OPEN function. If the manipulator valve is shifted to vent, the
spring force of the gate valve will close the valve and vent the fluid through
the SPM. The pilot is vented through the panel valve situated on the HPU
and back to the mixture tank.
321
Figure 10 - Schematic of a two-position circuit gate valve (normally

closed).
In principle, the circuit depicted in Figure 10 is also present when a fail-safe

assist system is installed for the accumulators on the BOP stack.
322
5 The operation of the straight-through

function
Functions that use small volumes of fluid sometimes use the pilot pressure
directly at the function and avoid the requirement of an SPM valve. The pilot
system-operated functions are pod latches, the AX release systems on
hydraulic connectors, stack-mounted SPM valves for stack-mounted
accumulators and sometimes secondary unlatch circuits for the hydraulic
connectors.
With these functions the pilot pressure is routed through the hose bundle
from the manipulator valves located on the HPU to the control pod. Pilot
pressure is routed directly through the pod to the pod latch piston or
through the pod to the stack-mounted SPM valves. However, due to the
small size of the pilot lines this only be done for circuits with a very small
volume. The response times are also slow. The advantage is that this
function can still be activated in case of a malfunction of the regulator. It
could for instance also be useful as a secondary unlatch function of a
connector.
323
Figure 11 - Schematic of Shaffer control system with straight-

through function.
In Figure 11 we see the straight-through function (36) to the pod lock

system that is independent of the HKR output.
324
6 Typical hydraulic pilot supply system
All the pilot control valves and regulators are located on the HPU on the
surface. Therefore, all the control functions must rely on pilot signals from
the surface. That is why the pilot circuit is vitally important to a successful
operation of the subsea BOP control system.
An example of a typical hydraulic pilot supply circuit is depicted in Figure 12.
Some rigs have one air-operated pump lined up as the pilot pressure pump,
while other systems have the pilot pressure circuit connected with the main
supply with or without a regulator (depending on the make of system). The
pilot system of the Cameron-Payne system operates with 2,200 psi; the pilot
system at Shaffer-Koomey systems operates with 3,000-psi pressure.
In the diagram shown in Figure 12 the control fluid reservoir provides the
supply for the air-operated pilot pump. The suction line of this air-operated
pump is connected to the main mixture tank of the HPU. The mixture tank
supplies an adequate amount of operating fluid for the pilot system and the
level of the tank is automatically regulated.
A shut-off valve is located in the suction line; it remains open during normal
operation and is closed only during servicing. The suction lines normally
have suction filters installed. The pilot pressure pump has a dedicated
pressure switch, which is set to start the pump at 2,700 psi and stop the
pump when the pressure reaches 3,000 psi (Shaffer-Koomey system).
On the discharge side of the pilot supply pump, a differential pressure in-line
valve is installed so that the main, electrically driven pumps can also be
used for the pilot supply.
The differential pressure bias is set for the air pump’s dominance; however,
in the event of failure of this pump, the differential in-line check valve will
open and allow the main hydraulic supply to replenish and maintain the pilot
system pressure via the dedicated accumulators.
The high-pressure pilot supply is stored in two 11-gallon accumulators.
These accumulators need to be precharged with nitrogen to 1,500 psi; this is
contrary to the normal surface bottles, which are normally precharged to
1,000 psi. The pilot accumulator bottles normally have isolation and bleeder
valves installed for servicing. In normal operations, the isolation valve is
open and the bleeder valve is closed.
The hydraulic supply is connected to the hydraulic manifold to supply all the
¼-inch manipulator valves and the hydraulic regulators. A check valve (non-
return valve) is installed between the control fluid supply to the pod selector
valve and the hydraulic pilot supply. In the event that the pilot supply
pressure should drop, this check valve will seat to ensure that the high-
pressure pilot supply is maintained.
325
Figure 12 - Schematic of a typical hydraulic pilot supply circuit.
Be aware that the pilot accumulators require a higher precharge pressure

than 1,500 psi to ensure that the fluid quality is improved, as the “last-
drop-out” fluid will have a pressure of 1,500 psi, which is required to
overcome the spring force of the SPM valves.
326
7 Typical hose reel manifold function

operation
The hose reel manifold provides control of the selected BOP functions that
are required while running or retrieving the BOP stack. The manifolds are
mounted at the side of the blue- and the yellow-pod hose reels and provide
the only point of control during stack-running and -retrieving operations.
The jumper hoses coming from the HPU on the accumulator surface unit
must be disconnected at the RBQ plate to enable the reel to rotate.
Caution: Before activating or deactivating the hose reel manifold, the BOP
stack must be in the SAFE mode. The BOP should either be locked to the
subsea wellhead on the surface stump, or supported by the spider beams!
With the BOP stack in the SAFE mode (the centre, ‘block’ position), all the
¼-inch four-way manipulator valves on the hydraulic manifold are located
on the HPU. This will vent the pilot pressure of all the hydraulic pilot hoses
going to the SPM valves in both control pods.
Take your time to put each function separately in block; check the read-
back pressures and “zero” the flow meter each time.
Do not put all the functions in block at the same time, because then you will
have no indication what is happening. Refrain from MONG operations!
The blue- and yellow-pod latch valves must remain in the LOCK position.
These functions are not going through the jumper hoses from the HPU to the
pod hose reels. Next, vent the pilots of all the HKRs and check whether all
the read-back pressures are venting to zero psi as well. The pod selector
valve needs to be selected for either the yellow or the blue position. This will
supply control fluid to the selected manifold.
See Figure 13 for a typical hose reel manifold function operation. The hose
reel manifold supply valve and the regulator shut-off valve must be closed.
All the ¼-inch selector valve handles on both reel manifolds should be
placed in the centre position and the gauges should read zero pressure. The
jumper hose bundles can then be disconnected by removing the RBQ
junction plates.
Do not disconnect the 1-inch supply line or the pod latch pilot line. These
lines are not connected to the RBQ junction plates, but to the reel shaft by
means swivel joints. They must remain live and pressurized at all times (the
reel selected by the pod selector).
After disconnecting the jumper hose bundles, the supply and the regulator
shut-off valves on both reels must be opened. The MKRs on both reels must
then be set to the desired pressure, which is normally 1,500 psi. The pod
hose reel regulators supply pilot pressure to the hydraulic pod regulators
(HKRs) of the manifold pressure circuit in order to supply main flow pressure
for the hydraulic connectors. The pod hose reel regulators, which are mostly
MKRs, are located inside the reels; the regulated pressure is indicated on the
gauges, which are located on the hose reel manifolds.
Switch the pod selector valve first to the yellow or blue pod, and then to the
opposite pod. Then set the MKR regulators on both reels to 1,500 psi.
327
Next, the ¼-inch selector valves should be function-tested on both pods and
the subsea engineer is to verify that all the functions operated from both the
yellow- and the blue-pod hose reel manifolds are functioning properly.
After the function tests, all the ¼-inch selector valves are to be set in their
desired position, i.e. identical on both pod hose reel manifolds.
The selected BOP functions can be controlled from the reel, receiving control
fluid supply through the pod selector valve. Most of the time, the valve
handles are removed from the ¼-inch selector valves during the running or
pulling of the BOP to prevent the MONGS from interfering while the BOP is in
transfer.
Figure 13 - Schematic of typical hose reel manifold function.
328
8 De-activating the pod hose reel

manifold after landing BOPs or securing
them on test stumps
With the BOP in the SAFE mode, close the supply and the MKR shut-off
valves on both reels. The HKR on the selected reel receiving pressure should
be vented to zero psi in order to ensure that its output pressure is reduced
to zero. The regulators on the opposite pod should also be vented to zero
pressure.
Place all the selector valves a little past centre in order to vent all the pilot
pressure from the hose reel manifold. Ensure that you vent only one selector
valve at the time! The valves of both hose reels should be placed in the
centre position. Be aware that the pilot lines are isolated when the selector
valves are in block. Engage the hose reel locking pins before
connecting the jumper hose bundle to both pod hose reels. Put the
pod selector valve in block. Install the pod hose jumper hoses on both reels
connecting the HPU with the pods.
The regulators on the HPU hydraulic manifold should be set to their desired
operating pilot pressure and then the pod selector can select a pod. Next,
each ¼-inch manipulator valves on the HPU hydraulic manifold can be
placed in their normal operating positions one by one while monitoring the
read-back gauges. “Zero” the flow meter after each function and put the
BOP in drilling mode.
Figure 14 - Typical pod hose reel panel.
Notice on the photo in Figure 14 that the valve handles have been removed.
Do NOT connect the vents of each ¼-inch selector valve with each other, as
common vents can charge the other valve and, in certain conditions, they
can open the riser connector. The next thing is that you might have dropped
your BOP stack (this is known as the OOPS factor)!
329
9 Manipulator valves and selector valves
As you have read in the last chapter, the valves on the HPU and the valves
on the control panels on the pod hose reels have different names. The
valves on the hydraulic manifold panel are called manipulator valves and
the valves on the reels are called selector valves. The difference between
the two valves cannot be seen from the outside, but the internal
components of the two types of valves are different.
The Shaffer Koomey manipulator valves are venting both the pilot lines right
and left of the valve when put in the centre position (marked “cyl 1” and “cyl
2”). The selector valves pilot lines can only be vented when the valve moves
from the right or left position in transit. As soon as the selector valve is in
the centre position, the pilot lines are isolated.
If the selector valve would vent the pilot lines, it would not be possible to
have the pilot lines connected with T-pieces inside the pod hose reels with
the pilot lines coming from the HPU.
Figure 15 - Manipulator valve layout.
330
Figure 16 - Selector valve layout.
Both the selector valves and the manipulator valves are three-position four-
way valves and the only difference is the porting of the rotor, which is item
No. 23 in Figure 17 below. Installing one of these valves in a BOP control
system that has an incorrectly ported rotor can lead to serious consequences
during operation. This problem has occurred many times in the history of
subsea engineering and it is our objective that you never make this mistake!
Remember that:
• The manipulator valves are CENTRE VENT and used on hydraulic
manifolds;
• The selector valves are CENTRE BLOCK and used on hose reel panels.
331
Figure 17 - Manipulator and selector valve components.
332
10 The accumulator isolator function

operation
The accumulator isolator pilot valve on the HPU manifold directs the pilot
pressure to operate the surface accumulator isolator valve, the pod-mounted
isolator valves and the stack-mounted isolator valve (see Figure 18). The
surface accumulator isolator is mounted in the control system line
downstream the accumulator isolation valves. When the pilot valve is placed
in the open position this valve is opened to allow control fluid pressure to
flow in and out of the surface accumulators.
This pilot signal, which is called AIO (Accumulator Isolator Open), is also
sent through a line in the jumper hose and the junction box to the hose
reels, down the subsea hose bundle to the control pods. Upon receipt of pilot
pressure, the pod-mounted accumulator isolator valve is energized open.
This allows the main hydraulic supply to flow into and out the BOP stack-
mounted accumulators.
When the accumulator isolator pilot valve is in the closed position the pilot
signal closes the surface accumulator isolation valve. This isolates the
surface accumulators and all pressure from the pump is directed through the
jumper hose and reels down the subsea pod hose bundle into the control
pod. Closing the pilot valve also vents the AIO pilot signal. Since the pod and
BOP stack-mounted accumulator valves are two-position spring-return
valves (SPM valves), they close with the release of pressure. This isolates
the stack-mounted accumulators from the control pods.
The stack-mounted accumulator valve contains a plugged vent port, so that
the control fluid will not vent when the AIO pressure is released, for instance
when retrieving a control pod. Retrieving the pod only vents the AIO pilot
line. However, the pod-mounted accumulator isolator valve vent port is not
plugged.
Venting the pod selector valve by putting it in the BLOCK position while pilot
pressure has the subsea accumulator isolator SPM valves in the OPEN
position will dump the fluid from the stack-mounted bottles through the 1-
inch pod selector valve and back to the mixture reservoir.
333
Figure 18 - Accumulator isolator circuit.
334
11 Introduction to regulators
The control fluid supply for the subsea BOP control system is normally
maintained at 3,000 psi or 5,000 psi, depending on system. This pressure is
too high for most BOP stack functions. Therefore, the system contains
hydraulic-pressure-reducing/-regulating valves to adjust the control fluid to
the various specific pressures needed to safely operate the BOP stack
functions.
All BOP control systems will have several regulators, at least two: one for
the manifold-regulated pressure functions and the other for the annular
preventer(s). Most deepwater rigs have two annular preventers installed on
the BOP stack: one on the LMRP and the other on the BOP stack itself.
Some drilling contractors find it operationally preferable to install a
dedicated regulator for each annular preventer, thereby optimizing the
options for both stripping operations and shutting in the well. On first-,
second- and some third-generation rigs a lower ball joint may be installed on
the LMRP of the BOP stack. This necessitates the use of a separate regulator
in order to supply the pressure-balanced ball joint. Newer rigs can have a
dedicated regulator for the wellhead connector and the Koomey 80 system
uses a fail-safe assist regulator.
Almost without exception, all the regulators in use on BOP control systems
are of the shear seal type. There are four types in general use:
1. The manual regulator (MKR)
This regulator is manually adjusted with an adjusting screw. The
adjustment is infinitely variable and once set can be mechanically
locked.
2. The hydraulically operated regulator (HKR)
The set regulated output pressure is controlled by a hydraulic pilot
signal that acts upon a plunger. Output versus pilot ratio is 1:1.
3. The air-operated regulator (AKR)
An air pilot signal acts upon a diaphragm that in turn controls the
vertical position of the regulator’s plunger. If the air pilot signal is lost,
the regulator output will reduce to zero as the diaphragm relaxes.
4. The fail-safe or true-reading regulator (TR-type)
Operation is via a combination of air- and manually operated valves. The
regulator is normally driven by an air motor that drives a gear pinion
and rack. However, the output of the regulator can also be manually set
with a manual override control. Unlike the air-operated regulators, the
TR regulator maintain the latest set output upon loss of its air supply.
General
The manual regulator is used to supply a common regulated pressure to all
ram preventers, the choke and kill gate valves, the riser and wellhead
connectors and the mini connectors used on the choke and kill line stabs
between the BOP stack and LMRP receiver plates.
HKRs used to control the operating pressures for the BOP stack functions are
located inside the control pods. These regulators are piloted from the surface
by a ½-inch pilot regulator (preferably a TR-type regulator) located in the
main HPU.
335
By design, the subsea regulators output is a 1:1 ratio, whereby the

regulated output pressure equals the hydraulic pilot signal pressure (a
1,500-psi pilot pressure signal equals a 1,500-psi pressure regulated output
pressure from the subsea HKR).
The ½-inch TR-type regulators on the HPU receive their supply pressure
from the hydraulic pilot supply circuit (see Figure 19). These TR-type
regulators can be adjusted from the main HPU or the remote-controlled and
the driller’s panel.
The HPU contains a ¼-inch air selector valve that is used to select the point
of regulation: remote-controlled or hydraulic. If the selector valve is placed
in the UNIT position, the TR-type regulator receives its signal from a small
manual air regulator mounted on the HPU panel.
If the ¼-inch selector valve is place on the REMOTE position, it blocks the
signal from the air regulator and receives a signal from a set of two
electrically operated solenoids in order to either increase or decrease the
regulator set point. These solenoids are mounted in an explosion-proof box
on the HPU. An electrical pressure transducer is placed in the output line of
the regulator to convert the pressure into an electrical signal, which is
displayed on an electrical meter as pilot pressure on the remote-controlled
and the driller's panel.
The pilot signal is then sent to both the blue and the yellow control pods. It
passes through the jumper hose bundle and junction box to the hose reels,
and transits the hose bundle to the subsea control pods. Once in the pods, it
pilots the pod regulators in both the yellow and the blue pod. However, only
the pod selected by the pod selector valve receives the main hydraulic
supply (MHS) and this will be the operational pod.
In order to verify the actual setting of the subsea regulator output pressure
for the functions it serves, a read-back signal is taken from the output or
downstream side of the HKR in the control pods. The read-back signal is
hydraulically transmitted to the surface via the hose bundle, through the
reels, junction boxes and jumper hose bundle, to the main HPU. At the HPU
the signal is indicated on a read-back pressure gauge and a pressure
transducer is fitted in the HPU circuit. The transducer converts the hydraulic
signal into an electrical signal and sends this to the meters on the driller’s
panel.
Fundamental principles of a shear seal regulator
The shear seal regulator is the fluid end of an MKR but the same process is
described here for the operation of this regulator as it applies as if it were
hydraulically operated by pilot pressure. The cavity outlet pressure opposes
the force on the seal carrier exerted by the spring.
In this position the inlet and vent ports are covered by shear seals and as
such there is no flow in or out the regulator (see Figure 19).
If the set pressure is increased, the additional spring force will push the
seal carrier downwards until the inlet port is uncovered. Inlet pressure will
flow into the regulator until the cavity outlet pressure is sufficient to
overcome the spring and return the seal carrier to the neutral position. If the
set pressure is decreased, cavity pressure will lift the seal carrier until the
vent port is exposed. Cavity pressure will vent until the spring force can
push the carrier back to the neutral position.
Any fluid use downstream of the regulator will reduce the cavity pressure.
The carrier will be pressed down and a fluid flow through the regulator will
occur. When the fluid usage is complete, the cavity outlet pressure will build
up, lift the carrier and seal off the inlet port.
336
Figure 19 - Fundamental schematic of shear seal regulator.
337
A manual regulator cross-section is shown in Figure 20 and the shear seals

are shown clearly in elevation.
Figure 20 - Koomey-Shaffer manual regulator.
Figure 21 and Figure 22 show photographs of some regulators, all of which

are subsea regulators and fitted on or inside BOP control pods. These units
are constructed from a stainless-steel alloy and machined to very fine
tolerances. On most rigs the subsea department have a spare parts
inventory policy of maintaining a stock of these units, although these are
mainly rebuilt units since new regulators are extremely costly.
It is a good subsea engineering practice to maintain a stock of rebuilt units
since the time to change out one of these units is relatively short in
comparison to the scope of work and time involved in removing a unit from
a control pod and having to rebuild the unit with a repair kit. Most vendors
market a regulator test bench apparatus that, although expensive, is an
attractive asset for the subsea engineer because all rebuilt units can be
properly tested prior to being put into service.
338
Figure 21 - Subsea pod regulator by Cameron pilot versus output

ratio is 1:1.
Figure 22 - Manual regulator installed in Koomey 80 pods and most

MUX pods to reduce the accumulator pressure from
5,000 to 3,000 psi.
339
Figure 23 - The output

pressure is too low, the
regulator is in full
supply mode, the vent
is closed and the
supply is fully open.

pressure is too high,
the regulator is in full
vent mode, the supply
is closed and the vent
is fully open.

pressure is equal to the
pilot pressure; both the
supply and the vent are
isolated.
340
12 Operation of the increase/decrease

function
The regulator function on the panel consists of two solenoids operated in the
same manner as a normal two-position function. The regulator circuit has no
lamps installed. When the INCREASE solenoid is operated, air passes
through the normally closed valve, past a check valve and a manual three-
way selector valve (Unit/Remote), to an air receiver.
The air pressure trapped in this air receiver exerts pressure on an air-piloted
Koomey regulator (AKR). This pressure will continue to increase as long as
the INCREASE solenoid is energized, or until maximum air pressure is
reached.
With the voltage removed from the solenoid it will de-energize, but the air
remains trapped due to the check valve in the decrease line. To decrease the
air pressure, the decrease solenoid is operated. When the decrease solenoid
is energized, it will vent the trapped air pressure to the atmosphere (see
Figure 26 and Figure 27).
Figure 26 - Typical increase/decrease circuit surface.
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Figure 27 - Typical increase/decrease circuit.
342
13 Electrical operation: typical two-

position function
Solenoid valves on the HPU are used to operate the function pilot valve
handles. The solenoid valves have a common positive (+ve) terminal.
Energizing a solenoid requires a negative signal from a push-button contact
in one of the remote panels at the driller's or the toolpusher's cabinet to
complete the circuit.
The pressure switches, which are mounted in the explosion-proof cabinet at
the HPU, indicate the valve function positions by allowing a negative (-)
signal to be sent to the proper indicator lights on both remote panels (see
Figure 28). The pressure switches have a common negative (-ve) terminal.
The remote panels contain indicating lights to display the unit status and
push-buttons to remotely control the HPU functions. The push-button
switches operate on a negative
(-ve) signal which serves as a common to each individual switch. The
indicating lights are wired with a common positive (+ve) and a common
negative (-ve) signal from the pressure switch box as an indicating control
signal for that function.
Figure 28 - Typical two-position electrical circuit (pressure

open/vent/close).
343
14 Electrical operation of a typical three-

position function
Function operation is initiated by pressing both the PUSH-AND-HOLD button

and the function push-button at one of the remote panels. The circuit is
complete when both switches are simultaneously closed, thus completing a
circuit through the interconnecting cable and corresponding solenoid in the
HPU control box (see Figure 29).
If the function is operated OPEN, the OPEN solenoid will be energized, which
causes the four-way valve on the HPU to be shifted to the open position.
Pilot pressure from the OPEN line causes the OPEN pressure switch to
operate. The vented CLOSE pressure switch contacts (normally closed) are
closed, along with the normally open contacts in the OPEN pressure switch.
With these two contacts closed, the OPEN lamps on the remote panels are
illuminated.
Also included in the remote panels are memory circuits. The purpose of the
memory circuit is to show the operator the last position of a function that
was selected prior to going into the BLOCK position. In the next chapter this
will be explained in more detail.
When the BLOCK button is pushed, both the OPEN and the CLOSE solenoids
are energized. Air pressure then passes to both sides of the balanced air
cylinder, which is connected to the manipulator valve at the HPU (in case
this is a Shaffer system). When this occurs, the manipulator valve will go to
the centre or BLOCK position. This releases pressure on both pressure
switches, allowing them to assume the position as shown at Figure 29. This
will activate the BLOCK light.
Alternatively, another arrangement is possible, namely that a separate
solenoid be provided to operate the block function. This system is provided
by Koomey. Pressing the BLOCK and the PUSH-AND-HOLD button
simultaneously causes the BLOCK solenoid to be energized. This solenoid
causes the four-way valve to be centered, which causes both pilot lines to be
vented. This in turn causes both the OPEN and CLOSE pressure switches to
relax. A ground signal is then applied to the BLOCK light through both
pressure switches, which illuminates the light. This is primarily an advantage
on critical functions.
When operating two solenoids simultaneously, the failure of one solenoid
valve to fire may put a function, such as the shear rams, in an undesirable
position (again, the OOPS factor). When using a single solenoid to put a
function in BLOCK, either function will go to block or remain in its original
position.
344
Figure 29 - Three-position function.
345
15 Memory circuit
As previously discussed, all pressure is removed from a particular function

when the hydraulic manipulator is moved to the BLOCK position. In order to
‘remember’ and illuminate the position the manipulator valve was in prior to
moving to the BLOCK position, a memory circuit is used. Each three-position
circuit has its own individual memory, which consists of two relays: K1 and
K2. This memory in no way interferes with the normal operation of the
system. It is intended to assist the operator in being aware of the complete
status of the BOP stack.
Open memory
As in the three-position circuit, pressure applied to the OPEN pressure switch
will turn the OPEN lamp on. At the same time that voltage is applied to the
OPEN lamp, it is also applied to the coil of relay K1. When energized, K1
closes a set of normally open contacts (=), which are connected between a
positive (+) voltage and the K1 coil.
At the same time that the normally open contacts are closed, the normally
closed contacts of K1 (=) are opened. The normally closed contacts are
opened to prevent K2 from energizing. When the hydraulic pressure is
removed from the OPEN pressure switch, it will deactivate and complete the
circuit to turn on the BLOCK lamp. Since nothing has happened to de-
energize K1, the OPEN lamp will remain on as well.
Close memory
The CLOSE portion of the memory operates on the same principle as the
OPEN memory. The only difference is that the CLOSE uses the opposing
relays to the OPEN. When pressure is applied to the CLOSE pressure switch,
the switch will activate the CLOSE lamp. At the same time, the OPEN
memory loses one part of its circuit power and K1 will de-energize.
In conjunction with the pressure switch activation and K1 de-energizing,
power is applied to the coil of relay K2. When K2 is energized, it closes a set
of normally open contacts, which are connected to the negative (-) voltage
and the K2 coil. At this time the normally closed K2 opens also. The normally
closed contacts are opened to prevent K1 from energizing.
When hydraulic pressure is removed from the CLOSE pressure switch, it will
deactivate and complete the circuit to turn on the BLOCK lamp. Since
nothing has happened to de-energize K2, the CLOSE lamp will remain
activated.
346
Figure 30 - Typical memory circuit.
347
16 The pressure transducer circuit
The pressure transducer circuit is made of three basic components: a

voltage regulator, a pressure transducer and a remote meter. There will be
one voltage regulator to supply the +5 volts to all the transducers located in
the control box at the HPU (see the schematic in Figure 31).
Voltage regulator
The voltage regulator has an input voltage of +24 volts DC or +120 volts
DC. The input voltage is reduced to an output voltage of +5 volts DC. If
there are any problems with the regulator, it should be replaced.
Pressure transducer
The pressure transducer is a so-called potentiometric transducer. This
potentiometric transducer is a variable resistor with a range of 0 to 2,000
ohms, which changes the resistance in response to pressure in a helical
bourdon tube. As pressure is applied, the resistance varies. With +5 volts
DC applied across the transducer (pins 1 and 3 in Figure 31), a signal of 0 to
5 volts DC will occur across pins 1(-) and 2 (+).
With no pressure applied, there will be no voltage output. With full pressure
applied, the resulting voltage will be +5 volts DC. A 3,000-psi transducer will
have an output of +5 volts DC at 3,000 psi. Consequently, a 5,000-psi
transducer will have an output of +5 volts DC at 5,000 psi. A
correspondingly calibrated electric meter must be used to achieve a proper
readout.
Meter
The remote meter circuit consists of a 100-microampere meter. A 24.9-ohm
fixed resistor and a 25-kohm variable resistor are used to calibrate the
transducer.
Note: In general, the meters up to a regulated supply of 5 volts DC are not
applicable to a system using 120 volts DC.
Figure 31 - Typical pressure transducer circuit.
348
17 The lamp test
The testing of all lamps is accomplished by the use of so-called steering

diodes. When the LAMP TEST button is pressed, voltage is applied to the
LAMP TEST bus. From this bus, through the steering diodes, voltage is
applied to all the lamps. These diodes are required since all lamps are
connected together by the bus. The diodes prevent all lamps from
illuminating when only a single lamp is energized in normal operation.
Figure 32 - Lamp test circuit.
349
18 Hydraulic BOP control system: general
We discussed the basic principles of a BOP control system in module 1,

however from this module forwards, we will examine all sub components of
the system in far greater detail. We will repeat some aspects from module 1
and continue to improve our understanding of the system further in this
module.
Every component in a subsea BOP stack is hydraulically operated. All rams
and annular preventers, valves and hydraulic connectors are operating by
moving a piston linearly either in the vertical or horizontal plane. Thus a
function on the BOP control system is to direct hydraulic fluid to the
appropriate side of the operating piston and to provide the means for the
fluid on the other side of the piston to be vented.
We will discuss the Koomey Shaffer system and the Cameron systems and
their particular differences. For the conventional hydraulic systems, fluid
used to operate the functions on the BOP stack is delivered from the HPU
through the hose reel, the pod hoses and then to the control pods on the
LMRP.
The pods contain control valves which direct power fluid to the various BOP
stack and LMRP functions on receipt of commands from the surface HPU. The
control valves or SPM valves are operated by hydraulic pilot fluid supplied
through small 3/16 inch individual pilot hoses, which connect the valves to
the hydraulic control manifold located at the surface HPU.
The surface HPU contains ¼ inch panel valves, which direct pilot fluid
pressure to the pod SPM valves. These panel valves are generally equipped
with solenoid actuated air cylinders which allow remote control of the BOPs
from the driller's panel and the drilling office mini remote panel. To provide
redundancy for the subsea portion of the control system, two independent
hose reels, hose bundles and pods are used, known as the Yellow and Blue
pod.
To provide more detail, the following system description begins at the
subsea BOP stack and concludes with the surface controls.
Remember that the primary function of each item on the system is to get
fluid to the selected equipment at the desired pressures in the minimum
amount of time.
The BOP Control Pod
The subsea control pod provides means of transfer fluid from the subsea
equipment to the equipment at the LMRP and the BOP stack. The overall
assembly consists of:
1. The riser-mounted receptacle;
2. The stack-mounted receptacle;
3. The control pod.
350
Figure 33 - Riser-mounted receptacles.
Figure 34 - Koomey 80 BOP stack-mounted receptacle.
The hydraulic control system is always equipped with two control pods,
designated the Blue or Yellow pod. To maintain a fully redundant control
system, both pods must be operational at all times. If a control pod should
become inoperable drilling operations are normally suspended and the BOP
stack controlled with the working pod until repairs are completed and tested.
More recently with the advent of deepwater drilling, the majority of oil
companies will not allow continued drilling operations for the retrieval of one
pod to surface for repair. If repairs are to be performed in the midst of a
drilling programme, drilling operations are suspended, the well made safe
and the entire LMRP retrieved to surface to repair the faulty control pod. The
active, and selected control pod is normally alternated between the pods
weekly or after a BOP stack test.
351
Figure 35 - Koomey 80 control pod in the retracted position.
The development of control pods has been driven by the increasing

complexity of BOP stacks, the move into deeper water with the attendant
customer remit for better reliability. The control pod shown on the preceding
pages was a very early model with the minimum number of functions, called
from this point forwards: ‘number of lines.’
352
The Koomey Shaffer 42 line retrievable pod features a double female

receptacle design. The separate receptacles enable both the pod to be
retrieved or else the entire LMRP.
Figure 36 - The Koomey Shaffer 42-line retrievable pod.
353
Later, Shaffer introduced a 64-line control pod, which, while featuring a

different geometry (cubical rather than cylindrical) operated in the same
manner and was intended for retrieval during drilling operations.
Figure 37 - The Koomey Shaffer 64-line retrievable control pod.
Finally, to conclude this pictorial overview on subsea control pod

development, Figure 38 shows an exploded component view of an ultra
deepwater (3,000 metres) subsea control pod illustrating its modular
construction. This pod is used exclusively in a multiplexing BOP control
system, is not retrievable and features 101 lines.
354
Figure 38 - Installing the blue control pod (Shaffer MUX IV) on the
Saipem 10000 BOP stack.
355
Power fluid is supplied to the pod through the 1 inch hose centered in the
hose bundle.
The pilot hoses are normally 3/16 inch and rated to 3,000 psi (though can
be 5,000 psi).
Figure 39 - Typical pod hose layouts.
Proprietary manufacturers of subsea hose bundle strive to provide a product

which has a low volumetric expansion characteristic (VEC). This ensures that
API closing times are not exceeded for ram type and annular type
preventers. In the conventional hydraulic control system, the single greatest
contributor to lengthening response times is the hydraulic pilot pressure
build time (while the hoses are expanding) and transport time.
The main hydraulic power supplied to the pod is at the full rated working
pressure of the system which is normally 3,000 psi and on the deepwater
systems 5,000 psi. Since the BOP equipment is operated at a pressure lower
than 3,000 psi is the power fluid directed through a manual operated
hydraulic regulator installed inside the pods.
The subsea hydraulic operated regulators are serving two purposes:
a) Reduce the higher pressure to a preset lower pressure, usually 1,500
psi.
b) To maintain and regulate the set pressure should external forces
attempt to increase or decrease the pressure, for example during
annular preventer stripping operations.
The hydraulic regulators inside the pods are usually 1-½ inch regulators.
One dedicated regulator is used to supply the SPM valves controlling the
annular preventer(s) and is labeled as the annular pressure regulator on the
HPU.
356
Figure 40 - Cameron HKR.
Normally, the annular preventer regulators are set at 1,200 ~ 1,500 psi,
depending of the design of the annular preventer installed. The annular
preventer regulators should be capable of operating up to 3,000 psi. One
regulator is used to supply the pod valves for the ram preventers, the
hydraulic connectors and the gate valves, this regulator is commonly called
manifold regulator.
Some rigs have a third regulator installed for the fail-safe assist system.
New MUX systems might have up to 6 HKR installed, with dedicated regulars
foe each annular BOP and a dedicated wellhead connected regulator.
Normally, the manifold regulators are set at 1,500 psi. This depends of the
closing ratio of the Ram BOPs. The manifold regulators should be capable of
operating up to 3,000 psi.
Some rigs have a third regulator installed to supply pressure to the common
failsafe assist system for BOP-mounted valves and those regulators are
usually set at 400 ~ 600 psi.
The downstream side of each hydraulic regulator installed inside the subsea
control pod is connected through a pilot hose in the hose bundle returning to
the HPU and the gauge on the HPU panels reads ‘Annular read-back
pressure’ or ‘Manifold read-back pressure’. This gauge is fitted to monitor
the output pressure from the active regulator either from the Yellow or
Blue pod: depending which pod was active or selected.
A small shuttle valve located at the back of the read-back pressure gauge is
installed to isolate the signals coming from the active pod against the
inactive pod regulator.
357
Figure 41 - Slug-type shuttle valve.
When a ram BOP function is operated, the read-back pressure gauge is used
to indicate when full closure of the functions occurs. The first small ‘pressure
spike’ will appear on the read-back gauge after approximately 6 ~ 10
seconds, caused by the ‘firing’ of the SPM, followed by a sharp drop off in
read-back pressure which continues until the piston of the ram BOP reaches
the end of its stroke.
The drop in read-back pressure is caused because the regulator simply can
keep up with the large fluid demand, the regulator is fully open but the
amount of fluid required to open/close a ram is too much, so the regular
output pressure is dropping. This read-back pressure drop is even larger
when an annular preventer is closed.
This abrupt end of the stroke results in a fast ‘pressure spike’ and rapid
increase of the read-back pressure equal to the pilot pressure. This increase
is not so rapid for the annular preventers due to the famous “packer-creep”.
Only with the read-back pressure gauge, is it possible to exactly measure
how fast the function is opened or closed, the flow meter tends to continue
to record system flow after the function is already closed.
The flow meter will be merely used to investigate whether the appropriate
amount of fluid was used corresponding with the equipment specifications. It
is a good practice to “zero” the flow meter every time a function is used.
358
Figure 42 - Typical modern BOP control panel.
This panel enclosure is a modern unit which is arranged as adjacent

sections. The left hand side shows the mimic of the BOP stack: both the
LMRP and the BOP stack fitted with pushbuttons for open, close and block
positions. On the right hand side you can see the complete BOP functions, at
the bottom the Yellow and Blue pod functions.
On the left hand side you see the HPU panel with alarms, all pilot and read-
back gauges and adjustment buttons and the diverter control panel. The
functions in “normal drilling mode” do have a green light, the opposite
functions use a red light. So the “Lower Kill Valve Close” is a green light and
the “Lower Pipe Ram Open” is also a green light.
When the BOP is in “drilling mode” all lights must be green.
359
The SPM Valves

Sub Plate Mounted valves (SPMs) are hydraulic relay valves. There are three
different sizes of SPM valves installed in the control pods.
a) The ¾ inch SPM valves for the small volume functions like the gate
valves and some of the hydraulic connectors. (< 10 US gallons)
b) The 1 inch SPM valves for the Ram Type BOP functions which use
medium amounts of fluid. (20 ~ 30 Gallon US gallons)
c) The 1 ½ inch SPM valves for the supply of the subsea accumulators and
the annular type preventers. (40 ~ 85 US gallons)
The Sub Plate Mounted valves (SPM) are normally closed valves which are
kept closed by a powerful spring force. When the SPMs are closed, the
spring forces the spindle against the lower valve seat, closing off the inlet
port and connecting the outlet port to the vent port.
When pressure is applied to the pilot port, the spindle is forced upward,
against spring tension, to the upper valve seat. In this position, the inlet and
outlet ports are connected and the main hydraulic pressure (regulated) is
applied to the preventer function. At the same time the vent port is covered
in order to maintain pressure on the preventer. When the pressure is
released from the pilot port, the spring tension forces the spindle against the
lower valve seat. This causes the inlet port to close off and the pressure on
the preventer is vented to the sea through the outlet and vent ports.
The SPM valves requires > 950 psi pilot pressure to be opened against the
spring force. Normally two SPM valves are required to operate the BOP
preventer; one SPM valve for the open function and one SPM valve for the
close function.
Subsea fluid flows from the subsea accumulators at 3,000 psi and is
regulated by the HKR regulator down to 1,500 psi. The regulated hydraulic
pressure flows through the SPM valve to the shuttle valve and subsequently
to the preventer's cylinder CLOSE or OPEN side.
At the same time the 3-position, 4-way surface control valve located on the
HPU relieves pilot pressure on the preventer's OPEN or CLOSE SPM valve.
The spring forces the piston to its lower seat and vents pilot fluid to the
surface. Hydraulic fluid from the OPEN or CLOSE side of the preventer
cylinder is vented subsea through this valve. Regulated power fluid pressure
acts on a small piston area on the spindle to aid the spring in holding the
SPM closed.
The surface control valve, being a manipulator valve, vents the pilot
pressure from both SPMs when centered. This allows both SPM valves to
block or seal off the regulated operating power fluid and vents both sides of
the preventer actuating cylinder to the sea. When the control valve is in this
position, it is said to be in the ‘centered’ or ‘block’ or ‘vent’ position.
The SPMs are two-position valves open by hydraulic pressure from the pilot
signal and close by the spring force.
360
Figure 43 - ¾-inch SPM valve (diaphanous view).
361
Figure 44 - Koomey SPM in OPEN position, supplying fluid.
362
Figure 45 - Koomey SPM in CLOSED position, venting fluid.
363
Figure 46 - SPM internal parts.
The SPM valve seals on Teflon seal plates at the top and bottom. The top
seal isolates the supply from the vent and is used when the SPM is in the
vent position. The bottom seal isolates the vent from the supply when the
main flow is passing through the SPM when the SPM is in the open position.
It important that during PM the seals are inspected, O-rings are renewed
and the length of the spring is compared with a new one spring. Some SPM
valves have short stems around the spring cartridge and some have long
stem, do not mix these up! If you mix the long stem with a short stem then
the SPM remains open all the time!
After passing through the SPM valve, the power fluid exits the pod and flows
through the appropriate function, firstly through the hydraulic hose located
underneath the female pod receptacle and then to the shuttle valve, which
separates the yellow from the blue side.
The shuttle valve outlet should be installed with a rigid steel pipe nipple
directly on the BOP function body so that the common section is NOT a hose.
A single hose failure should never have the result that BOTH the yellow and
the blue pod function is lost!
The shuttle valves, which isolate the inactive pod from the operated function
are an integral part of the redundant two pod design. Shuttle valves are
used to direct power operating fluid from the active pod to the function while
at the same time isolating the inactive pod from the control pod in use.
When the pods are switched, fluid from the active pod shifts the shuttle in
the valve to isolate the inactive pod from the function.
Also note that the corresponding SPM valve in the inactive pod is piloted
open concurrently with the valve in the active pod, however no power fluid
flows from the inactive pod's valve because the hydraulic fluid line has been
vented to the surface.
364
Figure 47 shows a ‘positive’ shuttle valve, made by Cameron. This type of

shuttle valve does not have ‘interflow’ (or leaking) during shuttle valve
shifting and is mostly used on secondary unlatch functions on hydraulic
connectors.
Figure 47 - Positive-displacement shuttle valve (Cameron).
Not all functions on the BOP are controlled through valves on the pod.
Functions that require less volume, e.g. ball joint pressure, pod locks, AX
release systems etc. are controlled directly from the surface through small
hoses in the hydraulic hose bundle.
The fluid flows through a hole drilled directly through the pod. These
functions are called ‘straight-through’ functions as opposed to functions
requiring SPM valves.
365
The pods must have additional capabilities to meets today's needs. Some of
them are:
a) The ability to be run and retrieved independently when the pod hose is
connected to the pod wire.
b) The ability to be run and retrieved with the riser package (LMRP).
c) Full redundancy.
d) The ability to have all hydraulic seals on the retrievable portion of the
pod.
e) The ability to have all functions go to the exhaust position if
communications are lost with the surface.
f) The ability to isolate any leaks occurring downstream of the pod, either
at the pod or upstream of the pod.
Figure 48 - Shaffer 1-inch SPM valve.
Note the difference style SPM of Shaffer compared to the Koomey one, so
always check the original drawings of the SPM which are in use on your rig!
366
Figure 49 - Typical control pod circuit (Shaffer).
Figure 50 - Shaffer MUX IV control pod SPM valves with integrated

solenoid valves called direct-drive valves (DDVs).
367
Figure 51 - Koomey type-80 control pod.
Figure 52 - Incorrectly connected riser connector circuit.
368
Figure 53 - Incorrectly connected and routed riser connector circuit.
Figure 54 - Incorrectly connected wellhead connector circuit.
Hydraulic hose bundle and storage reel

In the conventional hydraulic system, the subsea pilot signals for the control
valves are transmitted through a hydraulic hose bundle that extends from
the surface manifold unit, through a jumper hose to the hose reels and from
the hose reels to the subsea pods. The main power supply is routed from the
HPU with rigid piping to the hose reels passing through a swivel and through
the shaft of the reels going to the pod hoses of the reels and down through
the 1-inch hose inside the pod hose to the subsea accumulators.
Also hydraulic fluid from the regulated side of the subsea regulators is
transmitted back through a 3/16 inch hose inside the hose bundle to
pressure gauges labeled ‘pressure read-back’ on the HPU control panels.
MHS fluid is supplied only to the hose bundle of the active pod inside the 1
inch hose. The pilot pressures going to the SPMs and the regulator pilots are
supplied to both the active and the inactive pod.
369
Figure 55 - Pod hose reel.
The hose bundles used most commonly are composed of a 1 inch ID main
supply hose (MHS) which supplies power to the pods and subsea
accumulators and 3/16 inch ID pilot hoses for activation of the individual
control valves and pilot and read-backs of the HKR regulators.
The supply and pilot hoses are typically bundled with the supply hose in the
centre surrounded by pilot hoses. (see Figure 39 and Figure 48.)
Polyurethane is the preferred outer covering material for the bundle because
of its superior physical properties. The hose reel stores and supplies the
hose bundle which vary from 2,000 feet to maximum 5,000 feet or more.
A separate pod line wire tensioner is available for easy running and retrieval
of the pod.
When the pod is run or retrieved, the junction box for the jumper hose is
disconnected from the hose reel. The RBQ plates of the hose reels have on
each side quick disconnect fittings installed and both the male and mating
female units are fitted with self sealing check valves.
It is important not over-tighten the Quick connect fittings or misalign the
fittings as these fittings can crack easily. When the plates are not lined up
properly or the RBQ plates are not completely made up it might be possible
there is no pilot going to the SPM consequently the SPM will not fire.
Ensure the pilot is actually going to the SPM and when in doubt make a by-
pass over the RBQ plate before you are going to pull the LMRP to repair a
faulty SPM valve, creating tremendous amount of down-time which is not
necessary as the source of malfunction is on surface and not subsea!!
370
When the pod hose jumper is connected to the hose reel, the reel must be
mechanically locked to prevent inadvertent rotation. A lock pin is provided
for this purpose (Figure 57).
If the reel is rotated whilst the hose bundle jumper from the HPU is still
connected, in less than one revolution of the reel, severe shearing damage
will occur to the delicate pilot lines.
Figure 56 - Pod hose

reel viewed from
manifold end.
Figure 57 -
Component parts of a
standard hose reel
for a conventional
hydraulic system.
Figure 58 - Turndown
roller sheave parts:
banana turndown
sheave.
371
Figure 59 - RBQ plate inside pod hose reel with quick-disconnect

fittings.
Figure 60 - RBQ plate of jumper hose with bent fittings.
When the pod is run or retrieved, the junction box for the jumper hose is
disconnected from the hose reel. However, in order to keep selected
functions live during the running and retrieval operations, a few control
stations are mounted on the pod hose reel manifold attached at the side of
the reel. (see Figure 57) The bent fittings shown on figure 2.6.18-31 are a
result of rotating the hose reel while the jumper hoses were NOT removed
yet, beware of “helpful” MONGS !
372
The live functions include at least the riser and the wellhead connectors latch
/ unlatch and secondary unlatch and the LMRP isolation/test gate valves.
Contractors may select to additionally operate one or more pipe rams and
wedgelocks for the rams.
The hose bundle leaves the reel and runs over a roller sheave down to the
pod. (see Figure 60) The bundle is clamped to the pod wire line attached to
the top of the pod at the pod latch rod and connected with pod hose wire
clamps at ~25 ft intervals. Some operations demand to have the pod hoses
are connected to the marine risers kill and choke lines. That means the pods
are no longer retrievable but due to deeper water or excessive sea currents
this set up might be necessary.
The pressure drop in the power hose can be substantial when a function is
actuated. particularly for long pod hose lengths. One way to compensate for
this pressure loss and assure faster actuation times is to place subsea
accumulators on the LMRP and/or the BOP stack.
Other means to supply control fluid to the control pods is using rigid conduit
lines varying from 2-3 inch ID. The rigid conduit line is integrated in the
marine riser. This arrangement is normally only encountered using MUX BOP
control systems.
It is necessary to prevent the pod hose from getting kinked just above the
connection of the pods, several system are in use. A stainless steel cover
similar to the Coflexip hose armor was used in the past but proved not to be
reliable enough. The pod hose still could get damaged and the armor
showed frequently cracks. Newer set up for instance the ABCO radius limiter
systems are used more frequently shown in Figure 61.
Figure 61 - Abco modular radius limiter in use for a Shaffer 42-line pod hose.
373
Following are the ANSI Y.32.10 codes of the symbols used in the hydraulic
schematics.
374
375
376
377
378
379
19 Cameron valves
We discussed the SPM valves, the shuttle valves and hydraulic regulators in
the previous chapter. All the valve equipment discussed and illustrated was
the manufacture of Shaffer or Koomey. In this chapter we will discuss the
Cameron control system.
The main differences between the Koomey and the Cameron control system
are:
a) The HPU panel valves have built in air operators and no separate
pneumatic cylinders to shift the valves.
b) The panel pilot pressure at Cameron systems is not 3,000 but 2,200 psi.
c) The Cameron accumulators have all an individual isolation valves, the
Koomey/Shaffer are normally installed in sets of 10 or 20 bottles.
d) The regulators of the Cameron system were all AKR type regulators
although several operators have modified their panels and installed TR
type regulators.
e) The Cameron triplex pumps are belt driven, the Koomey pumps are
chain driven.
f) The Cameron control pods have pressure-energized seals on retractable
stabs for the riser and the stack functions. The Koomey pods have no
retractable stingers nor pressure-energized seals.
g) The Cameron valves and HKR regulators inside the pods have special
vent plugs installed to vent the pilot fluids easily.
h) The Cameron valves do not seat on the pod like the SPM valves, they
are only connected with the main supply and the pilot supply inside the
pods.
i) Several Cameron slide valves have two outlets this means one valve for
one BOP components, both OPEN and CLOSE function.
Figure 62 - Cameron 1½-inch valve.
380
The Cameron 1½ inch is a 3-way, pilot operated hydraulic and spring return
valve. This valve was designed to provide the large flow rates required to
achieve a rapid closure of the new large diameter high-pressure annular
preventers. The valve is closed by the hydraulic pressure and spring action.
It is used in pairs, one to open and one to close the function.
In the closed position the power fluid supply is shut off and the remaining
pressure is vented from the (annular) BOP operating cylinder. The valve has
a full 1½ inch flow passage and a Cv of 35.
The Flow Coefficient - Cv

It is often convenient to express the capacities and flow characteristics of
control valves in terms of the Flow Coefficient - Cv. The flow coefficient - Cv
- is based on the imperial units system and is defined as:
The flow of water at 60 o Fahrenheit through a valve in US gallon/minute
with a pressure drop of 1 psi.
The flow coefficient is commonly used in the U.S.
The Flow Factor - Kv
The metric equivalent of the flow coefficient - Cv - is based on the SI-system
and is called the Flow Factor - Kv. The flow factor - Kv - is based on metric
units system and is defined as:
The flow of water at 20 o Celsius through a valve in cubic meters per hour
with a pressure drop of 1 kg/cm2 (1 bar).
The flow factor is commonly used outside U.S.
Converting between Flow Coefficient Cv and Flow Factor Kv
The connection between Cv and Kv can be expressed as:
• Cv = 1.16 Kv (1)
• Kv = 0.853 Cv (2)
Example - Flow Coefficient Liquid
The flow coefficient of a control valve which in the full open position passes
35 gallons per minute of water with a 1 psi pressure drop can be calculated
as:
Cv = 35 (gpm) (1 / 1(psi))1/2 = 35 (Note square root of 1 is 1 !)
381
Figure 63 - Cameron ¼-inch spring-centered valve.
The ¼ inch 4-way 3-position spring centered hydraulically piloted valve has
a design pressure of 5,000 psi. The Cv is 0.9. In the center position, supply
is shut off and both outlets are vented. It is used for functions, which require
less fluid then the ram or annular preventers.
Figure 64 - Cameron ¼-inch two-position valve.
Figure 64 shows a modern Cameron ¼ inch valve as used on Cameron MUX

pods.
382
Figure 65 - Cameron 1-inch slide valve.
The Cameron Pilot-Operated Slide valves operate dependably without

attention under usually adverse conditions. Internal parts are manufactured
from stainless steel and bodies are coated for operation in salt water. The
1-inch pilot operated hydraulic and spring return valve has a design pressure
of 3,000 psi. The Cv is 15. It is used in pairs one to close and one to open
ram type preventers. In the closed position, the power fluid supply is shut
off and the pressure is vented from the preventer operating cylinder.
383
Figure 66 - Cameron panel valve.
The Cameron panel valves are mounted on the HPU panel. At the top of the
valve is a supply port that can be connected to pneumatically operate the
valve:
• Port ‘A ‘ is the open function connected to both the Yellow and the Blue
pods.
• Port ‘B’ is the close function connected to both the Yellow and the Blue
pods.
Figure 67 - Cameron lever-operated panel valve.
384
Figure 68 - Component parts of Cameron panel valve.
385
Figure 69 - Cameron four-way/two-position hydraulically operated

spring return valve.
These valves are installed inside the Cameron control pods. The pilot
operates a single pilot cylinder against the valve's spring return mechanism.
When pilot pressure is applied, the supply line flow changes which routes the
outlet port ‘A’ to the outlet port ‘B’. When pilot pressure is removed, supply
line flow changes which routes the flow back to outlet port ‘A’. These valves
are used for typical two position functions, like the failsafe gate valves or the
secondary unlatch function of the hydraulic connectors.
Figure 70 - Cameron ¼-inch four-way/three-position pod valve.
386
This spring-centered valve is installed on the control pods and are typically
used for three position functions with small volumes, for instance the latch
and unlatch functions of the connectors and the gate valves if they are
installed on both the close and the open side. This valve is operated by
either of two pilot sources. When pressure is applied from source ‘A’ then
the valve slides to the left routing the supply line flow downstream through
outlet port ‘A’. When pilot pressure is applied from source ‘B’, then the valve
slides to the right routing the supply line flow downstream through outlet
port ‘B’.
Figure 71 - Cameron 1-inch four-way/three-position spring-centered

dual valve in the centered position: the fluid is vented.
This 1 inch spring centered hydraulic dual valve is installed inside the
Cameron control pod and is normally used for the ram preventer functions.
The valve is operated by either two pilot sources. When pilot pressure is
supplied from source ‘A’, the valve slide moves downwards routing the
supply flow line downstream through the outlet port ‘A’. When pilot pressure
is supplied from source ‘B’, the valve slide moves downwards routing the
supply flow line downstream through the outlet port ‘B’.
387

dual valve in the open position: opening supply fluid
flows to port B.
388
Cameron solenoid valves for MUX pods
Figure 73 - Solenoid two-position/three-way valve.
Figure 74 - The solenoid valves are electrically operated inside the

Cameron MUX pods.
389
Figure 75 - Exploded view of Cameron solenoid valve assembly.
Cameron HKR regulator

The Cameron regulator are operating similar then the Koomey-Shaffer
designs. The inlet-outlet is located on the same block.
Figure 76 - Cameron hydraulic pressure regulator.
390
Questions Hydraulic Control System

1. What is the function of the pod selector valve on the HPU? What kind of
valve is this valve: a manipulator or selector valve? Explain your choice.
2. What is the function of the MHS?
3. What is the ratio of the subsea regulators (HKR)?
4. How does the read-back pressure signal get back to the HPU?
5. How are the yellow and blue main flow circuits separated on the BOP
stack?
6. For what reasons are emergency air systems required?
7. Mention all the differences between an AKR and a TR-type regulator.
8. Explain the difference between the two-position function and the three-
position function.
9. Mention what BOP equipment uses the three-position function and what
equipment uses the two-position function.
10. Mention and explain the difference between the Koomey panel valves on
the manifold and on the pod hose reel manifold.
11. What is the reason that Kevlar was used on the pilot line covers inside
the pod hoses?
12. What does the light indication on the rig floor tell us?
13. Draw the symbols for:
• A pneumatic-operated regulator (AKR)
• A panel valve ram
• A pilot-operated check valve
• A pod selector valve
• A SPM valve
• A shuttle valve
14. Explain the use of the standard and the positive-displacement shuttle
valve. What is the difference between the two?
15. Explain the difference between the Koomey and the Shaffer solenoid
layout on the BOP HPU. What can be the danger of the Shaffer solenoid
layout?
16. What will be the result if the pod hose reel RBQ plates are not connected
tight enough? What will be the result of them being too tight?
17. What is the reason that we install an MKR in each pod hose reel
manifold?
18. Explain why we use a selector valve on pod hose reel manifolds.
19. How can you isolate the accumulator bottles subsea, why would you do
this?
20. What is the indication on the remote panels that the subsea accumulator
isolation valve is still closed?
21. Why do we have to vent most subsea accumulator bottles prior to pulling
the BOP out of deep water?
22. Why do we have to vent the pilot lines of the non-used functions on the
pod hose reels? Do we have to vent the functions on both reels?
391
23. What is the indication of a small leak on the hydraulic circuit of the
subsea BOP (when the flow meter is not running)?
24. What is the purpose of the memory switch? Explain its operation.
25. How is the pod latch and the MHS supply transferred from the HPU past
the pod hose reels to the subsea unit?
26. Explain the operation of the SPM valves.
27. Why do we use different-sized SPM valves for different functions?
28. Why is it incorrect to install a hose on the outlet of the shuttle valves on
the BOP stack?
29. Why do we reel off the excess length of the pod hose after we land the
BOPs?
30. What should prevent the misalignment of the RBQ plates?
31. What causes the bent fittings on the jumper hose RBQ plates?
32. What is the advantage and disadvantage of connecting the pod hose on
the marine risers? What can be the alternative?
33. What is the difference between the Cameron control system and the
Koomey/ Shaffer system?
34. What is the difference between Cameron valves and Shaffer SPM valves?
35. What is the difference between Cameron control valves and Koomey
valves installed on the HPU panel?
36. Why is it much easier to vent Cameron pilot lines than the Koomey
system?
37. What is the only reliable indication that a ram BOP is closed?
38. How do you time a function during a function/pressure test?
39. Explain, step by step, what happens if you change from the yellow to the
blue pod.
40. How can you solve the problem of a leaking pilot line?
41. Explain how to change from the HPU panel to the pod hose reel panels.
42. Why should we have a vent line installed underneath the box of the
pressure transducers on the HPU?
43. What is the pressure setting of the HPU relief valves?
44. What is the requirement of the size of the storage tank of the HPU?
45. Explain the difference of schematic valves with two blocks in the drawing
or with three blocks in the drawing.
392
20 Table of figures
Figure 1 -
HPU control panel manufactured by Cameron-Payne.............. 311
Figure 2 -
Typical main hydraulic system............................................ 312
Figure 3 -
Schematic of typical MHS going to the control pod. ............... 313
Figure 4 -
Driller’s panel with pilot and read-back gauges. .................... 314
Figure 5 -
Schematic of manifold and annular regulator pilot and read-
back circuits. ................................................................. 315
Figure 6 - Cameron panel valve with three-position/four-way
manipulator valve........................................................... 316
Figure 7 - Schematic for a single function using a three-position
manipulator valve........................................................... 317
Figure 8 - Schematic of hydraulic system of a typical three-position
function. ....................................................................... 319
Figure 9 - Hydraulic schematic of a typical two-position function............ 321
Figure 10 - Schematic of a two-position circuit gate valve (normally
closed).......................................................................... 322
Figure 11 - Schematic of Shaffer control system with straight-through
function. ....................................................................... 324
Figure 12 - Schematic of a typical hydraulic pilot supply circuit.............. 326
Figure 13 - Schematic of typical hose reel manifold function.................. 328
Figure 14 - Typical pod hose reel panel. ............................................. 329
Figure 15 - Manipulator valve layout.................................................. 330
Figure 16 - Selector valve layout....................................................... 331
Figure 17 - Manipulator and selector valve components. ....................... 332
Figure 18 - Accumulator isolator circuit. ............................................. 334
Figure 19 - Fundamental schematic of shear seal regulator. .................. 337
Figure 20 - Koomey-Shaffer manual regulator..................................... 338
Figure 21 - Subsea pod regulator by Cameron pilot versus output ratio
is 1:1............................................................................ 339
Figure 22 - Manual regulator installed in Koomey 80 pods and most
MUX pods to reduce the accumulator pressure from 5,000
to 3,000 psi. .................................................................. 339
Figure 23 - The output pressure is too low, the regulator is in full
supply mode, the vent is closed and the supply is fully
open............................................................................. 340
Figure 24 - The output pressure is too high, the regulator is in full vent
mode, the supply is closed and the vent is fully open. .......... 340
Figure 25 - The output pressure is equal to the pilot pressure; both the
supply and the vent are isolated. ...................................... 340
Figure 26 - Typical increase/decrease circuit surface. ........................... 341
Figure 27 - Typical increase/decrease circuit. ...................................... 342
Figure 28 - Typical two-position electrical circuit (pressure
open/vent/close). ........................................................... 343
Figure 29 - Three-position function.................................................... 345
Figure 30 - Typical memory circuit. ................................................... 347
Figure 31 - Typical pressure transducer circuit. ................................... 348
Figure 32 - Lamp test circuit............................................................. 349
Figure 33 - Riser-mounted receptacles. .............................................. 351
Figure 34 - Koomey 80 BOP stack-mounted receptacle......................... 351
Figure 35 - Koomey 80 control pod in the retracted position.................. 352
Figure 36 - The Koomey Shaffer 42-line retrievable pod. ...................... 353
Figure 37 - The Koomey Shaffer 64-line retrievable control pod. ............ 354
Figure 38 - Installing the blue control pod (Shaffer MUX IV) on the
Saipem 10000 BOP stack................................................. 355
393
Figure 39 - Typical pod hose layouts. ................................................. 356

Figure 40 - Cameron HKR................................................................. 357
Figure 41 - Slug-type shuttle valve. ................................................... 358
Figure 42 - Typical modern BOP control panel. .................................... 359
Figure 43 - ¾-inch SPM valve (diaphanous view). ................................ 361
Figure 44 - Koomey SPM in OPEN position, supplying fluid..................... 362
Figure 45 - Koomey SPM in CLOSED position, venting fluid.................... 363
Figure 46 - SPM internal parts........................................................... 364
Figure 47 - Positive-displacement shuttle valve (Cameron).................... 365
Figure 48 - Shaffer 1-inch SPM valve. ................................................ 366
Figure 49 - Typical control pod circuit (Shaffer). .................................. 367
Figure 50 - Shaffer MUX IV control pod SPM valves with integrated
solenoid valves called direct-drive valves (DDVs)................. 367
Figure 51 - Koomey type-80 control pod............................................. 368
Figure 52 - Incorrectly connected riser connector circuit. ...................... 368
Figure 53 - Incorrectly connected and routed riser connector circuit. ...... 369
Figure 54 - Incorrectly connected wellhead connector circuit.................. 369
Figure 55 - Pod hose reel. ................................................................ 370
Figure 56 - Pod hose reel viewed from manifold end............................. 371
Figure 57 - Component parts of a standard hose reel for a conventional
hydraulic system............................................................. 371
Figure 58 - Turndown roller sheave parts: banana turndown sheave....... 371
Figure 59 - RBQ plate inside pod hose reel with quick-disconnect
fittings. ......................................................................... 372
Figure 60 - RBQ plate of jumper hose with bent fittings. ....................... 372
Figure 61 - Abco modular radius limiter in use for a Shaffer 42-line pod
hose. ............................................................................ 373
Figure 62 - Cameron 1½-inch valve. .................................................. 380
Figure 63 - Cameron ¼-inch spring-centered valve. ............................. 382
Figure 64 - Cameron ¼-inch two-position valve. .................................. 382
Figure 65 - Cameron 1-inch slide valve............................................... 383
Figure 66 - Cameron panel valve. ...................................................... 384
Figure 67 - Cameron lever-operated panel valve.................................. 384
Figure 68 - Component parts of Cameron panel valve........................... 385
Figure 69 - Cameron four-way/two-position hydraulically operated
spring return valve.......................................................... 386
Figure 70 - Cameron ¼-inch four-way/three-position pod valve. ............ 386
dual valve in the centered position: the fluid is vented. ........ 387
dual valve in the open position: opening supply fluid flows
to port B........................................................................ 388
Figure 73 - Solenoid two-position/three-way valve. .............................. 389
Figure 74 - The solenoid valves are electrically operated inside the
Cameron MUX pods. ........................................................ 389
Figure 75 - Exploded view of Cameron solenoid valve assembly. ............ 390
Figure 76 - Cameron hydraulic pressure regulator. ............................... 390
394
Module 02 - 07 Fuzzy Maths 1.0
Chapter 07
Fuzzy maths
1 Fuzzy maths introduction........................................................ 396

2 Accumulator volume calculation for surface bottles..................... 397
3 Subsea accumulator bottles volume calculation.......................... 400
4 Calculating the poorboy degasser mud seal ............................... 403
5 Increase of closing pressure for Ram BOPs in deep water ............ 405
6 Calculations for flushing times of rigid conduit lines .................... 406
7 Calculations for ton cycles for the riser tensioners ...................... 407
8 Compressibility calculations .................................................... 408
9 Calculations riser space-outs................................................... 411
10 Exercises fuzzy maths............................................................ 420
11 Table of figures ..................................................................... 424
395
1 Fuzzy maths introduction
In this chapter we will go over the (in) famous fuzzy maths of this course.
We will discuss the calculations of the following:
a) Accumulator volumes surface and subsea
b) Pressures in the poor boy degasser
c) Adjustment pressures for the ram preventers operating in deep water
due to mud weight increase
d) Volumes of the rigid conduit lines and how long to circulate
e) Calculation of the ton-cycles for the tensioners
f) Calculation of the compressibility of test fluids
g) Space out of the marine risers joints
h) Calculation of riser tensioners tension during running and pulling the
BOPs, during the well operations and with different mud weights
396
2 Accumulator volume calculation for

surface bottles
Question:
How do you calculate the accumulator size for a typical BOP stack, as per
API RP 16D?
This example deals with four 18-3/4" 15,000-psi WP Cameron ram-type TL
BOPs and one 18-3/4” 10,000-psi WP Cameron DL annular preventer. One of
the rams is a Super Shear ram.
The volume for the Cameron 15M ram BOP type TL with ST locks is 23.4 US
gallons to open and 24.6 US gallons to close. The closing ratio 6.7: 1 so that
the minimum operator pressure is 15,000 : 6.7 = 2,239 psi.
Required volume:
Three pipe rams open : 3 x 23.4= 70.2 US gallons
Three pipe rams close : 3 x 24.6= 73.8 US gallons
One super shear ram open : 1 x 67.1= 67.1 US gallons
One super shear ram closed : 1 x 71.3= 71.3 US gallons
Annular preventer close : 1 x 45.1= 45.1 US gallons
Annular preventer open : 1 x 52.0= 52.0 US gallons
------------------------+
Total volume needed: 79.50 US gallons
Volume required (as per API RP 16D):

a. Total volume to open and close all ram preventers and one annular
preventer plus 50% reserve. This means 379.5 x 1.5 = 569.25 US
gallons.
b. The second method is to open and close four ram preventers and to
open and close one annular preventer; then the remaining pressure
should be equal to or higher than the closing ratio of the ram
preventers.
397
Figure 1 - Surface accumulators in three stages.
Question:
How do you calculate the usable fluid for the 11-US-gallon bag-type
accumulator bottle?
We use Boyle's rule, which says: P1 x V1 = P2 x V2 = P3 x V3

P1 = Pressure of the Nitrogen at the pre-charge stage (1,000 psi)
V1 = Volume of the Nitrogen at pre-charge stage (11 - 1 = 10 US gallons)
The volume of the bladder is 1 US gallon.
P2 = Pressure of the Nitrogen at fully charged condition (3,000 psi)

V2 = Volume of the Nitrogen at fully charged condition
P3 = Pressure of the Nitrogen at closing ratio = (2,239 psi)
The closing ratio of a 15M BOP is 1 : 6.7, which means 15,000 : 6.7 = 2,239
psi
V3 = Volume of the Nitrogen at ram closing ratio pressure
According Boyle’s law we use the following calculation:

P1 x V1 = P2 x V2 = P3 x V3
398
Next we will start filling in the figures:

1,000 x 10 = 3,000 x V2 = 2,239 x V3
V2 = 3.33 US gallons of Nitrogen, so 10 - 3.33 = 6.66 US gallons of fluid is

pumped in each accumulator.
This is the total amount of fluid we can pump inside each accumulator
bottle.
V3 = 4.80 US gallons of Nitrogen, so 10 – 4.46 = 5.54 US gallons fluid is

left in each accumulator.
This 5.20 US gallon is useless fluid of which we cannot use a single drop as
the pressure will then fall below the minimum pressure that the ram-type
BOPs need to hold full working pressure (= the ram closing ratio).
So, when we are using the ram closing ratio limit, the remaining control fluid
is: 6.66 - 5.54 = 1.12 US gallons of useable fluid for each accumulator bottle
(That is not much eh?)
In conclusion, the minimum amount of required accumulator bottles

is:
• For situation A: 569.25 : 6.66 = 85.47 or 86 eleven-gallon bottles (if we
just look at the total volume)
• For situation B: 379.5 : 1.12 = 338.8 or 339 eleven-gallon bottles (if we
use the useable volume at ram closing ratio)
API recommends using the figure “whichever is the greatest”, so that we

need a minimum of 339 accumulator bottles in this situation.
399
3 Subsea accumulator bottles volume

calculation
Question:
How much fluid can you pump inside the accumulator bottles subsea and
how much is the useable volume of each accumulator at the closing ratio of
the ram-type BOPs?
This example deals with four 18-3/4" 15M WP Cameron TL BOPs with ST
locks installed. The closing ratio of a 15M Cameron TL BOP is 6.7:1, which
results in:
15,000: 6.7 = 2,239 psi
Water depth: 4,045 feet

Hydrostatic pressure seawater: 4,045 x 0.445 = 1,800 psi
Temperature on the surface: 28°C
Temperature subsea: 4°C
P1 P2 P3
V1 V2
V3
T1 T2
T3
Total
Useable fluid
Useless
Fluid Fluid
Precharge Fully charged Closing Ratio
Ram BOP
Figure 2 - Subsea accumulators in three stages.
400
Boyle’s Rule states:
P1 x V1 P2 x V2 P3 x V3
= =
T1 T2 T3
P1 = Pressure of the Nitrogen at the pre-charge stage + hydrostatic

pressure seawater (1,000+1,800=2,800-psi)
V1 = Volume of the Nitrogen at pre-charge condition (11-1=10 US gallon)
The volume of the bladder is 1 US gallon.
T1 = Absolute temperature at the surface in degrees Kelvin (273 + 28 =
301°K)
P2 = Pressure of the Nitrogen at fully charged stage +hydrostatic pressure

seawater (3,000+1,800=4,800-psi)
V2 = Volume of the Nitrogen at fully charged condition
T2 = Absolute temperature subsea in degrees Kelvin (273 + 3 = 277°K)
P3 = Pressure of the Nitrogen at closing ratio + hydrostatic pressure of the

seawater (2,239 + 1,800 = 4,039 psi)
The closing ratio 15M BOP is 6.7:1, meaning 15,000 divided by 6.7 = 2,239
psi
V3 = Volume of Nitrogen at ram closing ratio condition
T3 = Absolute temperature subsea in degrees Kelvin (273 + 3 = 277°K)
We will use Boyle rule again with the temperature in the calculation:
P1 x V1 P2 x V2 P3 x V3
= =
T1 T2 T3
Next we will fill in the figure we found:
2,800 x 10 4,800 x V2 4,039 x V3

= =
301 277 277
93.02 = 17.32 x V2 = 14.58 x V3
V2 = 5.37 US gallons of Nitrogen, so 10 - 5.37 = 4.63 US gallons of fluid

is pumped in each subsea accumulator.
This is the total amount of fluid we can pump inside each subsea
accumulator bottle.
V3 = 6.38 US gallons of Nitrogen, so 10 - 6.38 = 3.62 US gallons of fluid
is left in each subsea accumulator.
This 3.62 US gallon is useless fluid of which we cannot use a single drop, as
the pressure will then fall below the minimum pressure that the ram-type
BOPs need to hold full working pressure (= ram closing ratio)!
401
If we are using the closing ratio, the remaining control fluid is:
4.63 minus 3.62 = 1.01 US gallons of usable fluid for each accumulator
bottle.
The subsea bottles in this example can deliver a total volume of 4.63 US
gallons per bottle and only 1.01 US gallon of useable fluid when the ram-
closing ratio pressure is used at the very limit.
402
4 Calculating the poorboy degasser mud

seal
We will calculate the hydrostatic pressure caused by the mud column that
will be the resistance for possible gas pressure build up in the poor boy
degasser. The mud seal must prevent the gas to blow back to the shakers or
the mud pits; instead the gas must be venting through the vent line in the
derrick.
We use the pressure calculation of a fluid column when using ft for the
height and pounds per gallon for the specific gravity of the mud, the
pressure will be in pounds per square inch (psi). If other units are used a
different constant needs to be used.
Gas Outlet
8-inch Minimum
Pressure gauge 0-20 psi

Approx 1/2 of Height
7-5/8-inch
Inner Sleeve
3/4-1 inch Holes on 3" Centers

16-ft Minimum Height
Inspection
Cover 30-inch OD
4" ID inlet ( Tangential= optional)

to Shell from Choke manifold
Half Circle Baffles

Brace arranged in "Spiral"
Configuration To Shaker
Ditch
4.5 ft
8-ft approx
2" Drain
or Flush Line
4-inch Clean-out Plug 8-inch Nominal U-tube
Figure 3 - Poorboy degasser.
403
Pmud = h mud x ρ mud x c

H = height in ft
Ρmud = specific gravity mud in ppg
C = constant 12 : 231 = 0.052
This converts the feet in to inches (x 12) and gallons into inch (: 231).
Note: the OD of the poorboy degasser or mud column is of NO influence on
the pressure!
On rig Heineken 444 we have a poorboy degasser with a mud seal of 12
feet. We are using a mud weight at the beginning of the well of 9.6 ppg and
at the end of the well we use 16.7-ppg mud.
Question:
How much is the pressure we lose in the mud seal at the beginning of the
well and what at the end of the well?
Answer:
Pmud= h mud x ρ mud x c
So, at the beginning of the well:
P mud = 12 x 9.6 x 0.052 = 6 psi
At the end of the well:
P mud = 12x 16.7 x 0.052 = 10.4 psi
If you look at these figures, you will realize that friction in the vent lines
needs to be avoided and circulating out a kick requires a slow circulation
rate normally within 1 barrel per minute.
It does not make much sense to install a 0-100-psi gauge on the poorboy
degasser.
The poorboy degassers are normally rated to withstand the pressure in case
the vent line is completely filled with mud.
So, this means for the mathematic wizards, while assuming a height of the
derrick of 200 ft: 200 x 16.7 x 0.052 = 174 psi, which is much more than
the normal pressure you will normally see inside the poorboy degasser. So,
most poorboy degassers are rated to 150 ≈ 200 psi.
404
5 Increase of closing pressure for Ram

BOPs in deep water
We have a 15M Cameron TL BOP that will be operating in 7,800 feet of

water. The closing ratio is 6.7:1. What must be the closing pressure increase
using mud of 10.2 ppg and with mud of 15.6 ppg?
∆P= H x (ρ mud – ρ water) x c
∆P = pressure increase( by the mud)
H = height of column
ρ mud = specific gravity of the mud
ρ water= specific gravity of fresh water
c = constant converting ft in inches (x12) and gallons into inch (:231)
c = 12: 231 = 0.052
Using 10.2 mud at the beginning of the well:

∆P = 7,800 x (10.2 - 8.3) x 0.052 = 770.64 psi
For this BOP we divide this figure by the closing ratio 770.64: 6.7 = 115 psi
extra closing pressure for the rams to overcome the forces creates by the
mud column.
Using 16,6 mud at the end of the well:

∆P = 7,800 x (15.6 – 8.3) x 0.052 = 2,960.88 psi
For this BOP we divide this figure by the closing ratio 2960.88: 6.7=442 psi
extra closing pressure for the rams to overcome the forces created by the
mud column.
Ram BOP Closing ratio
10M Cameron UII 1:6.7
15M Cameron UII 1:9.3
15M Cameron T with ST locks 1:6.7
15M Cameron TL with RAM Locks 1:7.31

15M Hydril 1:7.27
10M Shaffer SL/SLX 1:7.11
15M Shaffer SL 1:10.85
15M Shaffer NXT 1:13.93
405
6 Calculations for flushing times of rigid

conduit lines
After the BOP is landed and prior to connecting the hydraulics subsea, we
have to flush the rigid conduit line thoroughly. The accepted standard is that
we flush the rigid conduit lines 1.5 times their volume.
Example:
Rig Baccardi 12 has two 2-3/4” ID rigid conduit lines.
The Coflexip hoses in the moonpool are 70 feet long
The water depth is 7,500 feet.
The Coflexip hoses on the stack are 25 feet long.
The three quintuplex pumps are rated for 26 gallons per minute.
Question: How long must we circulate to flush both rigid conduit lines?
Answer: First are we calculate the complete length of the rigid conduit
lines:
Moonpool = 70 ft
Riser = 7,500 ft
LMRP = 25 ft
+
Total = 7,595 ft
Volume rigid conduit line is in gallons is ¼ x ∏ x (ID)² x H x C

(ID in inches, H in ft)
C= 12: 231 = 0.052. We need this to use gallons per minute and so the
length is converted first into inch (x 12) and the volumes from gallons to
inch (: 231)
Volume of one rigid conduit line is ¼ x ∏ x (2.75)² x 7,595 x 0.052 =
2,345.77 US gallons. As we have two lines the total volume of both lines is
2,345.77 x 2 = 4,691.55 US gallons.
We have to circulate 1.5 times the volume, so the total volume to circulate is
4,691.55 x 1.5 = 7,073.32 US gallons
We have three quintuplex pumps, which can deliver 3 x 26 = 78 US gallon
per minute.
The minimum total circulation time must be the total required volume
divided by the pump capacity, so that becomes 7,032.32: 78 = 90.22
minutes!
So, you have to realize that when we operate in deep water the rigid conduit
flushing times can be considerable.
Without proper calculations it will be very hard to convince a HEAD MONG to
allow you to circulate this long!
406
7 Calculations for ton cycles for the riser

tensioners
The tensioners are moving at one cycle per 6 seconds. The rig has 42 kips
per tensioner pull. How frequent do we have to slip and cut?
When a tensioner goes up and down we called that one cycle. We normally
measure cycles in seconds.
Each day has 24 hours.
Each hour has 60 minutes, so we have 24 x 60 = 1,440 minutes in one day.
Each minute has 60 seconds, so that makes 1,440 x 60 = 86,400 seconds
per day.
One kip (kilo pound) is 0.45 tons.
Load x seconds per day

= ton cycles per day
time for each cycle
Load = tons
Time of cycle = seconds
42x 0.45 x 86,400
= 272,160 ton/cycles per day
6
Normally we use approximate 30,000,000 ton/cycles as the limit to slip and
cut. After that, replace or slip and cut the riser tensioner cables.
So we have to slip and 30,000,000

= 110 days with these cycles/load
cut after 272,160
407
8 Compressibility calculations
Although we learned in school that you cannot compress fluids, this is not
entirely true. We can compress fluids by using high pressures. You may
think that the pressures we work with in our industry are not too high; in
fact we are working with extreme high pressures when testing our BOP
equipment. Each fluid has a compressibility factor; this factor provides a
figure that states how much you can compress the volume of the fluid per
psi pressure increase.
For instance, the compressibility factor of water is 0.0000034 per psi
pressure increase. That means that if we have one gallon of water and we
have to increase the pressure of that water to 1,000 psi, then we have to
pump the volume of 1,000 x 0.0000034= 0.0034 gallons. That does not
seem much, but if we have 1,000 gallons of fluid it means that we have to
use 3.4 gallons.
We normally work with pressures varying from 7,500 to 15,000 psi, so you
will see that we can actually calculate how much we have to pump (the
cementer) to bring up the pressure when testing the BOP, pressuring the
casing for a leak-off test, etc.
The formula for compressibility is:
ΔV = Vt x ΔP x C
ΔV = I increase of volume (volume to pump), expressed in barrels (one
barrel is 159 litres)
Vt = total volume which will be pressurized (in bbls)
ΔP = increase of pressure (in psi)
C= compressibility factor of water = 0.0000034/psi
Rig Johnny Walker III has the following data:

Cement unit to choke and kill manifold to moonpool (surface lines): 3” ID,
total length 120 ft
Moonpool flex hose 70 ft
Marine risers including slip joint 7,500 ft
Flex hose on stack 25 ft
Kill line on stack 35 ft
ID BOP is 18.75 inch
Test joint 5” OD
Distance test tool to bottom LRP is 4,2 ft
We have to pressure-test the BOP to 250-psi low pressure and 7,500 psi
high pressure.
Question: How many barrels of fluid do we need to pump to reach this
pressure (using water)?
408
We have to calculate the volume in barrels first:
The calculation to get barrels (bbls) from a volume ID² per ft of

of a tubular is 1029.4 tubular,
where we have converted a number of fixed numbers of into 1

a constant of 1029.4
Where is this 1029.4 coming from?

In the original equation we should use is ¼ x ∏ x (ID)² x h x 12 to get cubic
inches.
To convert this into gallons we have to divide the inch with 231.
To convert gallons into barrels we have to divide the gallons with 42.
¼ x ∏ x 12 1 which is the
So if we take =0.0009714= constant used
231 x 42 1029.4 here.
Total length of kill line is:

Surface lines + moonpool hose+ riser rigid conduit + LMRP hose + stack line
120 + 70 + 7,500 + 25 + 35 = 7,750 ft
ID² x 7,750 3² x 7,750

Volume complete line is: = 67.75 bbls
1029.4 1029.4
(D² - d²) x h
Volume BOP is: (D = ID BOP and d = OD drill pipe)
1029.4
{(18.75²) - (5²)} x 4.2

Volume BOP is: = 1.33 bbls
1029.4
Total volume (Vt) is 67.75 + 1.33=69.08 bbls
So if we use the formula here:
ΔV= Vt x ΔP x C
ΔV = increase of volume (volume to pump) we use barrels (159 litres)
Vt = total volume which will be pressurized in bbls
ΔP = increase of pressure in psi
C = compressibility factor of water = 0.0000034 psi
409
First the low pressure test we have to pump to reach 250 psi:
ΔV =?
Vt = 69.08 bbls
ΔP = 250 psi
ΔV = 69.08 x 250 x 0.0000034 = 0.058 bbls
So, we advise the cementer to use just ½ barrel maximum to reach the low
pressure.
To reach the 7,500-psi pressure for the high-pressure test we have to

pump:
ΔV =?
Vt = 69.08 bbls
ΔP = 7,500 psi
ΔV = 69.08 x 7,500 x 0.0000034 =1.76 bbls
So, we advise the cementer not to use more than 2 barrels to reach the high
pressure.
410
9 Calculations riser space-outs
When we are drilling a new well we have to calculate how much riser we
have to run each time. The distance of the top of the 20-inch housing to the
RKB (rotary kelly bushing) is used for the calculations of how much riser you
need (see Figure 4).
You will make an absolute IDIOT of yourself if you screw up when calculating
the correct amount of marine riser. Some MONGS run too many or too few
riser joints, which always results in downtime and loss of credibility of the
contractor towards the operator.
Nowadays many rigs use spreadsheets, but we will teach you to calculate
this yourself just to able to check the quality of these spreadsheets in use!
Trust NO-ONE!
The rig Bloody Mary VI has the following specifications:
• Distance RKB to datum 20” housing is 6,333 feet.
• Distance RKB to diverter flex joint riser crossover connection is 17 feet.
• The slip joint has a 66-foot stroke.
• The outer barrel is 75 feet long.
• The marine risers are 75 feet long.
• The complete BOP is 48 feet high.
• The LMRP is 24 feet high.
• The LBOP stack is 24 feet high. (from datum to top)
• The rig has the following riser pup joints: 40 ft, 20 ft, 10 ft and 5 ft.
Question calculate the riser string we have to use here:

Fixed distance we always have to subtract is:
Diverter including flex joint and crossover : 17 ft (E)
½ inner barrel of the slip joint : 33 ft (D)
Outer barrel slip joint : 75 ft (D)
Complete BOP stack height : 48 ft (B)
------------- +
Total fixed distance is 173 ft
That means we have to run a riser string of 6,333 – 173 = 6,160 ft

The riser joints are 75 feet long, so we need 6,160 : 75 = 82.133 riser
joints.
We have to run 82 riser joints and 0.133 x 75 = 9.99, so we chose a 10-foot
pup.
411
To check our running string we once more calculate the complete

set-up:
Total length of our string:
Fixed on your rig, slip joint mid-stroke 173 ft
Risers(82 x 75 joints + 1 x 10 pup) 6,160 ft
----------- +
Total datum to RKB 6,333 ft
If you cannot do this calculation, you’d better start a new career as an ice
cream salesman instead of becoming a subsea engineer.
As we always can make a mistake in space-outs it is a good practice to have
a smart head MONG check your calculations (provided there is one on your
rig).
Figure 4 - Space-out sheet for running riser.
412
Next we are going to run the BOP at the beginning of the well we need to
know how much weight we put on the tensioners and how much on the
compensator DSC or CMC.
The rig Bloody Mary VI has the following specifications:
• LBOP stack in water 348,000 lbs
• LMRP in water 156,600 lbs
Riser joints in air:

• Slick joints 75 ft 22,370 lbs
• Buoyancy joints 5,000 ≈ 7,000 ft 37,562 lbs
• Buoyancy joints 4,000 ft 35,762 lbs
The buoyancy risers lose 95% of their weight in water. The slick risers lose
13% of their weight in water.
Riser pups in air:
• 40 ft pup 12,800 lbs
• 20 ft pup 8,400 lbs
• 10 ft pup 5,400 lbs
• 5 ft pup 4,200 lbs
The riser pup will lose 13% of their weight in water.
• Slip joint outer barrel 45,000 lbs
• Slip joint inner barrel 10,690 lbs
• Tension ring assembly 25,000 lbs
• Riser running tool 3,550 lbs
The rig has 16 riser tensioners installed rated to 120 kips each.
We are going to use 82 riser joints and one 10-ft pup.

We are using 4 slick risers in the string.
We are using 78 joints buoyancy riser:

• 26 x 5,000 ≈ 7,000-ft buoyancy joints
• 14 x 4,000-ft buoyancy joints
We land the stack with one slick riser joint.
413
Weight calculation riser string for landing the BOP:

LBOP stack in water = 348,000 lbs
LMRP in water = 156,000 lbs
4 x Slick risers (4 x 22,370 x 0.87)= 4 x 19.462 = 77,847 lbs
26 x buoyancy risers 5,000 ft (26 x 37,562 x 0.05) = 48,830 lbs
1 x riser pup (1x 5,400 x 0.87) = 4,698 lbs
Slip joint outer barrel in air = 45,000 lbs
Slip joint inner barrel in air = 10,690 lbs
Tension ring assembly in air = 25,000 lbs
Slick joint (landing joint) in air = 22,370 lbs
Riser running tool = 3,550 lbs
--------------- +
Total weight landing BOP = 831,860 lbs
We will put 50,000 lbs landing weight on the assembly 50,000 lbs
--------------- -
781,860 lbs
We will use 75,000 lbs in the compensator 75,000 lbs
--------------- -
Total weight for the tensioners is 706,860 lbs
The rig has 16 tensioners installed, which means that for each tensioner we
have to set the riser tensioners to 706,860 : 16 = 44.178 kips each.
Notes:
• We assume this rig is a semi and the slip joint outer barrel is out of the
water.
• We need the landing weight to prevent the BOP from starting to “float”
before landing.
• We use 75,000 lbs in the compensator for the compensator either DSC
or CMC, as it is much easier and faster to adjust the pressure of the DSC
or CMC than that of the riser tensioners.
414
Pull on the riser tensioners after the ram is landed:

LMRP in water= 156,000 lbs
1 x riser pup (1x 5,400 x 0.87) = 4,698 lbs
Slip joint outer barrel in air = 45,000 lbs
--------------- +
String weight = 447,250 lbs
Overpull = 75,000 lbs
--------------- +
Total weight for the tensioners is 522,250 lbs
The rig has 16 tensioners installed, which means that for each tensioner we
have to set the riser tensioners to 522,250 : 16 = 32.64 kips each.
Next the rig starts drilling and is using 12.3 ppg mud how much should the
riser tension be adjusted?
We have to calculate the weight of the mud column from the RKB up to the
bottom of the LMRP. On our rig is the mud column of the inner barrel and
outer barrel is above the water level and the remaining mud column is
submersed in seawater.
The weight of column mud in a cylinder in air is calculated as:
Volume x specific gravity x height of column
The weight of the mud column of a cylinder submersed in sea water is:
Volume x (specific gravity mud- specific gravity sea water) x height of
column
When we have to do an emergency disconnect we the initial lift-off includes
the weight of the mud column. When there is more time for instance we are
already “waiting-on-weather” then normally the riser will be displaced with
seawater.
Calculation of the mud weight
The wall thickness of the risers is ¾ inch.
The OD of the riser joints is 22 inch.
The ID of the risers is therefore 22-(2x ¾) = 20.5”
The ID of the kill and choke lines is 3 inch.
The ID of the mud boost line is 4¼ inch.
415
Answers:
Mud above water will be inside the inner barrel/outer barrel and the diverter
Total length is 17 + 33 + 75 = 125 feet
ID inner barrel is also 20.5”
Weight mud above water is ¼ x ∏ x (ID)² x (ρ mud) x H x C
ID = ID riser in inches
ρ mud = specific gravity mud in ppg
H= height in feet
C= conversion ft into inches (x 12) and gallons into inch (: 231)
so C = 12 : 231 = 0.052
If we fill in our figures, we get: ¼ x ∏ x (20.5)² x (12.3) x 125 x 0.052 =

26,388 lbs
Next the mud weight in the kill and choke lines of the slipjoint
ID= ID choke and kill lines
H= height in feet
C= conversion ft into inches (x 12) and gallons into inch (: 231)
so C = 12 : 231 = 0.052
If we fill in our figures we get 2x ¼ x ∏ x (3)² x (12.3) x 75 x 0.052 = 678 lbs

Next the mud weight inside the mud booster line of the slipjoint
ID= mud booster line 4-1/4”
H= height in feet
C= conversion ft into inches (x 12) and gallons into inch
(: 231)
so C = 12 : 231 = 0.052
If we fill in our figures we get ¼ x ∏ x (4-1/4)² x (12.3) x 75 x 0.052 = 680 lbs

So, the weight of the mud above the water level is 26,338 + 678 + 680
=27,696 lbs (1)
The height of the mud column in marine risers is 82 x 75 + 10 = 6,160 ft
ID= ID riser in inches
ρ mud= specific gravity mud in ppg
ρ seawater = specific gravity seawater in ppg
H= height in feet
C= conversion ft into inches (x12) and gallons into inch (:231)
so C = 12 : 231 = 0.052
If we fill in our figures we get:
416
¼ x ∏ x (20.5)² x {12.3 – 8.6) x 6,160 x 0.052 = 391,186 lbs (2)

Each of the choke and kill lines are also filled with mud and creates a
considerable force as well in deep water.
The weight column inside the choke and kill lines submersed in seawater is
¼ x ∏ x (ID)² x (ρ mud- ρ sea water ) x H x c
ID = ID choke and kill line in inches (2 lines)
ρ mud = specific gravity mud in pp.
H= height in feet (riser joints + pup)
C= conversion ft into inches (x 12) / gallons into inch (: 231)
so C = 12 : 231 = 0.052
If we fill in the figures:

2 x ¼ x ∏ x (3)² x (12.3 – 8.6) x 6,160 x 0,052 = 16,755 lbs (3)
The rig is using a mud booster line with an ID of 4¼ inch.

The weight column inside the mud booster line submersed in sea water is:
¼ x ∏ x (ID)² x (ρ mud - ρ sea water ) x H x c
ID = ID mud booster line in inches
H= height in feet
C= conversion ft into inches (x 12) / gallons into inch (:231)
so C = 12 : 231 = 0.052
If we fill in the figures:

¼ x ∏ x (4.25)² x (12.3 – 8.6) x 6,160 x 0,052 = 16.813 lbs (4)
Inside the LMRP we have smaller ID:

¼ x ∏ x (ID)² x (ρ mud - ρ sea water ) x H x c
ID = ID LMRP in inches
ρ mud = specific gravity mud in p.p.g.
ρ seawater = specific gravity seawater in p.p.g.
H= height in ft
C= conversion ft into inches (x 12) / gallons into inch (: 231)
so C = 12 : 231 = 0.052
417
If we fill in our figures we get:

¼ x ∏ x (18.75)² x {12.3 – 8.6) x 24 x 0.052 =1,275 lbs (5)
Total mud weight: (1) + (2) + (3) + (4) + (5) =

27,696 + 391,186 + 16,755 + 16,813 + 1,275 = 453,725 lbs
That means we have to increase 453,745 : 16 = 28,35 kips for each

tensioner just for the mud weight . In deep water the mud weight creates a
considerable force!
Pulling the BOP weight calculations

If we pull the BOP we have already displaced the marine riser for seawater.
Weight of the string is:

LBOP stack in water = 348,000 lbs
LMRP in water = 156,000 lbs
1 x riser pup (1x 5,400 x 0.87) = 4,698 lbs
Slip joint Outer barrel in air = 45,000 lbs
Slip joint inner barrel in air = 10,690 lbs
Slick joint (landing joint) in air = 22,370 lbs
Riser running tool = 3,550 lbs
--------------- +
Total weight BOP = 831,860 lbs
Overpull = 75,000 lbs
--------------- +
906,860 lbs
In the compensator 75,000 lbs
--------------- -
For the tensioners 831,860 lbs
That means that eachtensioner needs to be set at 831,860: - 52 kips prior to

pulling the BOP.
418
Notes:
1. It is very good practice to record, prior to landing the BOP stack, the
landing weight by the driller so that you can confirm that your fuzzy
maths are within the parameters measured.
2. Some operators will use a higher overpull, which can vary from 50,000
lbs for shallow-water operations to approximately 100,000 lbs in
extreme deep-water operations. We do not recommend to go any higher
with the calculations; we just showed you if the rig is using riser
tensioner wires.
3. It was not very common to calculate the mud weight in choke and kill
lines and mud booster lines, as this force is never much in shallow
water. Our calculations showed that in deeper water these forces need
to be used as well to get a proper lift-off.
419
10 Exercises fuzzy maths
Problem 1: Rig Explosion 444

There are four 18-3/4” 15M Hydril ram preventers present:
Volume open : 16.7 US gallons
Volume close : 19.4 US gallons
Closing ratio : 1: 7.27
Opening ratio : 1: 2.15
There are two Hydril GX 10M annular preventers present:

Volume open : 58 US gallons
Volume close : 58 US gallons
Water depth : 4,200 ft

Mud weight : 15.1 ppg
Accumulators present:
There are 130 Shaffer 11-gallon surface accumulators pre-charged at 1,000
psi.
The accumulator bottles are installed in 4 equal sections.
The accumulator system is 3M.
On the stack are 24 Shaffer 11-gallon accumulators installed.
The storage tank of the mixing fluid measures 1,000 US gallons.
Temperature at the surface is 28 degrees Celsius.
Temperature subsea is 4 degrees Celsius.
Questions:
1. Calculate the volume required for this BOP for the accumulator test.
2. Calculate the total amount of fluid present in the surface and subsea
accumulator bottles.
3. Calculate the usable volume of the surface bottles.
4. Calculate the usable volume of the subsea bottles.
5. Is the accumulator capacity sufficient? If not, what can be done to solve
this?
6. Increase the pre-charge pressure to 1,200 psi for the surface bottles.
What is the new usable volume?
7. Is the volume of the mixture tank sufficient to satisfy API? If not,
calculate the minimum-required size for the mixture tank.
420
Problem 2: Rig MONG-24

The degasser has a mud seal of 12 feet.
The exhaust line is 12 inch ID.
The rig is using mud of 9.7 ppg at the beginning of the well and 16.8 ppg at
the end of the well.
The vent line in the derrick is 230 feet long.
Questions:
1. What can the mud seal hold at the beginning of the well?
2. What can the mud seal hold at the end of the well?
3. What should be the pressure rating of the poorboy degasser to handle
this heavy mud?
Problem 3: Rig Holy Diver III

The rig has a 15M Hydril ram BOP installed.
Closing ratio of the BOP is 1:7.27.
The water depth is 6,666 feet.
The rig is using mud of 9.7 ppg at the beginning of the well and 16.8 ppg at
the end of the well.
Question:
How much do we need to increase the closing pressure of the rams to
overcome the influences of the mud weight at the beginning and at the end
of the well?
Problem 4: Rig Tattoo King I

The rig is using 2-3/4” ID rigid conduit lines.
The hoses in the moonpool and on the LMRP are 3-inch ID.
The length of the moonpool hoses is 70 feet.
The length of the LMRP hoses is 22 feet.
The rig uses 82 marine risers of 75 feet.
There are four quintuplex pumps at the HPU that are rated to 26 US gallons
each.
We want to circulate the volume with 50% extra through both rigid conduit
lines.
Question:
How long do we have to circulate?
Problem 5: Rig Iron Maiden II

The rig has 46 kips on the tensioners.
The average cycle is 8 seconds
The wires need to be slipped and cut at 30,000,000 ton/cycles.
421
Question:
How many days can we operate under these conditions before we have slip
and cut?
Problem 6: Rig Jack The Lad III

Surface lines cement unit/choke manifold/moonpool: 185 feet
The moonpool flex hoses: 75 ft
The total riser string kill line: 4,444 ft
The LMRP flex hose: 22 ft
The kill line on the stack: 26 ft
The choke and kill lines and flex hoses have 3” ID.
ID kill and choke lines and flex hoses is 3”.
The distance between the test stump and the LPR: 4.6 ft
We are testing with a 6-5/8” test joint.
The distance of the test stump to the shear rams: 16.2 ft
The 9-5/8” casing has a wall thickness of 1/8 inch.
The length of the casing to the cement plug: 9,300 ft
We test the BOP to 250-psi low pressure and 7,500-psi high pressure.
The blind/shear rams are tested against the casing cement plug with
250/7,500 psi.
Questions:
1. How many barrels should we pump for the low-pressure test for the
LPR?
2. How many barrels should we pump for the high-pressure test for the
LPR?
3. How many barrels should we pump for the low-pressure test for the
BL/SHR?
4. How many barrels should we pump for the high-pressure test for the
BL/SHR
Problem 7: Rig Downhill 69

The following equipment is present:
Weight stack: 280,000 lbs (in water)
Weight LMRP: 225,000 lbs (in water)
Weight marine slick marine risers (in air): 18,000 lbs
Weight 40 ft riser pup in air: 14,000 lbs
Weight buoyancy risers in water: 500 lbs
422
The weight of the slip joint OB is 18,000 lbs in air.

The weight of the inner barrel is 8,000 lbs in air.
The length of the slip joint IB is 66 ft.
The length of the slipjoint OB is 75 ft
The length of the risers is 70 ft.
The ID of the slip joint inner barrel is 19-3/4" inch.
The weight of the tension ring is 14,000 lbs.
The weight of the diverter is 13,500 lbs.
The risers have an OD of 21 inch and have a wall thickness of 5/8-inch.

The ID of the kill and choke line is 3 inch.
The ID of the mud boost line is 4¼ inch.
Distance from RKB to the Datum WH connector is 5,326 ft.
The mud weight is 12.8 ppg.
The distance from RKB to the bottom of the diverter is 18 ft.
The height of the complete BOP is 48 ft. (from datum to top)
The height of the LMRP is 22 ft.
The rig uses four slick risers and the rest are buoyancy risers.
The buoyancy factor of the slick risers is 0.87.
The slip joint outer barrel is located above the waterline.
There are 12 riser tensioners installed; each set is using two APV bottles of
274 US gallons each.
Questions:
1. What would be the fixed figure we can subtract from the RKB Datum
height?
2. Calculate the amount of marine risers required for this well.
3. Calculate the tension required for each tensioner to land the BOP when
leaving 50,000 lbs landing weight and using 75,000 lbs for the DSC. A
standard slick joint is used to land the BOP.
4. Calculate the tension required for each tensioner after landing and
latching the BOP using a 75,000-lbs overpull with seawater.
5. Calculate the riser tension for each tensioner required when the rig
starts using this mud, and maintaining the 75,000-lbs overpull.
6. Calculate the riser tension for each tensioner with this drilling mud when
no buoyancy modules are used.
7. Calculate the riser tension required to pull the complete BOP using an
overpull of 75,000 lbs and a standard slick riser landing joint.
423
11 Table of figures
Figure 1 - Surface accumulators in three stages................................... 398
Figure 2 - Subsea accumulators in three stages. .................................. 400
Figure 3 - Poorboy degasser. ............................................................ 403
Figure 4 - Space-out sheet for running riser. ....................................... 412
424
Module 02 - 08 Marine riser systems 1.0
Chapter 08
Marine riser systems
1 Vetco marine risers................................................................ 426

2 Table of figures ..................................................................... 460
425
1 Vetco marine risers
In Module No. 1 we discussed the marine drilling riser, mainly the Cameron
riser. In Module No. 2 we will discuss the Vetco marine drilling riser in detail.
Figure 1 - General subsea systems by Vetco Gray.
426
The marine drilling riser provides a tubular conduit from the rig to the
subsea BOP and the wellbore below it. The marine riser system performs the
following functions:
1. Guides down-hole tools and equipment from the surface the wellbore.
2. Provides a flow path for drilling fluids to be returned to the rig.
3. Supports the BOP stack during running and retrieval of the stack.
The drilling riser is composed of a series of specially designed joints, which
are connected together with couplings. Choke and kill lines, mud booster,
hydraulic rigid conduit(s) and glycol injection lines are run integrally down
outside of the riser tube. This configuration represents the most complex of
auxiliary line arrangement. The most fundamental auxiliary line
configuration is simply one choke and one kill line.
The choke and kill lines have the same pressure rating as the ram BOPs, the
mud booster line is normally 5m or 7.5 M and the rigid BOP fluid line is 3M
or 5M rated. Marine drilling risers joint principal tubes are made from
seamless X52, X65 or X80 line pipe material and normally come in 50, 75 or
even 90 feet lengths.
Deep-water marine risers are made of FG 47T or RFG 57T material. Each
drilling riser joint will have a connector box and pin end welded on each end.
A set of pup joints is supplied with the riser string so that the riser can be
spaced out for any water depth. Pup joints of 5-foot, 10-foot, 20-foot, 25-
foot and 40-foot lengths are normally supplied.
Note: As of 2006, ABB departed Vetco Gray. The vendor is now known as
Vetco Gray.
427
Figure 2 - Vetco MR-4 riser joints with the pin/box connections

visible.
Support flanges and guide gussets are incorporated into each riser joint to
facilitate handling of the heavy riser joints and to provide longitudinal
strength. The flanges give support to the riser as it is run, provide recess for
the choke and kill lines and have detector plates to prevent hanging the
risers as it passes through the diverter housing. The choke and kill and all
other auxiliary lines are clamped to the body of the riser joints using
auxiliary line support clamps.
Usually three clamps are used on a 50-foot length. This eliminates the
welding of support brackets to the riser body. This feature avoids any
possibility of stress concentrations in the riser body that short surface welds
might produce. Riser joints that received illegal welding must be sent
back to the Vetco shop for NDT testing and must never be used.
A mud boost line is commonly installed on riser joints intended for
deepwater applications. The mud booster lines are installed to increase the
velocity of the mud returns in the large diameter riser systems when drilling
inside smaller diameter casing strings in deep water.
428
Deepwater rigs are using a MUX BOP control system and some conventional
deep water conventional hydraulic systems are using a single or double
configuration of rigid conduit lines to transport the BOP control system
hydraulic volume subsea to the BOP stack.
Gussets fabricated as a part of the support flange help to guide the riser
joint through the diverter housing after each connection is made. Riser
diameters are based on the size of the BOP on which they are run. The most
common sizes are 21 inch (OD) for 18¾ inch BOPs and 18-5/8 inch (OD) for
16¾ inch BOPs.
Riser system design and selection is based on a complex analysis of the
loads which the riser endures during use. This is based on the combined
tension and bending loads produced by the length of the riser string. Other
loads which should be considered are loads induced by the differential
pressure between the sea water outside the riser and the drilling fluids
inside the riser, loads induced by the kill and choke lines especially when
pressurized, loads induced by the buoyancy modules and loads induced
during handling. The riser coupling design capacities must be within the
stress levels induced by all the indicated loads.
API Recommended Practice 2R: “Recommended Practice for Design, Rating &
Testing of Marine Drilling Riser Couplings.” 1984, establishes the riser
coupling classes based on the tensile capacity of the coupling:
API Riser Coupling Class Tensile Capacity (106 lbs)

Class A 0.5
Class B 1.0
Class C 1.25
Class D 1.5
Class E 2
Class F 2.5
Figure 3 - Table, API Riser Coupling Rating.
Other American Petroleum Institute publications are applicable to evolving

marine drilling riser systems and are listed here:
• API RP 16Q Recommended Practice for the Design, Selection, Operation
and Maintenance of Marine Drilling Riser Systems. 1993
• API Spec. 16R Specification for Marine Drilling Riser Couplings. 1997
• API Spec. 16F Specification for Marine Drilling Riser Equipment. 2004
Drilling Riser Connectors

Vetco Gray has produced four types of drilling riser connector:
1. One using a split circumferential lock ring.
2. Various connector designs are using dogs for the locking mechanism.
3. A flange-style deep-water riser connector.
4. A boltless connector whose tooling is hydraulic and requires no hands-on
intervention.
429
The first drilling riser connector manufactured by ABB Vetco Gray was the BT
connector, which was modified to become the BTM and then the BTL. The
BTL box section has a series of bosses welded to the body which house
actuating screws. After the box section is stabbed over the tapered pin
section, the actuating screws are tightened to force the split lock ring into
the mating groove of the pin. This internal boss and actuating screw make
up method is still in use today with some of the newer connector designs.
The tensile load capacity of the BTL connector is rated at 750,000 pounds.
The need for a more durable connector has led to the development of the
MR-4 connector followed by the MR-4B, MR-6B, MR-6C and MR-6D. The
progression reflects the continuing need to increase the connector tensile
capacity for deeper water and longer drilling marine riser strings.
Other marine risers supplied by ABB Vetco Gray in the past include the FC
and the FD style couplings, the most recent of which were designated FC-8
and FD-8. These were also locking dog style couplings for shallow and
intermediate water depths.
Springs
Locking
Screw with hexagonal head
Figure 4 - Bolt-on-boss assembly.
MR-Type Riser Connector

The ‘MR’ type riser connector is characterized by a box and pin arrangement
which mate to make the connection. The box member has bolt on bosses
which contain hexagonal headed actuating screws. At the inner side of the
connector, dogs are attached to the actuating screws.
A double groove profile on the pin member provides the mating profile for
the dogs to mate with and lock the connector together when the actuating
screws are tightened, driving the dogs inward.
The mating grooves on the pin have a ten (10°) degree taper which forces
the connection together as they are made up, creating a pre loaded
connection with the load distributed evenly over the riser pin. An ‘O’ ring
430
seal carried in the connector box is the primary pressure seal. An additional
‘O’ ring on the pin below the mating profile keeps the trash and helps in
minimizing corrosion of the connectors moving parts.
The actuating screws on the MR series of connector require approximately
1,000 ft-lbs of torque to achieve the proper pre load. A set of air impact
wrenches of known output must be used to make up the connection. After
every air wrench connection the screws are to be checked using a calibrated
torque wrench.
The correct oilfield practice is to adjust the regulated air to the impact
wrenches to a make up torque value just below the torque wrench level to
ensure that the screws are made up not too tight.
The actuating screws should be kept lightly greased with a non-metallic
grease compound (not pipe dope: beware of the MONGS!) for the maximum
operational life of the connector.
Figure 5 - Bolt-on-boss locking dog.
The drilling riser column is subjected to a great deal of vibration, which could
potentially loosen the actuating screws on the connector. A spring-loaded
lock ring which captures the hexagonal head of the actuating screw as the
wrench is removed locks the actuating screw in the fully engaged position.
The support plates and bosses mounts on the ‘MR’ type connectors are an
integral part of the forging. The only welding required is transition weld
between the neck of the pin and box connectors and the principal tube. The
support plates have holes specially designed for easy handling using
shackles and slings. The choke and kill stabs mate easily and utilize dual
elastomeric Polypak seals. The seal for high-temperature applications are of
a different hardness.
431
The ‘MR’ type connector has been manufactured with either four or six
locking dogs. This includes the MR-4B, MR-4C, MR-6C, MR-6D and MR-6E. In
the designation the MR stands for ‘Marine Riser’, the number stands for the
amount of locking dogs and the B, C, D, or E stands for the API riser
coupling class (see table Figure 3).
The ‘MR’ type riser design has been developed for the use of Class ‘E’ riser
coupling. Class ‘D’ riser joints are typically good for water depths to 6,000
feet. Class ‘E’ risers are rated for up to for 8,000 feet.
Figure 6 - Choke and kill line clamp.
432
Figure 7 - Strengthening gusset plates on pin/box connectors.
Figure 8 - Choke and kill male pin assembly.
433
Figure 9 - Features of the MR-6E coupling.
Type HMF Marine Drilling Riser Connector

The need for a marine riser connector to be used for drilling applications in
water depths exceeding 6,000 feet has led to the development of the Vetco
Gray HMF connector. This high strength flanged marine connector, designed
with the aid of CADCAM and finite element analysis, is especially suited for
deep water drilling where high tensile and bending loads are encountered.
The connector has high pre load and fatigue strength, yet is designed for
easy field maintenance. Significant features of the HMF connector are:
a) Flange sections are compact and light weight in comparison to other
flange connectors. There are no threads in the connector body.
b) Tapered nose pin containing resilient seals allows for easy and uniform
connector stabbing and make up, even under conditions of severe vessel
motion.
c) Nose pin insert locks positively into the connector with set screws. If
damaged during drilling or production operations, pin inserts are easily
434
removed and replaced in the field. All other components are also
replaceable for simplified maintenance.
d) High pre loads provides for longer service life and increased fatigue
strength and ensures that no separation of the flanges take place under
maximum loading conditions.
e) The same type of integral choke and kill lines stabs that are already in
use on Vetco Gray marine riser systems.
f) Polypak tip type seals assure pressure integrity. An optional high
pressure metal-to metal-seal is also available.
g) Locking bolt assemblies are self contained with no loose parts. The bolts
are easily removed for (NDT) inspection. There are six or eight bolts on
a HMF connector depending on the riser diameter and customer
preference. The bolts require approximately 10,000 ft.lbs of torque to
achieve the pre load condition. Specially designed hydraulic tooling
wrenches are available for these connectors.
h) The HMF riser joints, designed as a deep water riser system, will
commonly be outfitted with syntactic foam buoyancy modules or air
cans. HMF riser joints are specifically designed for buoyancy module
installation.
i) The female choke and kill boxes are free to ‘float’, reducing stress in the
connector and the choke and kill lines when the riser is subject to
flexure.
Figure 10 - HMF riser pin and box sections.
435
Figure 11 - Cross-section of Vetco HMF pin/box connection.
436
Figure 12 - Vetco HMF riser coupling (advertised features).
437
Figure 13 - Vetco HMF riser joint with buoyancy (box end).
Figure 14 - Vetco HMF riser joint with buoyancy (pin end).
438
Figure 15 - HMF Box down, stabbed, bolts inserted and ready for
make-up.
Figure 16 - Making up the HMF riser using a Francis® hydraulic tool.
439
Riser-Handling Tools
Running the drilling riser system requires at least two marine riser-handling
tools and a marine handling spider and gimbal set, which is installed on the
rig floor above the rotary table. Riser-handling tools can either be manual or
hydraulically operated. The riser-handling tools have drill pipe stems with
the tool joint located at their upper ends.
The configuration of the lower end of the stem depends on whether the rig
runs riser pin down or box down. If the riser is run box down then the riser-
handling tools will be fitted with a box connector down to mate with the pin
up on successive joints being run.
If the riser is run pin down (the more common method), then the handling
tool will be fitted with a pin to mate with the box up on successive joints
being run. Two handling tools are normally used so that one can be used to
lower the riser joint through the rotary table, while the other is installed on
the next joint. This is dependent on the topsides design of the riser-handling
storage and handling system. Often is a third handling tool connected to the
slip joint.
Figure 17 - Vetco HMF manual riser running tools with box down.
440
Figure 18 - Vetco HMF hydraulic riser running tool with pin down.
441
The Riser-Handling Spider

The marine riser-handling spider can be a split, gimbaled, hinged or be
hydraulically operated unit. The spider is used to support the marine riser
and the BOP stack as the riser joints are lowered and landed on the rotary
table similar to a set of rotary slips. The marine riser support flange on the
riser connector pin or box rests on the dogs of the handling spider. It is
important to note that the correct size spider dog is to be used for the size
of the riser being run.
The dog segments must be extend in close to the connector body when
supporting a joint from the rotary table, otherwise, the weight on the riser
will be transferred to a flange alone rather than the pin connector body. A
shock absorbing gimbaled spider is popular device used to minimize the
peak stress on the support flanges. These units are particularly effective
when long riser strings are run.
Figure 19 - Vetco heavy-duty riser gimbal, designed for a 3,000-

metre water depth.
A single riser system requires adjustable spider dogs. One setting is for the
individual riser joint and the other is for large diameter of the outer barrel of
the slip joint. The handling spider used with a 37½-inch rotary table has
hinged end pieces for each dog, with provision for two adjustments. The
spider used with a 49½-inch rotary table has sliding dog segments
adjustable for five different positions. When running the BOP stack, periodic
pressure testing of the choke and kill lines is advisable to ascertain the
integrity of the stab sub seals.
442
Depending on the water depth, the frequency at which joints are tested is
dictated by the company man. On a deepwater rig this may be every 10
joints. The risk here is that the greater number of joints represents a greater
penalty of rig lost time if a leak is detected during a test.
If, for example, joints are tested every 5 joints then the rig time to recover a
maximum of 5 joints to find the leak source is a lot shorter than if the test
programme only called for a line pressure test every 10 joints. This is
‘swings and roundabouts’ in the quantifiable risk associated with the
frequency of auxiliary line testing when running riser.
Separate test caps or test caps integral into the riser-handling subs are used
to test the kill and choke lines. The kill and choke lines are normally tested
as a pair. Some riser-handling tools have the capability of testing all the
auxiliary lines together.
Figure 20 - Vetco HMF riser-handling tool with test caps.
443
Figure 21 - Manually operated riser spider for shallow water depths.
Figure 22 - Manually operated riser spider for deep-water

applications.
444
Figure 23 - Hydraulically operated riser spider for deep-water

applications.
Figure 24 - Vetco HMF riser spider deck for 3,000-metre riser

system.
445
Figure 25 - Stabbing riser joint with pin down to box of supported

riser joint.
Figure 26 - Spider/gimbal combination in use.
446
Telescoping Joints or Slip Joints

The telescopic joint or slip joint is the top joint in the drilling riser system. It
compensates for the effect of heave and tidal motion on the drilling vessel, it
also provides a means of connecting the diverter to the marine drilling riser
system.
The outer barrel supports the terminal fittings for the choke and kill lines
and other possible auxiliary lines. The outer barrel also provides the
attachment for the riser tensioner system.
Vetco Gray's Telescopic Joints have stroke capacity of 55 or 75 feet and a
tensile load capacity of greater than 1,000,000 pounds in the locked
position. Taking tidal conditions into consideration, the riser joints are
spaced such that the slip joint is at MIDSTROKE once the BOP is landed.
The telescopic joint is comprised of an inner barrel and an outer barrel. The
inner barrel is attached to the diverter, which in turn is installed in the
diverter housing which is an integral part of the rig floor sub structure. The
outer barrel is attached to the upper most joint in the riser string. Figure 29,
shown overleaf, shows a generic riser string, with all its components for a
deepwater application.
The telescoping joint packing elements, located in a packing box, provides
the annular seal between the inner and the outer barrel. The elements are of
a dual design. The outer element is either pneumatically (upper packer) or
hydraulically (lower packer) energised to contact with the inner element. The
inner packer element rubber extrudes around the slip joint inner barrel to
effect a seal.
Telescopic joints with two packing elements often have a split designed
rubber element in the top packer. Being of the split design, the element, if
worn or damaged, can be replaced without moving the upper end
connection from the inner barrel.
This can be done in the moonpool but this is a difficult and sometimes rather
dangerous practice and very seldom allowed in the North Sea region.
The operating pressure of the slip joints packers is low, approximately 15 ~
25 psi above the riser annulus pressure.
In operation it is suggested that just enough pressure is applied so there is a
light weeping between the packing and the inner barrel. This is depending
whether oil based or water based mud is used, no oil based mud is allowed
to pollute the marine environment. The small amount of leakage has a
lubricating effect and avoids excessive wear to the packing element. In most
cases, a constant flow of seawater is directed at the inner barrel just above
the packing box and provides better lubricity.
The lower elements are normally solid elements and are hydraulically
controlled. These elements are intended for use when higher than
expected pressure occurs in the marine riser. Therefore, is it not a wise
decision to configure both the upper and the lower packers for air operation.
By adopting such a configuration, we can say that we are effectively
downgrading the diverter system.
447
The lower solid packer assembly acts as a back up seal when the upper seal
malfunctions or wears out. The operating pressure of the lower solid packer,
which is hydraulically operated, is rated through a pressure range of 15 ~
300 psi depending on the marine riser internal pressure. A relief valve
should be installed to prevent too high pressures on the secondary slip joint
packer; too high pressure might damage the inner barrel (in excess of
design hoop stress limits).
The following images were recorded during a change-out of packers in a dual
packing box of a Vetco HMF telescopic slip joint.
Figure 27 - TJ packers change-out (photograph set part 1).
448
Figure 28 - TJ packers change-out (photograph set part 2).
The upper end of the inner barrel is threaded (left-hand threads!), so that
the marine riser connector pin or cross over adapter can be removed for
replacement of the solid elements. Be aware of the small lock screw locking
these threads!
449
The diagram shows the fundamental components of the telescopic slip joint.
The unit is shown ‘locked’, that is the inner barrel is fully engaged in the
outer barrel and mechanically locked.
The telescopic slip joint is the heaviest component in any riser string and its
integral strength in the locked position is critical since the entire suspended
weight of any riser string and BOP stack bears on this joint prior to landing
the BOP stack on the subsea wellhead.
Figure 29 - Vetco MR 4 telescopic slip joint.
The crossover adapters are normally secured with Allen-headed cap screws,
which prevent the adapter from coming loose in operation. These lock pins
are to be removed before the adapter can be removed.
The telescopic joint can be locked in the closed position by inserting pins or
engaging bolts.
These are special high-tensile pins or bolts that should NEVER be
substituted.
450
Figure 30 - Inner outer barrel mechanical lock system.
There have been a number of catastrophic accidents in the past caused by

badly corroded bolts and/or the thread forms in the threaded holes.
It is critical that these bolts and threaded holes are maintained in an as-new
condition since the entire weight of the riser string and BOP stack is
dependent on the integrity of these fasteners.
Modern slip joints feature hydraulically operated locking mechanisms to
secure the inner and outer barrel when the telescopic slip joint is in its
locked position.
The BOP is always landed and pulled with the slip joint into the locked
position.
451
Figure 31 - 105-foot Vetco HMF telescopic slip joint rated for a

3,000-metre water depth system.
452
Riser Tensioner Support Rings

The riser tensioning cables are connected to a riser tensioner support ring,
which is attached to the outer barrel of the slip joint. The support rings come
in many different configurations depending on customer requirements. The
support ring, with integral pad-eyes for attachment of the riser tensioner
cables, can be a permanently fixed solid ring or a removable hinged rotating
ring.
The advantage of this type of support system is the initial investment,
however, since these are normally pre attached to the outer barrel of the
telescopic joint, the individual tensioner cables must be attached to the pad
eyes while the unit is suspended in the moon pool. This can be difficult and
time-consuming task. An alternative is the use of a solid circumferential
support ring that has all the tensioner cables pre attached. This unit, called
the SDL support ring is stored underneath the diverter housing when not in
use.
After unlatching the SDL ring from the diverter housing, it is carried down
with the telescopic joint as it is lowered. The riser tensioners are normally
pressured so they can support almost the complete riser string thereby
offsetting the dynamic loading on the heave compensator which must be
open for landing the BOP stack on the subsea wellhead. This type of riser
support is much safer and less time consuming to install.
After the proper amount of tension has been applied to the riser string, the
choke and kill lines, plus possible auxiliary line terminations on the outer
barrel are attached to the drill floor manifold piping with high pressure
flexible lines (drape hoses) and terminal fittings. To increase personnel
safety and savings in rig time, a combination riser support ring and terminal
fitting assembly is available.
This assembly is known as the KT style support ting. The choke and kill
lines, plus possible auxiliary lines terminate into a mandrel carried on the
telescopic joint outer barrel. The KT support ring, like the SDL support ring
has all the tensioner cables pre attached. However, unlike the SDL ring, the
choke and kill lines, plus possible auxiliary lines are also pre attached. Once
the KT ring is mated with the telescopic joint outer barrel, sleeves are
hydraulically extended into pockets on the mandrel to seal the terminal
fitting drape hose interface.
On most MODUs, the terminal fittings with the drape hoses will now be
swung out from their stored position and made up to the male stab
terminations on the outer barrel of the telescopic joint. To contain them
while under pressure, the two terminal fittings for the choke and kill lines
are trapped under a thrust plate on the outer barrel.
The choke and kill and possible auxiliary stab subs on the terminal fitting are
identical to those on the integral marine riser joints, therefore they provide a
cross over connection from the choke and kill lines plus the possible auxiliary
lines extending from the choke and kill manifold on the drilling vessel's drill
floor. An automatic pull in attachment of the terminal fittings is an option
available on all slip joints.
The BOP, flex joint and the riser string are then lowered and soft landed
onto the high pressure wellhead housing using the combination of the
tensioners and the motion compensator. The last operation after landing is
to hook up the flow diverter.
453
Figure 32 - Features of the KT tensioner ring (1).
454
Figure 33 - Features of the KT tensioner ring (2).
455
Figure 34 - Features of the standard SDL tensioner ring.
456
Figure 35 - Key features the SLD tensioner ring with fluid bearing.
The optional fluid bearing has now been even further refined to include drive
motors which serve to assist the break-out torque required when a DP rig
changes its heading. This will be discussed in greater detail in later modules.
457
Figure 36 - Modern support ring in housed position on diverter

housing.
Figure 37 - Fluid-bearing tensioner ring with drive capability.
458
Questions Marine Riser Systems

1. Explain why buoyancy modules are used and why are there different
modules for different water depths.
2. What is the working pressure of the marine riser choke and kill lines?
3. What is the disadvantage of buoyancy modules? What is done to
overcome this problem?
4. What are the results of a too-low riser tension on the marine riser and
what are the results if the riser tension is too high?
5. Explain why a DP vessel cannot turn around the tension ring 360
degrees.
6. Why are the marine risers NDT-inspected and what intervals are used?
Indicate where the inspection should be performed on the schematic
drawing on page 10?
7. How much is the buoyancy factor of slick risers in seawater?
8. How do we know for sure that the risers are torqued up to the right
torque?
9. Where do we connect the slings on the Vetco risers?
10. Explain the difference between Class-C and Class-F marine risers.
11. Why do we have to use OEM equipment for the riser dogs?
12. What is the angle of the matching groove of the pin? Why is this
present?
13. Why do we have to break the dogs again after retrieving the risers prior
to storing them?
14. At what water depth are HMF risers rated?
15. What is the minimum torque of HMF studs?
16. How can you check that Vetco MR-6 risers are lowered all the way prior
to tightening the dogs?
17. Why do we use brackets on the top and on the bottom of the floatation
modules?
18. What are the advantages of the SDL tensioner support ring features?
459
2 Table of figures
Figure 1 - General subsea systems by Vetco Gray. ............................... 426
Figure 2 - Vetco MR-4 riser joints with the pin/box connections visible. ... 428
Figure 3 - Table, API Riser Coupling Rating. ........................................ 429
Figure 4 - Bolt-on-boss assembly. ..................................................... 430
Figure 5 - Bolt-on-boss locking dog.................................................... 431
Figure 6 - Choke and kill line clamp. .................................................. 432
Figure 7 - Strengthening gusset plates on pin/box connectors................ 433
Figure 8 - Choke and kill male pin assembly........................................ 433
Figure 9 - Features of the MR-6E coupling........................................... 434
Figure 10 - HMF riser pin and box sections. ......................................... 435
Figure 11 - Cross-section of Vetco HMF pin/box connection. .................. 436
Figure 12 - Vetco HMF riser coupling (advertised features). ................... 437
Figure 13 - Vetco HMF riser joint with buoyancy (box end). ................... 438
Figure 14 - Vetco HMF riser joint with buoyancy (pin end)..................... 438
Figure 15 - HMF Box down, stabbed, bolts inserted and ready for
make-up........................................................................ 439
Figure 16 - Making up the HMF riser using a Francis® hydraulic tool....... 439
Figure 17 - Vetco HMF manual riser running tools with box down. .......... 440
Figure 18 - Vetco HMF hydraulic riser running tool with pin down. .......... 441
Figure 19 - Vetco heavy-duty riser gimbal, designed for a 3,000-metre
water depth. .................................................................. 442
Figure 20 - Vetco HMF riser-handling tool with test caps. ...................... 443
Figure 21 - Manually operated riser spider for shallow water depths. ...... 444
Figure 22 - Manually operated riser spider for deep-water applications.... 444
Figure 23 - Hydraulically operated riser spider for deep-water
applications.................................................................... 445
Figure 24 - Vetco HMF riser spider deck for 3,000-metre riser system..... 445
Figure 25 - Stabbing riser joint with pin down to box of supported riser
joint.............................................................................. 446
Figure 26 - Spider/gimbal combination in use. ..................................... 446
Figure 27 - TJ packers change-out (photograph set part 1). .................. 448
Figure 28 - TJ packers change-out (photograph set part 2). .................. 449
Figure 29 - Vetco MR 4 telescopic slip joint. ........................................ 450
Figure 30 - Inner outer barrel mechanical lock system. ......................... 451
Figure 31 - 105-foot Vetco HMF telescopic slip joint rated for a 3,000-
metre water depth system. .............................................. 452
Figure 32 - Features of the KT tensioner ring (1). ................................ 454
Figure 33 - Features of the KT tensioner ring (2). ................................ 455
Figure 34 - Features of the standard SDL tensioner ring........................ 456
Figure 35 - Key features the SLD tensioner ring with fluid bearing. ......... 457
Figure 36 - Modern support ring in housed position on diverter
housing. ........................................................................ 458
Figure 37 - Fluid-bearing tensioner ring with drive capability. ................ 458
460

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Subsea Engineer Training Programme

Author: Jaap Peetsold

AUSTRALIA | CANADA | THE NETHERLANDS | SINGAPORE | USA | UNITED KINGDOM

ModuSpec accepts no responsibility for use or misuse of information contained herein.

Module 2 - Table of contents

1 Ram preventers ................................................................. 7

40 Shaffer ram blocks and fixed pipe rams ................................ 123

2 Annular preventers......................................................... 163

3 Gate valves on the BOPs ................................................. 199

4 Hydraulic connectors ...................................................... 241

5 Manifolds, chokes and valves ..........................................285

6 Hydraulic control systems ...............................................309

8 Marine riser systems .......................................................425

Day Time Activity

Monday 08.30 Introduction

Tuesday 08.30 Ram preventers Level 2

Wednesday 08.30 Gate valves on the BOPs level 2

Thursday 08.30 Hydraulic control systems level 2

Friday 08.30 Marine riser systems level 2

1. Repetition module 1................................................................... 9

28. Cavity clearances Hydril BOPs....................................................75

Figure 1 - Cameron TL BOP with ST-Locks installed.

2. Cameron type-U BOPs

Figure 2 - Cameron U-II with open bonnets.

3. Cameron type-U ram preventer

Figure 3 - Cameron type-U preventer with manual locks (which are

Specifics of the Cameron type-U ram BOPs

Cameron type U specifications

Size Working Fluid open Fluid close Closing Opening

4. Cameron type U-II ram preventer

Figure 4 - The Cameron type U-II ram preventer.

Specifics of the Cameron type U-II ram BOP

Cameron type U-II specifications

Size Working Fluid Open Fluid close Closing Opening

5. Cameron type-T and type-TL ram

Figure 5 - Cameron type T ram preventer with ST-Locks installed.

Specifics of the Cameron type-T ram BOPs

Cameron Type-T specifications

Figure 6 - 18-3/4 inch 15M Cameron TL-type ram BOP with

Specifics Cameron type-TL ram BOPs

6. 18¾ inch Cameron TL-type ram BOP

BOP size/ WP Closing volume Opening volume Opening

18¾”/10,000 21.3 19.3 10.89: 1 3.13: 1

Cameron TL BOPs with Wedgelocks

BOP size/ WP Closing volume Opening volume Closing Opening

18¾”/15,000 24.6 23.4 6.7: 1 3.1: 1

Cameron TL BOPs with ST-Locks

Closing volume Opening volume Closing Opening

8¾”/10,000 24.6 23.4 6.7: 1 3.1: 1

Note: ST-Lock locking 3.4 US gallons.

BOP size/ WP Closing volume Opening volume Closing Opening

18¾”/15,000 45.4 54.1 14.3: 1 6.9: 1

Note: ST-Lock locking US 3.4 gallons.

BOP size/ WP Closing volume Opening volume Closing Opening

Figure 7 - Cameron TL blind-shear rams with wear plates suitable

7. Cameron types U and U-II ram BOPs

Figure 8 - Cameron U-II hydraulic control system.

8. Cameron Wedgelock operation

Closing the wedgelocks

Opening the wedgelocks

Figure 9 - Severely damaged tail-rod by the wedgelock caused by

9. Balance chambers for Cameron U-II

(Source: Cameron Equipment Bulletins Nos. 533D and 575D)