Deepwater Drilling System

Reliable to the Extremes

Hydril Deepwater Drilling System

Reliable to the Extremes
Hydril: A Deep Commitment to Blowout Prevention
The annular blowout preventer. The rst hydraulically operated blowout preventer (BOP), and a history of record-

setting and market-changing technologies that reaches back to 1933. At Hydril, we work to increase the worlds energy potential, and we do so by designing, manufacturing and marketing the tools and technologies that protect both the environment and oileld personnel. Wherever drilling meets high pressure, high temperature (HPHT) extremes, the biggest names in the business rely on Hydril Pressure Control. Our shallow-to-medium depth, piloted subsea systems and high-quality surface BOP control units make easy work of demanding applications in extreme environments. And in the critical deepwater environment, the Hydril Deepwater Multiplex (MUX) BOP Control System repeatedly sets benchmarks for reliability and time spent on bottom. Count on Hydril to continuously redene reliability, with best-performing, world-class, industry-leading systems.

Pushing the Limits

Reliable BOP technology combined with advanced hydraulic circuit design, state of the art hardware and software design, robust materials and complete lifecycle support ranks Hydril systems among the most technically superior deepwater drilling systems in the world. Our current system can be congured to reach 12,500 ft below sea level, but we wont stop there. Look to future Hydril technologies to push both HPHT and water depth capabilities. A never-satised position on technological advances combined with a commitment to quality, performance and excellence has made Hydril synonymous with world class blowout prevention.

Hydril System Features and Benets

Runs for an entire year with zero downtime
A Hydril stack has stayed on the seabed for 364 days, with the stack pulled just once to escape a hurricane. While such performance is exceptional, its hardly unique for Hydril. Our standard design can provide one year of operation with zero downtime: All subsea components certied for an operational depth of 12,500 ft. Mechanical and electrical components designed for 20-year design life. Designed and manufactured in accordance with API 16A, D, E, NFPA 70 (NEC), NFPA 496, ISO and more.

Hydril pressure control equipment typically stays on the job for decades. Why? Read on. Time saving modular design
From factory acceptance testing (FAT) to installation and commissioning, Hydrils true modular design optimizes time upfront and minimizes downtime throughout the life of the system. Additional benets include: Greater commonality between systems. Easier troubleshooting: Quickly narrow down failure to a single module. More efcient maintenance, part replacement, manufacturing and delivery.

Deepwater Drilling System

Reliable to the Extremes

Works easily with a broad range of equipment

Hydril systems are as exible as they are durable. Our commitment to open architecture means we can adapt the Hydril MUX BOP control system to manage multiple stack congurations and interface with other shipboard computer systems, including DP systems, installation and workover interfaces, tree-handling systems and more.

Real time diagnostic and monitoring capabilities

Vital information is at your ngertips with these system displays: Event Screen: View a sequence of events without ever having to access a database or archival system. All digital events including commands, solenoid states and pressure switches are displayed in real time on the event screen. Active Alarms Screen: Continuously maintain observance of any system issues. The active alarms screen displays all active alarms in real time. Alarm Log Screen: View in real time the conditions that caused an alarm to become active or inactive without accessing a database or archival system. Network Topology Screen: View in real time a status display of processor, disk and memory utilization for all system nodesthose separate processors that exist on a networkand the network interface status for each network on all nodes. Examples of nodes include six (6) in the CCU (two (2) system controller, two (2) communication controller, and two (2) utility processors), two (2) in the drillers panel, two (2) in the tool pushers panel, the HPU and the diverter. System Conguration Screen: View the online/ofine status of all system nodes and all Hydril applications, as well as whether the applications are operating in primary, secondary or backup role. Also view the communication, master/slave and online/ofine status of all SEMS.

Battle-tested and universally certied software

More than 50 man-years have gone into developing the full life cycle of our software. Hydril meets the certication and compliance guidelines for every applicable international standard.

Full lifecycle reliability studies and testing

Extensive system tests subject all components to real-world work environmentsthose environmental extremes encountered by our customersincluding: Subsea Electronic Module (SEM) Electronics: Vibration and shock subsea and extreme temperature testing on the deck. All electronics assemblies and major components are extreme temperature rated. Pod SPM valves, shear seal pilot valves and regulators: Life cycle testing performed. All pod components: Tested at 5,600-psi external pressure at ambient and low temperatures.

Unparalleled safety features

While each control system includes many features designed to maximize uptime, two independent options can also be added to increase operations safety under specic emergency conditions: Hydril Autoshear The Hydril autoshear option adds valves to the MUX control pod and BOP stack, creating a hydraulic circuit that, once activated, performs automatic well shut-in under emergency conditions. In the armed state, the autoshear feature initiates when pilot pressure is removed from the hydraulic autoshear valve on the stack, as in the unplanned disconnect of the Lower Marine Riser Package (LMRP) from the BOP stack. Hydraulic uid from the stack mounted accumulators passes through the open valve to the close ports on the BOP, activating the blind shear rams to protect the well bore.

Integrated testing of the complete control system before shipment

We can conduct complete endto-end testing of the stack, pods and MUX control system in our deepwater assembly building. In our control system test lab we can load any systems software and troubleshoot issues that are occurring in the eld, shortening downtime and providing as close to a real world working environment as possible.

The Hydril Autoshear option satises the requirements of the Deadman as dened in American Petroleum Institute publication 16D, Specication for Control Systems for Drilling Well Control Equipment and Control Systems for Diverter Equipment. This occurs when the control pod suffers a catastrophic loss of both electrical power and hydraulic uid pressure, as in the case of the riser parting. Electrohydraulic (E/H) Backup System In the rare event that the subsea BOP Control System is inaccessible or nonfunctional, an optional independent control system known as the E/H backup system can be used to initiate emergency disconnect operations. The E/H backup system includes a small control panel powered by its own uninterruptible power supply (UPS) and dedicated conductors located in the MUX control cable that connect directly to specic circuits in the MUX control POD. The circuits in the control POD are dedicated to perform the minimum operations to allow the LMRP to disconnect from the BOP stack during these emergency situations. Users control the EH backup system with an E/H backup panel or through the E/H backup panel control screen on the toolpushers or drillers panels. This option is often used as an alternative to an acoustic back-up system.

programs is also housed within the Service Center to assist customers with service and warranty work. Training Hydril faculty combine comprehensive product knowledge, an understanding of our customers needs and the support of our engineering team into the hands-on and computer-based training available in our Technology Center. An experienced staff of instructors provides instructorled, hands-on and computer-based training in our state-of-the-art facilities. From rig-specic to custom designed courses, our faculty can keep your personnel certied in the use of all Hydril products and systems. Visit www.hydril.com for access to additional support information.

MUXLIFE: Upgradeable System Components

Extend the life of your control system with a Hydril MUXLIFE upgrade. Hydrils team of engineers and technical experts will personally assess your system, recommend appropriate surface electronics maintenance and/or upgrades and calculate the time required to implement the upgrades and optimize your system performance. All upgrades are performed on the rig with no docking required. Whether you need a new drillers panel, pod electronics, UPS, or ber optic communications, Hydril can upgrade your electronics to maximize the life of your system.

Hydril Service Organization

Technical solutions are a call, chat or handshake away through Hydrils global network of certied personnel: 24/7/365 Service & Support Call (281) 449-2000 to request serviceany day, any time. Live! Chat Support In non-critical situations, log on to www.hydril.com for live customer support. Field Service Whether it is a rig down, routine maintenance, new rig commissioning or anything in between, our service team is certied to work wherever you may need them and available to you any hour of the day or night. Remote Service Network (RSN) By joining the remote service network and purchasing the required hardware, customers gain access to remote diagnostic services by factory-trained Hydril technicians. To learn more about RSN, see Accessories. Service Center Located within the Hydril Technology Center, the Service Center was designed specically for the service and repair of control systems. A team dedicated to the management of purchased BOP maintenance

Energy, Safety, Protection

At Hydril we have built our reputation on a commitment to increase the worlds energy potential through technologies that protect both natural resources and oileld personnel. Our deepwater multiplex BOP drilling systems represent the very best of successive generations of innovation and experience. We continue to write the book on blowout prevention, and our story is one of reliability, quality and consistency.

Deepwater Drilling System Components

The Hydril subsea MUX control system supplies and controls the ow of hydraulic uid for actuation of the subsea BOP stack functions. The system includes surface components, the connecting control MUX cable/hose components and subsea components. SURFACE COMPONENTS: 1) Automatic Hydraulic Power Units
Rapidly charge the accumulator banks with the electric motordriven positive displacement hydraulic pumps in Hydrils pumping units. Designed to meet customer specications and applicable regulations, each power unit offers ease of use, long service life and the functions and renements born of many years experience. Features include: Three (3) electric motor-driven pumps per standard pump unit. Identied connections for rapid installation and easy inspection. unique features and benets that include: A 21 bore for easy passage of casing and well bore tools. Available in both single and dual congurations. Economical, easy installation, recovery and maintenance; the GH installs as a standard riser joint. Adaptable for any rig or riser system. Enhances safety for personnel and the rig.

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17) Riser Fill-Up Valve

The Hydril Riser Fill-Up Valve prevents collapse of the subsea riser wall due to a sudden evacuation of drilling uids from the riser. Sudden evacuations can occur during unplanned events such as a disconnect of the LMRP or a failure in the lower riser section. The Hydril Riser Fill-Up Valve backlls the drilling riser with seawater as heavier drilling uid evacuates the riser from the bottom. This prevents creation of a vacuum inside the riser that would collapse it. The Fill-Up Valve can be set to open automatically due to a sudden pressure differential inside and outside the riser, or it may be operated manually.

2) Fluid Reservoir Unit (FRU)/Mixing System

Hydrils FRU/Mixing System pumps the proper mixture of hydraulic uid concentrate, water and antifreeze from storage reservoirs into the mixed control uid reservoir, providing the necessary lubricity and freeze protection to maintain reliable BOP stack operations and long service life. Electrically driven metering pumps are mounted with the reservoir assembly.

3) Accumulator Banks
GPS Unit

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HPTU Skid HPTU Controller & VFD Subsea Workstation Datalogger

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The Hydril nitrogen-oil separator type accumulator is ideal for furnishing the hydraulic power to operate blowout preventers, valves and connectors from surface and subsea accumulator banks. When stripping drill pipe through closed annular blowout preventers or dampening quick acting control circuits, it also functions as a surge absorber.
Power Isolation J-Box

ACCESSORIES 18) Acoustic Control System (Emergency)

Similar to the E/H backup system, the acoustic control system has a separate stack-mounted acoustic pod for performing emergency disconnect operations. The system uses an acoustic link from the surface rather than the dedicated electrical circuits used by the E/H backup.

4) Drillers Control Panel

Achieve full system control at the drillers control panel. As the primary control station it provides for full control of the BOP stack and selected auxiliary functions. The panel design permits well control operations as required, even in adverse conditions. Units can be provided to meet requirements for hazardous area operation and all specications and regulations.

19) Cable/Hose Reel Control Console

Each of the two (2) Multiplex Cable Reels and one (1) Hot Line Reel are controlled from the freestanding control console. Manufactured from mild stainless steel, the console provides for the mounting of the control valves, gauges and indicators.

High Pressure Test Unit (HPTU) System

Diverter Storage Base

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20) Cable/Hose Sheaves

The half-moon MUX cable sheaves are appropriately sized to the outside diameter and minimum bend radius of the cables/hoses.

5) Toolpushers Panel
Designed for operation in safe (non-hazardous) areas, the toolpushers panel provides the same functionality as the drillers control panel, and serves as a secondary control station.

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Yellow Subsea XFMR

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Blue Subsea XFMR

21) Diverter Control Panel

The diverter control panel is a skid-mounted unit that actuates solenoids for the pilot-operated control of diverter valves. The unit contains a processor with network connection to the CCU for remote control, as well as full local control via valves and gauges.

6) Central Control Unit (CCU)

The CCU provides a common communications interface point for all surface panels and the subsea MUX pods. The CCU is designed to operate in safe (non-hazardous) areas. It contains control computers and network equipment and serves as a third control station.

Diverter Flowline Valve Yellow J-Box MUX Umbilical Flow Selector Blue J-Box MUX Umbilical

22) Electro-Hydraulic (E/H) Backup Panel

The E/H backup panel enables emergency disconnection should the surface BOP control system become non-functional. The system employs hardwired circuits to the MUX control pods for initiating disconnecting functions.

7) Uninterruptible Power System (UPS)

Surface ERA J-Box

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Diverter Vent Line Valve

Diverter Fill-Up Valve

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Should a power failure occur on the rig, the UPS provides a 2 hour minimum emergency power reserve for remote control panel operation and instrumentation. The system includes heavy-duty batteries, a rack and a battery charging control unit. It provides electricity to all electrically powered components with the exception of the electric motors.

High Pressure High Temperature (HPHT) Probe

(not pictured) The system uses an HPHT Probe to monitor well bore pressure and temperature. It will be mounted on an unused outlet of the lower Pipe Ram of the BOP stack. All components that come in contact with the well bore uid meet NACE MR01-75 requirements.

8) Power Distribution Panels (PDP)

Control the ow of power to and from each component of the MUX control system with the PDP. Our unique system architecture provides maximum reliability of quality power, ensuring that a power surge or loss of a major power bus will not affect operation.

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Goosenecks

High Pressure High Temperature (HPHT) Probe Assembly (not pictured)

The pressure/temperature probe is a 4-20mA device that interfaces to the blue and yellow pod electronics through the Remote Terminal Unit (RTU) (see below). Design specications follow: Environmental media: Seawater and well bore uid. Hyperbaric (external) pressure rating: 5,700 psi. Operating temperature: 0-150 degrees C (process media). Pressure sensor range: 0-25,000 psia operating. Pressure reference: Absolute.

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9) Hose/Cable Reels
Hose and cable reels provide live function and assured control of the hose or electric cable during running and retrieving operations. Reels are also available with constant torque winches for constant tension on cables and hoses.

10) Hydril FS 21-500 Marine Riser Diverter Annular Blowout Preventers: 25) GX Annular BOP
Expect more closures, stripping and uptime. Drilling contractors have called the Hydril GX the best annular in the business for one reason: exceptional uptime. Its single packing unit has provided continuous service for as long as a year, and it has continued to hold pressure after exposure to extreme temperatures and extensive stripping. In the eld and in laboratory tests, GX units have: Passed an ABS-witnessed, 10,000-psi API pressure test at 270 F. Stripped more than 30,000 ft of 6-5/8 drill pipe with 8-1/4 tool joints. Stripped 300,000 ft of 5 drill pipe with 6-3/8 tool joints. Held pressure in the eld after 328 closing cycles plus stripping. Annu-Flex (not pictured) A variation of our GX annular BOP, Hydrils Annu-Flex combines either a single or dual subsea annular blowout preventer with a maintenance-free, exible underwater riser joint. Together, the BOP head/ex joint combination reduces overall stack height and requires fewer stack connections. Additionally, the Annu-Flex offers rapid and economical maintenance, simple and reliable operations, and long service life.

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Hydril diverters are known for signicantly enhancing safety and rig protection. The FS 21-500, in particular, is fundamentally simplistic, designed to avoid the functional complexities that increase the chance for human error and equipment breakdown. With models available for use with 49-1/2 and 60-1/2 rotary tables, the FS 21500 is readily adapted to t virtually any rig conguration. Moreover: It closes on the open hole, eliminating a serious safety gap caused by cartridge inserts. It is used in conjunction with the Seal-All Diverter Insert to enhance safety further. The patented integral valve design eliminates sequencing of diverter valves and simplies the control systems need to operate the diverter system. There is no stagnant vent line space, caking of solids or ice formation that could obstruct or shut off the ow. Both models are rated for 2 million lbs up or down loading.

23) Remote Service Network (RSN)

The remote service network (RSN) and hardware allow Hydril technicians anywhere in the world to login to a customers system through the Internet for diagnostic purposes. The network is a link between the Hydril control system network and the rigs satellite communications network system. How does it work? A Hydril technician can log onto the Hydril control system network on a rig anywhere in the world by connecting through the ISPs to the land-based satellite uplink location nearest the rig. The satellite link then completes the path from shore to the rig satellite communications network and to the control system network. RSN features and benets include: Remote diagnostics of the control system. Reduces or eliminates automatic need for service trip. Download of software upgrades via link. Faster service response to system problems. End of well le maintenance and system check up. Save or eliminate downtime days.

SUBSEA COMPONENTS 11) Hydril Blowout Preventer Stack

Hydril invented the annular BOP and the hydraulically operated BOP. Since 1933 Hydril has been redening reliability and pushing the limits of BOP technology. The deepwater BOP stack can be congured with a variety of Hydrils proven BOPs.

Remote Terminal Unit (RTU) (not pictured)

The RTU is the serial communications module for reading the 4-20mA signals from the HPHT probe and converting them to signals that are communicated to the MUX pod. The housing is constructed of stainless steel and can withstand 15,000 psi external pressures while maintaining a one-atmosphere internal environment. The electrical connectors are two (2) 4-pin and one (1) 8-pin FCR type with face and radial o-ring seals.

Ram Blowout Preventers:

Quik-Loq BOP (not pictured) Change rams and resume drilling fast. Well suited for surface and subsea operations, the Boltless Hydril blowout preventer, the Quik-Loq, radically reduces downtime while enhancing safety and environmental protection. It accomplishes these goals in part by: Minimizing personnel exposure to safety hazards that are inherent to BOP maintenance on the rig by eliminating the need for tools and rigging. Allowing changeout of rams and/or operator assemblies in a matter of minutes rather than hours. Using Boltless bonnets, redundant operator seals, and redundant rod seals.

12) Multiplex Control Pod

The unique wedge-shaped Hydril subsea control pod assembly includes a male pod and female receiver and houses the subsea valve control manifold. The compact design features subplatemounted control valves and pressure regulators for all subsea hydraulically controlled functions96 in all. Two control pods on each stack provide system duplicity, and one receiver attaches to the Lower Marine Riser Package (LMRP).

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Subsea Accumulator Pressure Transducer (not pictured)

The pressure transducers are absolute pressure strain gauge type, temperature compensated, and packaged in a three (3)-section stainless steel housing with redundant seals at each housing section. Each pressure transducer is calibrated to determine the necessary offset for both the lower and upper roll off. Specications follow: Range: 0 - 10,000 psi. Temperature Limits Operating: - 30 to + 180 deg F. Compensated Range: 0 to + 160 deg F. Overpressure Limits Proof: 150% or 20,000 psi. Burst: 200% or 25,000 psi.

26) Compact Ram BOP

Hold pressure at 15,000 psi from 30 F to 500 F. The 18-3/4, 15,000-psi Hydril Compact Ram BOP delivers proven reliability for safe operation in the harshest environments. Rated for water depths to 12,500 ft, the Compact Ram has worked on the seabed continuously for one year during drilling of a 34,000-ft well. It also can add hundreds of hours of drilling time annually when congured to seal upside-down as a Subsea Stack Test Valve (SSTV) so that required pressure tests can be completed with the drill pipe in place. In the lab, this BOP has: Held full rated working pressure at 300 F for 8 hours using blind/shear rams. The tested unit then completed 3 additional closing cycles at low and high pressure. Passed API temperature testing to 350 F using blind/shear rams. Passed API temperature tests to 500 F using 5 xed-bore rams. All xed-bore ram sizes on the 18-15 Compact Ram are rated for this temperature. Passed API pressure tests at temperatures as low as 30 F for 5-1/2-7-5/8 and 4-1/2-7 variable rams. Sheared large-diameter pipe (16, 109 lb-per-ft, P-110) using optional, high pressure, 4,000 psi, 22 operators.

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13) Shuttle Valves

Long life, dependable Hydril shuttle valves compatible with the control system are available in 1 1/2, 1 and 1/2 sizes.

14) Subsea Accumulator Racks

Stack-mounted accumulator banks are equipped with a common headerthese subsea racks are hinge-mounted to the BOP Stack frame and swing clear of BOP components for ease of inspection and maintenance. If required, an option using large volume bottles (80, 160 gallon) eliminates the need for swing frame racks.

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15) Subsea Electronics Module (SEM)

The two SEM units located on each control pod provide a fully redundant system for control of all subsea valve operations and all communications with the central control unit (CCU).

24) Surface/Subsea Electronic Riser Angle System (ERA)

The Surface and Subsea ERA provides real time monitoring of the riser angle using angular deviation sensors. The control pods contain gyroscopes for measuring stack rotation, and information from the two systems is displayed in graphical plots on surface workstations.

16) Gas Handler

Hydril diverter systems are designed for strength and simplicity to provide safe venting of shallow gas ows. Located below the telescopic joint, the Gas Handler (GH) adds capabilities to standard diverter systems. The GH is a specialized annular closing device installed as part of the riser string for deepwater drilling. It allows the operator to circulate out gas entrapped in the riser string without the requirement to vent mud and/or gas overboard. This product has quick response time, a low risk of malfunction and several other

Conventional Ram BOP (not pictured) The 18-3/4, 15,000-psi Hydril Conventional Ram BOP delivers the same proven reliability as the Compact Ram for safe operation in the harshest environments. It is also rated for water depths to 12,500 ft.

Hydril Pressure Control 3300 N. Sam Houston Pkwy. E. Houston, Texas 77032-3411

PHONE: 281.449.2000 FAX: 281.985.3480

www.hydril.com

2008 Hydril Pressure Control