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Cameron BOP Control Systems

BOP CONTROL SYSTEMS TYPE ‘80 - AXON Energy Products

mcedd 04 opportunity to enhance BOP control pdf BOP control systems Authors Jan van Wijk, Shell P&T and Mel Whitby, Cameron With the development and possible deployment of the new Seawater Pressure Reduction Assembly (SPRA) on a deepwater vessel, Shell, Noble and

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BOP CONTROL SYSTEMS TYPE ‘80 - AXON Energy Products


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rol Systems Operational & Maintenance Manual

Description

Rowan Rig 0082,

EXL New OrIII leans BOP Control System Operation and Maintenance Manual

Cameron International Corporation ("Cameron") P

Box 1212,

Houston,

TX 77251-1212,

Chapter 7

Introduction While design,

and maintenance of most Cameron BOP Control Systems are similar,

there is additional information that is unique to each specific project

Noteworthy information pertinent to the Rowan Tarzan unit is contained in this chapter

Accumulator Unit Assembly This BOP Control System is a modular system

That is rather than everything being mounted on a master skid,

the pumps and reservoir are mounted on one skid and the accumulators and hydraulic control manifold are mounted on other separate skids

This unit is to be filled with Aquamarine 32,

Installation

Prepare Electric Pumps This unit is equipped with a selector switch to determine which triplex pump will be primary and which will be secondary

While the selector is in the pump #1 position,

go through the “Prepare Electric Pumps” procedure (2

When complete,

move selector to pump #2 position and repeat procedure

Start Pumps As in (7

ensure that the “Start Pumps” procedure (2

J) and “Check Pressure Switches” procedure (2

K) is followed for both triplex pumps

The #1 electrical pressure switch is set to cut out at 3000 psi and restart at 2700 psi

The #2 electrical pressure switch is set to cut out at 3000 psi and restart at 2600 psi

With the selector switch in the #1 position,

and should restart when the pressure in the accumulator manifold falls to 2700 psi

The #2 pump,

should then restart when the accumulator manifold pressure falls to 2600 psi

At this point,

Moving the selector switch in the #2 position will reverse the above

The #2 pump will now be the primary pump,

and should restart when the pressure in the accumulator manifold falls to 2700 psi

The #1 pump,

should then restart when the accumulator manifold pressure falls to 2600 psi

At this point,

Circulating Pump This unit is equipped with a manually operated circulating pump

The purpose of this pump is to circulate and filter the hydraulic fluid

This pump can only be operated from the Hydraulic Power Unit

remote operation is not possible

The pump should be operated by rig personnel on a weekly basis

Filter visual indicators should be checked and elements replaced as required

Alarms Audio alarm systems (horn) and visual alarm systems (flashing light) can be added to the BOP control system

The alarms include use of the lamp test/acknowledge button,

which deactivates the horn alarm

The light continues flashing until the system is restored to normal operating conditions

The alarms are activated by pressure switches

The low accumulator pressure alarm pressure switch is activated when the system pressure drops to 2200 2500 psi

The low fluid alarm pressure switch is activated by a float switch in the reservoir

When fluid level is low,

the float switch vents the air supply to the pressure switch

The low air pressure alarm pressure switch is activated when the rig air supply drops to 60 psi

Part Number: 2186200-71 Revision: 01 Description: BOP Diverter Control System ITEM 1

3 4 5 7 8

UNIT Ea

2186214-71

2186215-71

4 4 1 1

1 1 1 1

Ea Ea Ea Ea

2725649-01

2725649-02

2725649-03

SK-123200-71-17

COMPONENT 2186213-71

DESCRIPTION Hydraulic Control Manifold Accumulator Rack,

With Twenty (20) Fifteen (15) Gallon,

Accumulators Hydraulic Power Unit,

For Oilair 3000 Psi Accumulators Q/20 Ft & 50 Ft Hose,

Gauge Assy,

Nitrogen Adapter & 2" Extension (Tcg-3015) Spanner Wrench F/ Accumulator Extension 2" F/Nitrogen Charging Kit Cg-3000-Cam Interconnect Cable Diagram

EXL III

EXL III

EXL III

EXL III

EXL III

EXL III

EXL III

4-Feb-14

TC 9183 Rev 02 04/12,

page 44 and 65 Rams (One set) Open Close Gallons Gallons 17

Total Volume for 1

Fluid Reservoir Capacity Gas Volume per 15 gal accumulator bottle Bottle Pre-Charge Pressure Bottle Pre-Charge Pressure + 200 psi Fully Charged Pressure

Capacity of One 15 gal Accumulator on 13-5/8" 25K BOP Controls

bottles of 15 gal each gals psia psia psia gals

Volume 80 bottles of Accumulator on 13-5/8" 25K BOP Controls

~CAMERON 13-5/8" 25,000 PSI WP EVO BLOWOUT PREVENTER I

PHYSICAL OATA A

Lubricants 1

Ram lubricant,

Cameron PIN 713878 or water-resistant

Thread lubricant,

Cameron PIN 705444 or per the latest revision of API Bulletin SA

Multi-purpose

Multi-purpose

lubricant or grease for cold weather operation

Hydraulic operating system: a

Storage: Cameron PIN 718100 preservation fluid

Standard operation: Use a fresh water lubricant that forms a true solution rather than an emulsion when mixed with water andlor antifreeze

Seals and sealing surfaces: SAE 30 Weight Oil

Thread Sealants And Adhesives

Thread sealant Loctite 567,

Cameron PIN 711706 2

Removable thread adhesive Loctite 242,

Cameron PIN 597197-02 3

Permanent thread adhesive Loctite 277,

Cameron PIN 707741 4

Permanent thread adhesive primer Loctite 7471,

Cameron PIN 2724153-01 C

Dimensions (i)

Height: Double Studded X Flanged

Weights 1

EVa Bonnet Assembly 13-5/8" 25,000 psi WP

Average pipe ram assembly 898 Ib (407 kg) each

~CAMERON 2

Lift ram assemblies by installing a lifting eye in the threaded preparation ram

Handle all other subassemblies using appropriately

External Thread Connections for the EVO Bonnet Assembly

Description EVO

Bonnet Assembly

Location

Open Ports

Bonnet Body,

Close Ports

Bonnet Body,

Hydraulic Operating System Requirements 1

Use a fresh water lubricant in the hydraulic system that forms a true solution rather than an emulsion when mixed with water and/or antifreeze

Fluid requirement:

Closing Ratio

Opening Ratio

Fluid Requirement: Wedgelocks

Fluid Requirement: Ram Change Piston

Torque Values

Location

Size I I Hex Across Nut

Stud Size

Torque (API6A Thread Compound at

13 (OF)

Torque (Moly 503 at

07 COF)

Ring Gasket

End Connection

Outlet Connection

1281 ft-lb

739 ft-lb

Bonnet Bolts/Caps

5000 ft-Ib

5000 ft-Ib

'€CAMERON 13-5/8" 10,000 PSI WP DL ANNULAR BLOWOUT PREVENTER I

PHYSICAL DATA A

Lubricants: 1

Thread lubricant

Fel-Pro Paste #670,

or SLECT-A-TORQPaste #503 (4 Ib can PIN 705444)

Multi-purpose

Multi-purpose

lubricant or grease for cold weather operation

Hydraulic operating system: a

Storage

Standard Operation

Dimensional Drawings 1

SK-196677-01,

Bills of Material 1

13-5/8"

Weights and external dimensions 1

Total estimated weight: 35,486 lb

Lifting Lug capacity for each lug: 35 tons 3

Maximum capacity of all four lugs used together:

140 tons

Lifting and Handling 1

Lift BOP assemblies only with slings appropriately the BOP

rated for the maximum weight of

Handle all other sub-assemblies using appropriately

External Thread Connections NPT Fitting Size for Open and Close Ports: 1"-11-1/2

Hydraulic Operating System Requirements US Gallons to Open

US Gallons to Close

Normal pressure for the hydraulic operating system is 1500 psi

Maximum pressure for the hydraulic operating system is 3000 psi

~CAMERON H

Torque Specifications 1

Inner Cylinder Nuts (Item #31): 2220 ft-Ib

Pusher Plate Screws (Item #36): 68 ft-Ib

API Drift 1

API drift for 13-5/8"-10,000 psi is 13

Service Tools and Equipment Item No

I Description

I Wrench Size

Actuator Screw Assembly

Inner Cylinder Nut

2" Socket

Flange Nut

Lock Ring Access Port Plug

2" Wrench

Hydraulic Port Plug

Pusher Plate Screw

5/8" Allen

Actuator Ring Stop Screw

1" Allen

Insert Retaining Screw

3/8" Allen

Oil Injection Fitting

Temperature Rating of Annular BOP Packers: 1

Continuous Service

- 180 deg

- 82 deg

Extreme Service

- 200 deg

- 93 deg

C) Note: There is no industry accepted method of establishing BOP temperature ratings at this time

These are estimates based on lab testing and field performance

Temperature ratings for rubber components must take into account the environmental exposure history,

the chemical environment while at temperature,

Therefore,

a single number rating can be misleading if all conditions are not understood

APPLICABLE OPERATION

OPERATING

CHARACTERISTICS

AND PRINCIPLES OF

Packer/Donut Assembly 1

The packer is a cylinder of molded rubber combined with sixteen steel reinforcing inserts

The donut is made of homogeneous molded rubber that surrounds the packer

The packer inserts are flanged on the top and bottom

The shape of the flanges have been designed to maintain an unbroken barrier of steel above and below the packer rubber as the packer is closed,

regardless of the size or shape of the pipe or tool in the bore

RIG EQUIPMENT

LIST (lADe FORMAT)

H2S services

- yes/no

Side outlets

- Studded

183/415m

Bottom connection

183/415m

Top connection Shear ram boosters E3

- yes/no

Yes,TB/5K,

- number

2 X 5,5

5,6 5/8,

Available Rams (Installed and Spare)

Quantity

Type Size E3

BOP Ram Configuration (Normal)

Pipe Rams

Middle upper

Pipe rams

Middle lower

Blind shear

Pipe Rams

Annular Preventer

Quantity

- number

Makeltype

Working pressure

10,000 psi

Bottom connection

135/815m

Top connection

135/810m

Kill Line Valves

- number

3-1/16"

Working pressure

15,000 psi

Quantity Make/type

Gasket type

Hydraulic/manual/non-return

2ea manual

Choke Line Valves

Quantity

- number

3-1116"

Working pressure

Makeltype

Cameron 15,000 psi

Gasket type

Hydraulic/manual/non-return

2ea manual

Other Blowout

Preventers

BOP Control

Accumulator Unit

Makelmodel

Cameron

Location

Inside Port Cantilever beam

Fluid reservoir capacity

- US gal

Oillwater mix rate

- US gpm

Glycol reservoir capacity

- US gal

Total accumulator capacity (w/o pressure)

- US gal

System working pressure

NIA 3000 psi

Control manifold model

Cameron

Regulator type

Total useful accumulator volume equals all preventer opening and closing volumes

Accumulator Hvdraulic Pumps

- yeslno

RIG EQUIPMENT Electric driven:

- Quantity

- Quantity

- number

- USgpm

- yes/no

LIST (lADe FORMAT) 2 Triplex Pumps 100 hp 48 US gpm 3000 psi

- number

- USgpm

Primarv Control Panel

Control panel make/model

Cameron/Hoffman Nema 4X

Location

Drillers Cabin

Panel controls for the following functions:

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- yes/no

- number

- yes/no

- number

Yes Yes No-----Manual Yes Yes Yes Yes Yes Yes Yes Yes

Remote Control Panels

Make/model Location

Main unit under cantalever

Location

Control Room

Ability to operate main closing unit valves directly

- yes/no

System routing (direct or through panel) Remote control of system pressure regulator

- yes/no

Remote control of annular pressure regulator

- yes/no

- yes/no

Choke Manifold

All appropriate components H2S rated E6

Choke Manifold (for Instrumentation,

Nominal size

3-1/16"

Minimum 10

3-1/16"

Maximum working pressure

15,000 psi

Quantity of fixed chokes

- number

2 Cameron

Quantity of adjustable chokes

- number

3-1/16"

Quantity of power chokes

- number

Power choke remote control panel

- Location

- number

Glycol injection

- yes/no

Flexible Choke and Kill Lines (BOP to Manifold)

- number

Working pressure

15,000 psi

Quantity

Phoenix Beattie

Make/type

27-Jan-14

TC 9183 Rev 02 04/12,

Upper Double Upper Rams (4" or 3-1/2" Rams) Upper Double Lower Rams (Blind/Shear Rams) Lower Double Upper Rams (2-7/8" Rams) Lower Double Lower Rams (4" or 3-1/2" Rams)

Rams (One set) Unlock Lock Gallons Gallons 6

Rams (Two sets) Unlock Lock Gallons Gallons 12

Total Volume to Unlock (gals) Total Volume to Lock (gals)

Volume Needed to Unlock and Lock Wedgelocks

Total Volume for 1

Capacity of Accumulator System on Wedgelocks Controls (1/2 of 160 gals)

Ref: Calculation of Accumulator Size for 3,000 psi System,

BOP Controls Inc

1F Rev 02,

BOP Controls Inc

Air Motor Starts at Air Motor Shuts Down at Diesel Motor Starts at Diesel Motor Shuts Down at

'€CAMERON 13-5/8" 25,000 PSI WP EVO BLOWOUT PREVENTER I

PHYSICAL OATA A

Lubricants 1

Ram lubricant,

Cameron PIN 713878 or water-resistant

Thread lubricant,

Cameron PIN 705444 or per the latest revision of API Bulletin 5A

Multi-purpose

Multi-purpose

lubricant or grease for cold weather operation

Hydraulic operating system: a

Storage: Cameron PIN 718100 preservation fluid

Standard operation: Use a fresh water lubricant that forms a true solution rather than an emulsion when mixed with water andlor antifreeze

Seals and sealing surfaces: SAE 30 Weight Oil

Thread Sealants And Adhesives 1

Thread sealant Loctite 567,

Cameron PIN 711706 2

Removable thread adhesive Loctite 242,

Cameron PIN 597197-02 3

Permanent thread adhesive Loctite 277,

Cameron PIN 707741 4

Permanent thread adhesive primer Loctite 7471,

Cameron PIN 272415~-01 C

Dimensions (i)

Height: Double Studded X Flanged

Weights

EVa Bonnet Assembly 13-5/8" 25,000 psi WP

Average pipe ram assembly 898 Ib (407 kg) each

Lift ram assemblies by installing a lifting eye in the threaded preparation ram

Handle all other subassemblies using appropriately

External Thread Connections for the EVO Bonnet Assembly

Description

Eva Bonnet Assembly

Hydraulic Operating

Location

Open Ports

Bonnet Body,

Close Ports

Bonnet Body,

System Requirements

Use a fresh water lubricant in the hydraulic system that forms a true solution rather than an emulsion when mixed with water and/or antifreeze

Fluid requirement:

Closing Ratio

Opening Ratio

Fluid Requirement: Wedgelocks

Fluid Requirement: Ram Change Piston

Torque Values

Location

Size I I Hex Nut Across

Stud Size

Torque (API6A Thread Compound at

13 COF)

Torque (Moly 503 at

07 COF)

Ring Gasket

End Connection

Outlet Connection

1281 ft-Ib

739 ft-Ib

Bonnet Bolts/Caps

5000 ft-lb

5000 ft-Ib

02 04/12

BILL OF MATERIALS BILL OF MATERIALS BILL OF MATERIALS KEY: RIG AIR PRESSURE CONTROL SIGNAL FLUID-ATMOSPHERIC PRESSURE FLUID-REGULATED PRESSURE

FLUID-HIGH PRESSURE 3000PSI 4

SET @ 3300 PSI

ITEM QTY DESCRIPTION 16 11 GALLON ACCUMULATOR BOTTLES 1 2 1 PRESSURE GAUGE 0-300 PSI 4 2 1" 5M GLOBE VALVE 5 1 1/2" BLEEDER VALVE 6 1 MURPHY EMS448 CONTROLLER 7 1 FLUID RESERVOIR 8 1 MANIFOLD REGULATOR

5HP YANMAR DIESEL MOTOR 15 7 1" 4 WAY VALVE 3000 PSI

ITEM QTY DESCRIPTION 16 3 "Y" STRAINER 17 2 AIR OPERATED HYDRAULIC PUMP 19 3 5M CHECK VALVES 21 1 1" AIR LUBRICATOR 22 1 1" AIR FILTER 24 1 ANNULAR REGULATOR MODEL 2100 25 2 RELIEF VALVES SET @ 3300 PSI 27 1 HYDRO-PNEUMATIC PRESSURE SWITCH 28 1 PRESSURE GAUGE 0-3000 PSI 30 1 PRESSURE GAUGE 0-5000 PSI 31 1 PRESSURE GAUGE 0-5000 PSI 32 1 MURPHY ELECTRIC PRESSURE SWITCH

SET @ 3300 PSI

19 9 16

5 19 16

15 OPEN

15 CLOSE

15 CLOSE

15 CLOSE

15 CLOSE

15 CLOSE

15 CLOSE

15 CLOSE

C:\Users\60023082\Desktop\BOP CONTROL

BOTTOM 3 1/2" OR 4" PIPE RAM

BLIND SHEAR RAM

TOP 3 1/2" OR 4" PIPE RAM