Subsea - Page 4

BOP Hydraulic
Control
Systems
Subsea Engineers Handbook Section 4
In-Spec Inc. 1999 BOP Hydraulic Control Systems
Table Of Contents
Section 4
Page
1. General Description of Hydraulic Control System 1
2. Operation of a Surface Accumulator 2
3. Controlling the BOP Stack 3
4. Subsea BOP Control System Diagram 4
5. Stepping Through the Subsea Hydraulic Control System 5
a. Hydraulic Power Unit and Surface Control Manifold 5
b. Hydraulic Hose Bundle and Storage Reel 8
c. Control Pods 10
d. BOP Remote Control Panels 17
e. Diverter Control 20
6. Hydrostatic effects on Subsea Accumulator Bottles 22
7. API and MMS System Sizing, Response Guidelines 23
8. BOP Response Times 24
9. Hydraulic Systems Flow 26
a. Main Hydraulic Supply 26
b. Regulator Pilot Circuits 28
c. Operation of a 3 Position Function 30
d. Operation of a 2 Position Function 32
e. Operation of a Straight thru Function 34
10. Typical Hydrulic Power Unit Schematic 36
11. Typical Manifold Schematic 37
12. Typical Pod Schematic 38
13. Typical Stack Schematic 39
In-Spec Inc. 1999 BOP Hydraulic Control Systems
14. Hydraulic Symbols 40
15. Fitting Information 43
16. Troubleshooting: Pressure Losses 47
17. Troubleshooting: SPM Failure 53
18. Troubleshooting: Leaks and Malfunctions 56
19. Operation of the Electrical Portion of the System 66
In-Spec Inc. 1999 1 BOP Hydraulic Control Systems
General Description of a Hydraulic Control System
1) 5 Main Components of the Surface Hydraulic Power Unit (HPU)
Operation of the Surface Accumulator Bottle
Atmospheric Pressure
The accumulator bottle has a bladder of tough, synthetic rubber that is shaped like a
tapered cigar. It has this shape when there is no pressure on it. The tapered shape
is important because it gives a pushing or squeeze action when fluid is discharging.
The bladder completely separates the nitrogen precharge from the hydraulic fluid.
This prevents the gas from mixing with the hydraulic fluid.
Pre-Charged
The bottle is precharged with nitrogen through a valve at the top of the bottle.
Nitrogen is used due to its relative inertness and availability. At the bottom is the
port through which hydraulic fluid is pumped. The fluid also leaves the bottle from
this port. A poppet valve closes the port when the bladder pushes against it. The
1,000 psi of nitrogen precharge pushes the elastic bladder to the bottom of the bottle
and closes the poppet valve preventing the bladder from being pushed out of the
port.
Initial Charge
Next, hydraulic fluid is pumped into the bottle, and the 1,200-psi minimum pressure
Is reached quickly.
Fully Charged
At far right, the bottle is fully charged with fluid to 3,000-psi working pressure. The
additional fluid pumped into the bottle raises the pressure from the 1,200 psi initial
charge to the 3,000 psi fully charged state. As fluid is used from the bottle the
pressure will drop to 1,200 psi. The fluid delivered by the bottle during this process
is called the usable fluid available from the bottle.
Controlling the BOP Stack
To be useful we must control an entire BOP stack. The system power supply must be
obtained from more than 1 source so an air powered pump is added to the system.
Of course our stack will contain more than 1 ram so we have added more preventers
and a control valve for them. The same regulator is used for all the ram preventers and
is called the manifold regulator.
Since the annular BOP may require a different pressure from the rams, a separate
regulator is added to supply hydraulic fluid to it.
R
Annular Regulator
3000 PSI
Bladder
N
2
N
2
Float
Air Pump
1. Alternate Power Source
2. Operate more than one BOP
3. Operate Annular with its own
regulator
R
Stepping Through the Subsea Hydraulic Control System
1) Hydraulic Power Unit and Surface Control Manifold
The hydraulic power unit is usually mounted integrally with the surface control
manifold. It supplies the hydraulic fluid, a mixture of water soluble oil and
water, to the control system. The unit contains a reservoir section which
includes two reservoirs and a hydraulic fluid mixing system, a pump section
which includes both air and electric operated pumps, and an accumulator
section. The reservoir section has two reservoirs, one for water soluble oil, and
one for the mixed hydraulic fluid.
The water soluble oil reservoir has typically a 100 gallon capacity. The mixed
fluid reservoir contains at least enough fluid to fully charge the system
accumulators from their precharge pressure to the maximum system working
pressure. Both reservoirs are equipped with graduated sight glasses and low-
level alarms.
The fluid mixing system has the capability of supplying fluid at a rate greater
than the combined output of all pumps. In addition, the concentrate-water
mixing ratio will remain within 5 percent of its setting regardless of pressure
fluctuations which might occur in the mixture supply line.
The figure below shows a typical mixing system.
The mix water flows through a regulator which reduces the pressure and
maintains a constant flow rate. An independent air-operated pump injects the
water soluble oil at a constant rate, thus maintaining the proper mixing ratio.
The system is insensitive to pressure and volume fluctuations in the mix water
supply as long as the rig water system is capable of supplying water faster.
than the setting for the mixing system. The mix ratio can be adjusted by varying
the mix water and/or water soluble oil flow rate. To protect the hydraulic fluid
against freezing, the capability to mix glycol with the water soluble oil and water
is provided. The glycol would be added in a manner similar to that of the water
soluble oil. Glycol and water volumes are added when determining the amount
of lubricant to add.
The main pumps for the power unit are typically electrically driven triplex
pumps. The primary consideration when selecting the capacity of the pumps is
usually the amount of time it would take the pumps to charge the system
accumulators from their precharge pressure to the maximum system working
pressure. Charging times no longer than 15 minutes are desirable. There can
be other considerations which would override charging time and require more
pump capacity. These considerations usually involve saving rig time, the cost of
which makes the cost of additional pump capacity negligible. When pump
capacity requirements exceed 20 gpm, splitting the capacity between two
pumps prevents complete dependence on one pump.
To provide additional or backup pump capacity in case electric power is not
available, one to three air-operated pumps are usually installed. All pumps are
mounted so that any one can be isolated for repairs without interfering with the
operation of the others.
The pumps are equipped with pressure switches to start and stop the pumps at
selected pressures and suitable relief valves. To maintain maximum
accumulator fluid for a 3000 psi system, the pressure switch to stop the pumps
is set at 3000 psi. The relief valve vents at 3500 psi. The fluid from the pumps
is filtered by 40 micron filters. Two filters connected in parallel are used, with
each filter capable of being isolated to eliminate pump shutdown for filter
replacement.
Fluid travels from the pumps into accumulator banks. These accumulators
serve two purposes; first, they store hydraulic energy which can be used when
pumping capability is lost. Second, they supply fluid at rates much higher than
the pump capability and are used to achieve faster BOP actuation times.
Separator-type accumulator bottles are used in all of Shaffer control systems.
They have a rubber bladder than separates the gas precharge from the stored
liquid. The gas precharge is injected into the accumulator through the
precharge valve in the top. No fluid should be in the accumulator when it is
precharged. Cameron traditionally use float type accumulator bottles in their
systems. The float replaces the bladder and it is the dropping float which shuts
off the bottle outlet to prevent the nitrogen from escaping from the bottle as the
final fluid exits.
The surface control manifold contains all the controls and indicators necessary
to operate the valves and regulators on the subsea pods and monitor the
general status of the system. The manifold contains the pod selector valve,
which directs the power fluid to the active pod and vents the inactive pod to the
fluid reservoir located on the power skid. The manifold can be operated
remotely from any of several panels which will be discussed later. The
functions on the manifold can be broken into four categories, pilot valve control,
regulator control, pressure readback display, and pod selection.
Each piece of equipment on the stack has a corresponding surface control
valve on the manifold which pilots the pod control valve(s) that, in turn, control
that piece of equipment. The control valves for the Shaffer system are 1/4-inch
shear seal valves equipped with air operators to allow control of the valves from
the remote panels.
The hydraulic signal from each valve goes to both junction boxes on the
manifold unit, through both hose bundles, and actuates SPM valves on both the
active and inactive pods.
Only one subsea pod, the active pod, has power fluid or main hydraulic supply
(MHS) fluid supplied to it at any given time. The pod selector valve on the
manifold unit directs fluid to the active pod and vents the fluid from the inactive
pod. The pod selector (a 1-inch shear seal valve) operates exactly like the pilot
control valves and is equipped with an air operator for remote operation.
The controlled pressure side of each regulator in the subsea control pods is
connected through a 3/16-inch hose to a gauge labeled pressure readback on
the manifold unit. A pressure transducer transmits the readback pressure to
the remote panels. A shuttle valve connects the hoses from the pods at the
manifold unit and isolates the active and inactive pods.
Explosion-proof housings located on the manifold unit skid contain the
equipment which interfaces the remote control panels with the manifold unit.
This equipment includes the pressure transducers which transmit pressures
from the manifold to the control panels and pressure switches that provide
status information (open, close) for the remote panels. Also included are the
solenoid actuated valves which direct air to the air operators on the manifold
pilot control and pod selector valves and provide regulator increase/decrease
control.
2) Hydraulic Hose Bundle and Storage Reel
In hydraulic systems, the subsea power fluid supply, MHS, and all pilot signals
for the control valves are transmitted through a hydraulic hose bundle which
extends from the surface manifold unit, through jumper hoses to the hose reels,
and from the hose reels to the subsea pods. Also hydraulic fluid from the
regulated side of the subsea regulators is transmitted through the hose bundle
to pressure gauges labeled pressure read-backs on the control panels. MHS
fluid is supplied only to the hose bundle of the active pod while pilot pressure is
supplied to both the active and inactive pods.
The hose bundles used in most operations generally are composed of one 1-
inch ID supply hose, which supplies power fluid to the pods, and 3/16-inch ID
pilot hoses for activation of the individual control valves and readbacks. The
supply and pilot hoses are typically bundled with the supply hose in the center
surrounded by pilot hoses. 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 as required during drilling
operations. A separate cable reel provides the means 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. However, to keep selected
functions live during the running or retrieval operations, a few control stations
are mounted on a manifold attached to the side of the reel. The live functions
include at least the riser and stack connectors plus the pod latch. Contractors
may select to additionally operate one or two pipe rams, fail safe valves and
test valves. Below is a typical a typical diagram of reel piping through which the
power fluid flows to the controlled functions during the operation of the reel.
The hose bundle leaves the reel and runs over a roller sheave down to the pod.
The bundle is clamped to the wireline attached to the top of the pod at 30 to 50
foot intervals.
The pressure drop in the power hose can be substantial when a function is
actuated, particularly for long hose lengths. One way to compensate for this
pressure loss and assure faster actuation times is to place accumulators
subsea on the BOP stack. Another means is to supply fluid to the control pods
through 2 or 2-1/2-inch ID conduits integral with the marine riser. These
conduits are similar to small diameter choke or kill lines.
1) Control Pods
Flexibility in BOP stack configuration is provided by double female controls pods.
The flexibility is achieved by having discharge ports in both the upper and lower
female portions and utilizing a combination of 3/4 and 1 SPM valves for preventer
functions, depending on fluid requirements.
These control pods also are equipped with 1-1/2 regulators to provide large flow
and still maintain accurate pressure settings. The packer seals at the mated ports
between sections of the pod have been tested to 12,000 psi without leakage in the
transfer of high pressure fluid between sections. The subsea hose bundle
terminates at the pod through a hose radius guard attached to the junction box
cover. This protects the hose from kinking and prolongs its life.
The pods are run and retrieved by unitized guide frames. Keyed connections provide
reliable mating.
The retrievable pod incorporates 1 SPM valves and 1-1/2 regulators with the SPM
valves mounted in individual stainless steel pockets for ease of maintenance. Packer
seals make leakproof connections between pod sections, and special coatings
protect the pod against corrosion.
Power fluid to operate the preventer is supplied to the pod through a one-inch hose
in the hydraulic hose bundle or a rigid conduit integral with the marine riser. Power
fluid is also supplied from accumulators mounted on the BOP stack. Hydraulic power
fluid is normally supplied to the subsea control pod at full system working pressure;
nominally 3,000 psi surface gauge. A regulator in the pod reduces the pressure to
suit the requirements of the BOP equipment, normally 1500 psi surface gauge.
The purpose of a regulator is two-fold. First, to reduce higher (system) pressure to a
lower (working) pressure. Second, to maintain the preset pressure should external
forces attempt to increase or decrease it. The regulator is controlled from the surface
through a pilot hose in the hydraulic hose bundle. The shear seal type regulator
employs a sliding metal seat which seals on a fixed metal surface.
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More on Cameron Control Valves
Open
Supplying Fluid
Closed
Fluid Vented
Shaffer SPM Valve
The regulated hydraulic fluid is supplied to selected SPM valves mounted on
the subsea pod. Pods may have two or three regulators depending upon drilling
contractor requirements. Pods with two regulators use one to supply regulated
fluid to the valves controlling the annular preventers, the other supplies
regulated control fluid to the remaining functions (ram preventers and valves).
In some instances the connectors will have their own regulator.
The SPM valves are operated hydraulically from the drilling vessel through
small pilot hoses in the hydraulic hose bundle. When operated, they supply
control fluid to actuate the piston operators of preventers, valves and
connectors. At the same time they vent fluid from the other side of the pistons
to the sea.
SPM valves are two-position, three way valves and are available in 3 nominal
sizes, 3/4 inch, 1 inch and 1-1/2 inch. One-inch valves and one and a half inch
valves are used to control the annular preventers. The 3/4-inch valves are
used to control the other stack functions such as ram preventers, choke and kill
valves, and connectors. The SPM valve is a poppet type in which a sliding
piston seals on Delrin seats. In the normally closed position, a spring attached
to the top of the piston shaft keeps the piston on the bottom seat, blocking
hydraulic fluid from reaching the BOP. In this position, hydraulic fluid from the
inactive function is vented to the sea. When pilot pressure is applied to the
valve, the piston moves up against the upper seat and blocks the vent ports,
allowing control hydraulic fluid to reach and function the BOP.
Two SPM valves are required to operate a blowout preventer. The pilot fluid
flows from the control valve at the surface, through a pilot hose to the SPM
valve and lifts the valve spindle off its bottom seat. Regulated fluid flows
through the SPM valve to the preventer cylinders CLOSE side. At the same
time, the three-position, four-way, surface control valve relieves pilot pressure
on the preventers OPEN SPM valve. The spring forces the piston to its lower
seat and displaces pilot fluid to the surface. Hydraulic fluid from the OPEN 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 valve closed.
The surface control valve when in the centered position relieves both SPM
valves of pilot pressure, thus allowing both valves to block or seal off the
regulated power fluid and vent both sides of the preventer actuating cylinder to
sea. When the control valve is in this position, it is said to be in the centered,
block, or vent position. When SPM valves are operated in this manner, the
two valves act as one three-position, four-way valve.
After passing through the SPM valve, the power fluid exits the pod and flows to
the appropriate function first through a hydraulic hose and then through a
shuttle valve mounted adjacent to the function.
The shuttle valves, which isolate the inactive pod from the operated functions,
are an integral part of the redundant two-pod design. Shuttle valves are used
to direct power fluid from the active pod to the function while at the same time
isolating the inactive pod from the control pod in use.
A cut away drawing of the shuttle valve is located on page 40 where you can
see the internal operation.
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
valve in the active pod; however, no power fluid flows from inactive pods valve
because the hydraulic fluid line has been vented on the surface.
Not all functions on the BOP stack are controlled through valves on the pod.
Function that require less volume, e.g., ball joint pressure, 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 as opposed to functions requiring SPM valves.
Thus far, only the operation of a single function through the subsea pod has
been discussed. The pod must have additional capabilities or requirements to
meet todays drilling needs; some of them are:
Capable of being run and retrieved with the riser package,
Capable of being run and retrieved independently,
To be fully redundant,
To have all hydraulic seals on the retrievable portion of the pod,
To have all functions go to the exhaust position if communications are cut
with the surface and,
To allow any leaks occurring downstream of the pod to be isolated either at
the pod or upstream of the pod.
To meet the preceding criteria, the pods must be mounted on the upper stack
section (LMRP) which is retrieved with the riser.
2) BOP Remote Control Panels
The Driller's Control Panel is the primary operating centre for the BOP Control
System: the electrically operated Mini Remote Control Panel and the manual
operated hydraulic Control Manifold are secondary centres. Operating voltage for
The Drillers Control Panel is typically 12 VDC or 120 VDC. The control panel is
designed with a graphic overlay of the BOP stack and choke and kill lines. The
graphic overlay helps the driller locate quickly the functions to be operated. The
drillers control panel also enables remote operation of the diverter control functions.
The controls for the diverter functions are also arranged in a graphic overlay for ease
of identification. The entire control panel is protected from physical and
environmental damage by two Lexan doors.
a) Function Pushbutton/Indicator Lights
The main section of the Driller's Control Panel contains the push button/indicating
lights for control of the BOP Stack and Lower Marine Riser Package (LMRP)
functions.
These functions duplicate the functions on the Hydraulic Control Manifold. A
typical list of functions is listed below:
Stack & Riser Functions Function Positions
Pod Selector Blue. Block. Yellow
Accumulator Isolator Open. Close
Blue Pod Latch Vent. Latch
Yellow Pod Latch Vent. Latch
Upper AnnularOpen Block Close
Riser Connector Unlock. Block. Lock,
Riser Connector Secondary Unlock Vent
Shear Rams Open. Block. Close
Upper Pipe Rams Open. Block. Close
Middle Pipe Rams Open. Block. Close
Lower Pipe Rams Open. Block. Close
Outer Kill Open. Vent
Inner Kill Open. Vent
Upper Outer Choke Open. Vent
Upper, Inner Choke Open. Vent
Lower Outer Choke Open. Vent
Lower Inner Choke Open. Vent
Stack ConnectorUnlock. Block. Lock
Stack Connector Secondary Unlock. Vent
Upper Wedgelocks Unlock. Block. Lock
Lower Wedgelocks Unlock. Block. Lock
b) Lamp Test Pushbutton
To the left of the stack overlay, is the Lamp Test pushbutton. When this button is
pushed, all the panel lights should illuminate
c) Warning Panel
To the immediate right of the function pushbuttons is the warning panel. This
small panel typically contains five red alarm indicator lights for the following:
Glycol Level
Soluble oil Level
Accumulator Pressure
Fluid Level
Rig Air Pressure

If the pressures or levels of the above listed items drop to a predetermined low
level, the red indicating lights illuminates to warn the driller. The driller should
check the low pressures and low liquid levels and restore them to acceptable
levels before proceeding with control system operations.
When any of the red warning lights come on, an audible horn also sounds at the
Driller's Control Panel. To turn the horn off, the rig- hand presses the Horn
Cancel button at the bottom of the warning panel.

d) System Pressure Meters
To the right of the Driller's Control Panel are two electrically operated Pressure
meters. The Accumulator Pressure meter indicates Line Pressure or the main
hydraulic supply from the main accumulator bottles to the stack functions. The
PILOT PRESSURE meter indicates the pressure in the pilot system. The RIG
AIR PRESSURE meter indicates the rig air pressure to the Hydraulic Power Unit.
The correct meter readings are as follows:

Pilot Pressure 3000
Accumulator Pressure 3000
Rig Air Pressure 100- 125 psi

e) Flow Meter
A flow meter is located on the Driller's Control Panel immediately below the two
pressure meters. The flow meter on the panel indicates the amount of fluid that
has been used at the completion of a function operation. The electric flow meter
on the Driller's Control Panel is linked to the hydraulic flow meter on the
Hydraulic Control Manifold. The flow meter registers the volume in tenths of a
gallon. Careful observation of the flow meter can signal the driller that a leak is
present in the control system. After a function has been operated, the flow meter
at the Driller's Control Panel can be reset to zero by pressing the Flowmeter
Reset pushbutton to the left of the flow meter.

f) Pressure Regulation Stations
On the left side of the Driller's Control Panel are five additional electrically
operated pressure meters. These meters are:

Annular Regulator Pilot Pressure
Annular Regulator Readback Pressure
Manifold Regulator Pilot Pressure
Manifold Regulator Readback Pressure
Pilot Pressure
The readings on these meters correspond to the readings on the pressure
gauges on the Hydraulic Control Manifold.
To the right of the meters are two increase, decrease pushbutton stations. One
station is for the annular pressure regulator, the second is for the manifold
pressure regulator. Note that the three-way Unit/Remote Panel Selector switch
on the Hydraulic Control Manifold must be in the Remote Panel position before
the regulator pressures can be controlled from the Driller's Control Panel. When
the driller operates either the annular pressure regulator or the manifold pressure
regulator, the pressure is indicated on the Annular Regulator Pilot Pressure and
Manifold Regulator Pilot Pressure meters respectively. When the regulated
pressure pilot signal is retrieved subsea, the subsea HKR regulating valves send
signals back to the Drillers Control Panel. These return signals are indicated on
the two readback pressure meters. When all system equipment is operating
correctly, the Pilot Pressure and Readback Pressure meters for the two regulated
functions read the same.
3) Diverter Control Section
a) Function Pushbutton Indicator Lights
The right side of the typical Drillers control panel contains the controls for the
diverter control system. These controls enable remote operation of the diverter
equipment from the Drillers control panel. The diverter control section of the
Drillers control panel contains the pushbutton/ indicator lights and regulators for
control of the diverter functions. The panel is designed with a graphic overlay of
the diverter functions, which helps the driller locate quickly the functions, which
are to be operated. The seven functions reflect the functions of the diverter
substructure panel. The functions and positions are listed below :
Positions Function
Open, Close Diverter Element
Unlock. Lock Insert Packer Lockdown Dogs
Unlock. Lock Diverter Lockdown Dogs
Unlock. Lock Diverter Support Lockdown Dogs
Vent. Pressure Flowline Seals
Open. Close Shale Shaker Valve
Port / Starboard Open Overboard Valves
Unlike the panel functions or the BOP Control System, the panel functions for the
Diverter Control System do not contain Block positions. Diverter functions can be
put into the Block position only at the Diverter Substructure Panel.
b) Pressure Regulation Stations
Three sets or pressure regulation pushbuttons are located in the center of the
diverter control section. The three pressure regulators are for the Diverter
Element Regulator. Diverter Manifold Regulator. and Slip Joint Regulator. Each
regulator is provided with an Increase and Decrease pushbutton.
Note that the three way remote panel selector switches at the diverter
substructure panel must be in the remote panel position before the regulator
control pressures can be controlled from the drillers panel.
Pressure Meter Operating Pressure (psi)
Diverter Element Pressure 750
Slip Joint Pressure 300
Diverter Manifold Pressure Drillers choice
(usually 1000 to 1250 psi)
A fourth pressure meter for the Diverter Accumulator Pressure - Is located on the
diverter section on the Driller's Control Panel. This meter displays the
accumulator pressure or, the Diverter Substructure Panel and should, read 3000
psi.
Hydrostatic Effects on
Subsea Accumulator Bottle Precharge
3000 psi Working Pressure System
Water Depth
Precharge, psi
(1,000 psi + Water depth x .445psi/ft)
Available Fluid from
10 Gallon Subsea
Bottle
1
0 ft. 1,000 psi. 5.0 gal.
500 ft. 1,223 psi. 4.8 gal.
1,000 ft. 1,446 psi. 4.6 gal.
1.500 ft. 1,669 psi. 4.4 gal.
2,000 ft. 1,890 psi. 4.2 gal.

1
Calculated on a 3,000 psi WP system using 1,200 psi as the minimum usable fluid pressure. The % of
usable fluid delivered from the bottle is equal to:
(precharge + hydrostatic head) (-)minus (precharge + hydrostatic head)
(Min. pressure + hydrostatic head) (System WP + hydrostatic head)
API and MMS System Sizing and Response Guidelines
Reference Response Time Requirements
Accumulator Sizing
Criteria
API RP-53, 3
rd
Ed.
Response - Sec. 13.3.5
Volume - Sec. 13.3.2
Rams close in less than 45 sec.
Valves not to exceed rams
Annulars close in less than 60 sec.
LMRP Connector unlatch in less
than 45 sec.
Close & Open all rams plus one
annular with remaining
pressure to be 200 psi above
precharge pressure
API Spec 16D
Response - Sec. 2.2.2.1
Volume - Sec. 2.2.2.5
Rams close in less than 45 sec.
Valves not to exceed rams
Annulars close in less than 60 sec.
LMRP Connector unlatch in less
than 45 sec.
Open & close all rams plus one
annular plus 50% reserve with
remaining pressure to be above
precharge pressure
then
Open & close all rams plus one
annular with remaining
pressure above calculated
minimum ram or valve
operating pressure
MMS CFR 250
Chapter II Subpart D
Sec. 250.406-d-1
1.5x the volume to close all
preventers with remaining
pressure to be 200 psi above
precharge pressure
BOP Response Times
The closing time of a subsea BOP control system consist of two parts: signal time and
fill-up time.
The signal time is the elapsed time from when a function on a panel is operated until all
valves in the sub-sea pod have operated. The fill-up time is the elapsed time from when
the valves in the pod operate until the stack function if fully operated (open or close)
1) Signal Time
In an all hydraulic system there are five factors which affect signal time.
a) Hose length - this is a customer requirement and cannot be changed. For each
type hose the greater the length the slower the reaction time.
b) Hose Volumetric expansion - a stiffer hose, i.e., a lower volumetric expansion will
produce a faster signal transmission.
c) Hose diameter - for a constant length and stiffness, increasing the diameter of
the hose within limits will decrease the signal response time.
d) Temperature - tests or calculations at room temperature are inadequate.
Corrections must be made to account for the colder water (approximately 35
0
F)
since most of the hose will be underwater. Colder temperatures will cause a
longer response time. Response time calculations typically are at 35
0
F.
e) Amount of ethylene glycol - for adequate antifreeze protection, a 40% solution of
ethylene glycol should be used in the pilot lines while operating in sub zero
temperatures. Increasing the concentration of ethylene glycol will significantly
slow the response time of a given hose.
2) Fill Up Time
Fill up time of a preventer is affected by the supply of fluid and the hydraulic circuitry
on the stack.
a) Fluid supply to preventers is accomplished in two ways. Fluid is delivered from
the surface via hose or rigid conduit. Fluid can also be supplied from stack
mounted accumulators. If lines from the surface to the annular are not able to
deliver fluid at a minimum of 180 gpm for an 18 3/4 10,000 psi annular then
stack accumulators are necessary. The accumulators should contain enough
usable fluid to close one annular.
b) Hydraulic circuitry between the pod and preventer restrict the flow of fluid to that
preventer. Connections to an annular may include two one inch SPM valves
supplied by a 1 inch regulator and sufficient usable fluid in stack mounted
accumulators to close the annular. In tests on fill up time conducted on Shaffer
pods in the ship yard, to close an 18-3/4 inch 5,000 psi Spherical required 18 to
21 seconds. The 18 3/4 inch 10,000 psi Spherical with the same circuit will close
in 28-30 seconds. Connections to the annular included four one inch SPM
valves supplied by a 1 1/2 inch regulator and sufficient usable fluid in stack
mounted accumulators to close the annular.
HYDRAULIC SYSTEM FLOW
1) Main Hydraulic Supply
Hydraulic fluid, made up by automatically mixing potable water and water soluble oil
concentrate, is stored in a reservoir. It is picked up by electric pumps and/or air
pumps and flows through two 40 micron filters in parallel. The fluid then enters a
bank of accumulators where it is stored at a maximum pressure of 3,000 psi (with a
1,000 psi nitrogen precharge in accumulators). The hydraulic fluid also continues
through a flow meter (FM). An accumulator pressure gauge is located on the front of
the hydraulic control manifold and a pressure transducer (PT) transmits pressure
readings to the remote panels. A low accumulator alarm switch activates whenever
the accumulator pressure falls below 1,500 psi.
Hydraulic fluid flows from the accumulator bottles through a 1 check valve on its
way to a 1 manipulator type 4-way valve which selects the pod which receives the
Main Hydraulic Supply (MHS) The pod which receives MHS is called the active pod.
The pod selector valve is on the front of the accumulator unit and operates either
manually or remotely for a remote panel. When MHS flows from the valve to either
of the pods, the pressure activates either one of the pressure switches in the output
lines to operate the appropriate pod indicator light on the remote panels to indicate
the active pod.
Main hydraulic supply leaves the pod selector valve and flows to the BOP control
pod located subsea. This line is a 1 hydraulic hose located in the hose bundle. The
MHS line enters the pod through the large connection in the center of the kidney
plate. The flow then continues to the two subsea regulators (1 l/2 HKRs).
Some systems send the fluid subsea down a rigid conduit line. This is permanently
attached to the riser in a manner similar to a choke and kill line.
2) Regulator Pilot Circuits
We now need pilot lines to control the two subsea regulators (HKRs). Pressure is
supplied from the main accumulator bank through a 1 check valve to the manifold
pilot pressure regulator and the annular pilot pressure regulator. These two
regulators (1/2 AKRs) in the hydraulic control manifold apply pilot pressure through
the pilot lines (MR and AR) to the subsea manifold and annular HKRs, respectively.
Regulator pilot pressure is also fed to panel mounted gauges & pressure
transducers.
The subsea HKRs supply output pressure at a 1 to 1 ratio. A 1,500 psi pilot
pressure produces 1,500 psi output pressure from the subsea HKR for the blowout
preventers.
The output of the manifold subsea HKR goes to all of the ram preventer, valve, and
connector functions while the output of the annular subsea HKR supplies power only
to the annular preventers. A pilot line leaves each of the subsea HKRs and returns
back to the surface through the hose bundle. These two, 3/16 lines supply manifold
and annular readback pressures to gauges and pressure transducers located on the
hydraulic control manifold. A shuttle valve is located on the input to each gauge
between readback lines from both the blue and yellow pods (This Pod and That
Pod). Since there is no MHS to the inactive pod, only the active pod supplies
readback pressure through the shuttle valve to the gauge and pressure transducer.
3) Operation of a 3 Position Function
The pilot pressure required to control a function begins at the main accumulators
where 3,000 psi hydraulic fluid supplies two, ten gallon pilot pressure accumulator
bottles (with 1,500 psi precharge) through a 1/2 check valve. The pressure in the
pilot pressure accumulators is monitored by a gauge and pressure transducer.
These pilot pressure accumulators supply pressure to the manipulator valves on
the front of the hydraulic control manifold. Here we see a valve to control a Hydril
BOP. Pilot lines (number 29 and 36) leave the manipulator valve, connect to
pressure switches, then leave the manifold and go to both pods (both This Pod and
That Pod). Once in the pod, both lines connect to SPM valves. Both SPM valves
attempt to supply hydraulic pressure to either open or close the annular preventer.
Remember, only the active pod receives MHS and actually operates the preventer.
When the handle of the functions valve is operated, pilot pressure leaves the
manipulator valve through one pilot line and activates the associated pressure
switch to turn on an indicator light on the remote panel. The pilot pressure then
enters both hose bundles and continues subsea to the kidney plates. The pilot lines
then lead to the proper SPM valve in each control pod. Pressure forces the SPM
(Sub Plate Mounted) valve into the open position. This then allows hydraulic fluid to
flow from the subsea annular HKR and through the open SPM valve to operate the
annular preventer.
The opposite pilot line is simultaneously vented by the manipulator valve, releasing
pressure in that pilot line. When pilot pressure is released from the opposite SPM
valve, the SPM returns to the closed position by spring action and vents operating
pressure from the BOP into the sea.
Note that both pods receive pilot pressure but only one pod will actually be supplying
fluid to operate the preventer. This is the pod which is receiving Main Hydraulic
Supply (MHS) pressure from the pod selector valve.
In the center, or block position, the manipulator valve vents both pilot lines to the
Annular BOP. This allows both SPMs to close and vent all control pressure off the
preventer. The Block position indicates that the Control System blocks pressure
from going to the function and vents all control pressure off that function.
4) Operation of a 2 Position Function
A two position function differs from a three position function due to the presence of
only 1 pilot line from the pilot valve. The two position function reefers to the ability of
the circuit to only supply pressure and vent hydraulic pressure. These functions are
used for such items as subsea failsafe valves which must be pumped into the open
position or vented to allow them to close under their own spring power. Other
applications are Connector Secondary Unlock, where pressure is applied or vented.
Power for either pilot pressures originate in the pilot accumulator bottles. Only one
pilot line leaves the manipulator valve of a 2 position function. Leaving the valve,
the pilot line leads to a pressure switch and to both pods by way of the RBQs, hose
bundles, and kidney plates. The single pilot line then leads to the proper SPM in the
subsea control pod.
When it is desired to open a subsea failsafe valve, it must be pumped into the open
position against spring force. To initiate this, the manipulator valve is put into the
open position . This supplies pressure to the pressure switch in the pilot line which
turns on the indicator light on the control panel. The pilot pressure also enters both
pods through the pilot lines and activates the proper SPM valve. The SPM valve is
forced into the open position which allows hydraulic pressure to flow from the
subsea manifold HKR in the active pod, through the open SPM, and into the opening
chamber of the subsea failsafe (fail-safe) valve.
When it is desired to close the failsafe valve, the manipulator valve is placed in
the center, or close position, which vents off all pilot pressure to the subsea SPM
valves and the pressure switch. The pressure switch turns on the proper indicator
light on the remote panel. With pilot pressure removed from the SPM valves, they
return by spring force to the closed position and also vents pressure from the
opening chamber of the subsea failsafe valve. With no hydraulic pressure to hold it
in the open position, the failsafe valve closes due to spring force.
5) Operation of a Straight Through Function
Functions which use small volumes of fluid use 3000 psi pilot pressure directly at the
function and avoid the requirement of an SPM valve. These are often items such as
the pod latch (shown here as the manipulator valve on the far right-hand side), stack
mounted SPM valves for stack mounted accumulators, and ball joint pressure.
With these functions, pilot pressures are sent down to the pod through the hose
bundle from manipulator valves located on the hydraulic control manifold. Pilot
pressures flow through the pod directly to the pod latch piston or through the pod to
stack mounted SPM valves
Ball joint pressure originates at the ball joint pressure regulator located on the
hydraulic control manifold. The pressure is carried down a pilot line through the
upper female and to the ball joint.
Typical Hydraulic Power Unit Schematic
Typical Manifold Schematic
Typical Pod Schematic
Typical Stack Schematic
Shuttle valves for redundancy
1. Shuttle valve - the point where the redundant systems, blue and yellow, come
together.
2. Shuttle makes a decision "Who is going to operate this function, blue or
yellow pod"
3. Shuttle is passive. It is shifted by the active pod when pods are shifted.
4. Mounts directly onto the preventer since redundancy stops at this point
2
5. Stops flow out through shuttle into the inactive hose and pod if there should
be a leaking hose on the inactive pod.

2
Systems which are hard piped from the shuttle valve to the equipment port may deviate from this
general rule.
Hydraulic Symbols
1) Hydraulic and Air Lines
Preferred Acceptable ANSI
Hydraulic Air
2) Check Valves
Simple Pilot Operated
Check Valve (POCV)
3) Shuttle Valve
4) Relief Valves, Adjustable
5) Regulators
Manually Adjusted Hydraulically Piloted
6) Miscellaneous Items
Flow Meter Gauge Pressure Switch Pressure Transducer
7) Pumps
Air Driven Electrically Driven
8) Accumulator Bottles
9) Valves, 2-way
Needle or Ball Valve
10) Spool and Shear Seal Valves, 3 and 4-way
Manual
2-way
Manual 4-way
3-position
Selector
Manual 4-way
3-position
Manipulator
Return to
Reservoir
Plugged Unconnectable
Air Pilot and
Manual Operation
Hydraulic Pilot
Operation
with Spring Return
Solenoid
Operation
with Spring Return
Survey of Fittings Found on the BOP Stack
1) Threaded Fittings
a) Tapered Pipe Threads
The tapered pipe thread, either U.S. or British, has always had a sealing
problem. The U.S. thread is NPT (National Pipe Taper) and the British thread is
BSP.
The wedging action of the pipe taper will always be a problem. Any poorly
trained mechanic can take a large wrench to a pipe fitting and by putting too
much torque on the wrench he can split the casting of an expensive component
because of the wedging action of the taper. At sizes above 1" the NPT fitting is
not rated for pressures above 3,000 psi.
b) Straight Thread Fittings
To solve the problems of a tapered thread a straight thread has been developed
which seals with an O-ring. The thread machined into the housing is an SAE fine
thread, but at the top, a chamfer is machined which will accommodate the O-ring.
When the fitting is screwed into a port it can be tightened until the fitting makes a
metal-to-metal seat on the housing and the O-ring provides the fluid seal. Since
there is no taper on the threads, there is no wedging action to split the housing.
2) Flare Fittings
a) 45
o
SAE Flare Fittings
The concept of flaring tube to provide a seal and holding power to the connection
is very old. Its origin goes back to the early days of the automobile. Different
types of flared connections including 45
o
single and double flares, inverted flare,
30
o
flare, etc., were developed for coolant, fuel, brake and lube systems of the
automobile.
The SAE (Society of Automotive Engineers), formed in 1910, made itself
responsible for the manufacturing standards of all items used in automobile
manufacture, and tubing was one item to be so controlled. A set of dash
numbers was introduced so that the manufacture's part number followed by a
dash and a number would identify it as being made to SAE standards. Dash
numbers such as -5 for 5/16" O.D., were assigned with similar dash numbers for
other sizes.
A hand flaring tool was developed so mechanics could make an outward flare on
the end of a piece of copper tubing, and the inside flare surface always finished
off with an exact 45
o
angle. This became the standard angle for all SAE flare
fittings.
The thread, identifying dash numbers, and fitting to be used with each size tube
was regulated by SAE. This was the beginning of all the dash sizes we now
have in use in fluid power connectors.
The American made hose ends and adapter fittings did not match with those
made in other countries, especially in Europe and Asia. The confusion was
especially felt in the oil well drilling business as the drilling rigs were moved from
one location to another.
b) 37
o
JIC Flare Fittings
The 37
o
flared fitting is the most widely used fitting throughout the world.
Because the fitting can be used to connect to inch tubing, metric tubing and also
a hose assembly, this versatility offers the user a greater international
acceptance as compared to other fitting styles.
With American support, arrangements were made with manufacturers in many
other countries for an all-world seminar to arrange common standards. This
seminar was called the Joint Industry Conference and the standards which came
out of it were called JIC standards. The first thing to be done was to make an
easily noticed difference between an SAE and a JIC fitting. The face chamfer
angle on the female hose ends was changed to 37
o
, enough difference to be
noticed by the eye. Also, many thread sizes were made to different diameters so
JIC fittings would not mate with SAE fittings. In some cases the number of
threads per inch was made different. Each mechanic could tell that a JIC fitting
could not be used with an SAE adapter.
However, a variation of the dash numbering system was agreed upon for the
hose manufacturing trade, so that the I.D. sizes were in sixteenths of an inch.
Thus, 1/2" I.D. hose became 8/16 " or -8 size. The JIC hose ends for the "
hose have female JIC swivel end fittings are identified with the same dash
number, -8, for example.
3) Bite Type Fittings
The bite type fitting is a flareless fitting that consists of a body, a one-piece ferrule,
and a nut. On assembly, the ferrule "bites" into the outer surface of the tube with
sufficient strength to hold the tube against pressure, without significant distortion of
the inside tube diameter. The basic bite type fitting was first developed in Europe in
the early 1930s.
The bite type fittings provide a fairly secure and easily made-up method of
employing tubing on the control system. The bite type fittings are generally not
considered as "bullet-proof" as the 37
o
JIC fitting system.
The ferrule also forms a pressure seal against the fitting body. Bite type fittings
allow the fitting assembler to visually inspect the bite quality, thus significantly
minimizing the risk of improper assembly and related service problems
4) Flange Fittings
a) SAE Flange
The SAE flange hose end fitting has come into wide usage in the last several
years since system operating pressures have risen above 3,000 psi (the limit for
large diameter NPT threaded fittings). It is primarily intended for high pressure
connection of a hose to a component port pad. It is only for hose and is not
normally used on rigid plumbing. The flange end fitting is crimped on to the end
of a hose or the end of the hose is threaded into a flange block. These fittings
come either as a straight-through connection or with various angles from 22
o
to 90
o
. The flange is clamped to a machined port pad on the component, usually
a valve, pump, valve manifold, or BOP, by two half flanges using hex head cap
screws. An O-ring fits into a circular groove in the hose flange and makes a seal
against the port pad on the component.
These flange fittings are made in several pressure ratings, for pressures from
2500 to 6000 psi. They are available in sizes as small as 1/2" and up to 3
inches. Although they were originally built for mobile hydraulic systems, they are
being used on industrial systems as well. Size identification is with dash
numbers similar to those used on other fittings, expressed in sixteenths of an
inch.
Several variations of the basic design have been developed. The Code 62 is the
most common type used in BOP control systems.
b) SAE Flange with Integral Seal Sub
A modification of the SAE flange is to replace the face mounted O-ring seal with
a radial seal in both halves of the connection. A seal sub is an additional item
which is added to the assembly to form the radial seal in both halves of the
connection.
Troubleshooting: Pressure Losses
While the B.O.P. is down, pressure losses do occur. Isolating them as best as possible
and repairing the components where possible can keep downtime as a result of pulling
the BOP or Pods at a minimum. The areas that losses are sorted into 5 categories.
1) The Koomey Unit the Hydraulic Power Unit (HPU)
Components, which are the most common sources of pressure losses at surface,
are:
Pod selector valve.
Relief valve.
Check valves on the air and electric pumps discharges.
Hydro-air pressure switch.
Increase/decrease solenoids.
Manual regulator.
Tubing and piped connections.
Four way valves.
Most components above can be easily repaired (at an opportune time such as bit
trips, etc.) by securing pressure to the components and securing the air and electric
pumps.
Four way valves for instance one or another may not be possible to change out as
circumstances dictate and would have to be prolonged until the B0P/LMRP is pulled.
Operations will always dictate how and when repairs can be conducted safely.
2) The Pilot System
The pilot pressure system begins at the two pilot pressure accumulators at the
Koomey Unit and ends at each pod block. A pressure drop on the HPU pilot
pressure gauge while the unit is idle will indicate a loss of pressure in the system.
Components in the system are:
Tubing/pipework from the accumulators to the 4 way valves.
The 4 way valves, and regulators.
RBQ junction plates for each jumper hose.
The RBQ junction boxes at each pod reel.
The hose reel hot line system.
Any splices or damaged areas in each hose.
The termination of the pilot hoses to the kidney plate.
The stainless steel tubing and connections from the pod top plate assembly to
the pod valve block.
The pilot signal passage way in the pod valve block and the SPM.
a) Any leaks found in the tubing/piping can be visually found and stopped by
securing the pressure to that function.
b) On the 4 way valves most leaks can be detected by listening to the valve and
listening for a washed valve body. Also the regulators and the 4 way valves can
be checked for pressure loss by removing the vent return lines and watching for
a leak.
c) A visual check on the RBQ's both at the Koomey Unit and the hose reel and the
pilot line connections should reveal any leaks.
A way of decreasing the chances of having a leak at a junction box, is by first
visually inspecting the male/female check valves for debris, broken O-ring, and
secondly by placing all the functions, where possible, into the block position at
the 4 way valves when the junction box is removed or installed. If there is no
pressure on the check valves when mating them together there is less of a
chance of washing out or cutting the O-rings before the junction plates are fully
mated.
d) The pod reel hot line system gets its power from the 1" -3000 psi supply line and
it is still possible to lose pressure in the pilot system. Since the hot line system 4
way valves and regulators tie into the main pilot line/hose inside the reel, any
pressure applied to the pilot lines once the hose reel junction boxes are mated
can back flow through the components and be lost through the vents. By
securing the supply valves and keeping the check valves in good order, the
chance of this happening can be greatly reduced.
e) Although pressure losses can occur from damaged areas in the pod hose, this
will most likely be the last place that you'll look. Leaks here will be hard to detect.
That's why it is essential when the pod or BOP is on deck and being tested any
pressure losses should be scrutinised so that you can be absolutely sure that you
can eliminate this area as a possible source pilot line pressure losses.
f) As above, the termination of the pilot hoses to the pod top plate assembly and
the stainless steel tubing and the connections to the valve body are not areas of
high probability where you are going to have leaks. However if these areas are
corroded particularly at the kidney plate, they can become high suspect areas.
Also consideration should be given to this area if you know that an object (T.V.
frame, guideline tools may have hit or jarred the pod guide arms).
g) The SPM, besides the check valves at the pad hose reel, is going to be the most
likely place for a leak in the pilot line system.
SUMMARY
If you have a leak in the pilot line system and you can rule out the loss of
pressure is occurring top side then the way to find this leak is by systematically
placing each four way valve into the block position and observing the leak until
you find the pilot signal that is losing the pressure. Once the leak is found and
depending upon it's severity and the rigs situation any action or no action may be
taken.
3) The Accumulator/Pod Manifolds System and BOP Functions:
The accumulator/pod manifolds system provides the way for fluid to get to the SPM
at the right pressure to be sent on it's way by the SPM to the designated function on
the BOP. The components that must handle this fluid are:
Accumulator bottles at the Koomey unit.
Pod selector valve.
Pod hose, reel swivel connection, pod hose.
The 3000 psi pipe work from the pod top plate to the regulators and the
discharge piping to the valve block.
BOP accumulator isolator valves
The internal pod valve block manifolds.
Hoses from the pod receptacles to the shuttle valves.
Hoses from the shuttle valve to the functions on the B.O.P.
Most probable leak points are:
a) The accumulator bottles; unless there is a visual leak here in the pipe work to the
pod selector valve you won't have any problem.
b) Any leak associated with this entire system will show up on the flowmeter and on
the accumulator pressure gauge.
c) The Pod selector: the selector valve (which is of the manipulator type) can be
easily checked for leaks. Listen to the valve for leak noise with a mechanics
stethoscope. By breaking the pipe work on the return side of the 1 pod valve
any leak can be checked visually.
d) The Pod hose reel swivel connection, and pod hose; unless you can visually see
a leak in the top side of this system the only way to isolate the 1 hose down to
the pod is to do the following:
e) Bleed down both the pilot signals to the pad manifold and annular regulators and
put the riser connection 4 way valve into the block position, this will isolate the
3000 psi 1 hose, the 3000 psi pipe work in the pod and the 3000 psi system
downstream of the subsea accumulator SPM. A loss of pressure will be indicated
on the accumulator pressure gauge. To continue and to find the leak, send a pilot
signal to the Subsea accumulator SPM establishing communication to the
subsea bottles. Observe for leaks. If no loss of pressure is found, continue on by
placing each 4 way valve into block (thus closing all SPMs).
f) By putting a pilot signal to each regulator you will find if you have any leaking
SPMs while they are closed. Next, by placing each 4 way valve into the drilling
mode (rams open, annular open, failsafes closed) this will detect if the leak is
taking place from the open SPM to the designated function. If a leak is found
here, to determine if it's from the open SPM to the shuttle valve or from the
shuttle valve to and including the function just switch pods. Then place all 4 way
valves into block and individually open the suspected leaking function. If the leak
is not found here then this will tell you the leak is not from the shuttle to the
function. The problem must be the SPM or the hose going to the shuttle valve. If
the leak is still found on the other pod then the leak is from the shuttle valve to
the function.
SUMMARY
Once it is determined where the pressure loss is occurring, a number of actions
can take place. They are:
1. Put pressure on the leaking SPM/function line then place 4 way valve into
block position and leave it like that.
2. Switch pods.
3. Pull pod.
4. If leak is below (downstream) SPM/pod, the BOP stack or LMRP will have to
be pulled.
In conclusion, if the leak is to the main 3000-psi hose or pipe work or if a
regulator is leaking the pod will most likely have to be pulled and repaired. If the
SPM is working and you are losing pressure through it, and it holds pressure
when it is closed (the SPM) you can most likely leave it in the block position until
the BOP is pulled. And finally if the leak is from the shuttle valve to the function
depending upon the situation the B.O.P. will have to be pulled to repair the leak.
4) Hose Reel Manifold
The hose reel manifold is designed to give control to the pods so that a few primary
functions can be operated while the BOP is being run or pulled. The system should
be used during these times and not during normal operations.
The hose reel manifold receives its primary fluid pressure from the 1-3000 psi feed
into the reel via the swivel connection. A 3/16 I.D. jumper hose tee off from the 1"
line feeds the main shut off valve for the hot line system (manifold supply shut off).
The manifold supply shut off feeds a common manifold from which the following 4
way valves are fed fluid pressure:
Riser Connector - primary latch and unlatch SPM's.
Riser Connector - secondary unlatch SPM.
Wellhead Connector primary latch and unlatch SPM's.
A Shear or Pipe Ram open and closed SPM's (pending hook up).
A regulator for ball joint pressure. (This is no longer required but some older rig
systems may still have the regulator not hooked up).
A regulator for the manifold pressure command pilot signal to the live pod.
Selecting one of the above pod hose 4 way valves; Riser Connector Secondary
Wellhead Connector, Shear or Rams, and placing it in the desired mode of operation
sends a pilot signal to the pod to lift that particular SPM. With the manifold regulator
adjusted to 1500 psi and with the manifold regulator shut off valve open a pilot signal
is sent to the manifold regulator at the pad. With this signal the regulator will then
regulate the 3000-psi feed to the desired pressure (1500-psi). Now with the SPM
lifted off of its seat, manifold pressure can now flow to the desired function and
operate the function. With the 4 way valve kept in the desired mode (say riser
connect lock) and with the pod reel regulator adjusted to 1500 psi, the regulator will
reduce the 3000 psi feed to 1500 psi, and keep 1500 psi on the riser connector lock
while the BOP is being run or pulled. Obviously this is of primary concern whilst
running or retrieving a BOP stack - maintaining hydraulic closing pressure on the
L.M.R.P. connector.
An important consideration to keep in mind while working and the way valve is that
they are of the selector type . If a manipulator type body is installed once the reel
hot line system is shut down and the junction box is mated together any pilot signal
using the above 4 way valves can be bled off because a manipulator valve bleeds of
pressure from its functions while in block, where as the selector valve will hold
pressure in the block position. Therefore Pod hose valves should always be selector
type which will not bleed off pressure when thrown into a block position.
a) The procedure for activating the reel hot line system for running or pulling the
BOP is as follows:
Place the pod selector to either blue or yellow pod (use the same pod that
was previously used).
Go to the hose reel and check to see if all 4 way valves are in block, if not
put them in the block position.
Open the manifold supply shut off valve.
Open the manifold regulator shut off valve.
Adjust both regulators to the desired operating pressures (manifold 1500
psi).
If BOP is to be run, place riser connector to lock position wellhead connector
to open (unlatch) position. REMOVE THE HANDLE TO THE RISER
CONNECTOR VALVE WHILE RUNNING OR PULLING THE B.O.P. AS A
SAFETY PRECAUTION.
If BOP is to be retrieved put the riser connector to lock, and wellhead
connector to the latch position. Then put manifold pressure at pod reel to
minimum 1500 psi.
Go to Koomey Unit, place all four way valves into the block position, bleed off
regulators, place regulator selectors to block position.
Remove junction boxes from hose reels and activate hose reel functions.
You are ready to go about with your BOP stack operation.
b) To deactivate the hot line system if the BOP is down:
Mate on junction box, make sure air to motor and lock pin on reel is engaged.
Go to unit, place all 4 way valves into the drilling mode (rams open, annular
open, failsafes closed and (Connectors locked).
Select mode of operation for the regulators (electric or manual). Set
regulators to drilling pressures.
Go to the reel and secure the manifold regulator shut off valves.
Bleed down regulators.
Place 4 way valves into the block position.
Secure manifold supply shut off valve.
c) To secure the reel hot line system if BOP is on deck:
Secure ball joint and manifold regulator shut off valves.
Bleed down regulators.
Place 4 way valves into block position.
Secure manifold supply shut off valve.
d) A few comments about the Pod Reel hot line system:
To avoid any confusion at the pods, always use the reel hot line system on
the pod that is on line.
The hot line system is not to be used when the reels junction boxes are
mated.
The 4 way valves are of the selector type.
Troubleshooting: SPM Failure
1) 42 Line Pod
Scenario: B.O.P. on beams ready to be run or at the wellhead and a function fails to
operate. What should be done?
a) If no fluid flow is indicated by the flowmeter check the following:
The Pod selector valve is selected to proper pod.
The Regulator pressures: manifold and annular regulator selectors are in
proper mode and both regulators have the right amount of pressure on them -
Check read back gauges to verify.
Pod reel junction box is on and secured.
Pod reel hot line system is secured. To do this check:
a) 4 Way valves are in block position.
b) The Pod reel shut off valves (manifold supply, manifold regulator and the
prehistoric ball joint regulator if still in use) are closed.
c) The Regulators are bled off.
b) Switch pods, try same function again (same panel):
If function works this tells you that your problem is between the RBQs (for
that pad that did not work) at Koomey Unit to the shuttle value going to that
function.
If function still does not work check out:
a) Air pressure at Koomey Unit.
b) Electricity to unit (proper current, voltage).
c) Obstructions that may stop the 4 way valves from working.
c) Try function again from another source and if the function works then check out:
Panel which would not operate: The easy way to check out the solenoid is to
disconnect the air fitting to air piston. `Try functioning again and you should
get a shot of air. If you don't check out the electrics for that function and
solenoids. (Electrical box right hand side of main control panel).
If function still doesn't work review steps 1 a
If the function did work on the other pod, switch back to the pod which is
malfunctioning.
d) Try functioning it again, if it still doesn't work:
Go to pod reel, find proper pilot line and disconnect it on the inside of the reel
so that you can see if the signal is getting through the junction box check
valves. Be sure pod hose reels are locked out and can not be rotated.
If you are getting a good pilot signal through, then the signal you are getting
should be a good one at the pod. Obviously a leaking pilot line in the hose
bundle can prevent the signal lifting the SPM.
If you don't get a signal here, reconnect pilot line and disconnect it on the
outside of the pod reel before the check valves, if you get a signal here then
either the male or female check valve is damaged -change out the check
valve.
If you don't get a signal, go to Koomey unit and inspect the check valves on
the RBQ and also check to see if the correct pilot line is hooked up between
the unit and pod reel.
e) If you are getting a good pilot signal to the pod:
Try another function that will use the same regulator on the pod to determine
if the regulator is shot.
If the other function works you can be fairly sure that:
a) The SPM is not working.
b) The shuttle valve is jammed and not allowing the fluid flow to the function.
c) Or the component functioned is inoperable.
f) If at anytime that you operate the function and the fluid flow doesn't stop and the
function works on the other pod then you have a broken hose or connection on
the pod side to that particular function.
Once you have the problem isolated to an SPM, then the only operation to pull
the pod (see section on PULLING A POD).
After pulling the pod, repairing the SPM, function testing it on surface, rerun
the pod. Use a T.V. camera, don't stab it blind.
Function test pod.
If the function still doesnt work from any source, the shuttle valve must be
jammed. Depending on the particular function, wellhead connector, shear or
pipe rams, failsafes, or lower annular then both halves of the BOP will have to
be pulled. If the riser connector, upper annular, or choke and kill connector
SPM1S fail then your only need to pull the L.M.R.P. section to surface.
g) Basically a function needs only 4 requirements to be fulfilled and they are:
The regulators need a continuous feed of high pressure fluid (3000 psi).
A Pilot signal to the regulator telling it what pressure to reduce the 3000 psi
to.
A pilot signal (3000 psi) to the SPM, to lift it off its seat.
An uninterrupted means of letting regulated fluid to the function (hose, shuttle,
valve).
If you can be sure these requirements are met then it can only be 2 things:
the SPM or the function (ram operator, annular assembly, failsafe or
connector pistons).
Final Note:
Remember that the manner and way you troubleshoot your control
system problem is vital to the rigs safety. How you derive the problem
will determine whether you require to make a surface repair, pull a
pod, pull the L.M.R.P. or pull the complete BOP stack. Therefore know
your system well.
Troubleshooting: Leaks and Malfunctions
1) Leaks and Malfunctions
Normally, a fluid leak in the system is detected by watching the flow meter on the
driller's panel. If the flow meter indicates a fluid flow when no functions are being
performed, or if it continues to run and does not stop after a function is performed,
this generally indicates that there is a leak in the system.
Once you have determined that there is a leak, you should begin a check of the
system to determine the location of the leak. 'Me first thing to do is to make a
thorough visual inspection of the surface equipment. You do this by carefully
examining the hydraulic control manifold and accumulators to see if you can find a
broken line in the system or a fluid leak at any of the fittings. If no leak is found, next
check the jumper hoses and hose reels to see that all connections are tight and that
no hoses are damaged. Sometimes a bad connection at a hose reel R13C junction
box will result in a leak. Examine the connections carefully to be certain that they
have a firm seat.
While at the hose reel, check the hose reel manifold to make certain that all of the
valves are in the centre position. Also, make certain that the needle valve to the
manifold pressure supply shutoff is tightly closed. If this valve is left open when the
RBQ junction box is connected to the reel, it will allow fluid pressure to be forced
back through one of the surface regulators and vent into the tank, thus indicating a
leak in the system.
If you find this valve in the open position, then close it and check the flow meter to
see if the fluid flow has stopped.
If this procedure does not prove successful in locating and stopping the leak, you
should then return to the driller's panel to begin an item by item check of the system.
Upon returning to the driller's panel, change the pod selector valve to operate the
system on the other pod.
For example, if you are operating on the blue pod, switch over to the yellow pod.
This will tell you whether the leak is in one side, or both sides, of the system and will
let you begin to isolate the leak. If the leak stops when you change from the blue to
yellow pod, then you know that the leak is located in the blue side of the system.
If the leak doesn't stop when you change control pods, then you know that the leak
is either below the control pods or somewhere in the hydraulic control manifold.
Let's take a hypothetical example and say that the flow meter stopped when you
changed from the blue to the yellow pod. Ibis tells you that the leak is somewhere in
the blue side of the system. And, since you made a visual inspection of the surface
equipment earlier, you now know that the leak is probably subsea. If conditions
permit, you should now change back to the blue pod, and try to isolate exactly where
the fluid is leaking. Do this by blocking each function item by item, allowing plenty of
time for the function to operate. You should watch the flow meter very carefully while
blocking each function to see whether or not the leak stops. If the flow meter does
stop when a certain function is blocked, then you have isolated the leak, it is
somewhere in that specific function.
Since you are not sure exactly where the leak is, you should next lower a TV camera
into the stack. Then unblock the leaking function and try to determine the exact
location of the leak. The leak will show up in the water as a white mist seeping from
the leak area. If the leak is coming from the pod, there is either a bad regulator or
SPM valve in the pod. If the leak is bad enough, you can pull the pod and make the
necessary repairs.
Always use the schematic drawing to make certain you are working on the correct
valve and follow the repair procedures as outlined in the subsea manual.
If the leak is below the pod, and the problem is serious enough, you can either send
a diver down to make the necessary repairs or pull the stack and repair the leak on
the surface. If the leak is not of a serious nature, you can simply leave that function
in the block position until the next time the stack is brought to the surface and then
make the necessary repairs.
If the flow meter did not stop when the pod selector was switched, or when all
functions were blocked, you should check the master fluid return line to the tank- If
there is a fluid flow in this line, then one of the pilot valves or regulators is leaking.
First, check all pilot valves to make sure they are squarely in the block position or
fully opened or closed. Sometimes a partially opened valve will allow fluid to leak by
the valve.
If the valves are all fully thrown, next disconnect the discharge line from each pilot
valve one at a time. If fluid exhausts from one of the valves after the discharge line
has been disconnected, then the valve is bad and should be replaced with a new
one.
If the discharge lines on the pilot valves do not show and signs or leaks, then
disconnect the discharge lines on the regulators in the same manner checking for a
fluid discharge. Any fluid exhaust from the fluid return side of a regulator will indicate
that the regulator is bad and should be replaced.
Now, let's continue. For this example we will assume the system is operating
normally and you push a button to perform a function. The flow meter begins to
measure the fluid but then continues to run and does not stop at the number of
gallons that is required to operate that function.
Remember, the key words here are "continues to run". It is important to note that
each time a function is operated it will not take exactly the same amount of fluid
listed on the fluid capacity chart. It can vary either way of the listed capacity
necessary to operate the function.
However, if the flow meter continues to show a fluid flow after the time required for
the function to perform, then there is a leak somewhere in that function.
One possible cause is foreign material or trash in the SPM valve seat causing the
valve to stay open and bleed fluid through the system. The best way to check for
trash is to operate the valve several times to try and wash out the foreign material.
After operating the valve several times, observe the flow meter to see if the leak has
stopped.
Next, go to the hydraulic control manifold and check the one inch line in the other
jumper hose. This will tell you whether or not the shuttle valve for the function is
leaking. If it is leaking, there will be a fluid return to the surface through the other
hose. In other words, the fluid will be flowing down through the blue pod, leaking by
the functions' shuttle valve, returning to the surface through the hose to the yellow
pod. This fluid return will indicate a faulty shuttle valve. The leak can be stopped by
blocking that function in the desired position and then leaving it until repairs can be
made later.
If these procedures do not stop the leak, the problem is most likely caused by either
a broken line, a bad SPM valve or a bad seal in the function. 1he best way to
determine which of these is the problem is to lower a TV camera to observe the
system in operation. Any fluid leak should be easily seen as a white mist flowing
from the leaking area. If the leak is in the pod, the pod can be retrieved to the
surface and repaired. If the leak is somewhere on the stack, you send a diver down
and make the necessary repairs. Or, pull the stack, pressure test to locate the leak
and then repair it on the surface.
Up until this portion we have been concerned with fluid leaks. Now we will look into
some possible malfunctions that can occur in the hydraulic fluid system.
The first thing we will consider is a slow reaction time in the operation of a function.
For instance, if we push a button to operate a particular function that we know is
supposed to take 22 seconds, but the operation takes 60 seconds, then we know
that there is a malfunction somewhere in the system. This problem will most likely by
caused by: low accumulator pressure, a bad RBQ connection, or a partially plugged
pilot line.
First check the gauges to see if you have the proper operating pressures. If you do
no have the required pressures, then check the pumps to make certain they are
operating properly, and check the fluid tank to make sure you have fluid in the
system.
The next thing to check in looking for the cause of the slow reaction time is the
accumulators. Always make certain the shutoff valves between the accumulators
and hydraulic control manifold is open. If someone has been working on the unit,
they may have forgotten to reopen the valves when they finished.
If all pressures are good and you can find nothing wrong with the accumulators or
the hydraulic control manifold, next check all surface hose connections. If the RBQ
junction boxes are not tightly seated, they can restrict the flow rate of the fluid
through the connection and thus cause the function operate slowly.
If you have checked all connections and the pressure in the system is good, then the
final thing to do is to pull the pod and check the pilot lines for sludge which may have
settled out of the hydraulic fluid. This can be accomplished by disconnecting each
line at the pod one at a time. As each line is disconnected, it should be flushed out
by flowing new fluid through it.
Another malfunction you may encounter is no fluid flow meter indication when a
function button is pushed. This can be caused by one of the following problems: No
accumulator or pilot pressure, the valve on the hydraulic control manifold did not
shift, there is a bad SPM valve, or the flow meter is not working properly.
First, let's troubleshoot for no accumulator pressure or pilot pressure. The first thing
to do when troubleshooting for this problem is to check all of the pressure gauges
that monitor the system. Normally, these will give you an indication of where the
problem is located. Also, before leaving the driller's panel, press the 'Test Button" on
the panel to make certain that the lights in the function buttons are working properly.
Sometimes these lights bum out and will not indicate the position of a function.
If you have been unable to solve the problem at the driller's panel, you will next have
to go to the hydraulic control manifold and begin looking there. The first thing to do is
to double check the flow meter on the driller's panel. This is done by operating the
function again while monitoring the flow meter on the hydraulic control manifold. It is
possible for the impulse unit which sends the flow meter signal to the driller's panel
to malfunction. A bad impulse unit might not indicate a flow on the driller's panel
when the fluid actually is flowing through the system.
Another way to check for a bad flow meter is the regulator gauge for that function.
You can always tell whether or not a function operates by watching the regulator
pressure after you push the button to operate the function. If the pressure falls 300
to 500 psi after the button is pushed and then comes back up after the time required
to operate the function, then you will know the function has been performed
regardless of flow meter action.
Next, check the air regulator and the electrical supply to make certain that the proper
energy is getting to the hydraulic control manifold. Check the fluid level in the tanks
and check the pumps and their pressure switches to make certain they are in the
proper operating condition. If the fluid in the tanks has run dry, the triplex pump will
have to be primed again before you can get the system back into operation.
Also, check all filters to make certain that they are not plugged with trash.
Also, check the nitrogen pre-charge in the accumulator and bottles. Ibis is done by
bleeding the fluid from the bottles back into the tank. Then check each bottle
separately to make certain that each has the proper nitrogen pre-charge.
Next, we will give you some troubleshooting hints for what to do if the valve on the
hydraulic control manifold fails to shift when the button on the driller's panel is
pushed.
The first item to check is the air supply to the system. Too little air supply is one of
the biggest causes of unsatisfactory operation and valve malfunction. Check the air
gauge for excessive pressure drop. If the gauge shows less than 80 psi or an
excessive pressure drop during operation, the air supply is not enough to operate
the system satisfactorily.
people hang things over the handles and forget to remove them. These items can
sometimes prevent the handles from turning.
If you can easily operate the valve manually at the hydraulic control manifold, there
are three other areas to check in troubleshooting this problem.
The button on the panel and the electric solenoids and power relays to the valve.
Check the valve itself to make certain that it is not faulty. The best way to do this is
to simply replace the entire valve body assembly. If the function then works properly,
you will know that the valve needs to be repaired.
If a plugged pilot or main fluid line is preventing a function from being performed, the
only way to solve the problem is to disconnect the hose at the pod, and flush the line
with clean fluid.
If there is a bad SPM valve preventing a function from operating, the only solution for
this problem is to pull the pod and replace the valve. Always be certain that you use
the schematic in the subsea manual to locate the correct SPM valve before making
any repairs. It's always better to double check to be sure you are replacing the
correct valve than to run the pod back down and then discover that you replaced the
wrong valve by mistake.
Operation of the Electrical Portion of the System
THREE POSITION FUNCTION
OPEN PUSH BUTTON
When the open button is pressed on a remote panel, the open solenoid on the HPU will
be energized to the open position. Air pressure will then pass through the normally
closed solenoid to a 3 position air cylinder connected to the hydraulic panel manipulator
valve on the hydraulic manifold. The manipulator valve is then shifted to the OPEN
position. Opening hydraulic pressure pressurizes the pressure switch in the open pilot
line turning on the open lamp for this function.
When the open button is released, the air solenoid valve will return to its normally
closed position simultaneously venting air pressure off the air cylinder. If required, the
panel hydraulic valve may be shifted manually with the handle since air pressure is no
longer applied to the cylinder.
The lamps on a three position function use a combination of two pressure switches to
turn on the proper lamps. When pressure is applied to the Open hydraulic line, the
Open pressure switch is activated. Voltage is applied to the Open lamp through the
normally open (N.O.) contact of the OPEN pressure switch and the normally closed
(N.C.) contact of the CLOSE pressure switch.
CLOSE PUSH BUTTON
When the CLOSE button is pressed the close solenoid will operate. Air pressure will
then pass through the normally CLOSED solenoid to the same air cylinder connected to
the same hydraulic manipulator valve. The manipulator valve is then shifted to the
CLOSE position. Closing hydraulic pressure pressurizes the pressure switch in the
close pilot line turning on the close lamp for this function.
When pressure is applied to the CLOSE hydraulic line, pressure is released from the
OPEN hydraulic line. This causes the CLOSE pressure switch to activate and the
OPEN pressure switch to deactivate. Voltage is now applied to the CLOSE lamp
through the normally open (N.O.) contact of the OPEN pressure switch.
BLOCK PUSH BUTTON
When the BLOCK BUTTON is pressed, both the OPEN and the CLOSE solenoids are
energized. Air pressure then passes to both sides of the 3 position air cylinder which is
connected to the functions manipulator valve. When this occurs, the manipulator valve
will go to its center position. Pressure will be released from both pressure switches.
When pressure is removed from both the OPEN and CLOSE hydraulic lines, both
pressure switches are de-activated. The block lamp is turned on through the normally
closed (N.C.) contacts of both pressure switches.
MEMORY CIRCUIT
As previously discussed, all pressure is removed from a particular function when the
hydraulic manipulator valve is moved to the BLOCK position. In order to remember
and illuminate the previous position the manipulator valve was in before BLOCK, a
memory circuit is used. Each three position circuit has its own individual memory circuit
which consists of two (2) relays. The memory in no way interferes with the normal
operation of the system. It is intended to assist the operator in knowing the complete
status of the stack.
OPEN MEMORY
As discussed in the three position circuit, pressure applied to the OPEN pressure switch
will turn the OPEN lamp on. At the same time 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 the K1 coil. At the same time
the normally open contacts are closed a normally closed set of K1 contacts are opened
in the close portion of the circuit. The normally closed contacts are opened to prevent
K2 from energizing.
When the hydraulic pressure is removed from the OPEN pressure switch it will de-
activate and complete the circuit to turn on the Block lamp. Since nothing has happened
to de-energize K1, the Open lamp will remain on also.
CLOSE MEMORY
The CLOSE portion of the memory operates on the same principal as the OPEN. The
only difference being the CLOSE use the opposing relays to the OPEN. When pressure
is applied to the CLOSE pressure switch, the switch will turn on 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 energized, K2 closes a set of normally
open contacts which are connected between the negative (-) voltage and the K2 coil. At
this time a normally closed set of K2 contacts are opened also The normally closed
contacts are opened to prevent K1 from energizing. When hydraulic pressure is
removed from the CLOSE pressure switch it will de-activate and complete the circuit to
turn on the BLOCK lamp since nothing has happened to de-energize K2 the CLOSE
lamp will remain on.
TWO POSITION FUNCTION
OPEN PUSH BUTTON
When the open button is pressed, the open solenoid will operate. Air pressure will then
pass through the normally closed solenoid to an air cylinder connected to a hydraulic
manipulator valve. The manipulator valve is then shifted to the OPEN position.
Both the open and close lamps on a two position operate directly from ONE pressure
switch. Since a two position function is used only on fail safe functions or connector
secondary functions, the pressure switch is located on the OPEN or PRESSURE side of
the hydraulic line. When hydraulic pressure is applied to the pilot the line, the pressure
switch is activated and the OPEN lamp is turned on.
CLOSE PUSH BUTTON
When the CLOSE button is pressed, the close solenoid will operate. Air pressure will
then pass through the normally CLOSED solenoid to the opposite side of the same air
cylinder connected to the same hydraulic manipulator valve. The manipulator valve is
then shifted to the CLOSE position.
When pressure is removed, the pressure switch will switch back and the CLOSE lamp is
turned on.
LAMP TEST
LAMP TEST
The testing of all lamps is accomplished by the use of Steering Diodes.
When the LAMP TEST button is pressed, voltage is applied to a LAMP TEST buss.
From this buss, through the steering diodes, voltage is applied to all lamps. Since all
lamps are connected by the lamp test buss, the steering diodes are required to prevent
all the lamps from illuminating when even only one lamp is illuminated.
INCREASE/ DECREASE
ELECTRIC REMOTE CONTROLLED REGULATOR
The regulator function on the panels consists of two solenoids operated in the same
manner as a normal two position function. The regulator circuit has no lamps. 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 Operated 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 pressure is still trapped due
to the check valve in the increase line. To decrease the air pressure, the decrease sole-
noid is operated. When energized, it will vent the trapped air pressure to the
atmosphere.
PRESSURE TRANSDUCER CIRCUIT
The pressure TRANSDUCER circuit is made up of three basic components. There is a
voltage regulator, a pressure TRANSDUCER and the remote meter. There will be one
voltage regulator to supply +5 volts to all of the TRANSDUCERS located in the
hydraulic manifold.
A. VOLTAGE REGULATOR
The voltage regulator has an input voltage of +120 VDC (or 12 VDC, depending
on system voltage). The input voltage is reduced to +5 volts D.C. output. If there
are any problems with the regulator it should be replaced.
B. PRESSURE TRANSDUCER
The pressure transducer is a Potentiometric Type transducer. This
potentiometric transducer is a variable resistor (0-2000 Ohms) that changes
resistance in response to hydraulic or pneumatic pressure applied to its helical
bourdon tube. As pressure is applied, the resistance varies. With +5 volts
applied to the transducer (across Pins 1 and 3), a 0 to 5 volts signal will result
across terminals 1 (-) and 2 (+) proportional to the pressure applied. In other
words, with no pressure applied there will be no voltage output. With full
pressure applied +5 volts will be produced at terminals 1 and 2.
A 3000 psi transducer will have an output of +5 volts at 3000 psi (full pressure).
A 6000 psi transducer will have an output of +5 volts at 6000 psi.
C. METER
The remote meter circuit consist of a 100 micro amp meter. A
24.9 Ohm fixed resistor and a 25 K Ohm variable resistor. The resistors are
used to calibrate the meter to the transducer.
A 3000 psi meter will show full scale deflection of 3000 psi with +5 volts applied
to its terminals. A 6000 psi meter will show full scale deflection of 6000 psi with
+5 volts applied to its terminals.
Note:
Common all meters to 5 VDC regulated supply not to system 120 VDC.
A meter and pressure transducer of the same pressure rating must be used in the
same circuit.
Mul t i pl e x Dr i l l i ng Cont r ol S y s t e ms
Control Valves
Most of the valves and pressure regulators are based upon the
sliding, metal-to-metal, ceramic-to-metel shear-type seal. This
type of seal is known for its durability and for its capability to
operate with high reliability even with fluids which are highly
contaminated by particulates. The sliding action rubs away the
contaminants and actually improves the seal with a polishing
action between the seal rings and seal plates of the valve.
The earliest valves had carbon steel bodies and flanges
which were coated with special, baked-on finishes. The valve
trim, parts, the seal rings and seal plates were stainless steel.
However, it was soon realized that stainless steel structural
parts were, in the long run, more cost-effective and reliable.
All Cameron valves and pressure regulators for offshore
system installations are now manufactured completely from
stainless steel or other appropriate corrosion resistant materials.
The standard material for valve bodies and flanges is 303 stain-
less steel; type 316 stainless steel is available on special order.
The seal plates of most 1/4" valves for installation in the subsea
environment are alumina ceramic (aluminum oxide); all other
valves have type 440C stainless steel seal plates. The ceramic
seal plates result in valves which have an almost unlimited life.
The seal rings are 17-4PH stainless steel. Aluminum bronze or
17-4PH stainless steel is used in parts which are in moving
contact with 300 series stainless parts to prevent galling.
Springs in the valves are typically 17-7PH stainless steel. All
fasteners (cap screws, bolts, nuts, retaining rings, etc.) are
stainless steel. The magnetic circuit components of solenoid
valves employ carbon steel which has been electroless nickel
plated and all parts which would otherwise be exposed to sea
water are enclosed within a stainless steel outer housing.
1/4" Solenoid Valves
The 1/4", two-position solenoid valves are available in either
three-way or four-way configurations. The valves have direct-
acting coils and use shear-type seals. They are available with
24-28 VDC or 110-120 VDC coils. The valves have a Cv of 1.1.
These valves are available either for total sea water immersion
or for mounting onto pressure compensated, oil-filled chambers
which isolate the coils from exposure to sea water.
1/8" Solenoid Valves
The 1/8", three-way solenoid valves have a small orifice and are
designed to serve as pilot valves for larger valves of all sizes,
from 1/4" up to 1-1/2". They have direct-acting coils and use
shear type seals. The solenoid housings are designed for
mounting to a pressure compensated, oil-filled junction box.
They are available with 24-28 VDC or 110-120 VDC coils and
may have single or dual coils. The valves have a Cv of 0.05.
Control Valves
1/8" Three-Way, Solenoid Valve
1/8" Three-Way, Solenoid Valve Detail (1/4" valves are similar in
construction)
SD-8689
SD016228
Cameron hydraulic valves and pressure regulators have been noted for more than 25 years for their
ruggedness and reliability. The basic valve design was developed for use in the earliest subsea drilling
control systems.
1/4" Four-Way Valves
1/4" four-way subsea valves are available in two-position and
three-position versions. They are all sub-plate mounted, have
alumina ceramic seal plates. The three-position valve is cen-
tered by springs and the hydraulic pressure supply. The valve
Cv is 0.8. Pilot cylinder purge fittings are a standard part of the
valve. Valves are available for either captured exhaust or for
exhausting fluid to sea.
1" Four-Way Valves
The 1" four-way, three-position valve is mounted onto seal
subs for all hydraulic connections, including the pilot ports. It
is centered by both springs and the hydraulic pressure supply.
The Cv of the valve is 9.0. Pilot cylinder purge fittings are a
standard feature of the valve.
1/4" Three-Way, Non-Interflow Valves
1/4" three-way, non-interflow valves are available in several
configurations. They can be hydraulically piloted in both direc-
tions, or they can be hydraulically piloted with spring return
function. The valves may also be push rod actuated with
spring return. These valves are ideal for emergency functions
which require conservation of hydraulic fluid because no fluid
is ever lost during the valve shift.
1" Three-Way Valves
The 1" three-way valves are hydraulically piloted with spring
return assisted by the hydraulic pressure supply. The valves are
available in normally open and normally closed configurations.
The slide of the valve is stainless with ceramic coating for corro-
sion protection and durability.
1/4" Four-Way, Three-Position, Subsea Valve 1/4" Three-Way, Hydraulically Piloted, Non-Interflow Valve
1" Three-Way, Hydraulically Piloted Valve 1" Four-Way, Three-Position, Subsea Valve
SD-5403
SD-5083 SD016225
SD016224
1-1/2" Three-Way Valve
The 1-1/2" three-way valve is mounted onto seal subs,
including the pilot port. The valve is easy to remove from its
installed position for maintenance. The pilot cylinder is fitted
with a purge fitting. The valve is hydraulically piloted open
and closed and is also fitted with a fail-safe closing spring.
The Cv of the valve is 30, making it capable of closing a large
annular preventer very rapidly.
1-1/2 Pressure Regulator
The 1-1/2" hydraulic pressure regulator is sized to supply the
1-1/2" three-way valve shown above. The regulator has a
pressure rating of 5000 psig and a Cv of 30. It is mounted
onto seal subs so that it is easily removable for service. It has
a purge fitting on its pilot cylinder. The exhaust seal plates of
this regulator are alumina ceramic. The pilot/outlet pressure
ratio is 1:1.
Shuttle Valves
Shuttle valves permit the operation of hydraulic functions
from either of two control sources. Cameron slug-type
shuttle valves are available in 1/2", 3/4", 1" and 1-1/2"
sizes. The valve seats are metal-to-metal with elastomeric
backups. The 1" valve has a Cv of 21, and the 1-1/2" valve
a Cv of 35.
Positive Shuttle Valves
Positive shuttle valves are available in 1/4" and 1/2" sizes. The
positive shuttle valve ensures that a positive valve shift occurs
without any loss of fluid; it is a non-interflow valve; this is impor-
tant in the control of emergency functions. Unbalanced cylin-
der versions are specified when pressure may be applied simulta-
neously from both supply ports. In this situation a positive shift
of the valve is assured by the larger of the two actuating pistons.
1-1/2" Three-Way Valve
1" Shuttle Valve
1/2" Unbalanced, Positive Shuttle Valve
1-1/2" Hydraulically Piloted Pressure Regulator
SD-24134
SD016226
SD-8049 SD016227
Cameron P O Box 1212 Houston, Texas 77251 1212 Phone 713 683 4600 Fax 713 683 4306 http://www.camerondiv.com
Cameron GmbH Lueckenweg 1 29227 Celle, Germany Phone 011 49 5141 8060 Fax 011 49 5141 806333
Cooper Cameron Corporation, Cameron Division, 3/97,1MCHC, WR6090/TC1148

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