BOP CONTROL UNIT

TOPIC 1

CONTROL UNIT
ACCUMULATOR BOTTLES & CALCULATIONS.
PURPOSE OF ACCUMULATOR BOTTLES :-

1. To reduce the closing time of BOP functions

2. To enable the BOP’s to be closed in event of

power failure
 CONTROL UNIT
BOP control unit is to provide pressurised hydraulic fluid
that will promptly operate the blowout preventers
BOP control unit consists of
• Accumulator bottles for storing pressurized fluid.
• Hydraulic control fluid and its reservoir tank
• Charging system to pump hydraulic fluid into
accumulator bottles.
• Pressure regulating valves and an operating
manifold to operate the BOPs , choke and kill valves.
• Remote control panels for operating BOPs , choke
and kill valves from remote locations.
 SURFACE BOP CONTROL UNIT
Accumulator Guages
Bottles
Annular Regulator
Hi/Lo Bypass valve

4 way Valves

Manifold
Regulator

Electric
Starter

Hydro-Electric Electric Pump Pneumatic (Air) Hydro-Pneumatic

Pressure switch Pump Pressure switch
SURFACE BOP REMOTE PANEL
ACCUMULATOR BOTTLE WITH CHARGING & GAUGIING ASSEMBLY

Gas fluid
separation
Bladder

Shock
Dampner

Puppet Spring
Safety
Relief Port
Flow Port Assembly
USABLE FLUID:
Usable fluid is defined as the fluid that can be recovered
from Accumulator bottles between
Accumulator operating pressure (3000 psi)
&
Maximum of following three conditions:
1. 1200 psi
2. Precharge pressure + 200 psi
3. Operating pr. Based on C/R of BOP.
 1. 2. 3.

N2 N2
P1 P2-3000psi,
V2 N2
1000 +
100 psi
------------ P3-
------------ 1200 psi,
------------
V1 -V2 V3
10 gal fluid-------
------------
------------
------------ --V3
------------ fluid---------
---- -------
P2 = 3000 psi,
FLUID V3 fluid = ( 10 – V3 ) gal
V2 = P1*V1/P2
V2 fluid = ( 10 – V2 ) gal
Eg.1.
Operating Pr. To Close BOP < 1200 psi
P1 = 1000 psi
V1 = 10 gal
P2 = 3000 psi
V2 = P1V1 / P2
= 1000 x 10 / 3000
= 3.33 gal
P3 =?
= 1200 psi
V3 = P1V1 / P3
= 1000 x 10 / 1200
= 8.33 gal
USABLE FLUID = V3 – V2
= 8.33 – 3.33 = 5 gal
Eg.2.
Operating Pr. To Close BOP < 1200 psi
P1 = 900 psi
V1 = 10 gal
P2 = 3000 psi
V2 = P1V1 / P2
= 900 x 10 / 3000
= 3 gal
P3 =?
= 1200 psi
V3 = P1V1 / P3
= 900 x 10 / 1200
= 7.5 gal
USABLE FLUID = V3 – V2
= 7.5 – 3 = 4.5 gal
Eg.3.
Operating Pr. To Close BOP < 1200 psi
P1 = 1100 psi
V1 = 10 gal
P2 = 3000 psi
V2 = P1V1 / P2
= 1100 x 10 / 3000
= 3.67 gal
P3 =?
= 1300 psi
V3 = P1V1 / P3
= 1100 x 10 / 1300
= 8.47 gal
USABLE FLUID = V3 – V2
= 8.47 – 3.67 = 4.8 gal
Eg.4.
15M Cameron BOP , C/R of 10:1
P1 = 1000 psi
V1 = 10 gal
P2 = 3000 psi
V2 = P1V1 / P2
= 1000 x 10 / 3000

= 3.33 gal
P3 =?
= 1500 psi ( Operating Pr. To close BOP = 15000 / 10 =1500 psi )
V3 = P1V1 / P3
= 1000 x 10 / 1500

= 6.66 gal
USABLE FLUID = V3 – V2

= 6.66 – 3.33 = 3.33 gal

USABLE FLUID UNDER STANDARD CONDITIONS :
If
P1 = 1000 psi
V1 = 10 gal
P2 = 3000 psi

Then ,
USABLE FLUID = V3 – V2

= 10000 - 3.33 gal / bottle

P3
SIZING OF CONTROL UNIT ( for surface Stack )

Fluid vol. required to close all BOPs

Total Fluid = +
Fluid vol. required to open all HCRs

+ 50 % Safety Margin

No. of Bottles = Total Fluid

Usable fluid per bottle
SIZING OF CONTROL UNIT ( for Subsea Stack )

Total Fluid = Fluid vol. required to close and open

all BOPs
+
Fluid vol. required to Close & open all
failsafe valves
+ 50 % Safety Margin

No. of Bottles = Total Fluid

Usable fluid per bottle
Q. Given the volumes below how much hydraulic fluid
required to carry out operation with no safety margin?
One Annular BOP to close 18 gal
Three Ram BOPs to close 5.8 gal each
One HCR to open 1 gal

Calculation:
Vol. required to Close BOPs & Open HCR
= 18 + ( 3 * 5.8 ) + 1
= 36.4 gal
Q. P1 = 1000 psi, V1 = 10 gal, P2 = 3000 psi,
Minimum Operating pr. – 1200 psi.
One Annular BOP to close 18 gal
Three Ram BOPs to close 5.8 gal each
One HCR to open 1 gal
Calculate the no. of bottles required as per API RP53 :

Calculation:
Vol. required to Close BOPs & Open HCR
= 18 + ( 3 * 5.8 ) + 1
= 36.4 gal

Total Vol. required = 36.4 + 50 % Safety = 54.6 gal

No. of Bottles = 54.6 = 54.6 =

11 Fluid per bottle
5
Q. P1 = 1000 psi, V1 = 10 gal, P2 = 3000 psi,
One Annular BOP to close 18 gal
Two Ram BOPs to close 5 gal each
One Ram, 10M,C/R 7:1 to close 6 gal each
Two HCRs to open 1 gal each
Calculate the no. of bottles required as per API RP53 :

Calculation:
Vol. required to Close BOPs & Open HCR
= 18 + 10 + 6 + 2
= 36 gal

Total Vol. required = 36 + 50 % Safety = 54 gal

No. of Bottles = 54.0 = 54.0 = 15

Fluid per bottle
3.67
Q. A BOP stack contains one Annular, two Rams and one HCR.
Annular BOP requires 18 gals to close and 16 gals to open.
Ram BOP requires 6 gals to close and 5 gals to open.
HCR requires 1 gals to close and 1 gals to open.
Calculate the total fluid required to close , open and close all
functions, taking a safety factor of 20% :
Operation close open close
Annular BOP 18 + 16 + 18 = 52 gals
Ram BOP 2*(6 + 5 + 6) = 34 gals
HCR 1 + 1 + 1 = 3 gals
Total = 89 gals
S.F. (20 %) = 17.8 gals
Total Fluid required = 106.8 gals
 TOPIC 2

RESERVOIR TANK
CHARGING SYSTEMS
RESERVOIR TANK :
A reservoir tank provides means for storage of Hydraulic fluid.
The capacity of the reservoir tanks should be such when
system is not pressurised the level should be about one
inches below the inspection port and when the accumulator
bottles are charged fully at 3000 psi the level of the tank
should be at least one inch above the suction valves of the
pumps used in unit.
As per API recommendation the tank capacity should
be at least two times the usable fluid.
High quality SAE - 10W hydraulic oil should be used in the
system.
Prevent Hydrate formation - Methanol and Glycol
Antifreeze - Ethylene Glycol
CHARGING SYSTEM:
At least TWO pump systems with independent power sources.
SIZING OF PUMP SYSTEM
• With the Accumulators isolated , each pump system
. shall have the capacity to close ANNULAR BOP on the
. Minimum size D/P being used, open HCR valve and provide
the minimum system operating pressure within 2 minutes.
.

• The combined output of all pumps should be capable of

charging the entire system from pre charge pressure to
.

the control system RWP within 15 minutes.

.

• Each pump system should provide a discharge pressure

at least equivalent to the system working pressure.
.

• Air driven pumps should reach RWP with 75 psi air supply.
ELECTRICAL PUMP
The BOP control unit consist of one electric driven triplex or
duplex pump.
The pump output remains constant up to the maximum
pressure of 3000 psi, independent of system back pressure.
AIR PUMPS
The BOP control unit consist of two or three air pumps. It
consist of two main components, the air motor and the fluid
end.
The standard double action pumps are 60 : 1 or 50:1 ratio.
The pumps are double acting so air is exhausted on each
upstroke and down stroke of the pump.
REGULATORS
The BOP control unit consist of two regulators,
 one manifold regulator
 one annular regulator.
Manifold regulator is one which regulates the accumulator
pressure from zero to 1500 psi and in some of the unit from zero to
3000 psi. for the manifold line.
Manifold pressure operates all the functions except annular
preventer in BOP stack.
The manifold pressure should not be less than the calculated value
on the basis of BOP rated pressure and closing ratio of the ram
preventer and in any case normally it should not be less than 1200
psi when BOP is in operational mode.
ANNULAR REGULATOR
Annular preventer requires different operating pressure for
different requirements compared to other functions of BOP stack.
It regulates accumulator pressure to operate the annular preventer
from zero to 3000 psi.
There are two types of annular regulators, manual regulator with
air motor and air operated regulators.
The annular regulator should be operative from rig floor remote
panel. This is accomplished with the help of UNIT / REMOTE
Switch.  
 PRESSURE REGULATORS
MANIFOLD REGULATOR ANNULAR REGULATOR

• Operates Rams & HCRs • Operates Annular BOP

• Regulates Accumulator Pr.

• Regulates Accumulator Pr.
From 0 – 1500 psi. From 0 – 3000 psi.
• Pressure depends upon
RWP & Closing Ratio of • Air motor / Air operated
Ram BOP
• UNIT / REMOTE Switch to
• Pr. Normally 1500 psi but not regulate Annular Pr from
less than 1200 psi Remote Panel
• Bypass valve in HIGH
position – Accumulator Pr. In
Manifold.
THREE POSITION FOUR-WAY VALVE:
The operating manifold consists of several 3 position 4 way
valves, either manipulator or selector type.
All the manipulator or selector valve should be kept in
neutral when unit is not charged.

AFTER CHARGING, UNIT VALVES SHOULD BE IN

Open position for all ram type and annular preventer
Close position for choke and kill HCR valve.

To operate the valve move the handle in one swift motion.

Pausing will cause the valve to inter-flow, thus venting some of
the supply fluid and delaying operation.
PRESSURE TRANSMITTERS
Control unit consists of three pneumatic pressure transmitters.
Annular, accumulator and manifold pressures.
Operating pressures can be monitored on the remote control panel.
 The transmitters converts hydraulic pressure to air pressure and
sends a calibrated signal to corresponding air receiver gauges on the
remote control panel.
The air output is 3-15 psi, ensure that the air input to the
transmitter should not be more than 18 psi, if this pressure is more
than 18 psi it will rupture the diaphragm of the transmitter.
AIR FILTER
Located on the air inlet line. This filter removes contaminants
from the air supply which may damage the air pumps.
 It traps moisture to supply dry air to the accumulator unit. This
filter must be cleaned periodically to maintain maximum air flow.  

AIR LUBRICATOR
Its function is to lubricate the pump during operation.
Ensure that lubricator contains sufficient amount of SAE -10 oil.
Setting: Check the drip setting flows 6 drops per minute.
RESPONSE TIME
Closing Response Time begins when a function is activated at any
control panel and ends when a BOP is closed , effecting a SEAL
(Regulated pressure recovers to normal value)

SURFACE STACKS
RAMS < 30 Sec.
ANNULAR BOP, smaller than 18 ¾” < 30 Sec.
ANNULAR BOP , 18 ¾” & Larger < 45 Sec.
HCR Valves ( Open or Close ) < Min. observed Ram
close response time
 TOPIC 4

MGS, VACUUM DEGASSER

POOR-BOY DEGASSER

USED FOR REMOVING HI PERCENTAGE OF

GAS FROM THE MUD DURING GAS KICKS
 IDv

Vent line Hv

IDb
Mud Line

Hb
Baffle Plate

Body
HL

Cleaning Port

Base

Figure 5.70 MUD GAS SEPERATOR

1. Pressure build up in MGS depends on
-- VENT TUBE dimensions
-- Hv & IDv

2. Maximum Allowable Pr build up depends on

( Pressure beyond which gas blow through occurs)
-- Height of Liquid Seal
-- HL