BOP Closing Unit

Operation and Maintenance

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 Table of Contents
Page No.
Overview……………………………………………………………..….. 4
System components and hydraulics...……………………………….… 7
Reservoir……………………………………………………………. 8
Working fluid………………………………………………………. 8
Accumulators………………………………………………………. 10
Electric pump module……………………………………………... 13
Air pump module…………..……………………………………… 22
Pressure regulators………………………………………………... 31
Valves……………………………………………………………….. 33
Hydraulic control manifold……………………………………….. 35
Annular circuit……………………………………………………... 39
SPM…………………………………………………......................... 41
Diverter control…………………………………………………….. 43
Interface control panel (ICP)……………………………………... 46
HMI control………………………………………………………… 48
Remote panel……………………………………………………….. 54
Air remote control interface………………………………………. 56
System sizing recommendations
Sizing accumulator volume………………………………………... 62
Sizing air and electric pumps……………………………………... 65
Common maintenance and checkups
Routine maintenance………………………………………………. 67
Important work instructions……………………………………… 69
Checklists…………………………………………………………… 73
Troubleshooting……………………………………………………… 75
Glossary………………………………………………………………… 96
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Overview
One step backwards:
 What is B.O.P.?
Blow-out Preventer is the equipment mounted on well head to prevent blowing out of
formation fluids, by controlling any kick that might happen.

Blowout preventer equipment should be designed to:

1. Close the top of the hole.
2. Control the release of fluids.
3. Permit circulating into the hole.
4. Allow movement of the inner string of pipe.

Basic types of blowout preventers on drilling rig are:

1. Annular preventers
2. Ram preventers

Figure (1): BOP Stack

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 Figure (2): Single Ram BOP Assembly

 How does a B.O.P. work?

Fluid is supplied to rams pistons in order to move the ram towards the drill pipe to close
the annular space around the pipe. Thus, the influx emerging from wellbore is controlled.
When a ram is closed against wellbore pressure the wellbore pressure act equally and
opposite in all directions on the ram body, the only part of the ram body that is out of
balance is the area of the ram shaft (see Figure 3). The wellbore pressure acting upon the
ram shaft is opposed by the hydraulic pressure from the control unit.

RAM SHAFT OPENING CHAMBER

PISTON CLOSING CHAMBER

RAM
Figure (3): Operation of single Ram BOP

Thus, the operation of B.O.P. requires a system to pump hydraulic fluid to the B.O.P. via
suitcase lines. This is the core function of B.O.P. control system.

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Basic theory of operation for BOP Closing Unit:
The pump packages (air and electric) draw low pressure fluid through strainers from the
reservoir and pump high pressure fluid through a check valve into system piping. The high
pressure fluid is then pumped through filters (if equipped) before it goes into the accumulator
module. Once high pressure fluid enters the bottles it compresses the bladders that are charged
with nitrogen.
When the system pressure has reached working pressure which is typically 3000 psi, the
pumping systems shut off automatically.
This is an automatic process that starts when system pressure falls 10%. This system pressure is
manipulated through two different circuits which are called the manifold circuit and the annular
circuit.
The manifold circuit is supplied system pressure at the Bypass valve that offers two paths for
fluid flow: a High side or Low side. The LOW side takes system pressure and goes through a
regulator before being delivered to the Header manifold. This is typically referred to as the Low
side or regulated side as it is lower than system pressure. The High side takes full system
pressure and delivers it directly to the Header manifold. Once high pressure fluid is in the
Header, it can be manipulated through the 4-way integrated valves to the open and close lag
pipes that are connected to the customer’s BOP stack.
The annular circuit operates in theory the same except without a bypass valve and it only has one
valve.

Figure (4): Annular preventer internal parts

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System components and hydraulics
A Blowout Preventer (BOP) Control System is a high pressure hydraulic power unit fitted with
directional control valves to safely control kicks and prevent blowouts during drilling operations.
The primary function of the accumulator module is to provide the atmospheric fluid supply for
the pumps and storage of the high pressure operating fluid for control of the BOP stack. It
includes accumulators, reservoir, accumulator piping and a master skid for mounting of the air
operated pumps, electric motor driven pumps, hydraulic control manifold and interface module
for remote control of the BOP functions.
The BOP Control System is a closed-loop system where all vented fluid is returned to the
reservoir.

The guide lines for the design of BOP control system:

BOP systems should have sufficient usable hydraulic fluid volume (with pumps inoperative) to
close one annular-type preventer, all ram-type preventers from a full-open position, and open one
HCR valve against zero wellbore pressure. After closing one annular preventer, all ram-type
preventers, and opening one HCR valve, the remaining pressure shall be 200 psi (1.38 MPa) or
more above the minimum recommended precharge pressure.

As any hydraulic system, much care should be taken to prevent any contamination to BOP
Closing System components. Contaminants are mostly water and dust/sand.
The main source of dust contamination is from hoses connect and disconnect during rig moves.
So, person in charge of rigging closing unit should wrap hoses when disconnected, and to make
sure they are clean prior to reconnecting them. Also maintenance personnel should pay attention
to cleaning during maintenance jobs for system components.

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1. Reservoir
The reservoir is used to store the fluid for operation of the BOP control system.
It is designed to be capable to vent all the pressurized fluid to the reservoir tank when it is
recommended that the equipment be depressurized.
It contains baffles, fill and drain ports, fluid level sight gauge, troubleshooting inspection
ports and a clean out manway.
When the sight glass indicates that the fluid level is low or the low fluid alarm sounds
fluid needs to be added to the reservoir.
Filling the reservoir should take place when the system has no pressure on it. If the
system is pressured to working pressure there is the possibility that the operator could
overfill the reservoir and cause it to over flow the next time the system is pressured
down. Fill reservoir until the level is 4 inches from the bottom of the side bung.
Note: It is very important to inspect the reservoir periodically for contaminants that
may have entered the system.

2. Working fluid
Typical properties that we look for include: mineral based oil that is zinc free, non-
sheening, and meets environmental operating condition requirements. These oils have
proven to perform better, cut maintenance cost and reduce downtime in comparison to
most water-based fluids. These fluids are readily available throughout the world market.
Manufacturers do not recommend the use of water-based fluids. For example, CAD does
not recommend the use of such fluids; however, most systems are compatible with water-
based fluids manufactured for Surface BOP Control systems. With proper system
commissioning and testing along with a defined maintenance schedule these fluids can be
used successfully in our systems.

To date the only water based fluid CAD has performed testing on is the
Erifon CLS Series manufactured by Mac Dermid Off shore Solutions. The
testing was conducted with Erifon CLS 25 on a typical Surface (closed
loop) system during factory acceptance testing.
No adverse performance problems were noted during testing. All
regulators, valves, pumps, and other system components operated within
normal parameters and no excessive foaming was noted. This testing was
limited in scope and did not take into account long term usage in actual
field operating conditions.

CAD has been manufacturing and servicing control systems for 25 years and it has been
our experience that water-based fluids can contribute to a higher overall cost of operation
due to fluid maintenance, and reduced lubricity. On a few systems utilizing a water-based
fluid we have observed performance issues; especially for high flow circuits, where
returns to the reservoir create excessive foaming and aeration problems, which can lead
to pump cavitation and hydraulic hammering of the regulator valves.

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While we do not expressly forbid the use of water-based fluids we reserve the right to
analysis in detail warranty claims for hydraulic components and operational performance
if in our opinion it is due to the improper use and or maintenance of a water-based fluid.
In order to provide the best possible operating environment it is recommended that a
hydraulic oil meeting the criteria listed above be utilized. If a water-based fluid is chosen
it is recommended to utilize a product designed specifically for closed loop systems and
to follow all manufacturer guidelines and perform regular testing per the manufacturer’s
requirements to insure proper performance.

Note: No matter the choice of fluid it is incumbent on the equipment owner to

maintain a fluid monitoring and maintenance program on a consistent basis to
insure peak performance levels and limit system downtime and maintenance
expenses.

Important: All these regulations and limitations are for water-based fluids, not
water contaminated oils!

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 Pumping in BOP Closing Unit
Pumping in BOP control unit occurs in two stages:

Stage 1: Accumulators
They act as the first pumping stage to provide BOP with hydraulic fluid.

Stage 2: Pumping systems

In system initial start up pumping systems (electrical and pneumatic) initially charge
accumulators to 3000 psi or, in some systems, to 5000 psi.
In normal operations they back up accumulators to compensate working fluid
consumption caused by operating BOP when system pressure drops below set points of
system pumps.

3. Accumulators
Accumulators are devices, often referred to as accumulator bottles, used in the BOP
Control System to:
1. Provide sufficient accumulator capacity to enable BOP to be operated prior to any
power source. To be the first pumping stage in normal operation for BOP.
2. Provide sufficient accumulator capacity to enable the BOP to be operated in the
absence of any additional power sources.
In some applications, accumulators dampen system pressure fluctuations.
Energy is stored by compressing a precharged gas bladder with hydraulic fluid from the
operating or charging system. Depending on the fluid volume and precharge pressure of
the accumulator, hydraulic energy is then available to operate respective BOP stack
functions. Surface controlled BOP Control Systems are designed to
The accumulators can either be bottom or top loading. Top loading means the bladder or
float can be removed from the top while it is still mounted on the accumulator unit.
Bottom loading accumulators must be removed from the accumulator unit to be serviced.
Accumulators are pre-charged with nitrogen to a PSI setting based on calculations. The
pre-charge calculation is based on a number of factors to include BOP stack size, closing
ratio, gallons to close, working pressure of the BOP stack and operator’s policy in well
control. Always keep a charging and gauging assembly readily accessible.
However, each accumulator should be checked during installation and before the system
is put into use.
Accumulators are charged to system working pressure (typically 3000 PSI) through the
1” port by the high pressure pumps. When there is a demand for the high pressure fluid
the nitrogen forces the fluid out of the accumulator.
On separator accumulators the poppet valve keeps the bladder from extruding through the
port, and on guided float type (membrane type) accumulators it keeps the nitrogen pre-
charge from escaping.

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Figure (5): Accumulators

Figure (6): Accumulators’ lines

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Figure (7): Accumulator assembly

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4. Electric Pump Module
Safety considerations on performing maintenance for electric module:
The following list addresses potentially hazardous conditions for the electric pump
module. Please exercise great caution while maintaining or repairing components of the
electric pump module. Please contact CAD Control Systems for technical support for
assistance.
 DO NOT OPEN THE STARTER ENCLOSURE WHEN AN EXPLOSIVE
ATMOSPHERE MAY BE PRESENT.
 THE ELECTRIC PUMP MODULE STARTS AUTOMATICALLY. EXERCISE
CAUTION AND ISOLATE POWER SOURCES WHILE WORKING ON OR
AROUND THE UNIT.
 ALL BOLTS ON THE STARTER ENCLOSURE MUST BE TIGHTENED TO
PROPERLY SEAL THE ENCLOSURE.
 ONLY QUALIFIED PERSONNEL SHOULD WORK ON ELECTRICAL
EQUIPMENT.
 TROUBLESHOOTING EQUIPMENT SHOULD BE CONDUCTED WHILE
DE-ENERGIZED USING PROPER LOCKOUT PROCEDURES
 GROUNDING ON THE STARTER ENCLOSURE, PUMP, ELECTRIC
MOTOR, AND ELECTRIC PRESSURE SWITCH SHOULD BE INSPECTED
FOR A GOOD CONNECTION EVERY 6 MONTHS AND BEFORE INTIAL
START-UP ON THE UNIT.
 DO NOT MODIFY THE STARTER ENCLOSURE BY DRILLING
ADDITIONAL HOLES OR USING IMPROPER CABLE GLANDS AS PER
HAZARDOUS AREA CLASSIFICATION.
 ELECTRICAL SOURCES SUPPLIED FROM THE RIG SHALL BE
PROPERLY SIZED FOR CORRECT CABLE SIZE AND BREAKER SIZE AS
IMPROPER MATERIALS CAN CAUSE AN IGNITION HAZARD!
 ENSURE FREQUENY SUPPLIED ARE WITHIN DESIGN TOLERANCE AS
50 OR 60 HERTZ; I.E. SUPPLING 60 HERTZ TO SYSTEM DESIGNED FOR
50 HERTZ CAN SHORTEN THE LIFE OF THE MOTOR AND EQUIPMENT
IN THE STARTER ENCLOSURE. SUPPLIED VOLTAGE RANGE SHALL
MATCH THAT OF THE ELECTRIC MOTOR MANUFACTURER’S
DATATAG.
 ANY MAINTENANCE PERFORMED ON THE ELECTRIC MOTOR SHALL
MATCH THE ELECTRIC MOTOR MANUFACTURER’S
RECOMMENDATION.
 MOTOR BOLTS SHALL ALWAYS BE PROPERLY TIGHTENED TO
MAINTAIN PROPER BELT TENSION AND ALIGNMENT.
 MOTOR BEARING SHALL BE LUBRICATED AT REGULAR SERVICE
INTERVALS USING PROPER GREASE. UNCAP GREASE RELIEF
VALVES; RUN PUMP AND USING A GREASE GUN INJECT MORE
GREASE. FAILURE TO DO SO MAY CAUSE A POTIENTIAL IGNITION
SOURCE AND VOID WARRANTY.
 PUMP DRIVE GUARD SHOULD BE INSPECTED DAILY FOR PROPER
TIGHTNESS AND THE BELT SHOULD BE INSPECTED MONTHLY TO

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 ENSURE PROPER TENSION IS BEING MAINTAINED. THE BELT MAY BE
TIGHTENED 3 TIMES BEFORE REPLACMENT IS NEEDED.
 ONLY REPLACE DRIVE BELT WITH THE SPECIFIC BELT DESIGNED BY
CAD CONTROL SYSTEMS AND AS NOTED IN THE BOM IN THE
TECHNICAL DRAWINGS SECTION FOR THE ELECTRIC PUMP MODULE.
WHEN REPLACING THE BELT ENSURE THE POWER TO THE ELECTRIC
MOTOR HAS BEEN SHUT OFF.
 WHEN REPLACING THE BELT GUARD AFTER REMOVAL AVOID
INCORRECT INSTALLATION AS THIS WILL CAUSE SPARKING AND
DAMAGE TO OCCUR TO THE PUMP DRIVE.
 DO NOT OPERATE THE PUMP WITH THE SUCTION VALVE IN THE
CLOSED POSITION.
 DO NOT OPERATE THE PUMP WITH A CLOGGED SUCTION STRAINER.
 DO NOT OPERATE THE PUMP AGAINST A CLOSED VALVE AS THIS
WILL CAUSE THE RELIEF VALVE TO DISCHARGE PRESSURE BACK
 TO THE RESERVIOR AND THIS SYSTEM WILL NOT BE ABLE TO
REACH WORKING PRESSURE.
 TRIPLEX PUMP WHEN IN STROAGE SHOULD BE DRAINED OF ALL
PUMPED FLUIDS FROM THE PUMP WITH ANTIFREEZE SOLUTION TO
PREVENT FREEZING AND DAMAGE TO THE PUMP.
 NEVER OPERATE TRIPLEX PUMP WITH FROZEN FLUID.

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Overview
The electric pump module is a high-pressure pumping source used on the High Pressure
Unit.
It consists of a duplex or triplex reciprocating plunger type pump driven by an explosion-
proof electric motor. It is connected to the accumulator piping.
This assembly requires a customer to furnish a power source, usually 400/480 VAC,
50/60 cycles, 3 phase power. The amount of current required depends on the horsepower
of the electric motor. The electric pump assembly consists of the fluid suction manifold,
triplex pump, electric motor, drive assembly, starter, and pressure controlled switch. The
pump module builds pressure up to the system working pressure. This pump assembly is
very important to the overall performance of the BOP Control System. Therefore it is
necessary to understand its function and operation.
Theory of operation
With the starter in the ON position it enables control of the starter by the electric pressure
switch. Depending on the current status of the system pressure the switch sends an
ON/Off signal to the contactor inside of the enclosure. With system pressure at 0 PSI the
switch send an ON signal to the contactor and voltage is applied to the electric motor.
The electric motor turns the drive assembly and thus turns the triplex pump. The triplex
pump draws low pressure fluid through a suction strainer from the reservoir and
pressured fluid is pumped through a check valve into system piping. Once system
pressure is achieved the electric pressure switch sends an OFF signal to contact and the
pump package shuts off. When system pressure falls 10% of working pressure the electric
pressure switch then starts the process over by pumping the system to working pressure.
This system is set from the factory and is design to be let in the ON position from
automatic pumping to system pressure.

To manually start the electric pump package you must turn the switch to the “HAND”
position; this bypasses the electric pressure switch. If the system must be operated
manually (hand position) please observe all instructions and warnings in this manual for
safe operation.

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 Figure (8): Electric pump module

Figure (9): Electric pump

Figure (10): Electric pump module components

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Note: In the illustration the belts guard was removed for clarification. Never attempt to
run the motor unless the guard is installed and properly tightened.

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Figure (11): Triplex pump - exploded view for fluid end

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Figure (12): Triplex pump - exploded view for gear end

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Electric pressure switch can be set by adjusting the two switches shown. The low side is
the pressure that turns on the pump and the high side will set the pressure the pump will
turn off. The standard states that a pumping system must come on when the system
pressure falls 10% of working pressure. This adjustment should be made with the pump
off to avoid damaging the motor contactor. If there are two electric pumps installed set
the pump 2 to come on 50 psi lower than the first pump to avoid the two pumps coming
on at the same time.

WARNING: Do not remove any covers on this device when a explosive atmosphere is
present.
WARNING: High voltage is present with this model.

Figure (13): Electric pressure switch adjustment screws

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5. Air Pump Module
Safety considerations and precautions:
The following list addresses potentially hazardous conditions for the air pump module.
Please exercise great caution while maintaining or repairing components of the air pump
module. Please contact CAD Control Systems for technical support for assistance.
 DO NOT RUN PUMP DRY AS THIS CAN CAUSE EXCESSIVE SURFACE
TEMPERATURE. THIS CONDITION CAN ARISE IF THE PUMPS ARE
OPERATED WITH THE BALL VALVE IN THE CLOSED POSITION OR IF
THE STRAINER IS CLOGGED. THE OPERATOR MUST CHECK THE
CONDITION OF THESE TWO ITEMS DAILY BEFORE USE.
 IF GUARDS ARE REMOVED FOR MAINTENANCE THEY CAN EXPOSE
PINCH POINTS AND MUST BE REPLACED BEFORE UNIT IS RETURNED
TO SERVICE.
 THIS MODULE STARTS AUTOMATICALLY.
 HEARING PROTECTION SHOULD BE USED WHEN WORKING AROUND
THE UNIT AND THE MUFFLERS INSTALLED SHOULD NOT BE
REMOVED.
 LUBRICATORS CANNOT BE FILLED UNDER PRESSURE.
 THE GROUND IS REQUIRED ON THE AIR PUMPS AND SHOULD BE
CHECKED EVERY 6 MONTHS.
 USE ONLY SAE 10 OIL IN LUBRICATORS AND CONSULT THE MSDS
FOR ADDITIONAL WARNINGS.

When service is needed on one of the air pumps the operator must first isolate the
air supplied to the air pump as this module starts automatically. Then the fluid
supply valve should be closed to avoid the loss of system fluid. Once maintenance
has been performed ensure that the suction valve has been opened before putting
the pump back in service.

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Overview
The Air Pump Module is typically a back up to the main pumping source of the High
Pressure Unit (HPU). It consists of one or more air operated hydraulic pumps connected
in parallel to the accumulator piping. Air module consists of: (1) air supply manifold, (2)
fluid suction manifold, (3) air pumps and (4) air pressure switch.
(1) Air supply manifold
The customer furnished air supply should be connected to the air supply manifold that
must include:
1. Air Filter
This filter removes contaminants in the air supply which may damage air pumps.
This filter must be cleaned periodically to maintain maximum air flow.
2. Air Lubricator
This device impregnates the air with oil to lubricate the pumps during operation.
This lubricator should also be serviced periodically to replenish the oil.
3. Air Supply Gauge
A 0-300 psi gauge is mounted in the air supply manifold for monitoring of the air
supply pressure at the unit.
4. Air Supply Valve
One air supply valve is provided for each pump to enable independent operation.
Under normal operation, these valves should remain open at all times. To stop the
air pumps from operating, these valves should be closed.
(2) Fluid supply manifold
1. Suction Valve - This valve is used to isolate the pump(s) during servicing. In
normal operation it should remain open at all times.
2. Suction Strainer - The suction strainer helps to remove impurities from the fluid.
Impurities can enter the system through the preventers and return to the reservoir
with the vented fluid. This strainer should be serviced periodically.
(3) Air pumps
Air pumps operate in a manner that converts air pressure into hydraulic pressure.
Therefore these air pumps are normally associated with a ratio. This ratio is a
comparison of the air piston area to the fluid piston area. Typical ratio sizes range
from 45:1 to 60:1. If you apply 10 PSI air pressure to the air supply of a 45:1 ratio it
would produce approximately 450 psi in hydraulic fluid pressure. On the HPU skid
there is an air intake rated for rig air. The air travels through a filter and a lubricator
to prepare the air to be used in the air pumps.
These pumps have self-adjusting packing glands and therefore should require no
adjustment in normal operation.
Since these pumps are double acting, air is exhausted on each up and down stroke of
the pump. When these pumps exhaust the lubricated air it is normal to find oil on
surrounding equipment. Also, it is normal for the exhausted air to cause ice to form
on the air pump. This is caused by freezing of moisture in the exhausted air due to air
discharge. Excessive icing can reduce the performance of the air pump and therefore
the air supplied to the unit should be dry instrument air.

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(4) Air pressure switch
Normal operation consists of an automatic valve (hydro-pneumatic pressure switch) that
senses a system pressure drop. The valve will open around a 10% pressure drop and
allow air pressure to flow to the air pump. A gauge is supplied on the air manifold to
monitor the fluctuation of supply air pressure. The air moves the air piston up and down
causing a suction to develop on the fluid reservoir. Low pressure hydraulic fluid travels
from the reservoir through the suction ball valve and the fluid strainer. Once the fluid
enters the fluid end of the pump it becomes pressured according to the ratio of the pump
and is discharged through a check valve into system piping.
If the automatic air valve (hydro-pneumatic pressure switch) fails to come on there is a
bypass valve located in the air manifold circuit. This valve will allow the operator to
manually operate the air pumps until system pressure is achieved. If the automatic valve
fails to turn off the relief valves in the system pressure piping will relieve pressure until
air can be manual turned off by the operator at the air valves located before the air pumps
(isolator valves for air pump).

Figure (14): Air pressure switch

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Figure (15): Air pump module parts

Figure (16): Air pump module

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Figure (17): Air pump motor assembly

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Figure (18): Air pump assembly

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Figure (19): Air motor assembly

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6. Pressure Regulators
a. Annular Regulator Assembly – The annular regulator is used to reduce the
accumulator fluid pressure to a maximum of 1500 PSI for the operation of the
annular preventer. Pressure settings on the annular are very important to
prolong the life of the element in the preventer. It will be necessary to consult
the manufacturers’ recommendation as to the maximum operating pressure
when controlling the well and during stripping operations. In many cases the
driller will require regulation of the annular operating pressure from the drill
floor. This requires an air pilot-operated regulator on the annular circuit. This
can be controlled at the driller’s remote panel and by the annular regulator.
Counter-clockwise rotation decreases pressure and clockwise rotation
increases pressure. Always check the annular pressure gauge when adjusting
the pressure on the annular regulator.
It can either be adjusted manually at the control system skid, or remotely from
remote control panels.

Figure (20): Annular pressure regulator

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b. Manifold Regulator Assembly – The manifold regulator reduces the 3000 psi
fluid pressure from the accumulators to a maximum of 1500 psi. This
regulated pressure becomes the supply to operate the ram type preventers and
gate valves. The pressure setting of this regulator is normally manually
adjusted.

Figure (21): Manifold pressure regulator

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7. Valves
a. 4-Way valves

Figure (22): 4-Way valve

• Manifold valves
To direct pressurized working fluid from manifold header to BOP stack via
suitcase lines to open and close BOP modules.
They are 3-positions valves: Open-Close-Neutral.
Its center position is “closed center” which means all ports are blocked. This helps
BOP pistons to keep its positions even if the valve is on the neutral position.

Figure (23): Manifold 4-way valve positions

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 • Manifold bypass valve
It is of same description as manifold valves. However, its function is to switch
manifold pressure from the low range of 1500 psi to the high range of 3000 psi.

Figure (24): Bypass 4-way valve positions

b. Relief valve
It is located in the circuit to protect it from over pressure. It is set to 3500 psi.

WARNING: Never remove safety relief valves and operate this system as they
protect the system piping and accumulators.

c. Check valves
They are installed at pump outlets to protect pumps.
d. Isolators
• Isolating accumulators: This isolation occurs when the ball valve on the end of the
bottle manifold is closed, to allow maintenance to occur without having to
depressurize the entire system. Then pressure is relieved on the isolated manifold
by slowly opening the bleeder valve located on top of that manifold. The gauge
must read 0 psi before the manifold can be considered safely isolated.
• Isolating unit’s air supply
• Isolating air inlet valves for air pumps.
• Isolating suction valves for air and electric pumps.

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8. Hydraulic Control Manifold Circuit
The manifold control circuit involves the Header manifold, manifold regulator, bypass
valve, 4-way integrated valves, manifold pressure gauge and a bleeder valve. The
manifold regulator is used to reduce accumulator pressure to a maximum of 1500 PSI.
This regulated pressure is the supply pressure to the ram type preventers and gate valves.
This regulator can be manually adjusted at the regulator itself, or it can have a failsafe
head like the annular regulator. To make adjustments in the pressure setting of this
regulator, first loosen the lock nut on the handle and hold with one hand. With the other
hand, rotate the regulator’s adjustment handle clockwise to increase pressure and counter-
clockwise to decrease pressure to desired setting. Always check the manifold pressure
gauge while setting the pressure on the manifold regulator. On models with a failsafe
head the regulator can be adjusted by a remote panel or at the gauge panel with the use of
a versa valve. After the regulator is set at the desired pressure, tighten the lock nut on the
adjustment handle. For operating pressures up to 3000 PSI for the manifold regulator
assembly includes a quick opening bypass valve. In normal operation this valve should be
in the low pressure (open) or regulated pressure position.
For pressure up to 3000 PSI the valve must be operated to the close or high pressure
position. This shuts off the supply from the manifold regulator and directs accumulator
fluid pressure to the ram preventers and gate valves. Pressures above 1500 PSI cannot be
regulated.

Figure (25): Regulator and bypass valve

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Figure (26): Manifold header

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Figure (27): Typical control fluid circuit

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Figure (28): Typical manifold circuit

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9. Annular Circuit
Annular Regulator Assembly – The annular regulator is used to reduce the accumulator
fluid pressure to a maximum of 1500 PSI for the operation of the annular preventer.
Pressure settings on the annular are very important to prolong the life of the element in
the preventer. It will be necessary to consult the manufacturers’ recommendation as to the
maximum operating pressure when controlling the well and during stripping operations.
In many cases the driller will require regulation of the annular operating pressure from
the drill floor. This requires an air pilot-operated regulator on the annular circuit. This can
be controlled at the driller’s remote panel and by the annular regulator. Counter-
clockwise rotation decreases pressure and clockwise rotation increases pressure. Always
check the annular pressure gauge when adjusting the pressure on the annular regulator.

Figure (29): Annular circuit

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Figure (30): Annular circuit components

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10.SPM
The SPM valve is a high pressure, high flow two position, three way directional control
valve. The term SPM is an acronym for “Sub Plate Mounted” valve. These valves are
installed into a single or multi pocket block or manifold. This allows for the removal and
installation of the valve’s functional components for maintenance without disturbing the
fluid connections. The design of the SPM valve is configured as either “Normally Open
(NO)” or “Normally Closed (NC)”. Upon actuation, the valve configuration immediately
moves to the opposite position, that is, either closing off the flow of fluid or allowing full
flow.
For CAD manufactured control systems the Annular Circuit SPM valves are in a
Normally Closed (NC) default position that requires constant pilot pressure to open. Any
loss of the pilot pressure will result in both the “OPEN” and “CLOSED” SPM valve
closing and will be unable to function until pilot pressure has returned. The pilot pressure
is supplied direct from the main system accumulator pressure and held with a check
valve. This circuit also includes a gauge which indicates the pilot pressure supplied to a
¼” manipulator 4-way control valve (capable of either being manually or remotely
actuated) which supplies the pilot pressure to either the ”OPEN” or “CLOSE” SPM
valve. This pilot pressure can be bled down from the ¼” manipulator 4w� ay control
valve and SPM valves by using a needle valve installed below the pilot pressure gauge.

Figure (31): SPM valve

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Figure (32): Annular preventer circuit with SPM

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11.Diverter Control
Diverter:
“Assembly of annular sealing device, flow control means, ventilation system components
and control system that facilitates closure of upward flow path of well fluids and opening
of the vent to atmosphere.”
The requirements to pressure and volume supply to the Diverter System are normally
lower than those for the BOP system. This means that the Diverter System can share the
pressure and volume supply System (BOP Control unit) with the BOP System since they
are not in use at the same time.
A Diverter is used to divert / direct flow away from the rig. In worst case scenario it will
only buy the rig crew time to get of the rig.
In order to avoid closing in the well, an automatic system can be installed to ensure that
one overboard line is open before the diverter packer and main flow line valve are closed.
The automatic system is external control of the sequence of valve operations. The
sequence is set prior to operation, according to wind direction. When the Diverter is to be
used only one button has to be functioned for the sequence to start.

Figure (33): Diverter setup

Figure (31) above illustrates how a system could be set-up. Here the overboard valve
(port or Starboard depending on wind direction) should be opened before closing packer
and shaker valve.

The Diverter Control System is designed to allow for operation of a diverter packer and
two overboard valves. The diverter control system is initiated from the main HPU skid or
either remote panel by a set of push buttons.
The diverter control system can be utilized from either the main HPU unit or from either
of the two remote control stations. Function from each varies slightly and the main
control point should be from the remote system. The main HPU must have a minimum of
1500-psi hydraulic pressure in order to test or operate the diverter system.

43
Remote operation if diverter system
While in diverter mode all BOP function control at the remote stations are inactive and
cannot be functioned from the remote system. The BOP functions can still be manually
operated from the main HPU.

Function diverter to open position:

 Diverter valve moves to open position
 Both overboard valves remain in their current position

Function diverter to closed position:

 Both overboard valves (port & starboard) move to the open position
 When the Control system gets confirmation (hydraulic pressure switches on open
line of port &starboard control valves) that both overboard valves are open the
Diverter packer valve is moved to the closed position.

Safety sequence for diverter close function:

 Upon engagement of the diverter close function a five second timer is initiated
through the system and resets if both overboard valves indicate they are in the
open position. If after five seconds the system indicates only one overboard is
open it will commence with the diverter close function. If after five seconds
neither overboard indicates an open position the diverter WILL NOT close in
order to prevent a well shut in condition.

Function overboard valves with diverter in open position:

 With the diverter in the Open position the overboard valves are free to be moved
to any position from the remote panels. No interlocking is engaged and all other
valves remain their current position.

Function overboard valves with diverter in closed position:

 When the Diverter is in the closed position the interlocking sequence is engaged.
This will prevent both overboard valves (port & starboard) from being closed at
the same time. When either valve is functioned to the closed position the system
will first verify that the opposing overboard valve is in the open position. If the
opposing overboard is in the closed position the system will automatically open
that valve prior to closing the selected valve.

HPU operation of diverter system

In order to operate the diverter logic from the main HPU the system must be switched to
diverter mode on the main HPU panel or the remote panels. While in diverter mode all
other BOP function controls at the HPU remain active and can be functioned. HPU
operation of the diverter system is controlled through a system of pneumatic/hydraulic
relays and valves.

44
Function diverter to open position:
 Manually move the diverter four-way valve to the open position
 Both overboard valves remain in their current position

Function diverter to closed position:

 Manually move the diverter four-way valve to the closed position
 Both overboard valves (port & starboard) will automatically shift to the open
position.
 Five seconds after both overboard valves are open you may preselect which
overboard valve to close.

Function overboard valves with diverter in open position:

 With the diverter in the Open position the overboard four-way valves are free to
be moved to any position. No interlocking is engaged and all other valves remain
in their current position.

Function overboard valves with diverter in closed position:

 When the Diverter is in the closed position the interlocking sequence is engaged.
This will prevent both overboard valves (port & starboard) from being closed at
the same time. When either overboard is moved to the closed position the
opposing valve is locked in the open position. This is accomplished by applying a
constant air supply to the remote control cylinder.
 To switch the position of the valves the closed valve must first be moved to the
open position. This will then unlock the opposing valve and allow it to be moved
to the closed position at which point the other valve will be locked open.

The API recommendation is for a diverter closing time is that it should not exceed 30
seconds for Diverter smaller than 20”, and not exceed 45 seconds for Diverters Larger
that 20”.

45
12. Interface Control Panel (ICP)
SAFETY CONSIDERATIONS AND PRECAUTIONS
 WARNING - PRESSURIZED ENCLOSURE
 POWER SHALL NOT BE RESTORED AFTER ENCLOSURE HAS BEEN
OPENED UNTIL ENCLOSURE HAS BEEN PURGED ACCORDING TO THE
INSTRUCTIONS NOTED ON THE HPU ENCLOSURE.
 HPU IS EQUIPPED WITH A PROTECTIVE GAS SUPPLY VALVE-
FOLLOW INSTRUCTIONS AS NOTED BEFORE CLOSING.
 RECOMMENDS THAT THE EQUIPMENT IS NOT ENERGIZED DURING
TROUBLESHOOTING IF IT IS OPERATED IN A HAZARDOUS AREA.

It controls and monitors all of the conditions on the main HPU skid. This panel houses
the CPU that monitors the following: Accumulator pressure, Manifold Pressure, Annular
Pressure, Air Pressure, Lag pipe pressure, Pump run, Low fluid, Communications, and
UPS alarms. When a system alarm occurs the Horn will sound and the alarm light will
flash. By pressing alarm acknowledge the horn will silence and the alarm light will stay
on till the alarm has been cleared. It is important to daily press the Lamp test butt on to
ensure all alarm lights are working. Press and hold the lamp test butt on for 10 seconds
and this will test the horn. If there are any defects fix as soon as conditions allow. This
panel controls using pneumatics: valve position, Regulator pressure, Bypass position, and
Air pumps. The panel is designed for operating conditions up to IP-56. The ICP is purged
to obtain ratings such as Class 1 Div. 1 and Zone 1 ATEX. Remote controls that are
compatible are electric push button and touchscreen. Failure of this panel would cause a
loss of all remote control and status indication. Detailed circuit diagrams are provided in
Appendix A in data book.

WARNING: THIS PANEL SHOULD NEVER BE OPENED WHEN AN EXPLOSIVE

ENVIROMENT IS PRESENT.

The air receiver tank is in place to allow operation of the pneumatic valves in the event
the system losses rig air pressure. The pressure switches monitor pressure in the lag pipes
and when it reaches 900 psi it gives positive position indication on the remote panels. The
festo manifold sends the pneumatic signals through SS tubing to change position of
valves and other functions. The vortex cooler is used to cool the panel in extreme heat
conditions and is controlled by a thermostat in the ICP. The air regulator takes rig air
pressure and lowers it to be used in the festo control valve.

46
Figure (34): Interface control panel (ICP)

47
13. HMI Control
The HMI panel is located in the HPU cabinet on the main BOP Control System skid. It is
a touchscreen device used to set system operational set points.

Main menu
Note: Screen may be blank at first viewing (screen saver mode). Simply touch the screen
to put the HMI into the active state.
Pressing the F1 butt on will open the “ANALOG SETPOINTS DISPLAY 1 of 2”. This
display will show the current set points and allow navigation to the display where these
set points can be modified. Also, navigation to “ANALOG SETPOINTS DISPLAY 2 of
2” is obtained from this display.
Pressing the F2 butt on will open the “TIMERS PRESETS DISPLAY 1 of 2”. This
display will show the current timer presets and allow navigation to the display where
these presets can be modified. Also, navigation to “TIMERS PRESETS DISPLAY 2 of
2” is available from this display.

Figure (35): Initial HMI Main menu screen

48
Password protected areas
To enter any protected areas you must first enter a password. The screens below will
automatically be displayed if a password is needed. Once logged in the user will remain
logged in for 5 minutes. The user is required and will be prompted to enter log in
information every 5 minutes.

To enter log in information:

Touch the password area to enter
the user password.
The following screen will display
and allow the user to enter
password information.

Once the password has been

entered, for security concerns, the
password will be displayed as a
series of asterisks(*).

Click OK to finalize and accept the

password.
Figure (36): HMI login

Touch the password area to enter the user password.

The following screen will display and allow the user to enter password information.

Touch the “0-9” butt on to display

numerical value buttons.

Touch the return butt on to accept

the entered password.

Figure (37): Password keypad

49
Analog presets display
The graphics below are the Analog Presets Display. These windows allow viewing of the
actual set points.
Pressing this butt on opens the
second of two displays that allows
viewing of the analog set points.
The F1 button also allows the user
to toggle between the 2 analog set
point screens.

To modify a set point, press the

“Modify Set Point” butt on to open
“Analog Presets Modify 1” display.
Note: password required.

Press the “Main Screen” butt on to

return to the main screen.
The F4 butt on will also return the
user back to the main screen.
Figure (38): Analog Preset Display (1 of 2)

Pressing this button opens the first

of two displays that allow viewing
of the analog set points.
The F1 button also allows the user
to toggle between the 2 analog set
point screens.

To modify a set point, press the

“Modify Set Point” button to open“
Analog Presets Modify 2” display.
Note: password required.
Press the “Main Screen” butt on to
return to the main screen.
The F4 butt on will also return the
Figure (39): Analog Preset Display (2 of 2) user back to the main screen.

50
Analog presets modify display
The graphics below are the Analog Presets Modify display. These windows allow editing
of the actual set points.
Pressing any of these buttons allows
the user to change the specific set
point value.
A numeric keypad will be displayed
where a new value can be entered.

As the system accepts new set

points, they will be displayed in
these numeric windows.
Pressing F4 will return the user to
the “Main” display.
Pressing F1 will return the user to
the “Analog Presets Display”.

Figure (40): Analog Preset Modify (1 of 2)

Pressing any of these buttons allows

the user to change the specific set
point value.
A numeric keypad will be displayed
where a new value can be entered.

As the system accepts new set

points, they will be displayed in
these numeric windows.
Pressing F4 will return the user to
the “Main” display.
Pressing F1 will return the user to
the “Analog Presets Display”.
Figure (41): Analog Preset Modify (2 of 2)

51
Timer presets display
The graphics below are the Timer Presets display. These windows allow viewing of the
actual set points.
Pressing this butt on opens the
second of two timer preset displays
that allow viewing of the timer set
points.
The user may also press F1 to
toggle between screen 1 and 2.

To modify a set point press the

“Modify Timer” button to open the
“Timer Presets Modify 1” display.
Note: password required

Press the “Main Screen” butt on to

return to the Main Screen.
The user may also press F4 to
Figure (42): Timer presets display (1 of 2) return to the main screen.

Pressing this butt on opens the first

of two timer preset displays that
allow viewing of the timer set
points.
The user may also press F1 to
toggle between screen 1 and 2.

To modify a set point press the

“Modify Timer” button to open the
“Timer Presets Modify 2” display.
Note: password required

Press the “Main Screen” button to

return to the Main Screen.
The user may also press F4 to
Figure (43): Timer presets display (2 of 2)
return to the main screen.

52
Timer presets modify display
The graphics below are the Timer Presets Modify display. These windows allow editi ng
of the actual set points.

Pressing any of these buttons allows

the user to change the specific set
point value.
A numeric keypad will be displayed
where a new value can be entered.

As the system accepts new set

points, they will be displayed in
these numeric windows.
Pressing F4 will return the user to
the “Main” display.
Pressing F1 will return the user to
the “Timer Presets Display”.
Figure (44): Timer presets modify (1 of 2)

Pressing any of these buttons allows

the user to change the specific set
point value.
A numeric keypad will be displayed
where a new value can be entered.

As the system accepts new set

points, they will be displayed in
these numeric windows.
Pressing F4 will return the user to
the “Main” display.
Pressing F1 will return the user to
the “Timer Presets Display”.

Figure (45): Timer presets modify (2 of 2)

53
 14. Remote Panel
The remote panel communicates with the Interface control panel and can operate and
monitor just about everything on the HPU main skid. The digital meters indicate pressure
for the header manifold, annular, accumulators, and rig air. Illuminated pushbuttons
indicate the positions of the BOP stack. In order to Open or Close a function the operator
must press the Push-to-Operate button and the function desired. Once 900 psi is reached
in the lag pipe of that function the light will illuminate giving a positive position
indication. If failsafe heads are installed on the hydraulic regulators these can also be
remotely functioned.
Alarm lights and a horn give system warnings and work in the same manner as the
Interface control panel.
This panel can be rated to Class 1 Div. 1 NEC or Zone 1 Atex. Class 1 Div. 1 is
obtained by the same means as the ICP, but the Zone1 rating is achieved through intrinsic
safety. Only install this panel in areas that it is rated for. Consult the data tag for
information on environmental ratings.

System alarms:
Warning horn will sound. Warning lights will flash and become steady upon acknowledgement
1. Low Fluid Alarm: Fluid in the reservoir is too low.
2. Low Accumulator Pressure: System pressure has fallen below 10% of working pressure.
3. Low Rig Air: Supplied air from the rig / installation has fallen below a set point.
4. Low Air Purge: Failure of the purging system in an electrical panel.
5. Communications Alarm: Electric remote can not communicate with the system CPU.
6. On Emergency Power: Normal control power has failed and the system is being powered
by UPS.
7. UPS Fault: Summary alarm that the UPS has a fault.

54
Figure (46): Remote panel

55
15. Air remote control interface assembly
Air remote control interface assemblies are required when an air remote control panel is
included with the BOP Control System. Air remote control is not recommended when the
distance to the remote panel exceeds 150 feet, for offshore installations or when the
system is required to meet the requirements of API RP 16E. These assemblies contain all
of the components that must be added to the accumulator unit assembly for air remote
operation. These components include air cylinders, fixed plate half of an air junction box
and all necessary stainless steel tubing and fittings. For panels with remote regulation and
pressure monitoring, these components also include the air motor operator for the annular
regulator and a pressure transmitter assembly. When two air remote panels are included
on one BOP Control System the interface assembly also includes an additional fixed plate
half of an air junction box and air shuttle valves.

Air Remote Control Panel(s)

Air remote control panels provide partial or complete control and pressure monitoring
of the BOP Control System. This enables the accumulator unit assembly to be placed
in a safe area so that it can remain operational in emergency conditions. Multiple air
remote control panels can be added to a control system with minimal additional cost to
enhance the safety of drilling operations. Air remote control panels can be provided in
a wide variety of sizes, styles and configurations to meet specific space and
operational criteria. All air remote control panels contain a master control valve which
must be operated simultaneously with the selected function to initiate operation. They
all contain four-way spring centered air control valves and require a customer
furnished air supply and interconnect cable assembly.

Interconnect Cable Assembly

Air interconnect cable assemblies are used to carry signals from the air operated
remote control panels to the air interface assemblies on the accumulator unit. They
include a customer specified length of a flame resistant multi-conductor air cable.
The air cable consists of several spirally wound 3/8" 00 polyethylene air lines in a
Polyvinyl chloride (PVC sheath. The junction boxes consist of a hose end half of an
air junction box on each end which mates to the fixed plate halves mounted on the air
panels and on the air interface assemblies.

Cylinders
Air cylinders are mounted on each four-way control valve on the hydraulic manifold
that requires remote operation. The cylinder piston is connected to the handle of the
control valve. An air pressure signal initiated from the remote panel causes the
cylinder piston to extend or retract. This movement causes the handle to rotate thus
operating the function. The cylinders should be serviced periodically to ensure proper
operation.

56
Transmitters
Transmitters are required in the interface assembly when the BOP Control System
operating pressures are to be monitored on the remote control panel. These bourdon
tube type transmitters convert the hydraulic pressures into calibrated air pressure
signals. These signals are then registered on the air receiver gauges on the air remote
control panel as an equivalent hydraulic pressure reading. The transmitter air supply is
obtained from the transmitter air regulator which should be set at 15 psi.
Transmitters are included for:
1. Annular Pressure: 0-3000 psi; 0-6000 psi for Cameron “D” Annulars
2. Accumulator Pressure: 0-6000 psi
3. Manifold Pressure: 0-6000 psi

Figure (47): Pressure transmitter Figure (48): Transmitter ports

57
Figure (49): Transmitter main components

58
Figure (50): Oil signal flow

Figure (51): Air signal flow

59
Air Junction Boxes
All of the signal lines included in the interface assembly terminate at the fixed plate
half of an air junction box which mates to the hose-end half attached to the
interconnect cable assembly. This junction box facilitates handling of the BOP Control
System equipment during rig moves or when relocating the equipment.

Figure (52): Air interface control panel

60
Figure (53): Air interface circuit

61
System sizing recommendations
Correct sizing of accumulator units provide ample accumulator capacity (fluid stored under
pressure) to immediately control the preventers during an emergency. The pumps are designed to
charge these accumulators within a reasonable time period, and to maintain this charge, as
pressure is used to control the preventers. Pump systems should additionally be sized to
individually close the annular and open the HCR within two minutes. The following steps for
sizing the BOP Control System have been prepared to assist the customer in selecting a safe and
reliable BOP Control System.
The following is an example for method of sizing calculations are generally accepted throughout
the industry and in most cases meet API RP l6E recommendations for operating blowout
preventers with a maximum working pressure of 10000 psi or less. Some 10000 psi MWP BOP's
and all 15000 psi and above BOP Control Systems should be sized by the control system
manufacturer. Calculations should additionally consider the drilling venue and local certifying
agency requirements where applicable. There calculations represent the minimum acceptable
method.
Note: All recommendations are API as the industry in general is using API, as a minimum.
But local Rules and Regulations might be different and to a higher standard.

Sizing Accumulator Volume

The total accumulator volume for a 3000 psi BOP Control System should be sized to fully close
the annular and all ram preventers with the pumps out of service while maintaining a minimum
of 1200 psi operating pressure (200 psi above precharge). An additional 50% safety factor is
required to compensate for interflow and fluid loss in the control system.

Preventer Working Gallons to

Manufacturer Model Size
Type Pressure Close
Annular Hydril GK 13-5/8” 5,000 psi 17.98
Pipe Ram Cameron U 13-5/8” 10,000 psi 5.54
Blind
Cameron U 13-5/8” 10,000 psi 6.78
Ram
Pipe Ram Cameron U 13-5/8” 10,000 psi 5.54
Total 35.84
Table (1): Fluid Requirements for typical BOP stack

62
Calculations:
1. Determine total gallons of usable fluid required [See table (1)]
Example:
Total gallons to close = 35.84
50% safety factor = 17.92
Total gallons of usable fluid required, VR = 53.76

2. Calculate the total accumulator volume (Nitrogen and fluid) required (derived from
Boyle’s Law, P1V1 = P2V2):
P1 = Maximum pressure of accumulator when completely charged (3,000 psi)
P2 = Minimum operating pressure of accumulator (1,200 psi)
P3 = Nitrogen precharge pressure (1,000 psi)
V1 = Volume of nitrogen at maximum pressure
V2 = Volume of nitrogen at minimum pressure
V3 = Total accumulator volume of (nitrogen and fluid)
VR = Total usable fluid required including safety factor

63
 𝑉𝑉𝑅𝑅 53.76 53.76
𝑉𝑉3 = 𝑃𝑃3 𝑃𝑃3 = 1000 1000 = = 107.52 𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺
− − 0.5
𝑃𝑃2 𝑃𝑃1 1200 3000

𝑃𝑃3 𝑃𝑃3
Where, the value of [ − ] is the actual fluid capacity factor.
𝑃𝑃2 𝑃𝑃1
3. Determine the number of accumulators required by dividing the total accumulator
volume (Nitrogen and fluid) by the nominal accumulator capacity. The nominal
accumulator capacity is the accumulator size in gallons, less one gallon to allow for
bladder/float displacement.
Example using 11 gallon accumulators:
Total accumulator volume required (V3) = 107.52 gallons
Nominal Accumulator Capacity (11 – 1 = 10) = 10.00 gallons
Number of eleven gallon accumulators = 10.75 ≈ 11 bottles
Total “usable” fluid volume (from 3,000 psi to 1,200 psi) = 55 gallons

64
Sizing Air and Electric Pumps – Standard
The combination of pumps for a 3,000 psi Conventional BOP Control System should be capable
of charging the entire system accumulator capacity from minimum pressure to 3,000 psi in
fifteen minutes or less. Either individual pump system (i.e. electric and air) should individually
be capable of closing the annular and opening the HCR (choke) valve within two minutes
whichever is greater.
1. Determine the required pump GPM by multiplying the number of accumulator bottles
(Obtained in Step 3 of Accumulator sizing) by 6.67 (volume difference between
precharged and charged bladder) and divide by 15 minutes:
Example:
Total number of bottles = 11 bottles
Volume required to charge each bottle = 6.67 gallons
Total volume required = 73.37 gallons
Divided by 15 minutes = ÷ 15 minutes
Required GPM from all pumps in the system = 4.89 GPM
2. Determine the required GPM of either individual pump system by dividing the total fluid
required to close the annular BOP and open the HCR by two minutes.
Example:
Gallons to close Annular = 17.98 Gallons
Gallons to open HCR = 1.00 Gallons
Total = 18.98 Gallons
Divided by 2 minutes = ÷ 2 minutes
Required GPM from each pumping system = 9.49 GPM

3. Select the pump model numbers each with a pump output greater than the total GPM
required above. You may use Tables 3 & 4 as an example.
4. It is not recommend air pump ratios less than 50: 1. Rig air pressure may drop as low as
60 psi under normal operating conditions which would not allow lower ratio pumps to
attain the required 3,000 psi output (See Table 2)

Pump Ratio Air Supply Stall Pressure

60:1 60 psi 3,600 psi
50:1 60 psi 3,000 psi
40:1 60 psi 2,400 psi
35:1 60 psi 2,100 psi
Table (2): Example of air pump stall pressures

65
 Air Motor No. of Approximate GPM @ 125 psi Air
Model No.
Dia. (in.) Pumps 1200 psi 2000 psi 3000 psi
UA8616 8 1 5.6 4.6 3.6
UA8626 8 2 11.2 9.2 7.2
UA8636 8 3 16.8 13.8 10.8
UA8516 8½ 1 6.0 5.0 3.9
UA8526 8½ 2 12.0 10.0 7.8
UA8536 8½ 3 18.0 15.0 11.7
UA8546 8½ 4 24.0 20.0 15.6
Table (3): Air pump specifications

Plunger Approx. Nom.

Model No. HP Size Volts flow @ Ph Hz FLI
(in.) 3000 psi Amps
UET10HT460 10 5/8 460 4.20 gpm 3 60 13.2
UET15HT460 5 3/4 460 6.10 gpm 3 60 20
UET20HT460 20 7/8 460 8.2 gpm 3 60 22.4
UET25HT460 25 1 460 10.70 gpm 3 60 31
UET30HT460 30 1 460 12.20 gpm 3 60 37
UET40HT460 40 1 1/8 460 17.00 gpm 3 60 47
UET50HT460 50 1 1/4 460 19.70 gpm 3 60 61
UET60HT460 60 1 3/8 460 23.9 gpm 3 60 75
Table (4): Electric pump specifications

66
Common maintenance and check ups
The entire system should be tested a minimum of once a week. This may involve simply
operating all functions and noting gauge readings.
Note: BOP Control Systems are a safety mechanism that must be maintained properly to ensure
the safe and effective operation as intended.

Routine maintenance
Daily
• Verify that unit is in a good condition.
• Alarms: Make sure there are no active alarms. Carry out test for alarms.
• Check for leaks: Oil and air.
• Suction valves for all pumps are opened
• Check oil level for triplex and chain case.
• Make sure drive belt guard is tight.
• Check all gauges readings: Annular circuit, manifold, accumulators.
• Make sure electric pump switch is on auto position
• Check supply air pressure and regulated air pressure (for air control interface systems)
• Check lubricator oil level
• Drain air filter
Weekly
• Perform daily maintenance
• Check oil level in reservoir.
• Operate pressure regulator valves from 0 to 1500 on HPU and remotely.
• Check set points for pressure switches:
Electric  2650 – 3000
Air  2500 – 2900.
• Apply light oil on detends for 4-way valves.
Monthly (or during BOP test)
• Perform weekly maintenance
• Drive belt:
V-belts: Depress to be ½” in the middle of the belt. Check belts condition.
Chain belt: Check chain condition for broken links.
• 4-way valves:
Check for proper movement and ensure they are operational.
Grease valve body and mounting bolt.
Clean, apply emery paper on piston rods for actuating cylinders. Coat rods by silicon
based grease.

67
 • Open 4” inspection ports to check for valves leaking.
• Check hydraulic fluid cleanliness.
• Clean suction strainers for all pumps by warm water or kerosene.
• Test pumps operation.
• Clean sludge build up in air exhaust
• Check end caps for leaks
• Drain air reservoir (if equipped)
• Check high pressure filters (if equipped)
6 Months
• Perform monthly maintenance
• Draw oil sample and send it to Cairo for analysis: Sample to be drawn from the top of oil,
not from the bottom of the tank.
• Draw an oil sample from triplex pump. Change oil.
• Change oil for chain case (for chain driven pumps)
• Replace hydraulic filter (if equipped)
• MPI for lifting and critical points
1 Yearly
• Perform 6 months maintenance
• Change reservoir fluid
• Inspect 4-way valves for leaks with full system pressure in close, block, open position.
• Carry out calibration job via 3rd party on: Pressure gauges, pressure switches, safety relief
valve(s) and pressure transmitters.
• Check pumps packing and replace as required
Note: The packing glands should be tight enough to eliminate leaking and loose
enough to lubricate the plungers with a fine oily film. Overtightening the packing
will damage the motors.
5 Yearly
• Perform annual maintenance
• Carry out integrity test for accumulator bottles (wall thickness measurement and pressure
test through re-certification of approved third party)
• Dismantle all 4-way valves for inspection and cleaning, and overhaul if required
• Disassemble triplex pump and overhaul if required
• Disassemble air operated air pump and overhaul if required
• If the unit to be sent to Cairo workshop, make sure it is depressurized – all oils drained –
clean.

68
Important work instructions
Chain Tension Adjustment and Initial Setting
Adjust drive centers and chain tension:
1. Horizontal drives should be installed with initial sag equals to two percent (2%) of
sprocket centers.
2. Vertical center drives should be operated with both spans of chain close to being
taut. Periodic inspection of such drives should be made to avoid operation with
excessive slack and to maintain proper chain tension.
Determine the amount of sag.
1. Pull one side of the chain taut, allowing all the excess chain to accumulate in the
opposite span.
2. Place a straight edge over the slack span and pull the chain down at the center,
measure the amount of sag. When necessary, adjust drive centers for proper sag
that will result in correct chain tension.

Figure (54): Tensioning chain belt drive

69
Precharging accumulators with nitrogen:
• Use DRY NITROGEN ONLY to precharge the accumulator.
• Use the charging assembly recommended in the manual to charge the accumulator to the
required precharge if it is not already charged at the factory. Precharge level is listed at the
accumulator racks on the unit.
• Make sure bleeder valve is opened and system pressure is zero prior to precharging
bottles.
• Check the charging valve for leaks using a snoop or soap water.
• Tighten the jamnut at the gas valve stem and also the locknut on the fluid port with a
wrench.
• Tighten the protective cap on the gas valve stem to hand tight.
• Check the gas precharge pressure periodically. This must be done after all the hydraulic
system pressure is released.
• If the gauge pressure reads “0,” tighten the valve core using a valve core tool, apply 200
psi nitrogen and watch for a pressure drop. If the pressure drops – apply a drop of oil to
the top of the valve stem, if it bubbles, replace the damaged valve core. If nitrogen is
escaping from the bottle and out through the bleeder valve on the control manifold,
replace the bladder in that bottle.
Note: The precharge must be checked once in the first week of operation, and then every six
months during normal working or every month during high cycling or high temperature
condition; or after rig moves.
WARNING: Dry Nitrogen is the only approved gas for pre-charging of Accumulator
bottles. Use of any other substance/gas may result in catastrophic failure of equipment
and / or serious injury or death.

Bladders replacement:
WARNING: Never try to service an accumulator while the BOP Control System is
pressurized. Overhaul/re-certification for continued safe use of gas-loaded accumulators
shall be carried out only by skilled personnel. Before disassembly of a gas-loaded
accumulator commences, it shall be fully depressurized on both liquid and gas sides.
Once it has been determined that a bladder needs to be changed; isolate the manifold that
supplies pressure by closing the isolation valve located at the end of the bottle manifold. Then
open the bleeder valve that is located on the bottle manifold.
The Accumulator Gauge should indicate 0PSI before proceeding. Once it is verified that all the
hydraulic pressure has been safely removed remove the accumulator from the hydraulic system
and place it horizontally in a vice or a clamping device.
Protect the clamping jaws with wood or rubber so as not to damage the accumulator shell.
1. Remove the protective cap on the gas valve.
2. Remove the valve sealing cap from the valve adaptor.
3. Connect a suitable charging & gauging assembly to the valve adaptor and release all the
nitrogen precharge pressure from the accumulator until the gauge reads zero.
4. Remove valve adaptor from the gas valve body. (2 piece valve stem design).
Remove valve core if the gas valve body has a core inside. (1 piece valve stem design)

70
5. Remove the jamnut and the name plate from the gas valve body. While removing the
jamnut hold the gas valve body with a wrench so that the bladder will not rotate.
6. Remove the bleeder plug from the fluid port. Loosen locknut with a spanner wrench by
turning 2 or 3 threads. Then push the fluid port body into the accumulator shell if there is
no hydraulic pressure. If the fluid port body does not go inside, then there is some
hydraulic pressure left inside the accumulator. If this happens, do not attempt to do any
maintenance and make sure pressure is released.
7. Remove the locknut and then remove the spacer.
8. Push the fluid port body into the shell and remove the back-up ring, “O” ring and the
metal back-up ring.
9. Slide the anti-extrusion ring off of the fluid port. Carefully fold the anti-extrusion ring
until it’s sufficiently folded to allow removal from the shell and remove fluid port from
shell.
10. By squeezing the bladder discharge as much air as possible by hand, and then pull the
bladder out slowly through the fluid port opening of the shell.

Clean all the metallic parts of the accumulator with an organic solvent. Avoid exposing the
rubber parts to the solvent to prevent any attack on the rubber. Inspect the condition of the
metallic components of the fluid port (poppet, spring, stop nut and piston) and replace the
complete fluid port assembly if any of the components are damaged. Push the poppet valve
head to make sure it slides freely through the guide in the fluid port. Clean the bladder with
isopropyl alcohol or equivalent. Inspect the bladder for any visual damages. Replace if
necessary. Check that there is no corrosion inside or outside of the shell. Replace all parts
considered defective. The “O” Rings and back up rings must be replaced.
1. Squeeze the bladder to discharge air from it by rolling it up from the bottom.
2. Install the valve adaptor to a torque value of 90 in. lbs. (10 Nm). (For the two piece valve
stem design).
Install the valve core to a torque value of 4 in. lbs. (0.45 Nm). (For the one piece valve
stem design).
3. Lubricate the accumulator shell and the bladder either with the medium used in the
system or a similar product. Attach the bladder pull rod to the valve and fold the bladder
and pull into the shell. Avoid twisting the bladder while pulling it into the shell.
4. Reinstall the name plate and the jamnut. Do not tighten the jamnut.
5. Insert the fluid port and the anti-extrusion ring into the shell.
6. Slide the anti-extrusion ring over the fluid port. Pull the fluid port through the port
opening.
7. Install a charging and gauging assembly on the gas valve and put a low precharge of 30
psig (2 bar) to seat the fluid port and the anti -extrusion ring in place.
8. Hammer slightly the fluid port body at various angles using plastic hammer.
9. Install the metal back up, O-ring, rubber back up and spacer in that order.
10. Tighten the locknut.
11. Install the bleeder plug and tighten it.
12. Rotate the accumulator shell around its axis to lubricate its inner wall evenly all around.
13. Using a charging and gauging assembly, precharge to the desired pressure at a moderate
rate, using DRY NITROGEN only.

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 14. Install the bottle back on HPU skid. DO NOT PRECHARGE BLADDER UNTIL IT IS
IN ITS UPRIGHT POSITION.
15. Check the valve for leaks with snoop or soap water.
16. Remove charging and gauging assembly, install valve cap and protective cap. Retighten
the Assembly locknut & jamnut.

Control fluid change:

1. System must be bled down to 0 PSI.
2. Check precharge in all accumulator bottles.
3. If any bottles have 0 precharge, they must be precharged to ensure all fluid has been
removed from the bottles.
4. Pump all fluid out of reservoir into suitable containers for disposal.
5. Remove all inspection and drain plugs from reservoir and pressure wash the entire inside
of the reservoir to remove all contamination.
6. Flush the entire system with 60°C(140°F) hot water. Optional: Circulate a bactericidal
solution through the system. A warm to hot solution is recommended. Rinse the system
with hot water.
7. Pump system up to 3000 PSI and then function all Blowout Preventers to remove all
contaminated fluid from the open and close cavities and all BOP lines.
8. Disconnect the BOP lines and drain all fluid from them.
9. Connect an air hose with an air valve to all ports of the BOP stack (one at a time), very
slowly open valve and allow air pressure to function BOP to remove all water remaining
in open and close cavities.
10. Drain BOP unit reservoir again.
11. Remove all inspection and drain plugs from reservoir and pressure wash the entire inside
of the reservoir to remove all contamination and water.
12. Ensure that reservoir is dry before reinstalling plugs.
13. Fill with new fluid.

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Checklists
Before rig up and start up
• Accumulator precharge
• Hydraulic connections are clean
• Hoses in good condition
• External leaks
• Internal leaks (inside reservoir)
• Pressure switches cut out
 After the system pressure has reached 3000 psi and the pumps have stopped,
open the manifold bleeder valve.
 Pumps should automatically start when accumulator pressure is 2,500-2,700
psi. If lower, the pressure switches need adjustment.
 Close manifold bleeder valve and recharge the system to 3,000 psi.
• Supply air
• Air lubricator
• Water separator on supply air line
• Air pumps: air valves opened, suction valves opened.
• Electric pumps: switch on Auto position, suction valve is opened. Check oil levels: crank
case and chain case.
• Gauges
• Remote control
• Valves positions: Upon starting put them all on center (neutral) position, and bypass
valve on low pressure (1500 psi). After the system is charged, put all valves on normal
positions: All pipe rams Open, bypass on 1500 psi, HCR valves on Close.
Starting pumps:
• With the manifold bleeder valve in the "OPEN" position, alternately open the air supply
valve to each pump to ensure that each pump operates smoothly and without leaks.
• Close the air supply valve to each pump. With the rig main generator power "ON", place
the triplex pump motor starter switch to the "AUTO" position. Check that the pump runs
smoothly and without leaks.
• Close the manifold bleeder valve.
• Open all air supply valves.
• Set air lubricator to 6 drops per minute.
• Pumps should continue running until accumulator pressure reaches 3,000 psi.

The following list identifies the normal operating position of the shut-off valves and control
valves of the BOP Control System:

• Shut-off Valves
 Air pump supply valves - "OPEN".
 Air and electric pump suction valves - "OPEN".
 Accumulator bank isolator valves - "OPEN".
 Accumulator bank bleeder valves - "CLOSE".

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  Manifold bleeder valve - "CLOSE".
 Air pressure switch bypass valve (if so equipped) - "CLOSE".
• Control Valves
 Annular - "OPEN".
 Pipe and blind rams - "OPEN".
 Choke and kill valves - "CLOSE".
 Manifold regulator bypass/internal override valve - ''LOW
 PRESSURE" (Handle Left).
 Annular regulator lock handle: ''TIGHTEN FOR REMOTE OPERAION".

74
Troubleshooting
Problem Possible Cause Remedy
Air Supply problems No lubricant in bowl - Shut off air supply.
- Open petcock at bottom of air lack of air
lubrication bowl.
- Drain off any moisture or emulsified oil. Refill
lubricator with 10W motor oil.
CAUTION:
Do not use synthetic or Air-o-matic oil.
Lubricator out of - Close accumulator isolator valves.
adjustment
- Open manifold bleeder valve.
- Operate air pumps at full capacity.
- Use a thin screwdriver to adjust lubricator to
provide six drops of oil per minute.
- Close manifold bleeder valve.
- Open accumulator isolator valves.
Air operated pumps
icing over or freezing - Shut off pumps.
– moisture in rig air - Close valve at air receiver.
supply
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 - Drain accumulated liquid from air receiver.
- Next, remove plug from “Y” shaped strainer and
open air valve at receiver. This will purge
moisture from the supply line.
- Shut off air from receiver and replace plug at the
“Y”.
- Turn on air supply.
- Close accumulator isolator valves and open
manifold bleeder valves.
- Run air pumps at full capacity until all moisture
has been removed.
- Stop pumps.
- Open accumulator isolator valves and close
manifold bleeder valve. Air pumps are now ready
for service by restarting air pump.
Accumulator (float 1. Poppet valve being - Pressure up accumulator to 200 psi fluid pressure.
type) Problems – held open by
Loss of accumulator - Open bleeder valve to flush out debris.
debris
precharge pressure - Repeat procedure several times. If no
improvement, release all pressure from
accumulator, remove poppet and repair.

76
 2. Faulty precharge - Tighten valve core snugly with valve core tool.
valve permits - Precharge accumulator to 1000 psi.
nitrogen to escape
- Observe precharge pressure on precharge gauge.
- If pressure does not decrease, remove gauge and
place a drop of saliva across top of the core. Thin
oil may also be used. If no bubble is observed,
valve is holding. Accumulator is ready for
service.
Accumulator (float Float partially filled - Bleed off precharge.
type) Problems – with fluid
Premature closing of - Remove poppet valve assembly and guide rod,
poppet valve upset float and drain liquid.
- Replace guide rod and poppet valve assembly.
- Precharge accumulator with nitrogen.
- Close bleeder valve and pressure up accumulator
to 3000 psi fluid pressure.
- Open bleeder valve to expend fluid rapidly.
- If poppet valve pre-closes prematurely again –
float may be damaged and vessel needs to be
repaired.
Accumulator (float Float fully filled with
type) Problems – fluid - After accumulator has been charged with 3000
77
Poppet valve closed psi fluid pressure and any attempt to expend fluid
fails – pressure must be bled from accumulator
through the precharge valve.
- After pressure has been reduced to zero,
disconnect accumulator and remove poppet
assembly and guide rod.
- Upset float and drain all liquid from float.
- Re-install removed parts and reconnect
accumulator.
- Precharge accumulator with 1000 psi of nitrogen.
- Close bleeder valve and pressure up accumulator
with 3000 psi of fluid.
- Open bleeder valve to dump fluid rapidly from
accumulator.
- If poppet does not close prematurely,
accumulator is ready for service.
- If float sinks again, remove accumulator and
repair float.
Electric Motor Pressure switch - Turn off power at main panel.
Problems – Motor faulty
fails to start - Disconnect leads to from electrical pressure
switch to starter.

78
 - Use an Ohmmeter to check resistance across
terminals of pressure switch.
- If resistance is observed, the switch is working
properly and additional trouble shooting is
required.
- If no resistance is found, replace the micro
switch.
- If time is limited, replace the entire pressure
switch assembly.
Electric Motor 1. Voltage - When pump pressure is at proper setting and
Problems – Motor fluctuation pump stops frequently, voltage may be too low.
runs erratically 2. Pressure switch - Turn off pump switch at motor. Check and
span adjustment correct voltage at electric panel.
- If pump continues to stop and start after reaching
proper pressure setting, switch adjustment may be
necessary.
- Remove pressure switch cover.
- With starter switch in “auto” mode move white
indicator down or towards the front.
- Open bleeder valve and reduce manifold pressure
to desired pump starting pressure.

79
 - Move adjustment lever back (up or towards rear)
until pump starts.
- After pump stops, check results to make sure that
proper setting has been obtained.
A four way valve 1. Debris in the valve - Debris can frequently be disclosed by manually
interflowing 2. Washed out or shifting the valve through the full range. Repeat
NOTE: Valve damaged seals shifting several times until interflow has been
venting may be 3. Actuator rod out cleared up.
caused by leaking of adjustment
seals in the preventer - The valve must be removed and rebuilt. Use
4. Air actuator faulty special kits containing necessary parts for
5. Insufficient air overhaul. Consult maintenance instructions.
pressure
- Adjust actuator rod to obtain full travel. Check
lever travel.
- Remove air cylinder and inspect for debris, wear
or other damage. Repair or replace as necessary.
- Check all interface points for air leaks or open
connections.
Gauge problems – Shock due to rough - If gauge is used to check manifold or annular
out of adjustment treatment pressures, close accumulator valves and bleed off
manifold pressure by opening bleeder valve.
- Remove gauge face covering and use a thin
screwdriver blade to adjust gauge indicator to
80
 zero setting.
- Close bleeder valve.
- Open accumulator isolator valves.
- Bleed off any air trapped in the gauge by
loosening fitting. Tighten fitting.
- After full pressure is indicated, close accumulator
isolator valves and bleed off manifold pressure at
500 psi increments.
- Observe gauge reaction each time.
- When no manifold pressure remains, gauge
should read zero psi.
- When fluid filled gauges are out of calibration,
replace defective gauge with serviceable unit and
send defective gauge to vendor for factory
calibration.
- If the affected gauge was used to measure
accumulator pressure, proceed as follows:
- Bleed pressure from accumulators and repeat
steps outlined previously.
- An alternate method of checking the faulty gauge
can be used:

81
 - Connect the faulty gauge to a common
manifold with a gauge of known accuracy.
- Adjust faulty gauge if possible.
- Acceptable indication limits are plus or
minus 50 psi from true pressure.
Gauge Problems – 1. Supply line or - When gauge responds slowly or in an erratic
Respond slowly snubber clogged – manner during operation, stop all pumps.
accumulator - Close accumulator isolator valves.
pressure
2. Supply line or - Open bleeder valve to relieve manifold pressure.
snubber is clogged - Disconnect gauge supply line.
– manifold and - Purge supply line with hydraulic fluid from one
annular pressure air operated pump only. Re-assemble and check.
- If pressure gauge is installed with a snubber,
remove snubber from gauge and connect to
supply line.
- Start air operated pump and slowly close bleeder
valve.
- If fluid does not pass through snubber, stop pump
and open bleeder valve.
- Remove snubber and install a new one on the
gauge.
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- Start one air operated pump to purge assembly.
- Close bleeder valve and operate pump.
- If gauge is still sluggish or erratic, replace the
gauge.

- Place valves in central or “block” position.

- Reduce hydraulic pilot pressure to zero. Remove
snubber and tubing from gauge.
- If gauge indicated pressure, recalibrate gauge
disconnected from gauge, increase pilot pressure
to regulator.
- If fluid flows freely from open tube, reduce pilot
pressure back to zero.
- Attach snubber to the hydraulic tubing and
increase pilot pressure.
- If no fluid escapes, the snubber is blocked and
should be replaced.
- Reassemble tubing, snubber, and gauge.
- Cycle regulated fluid pressure to 1000 psi and
back down again to zero.
- Gauge should indicate zero. If it does not, replace

83
 gauge with a serviceable part.
Pumps operate 1. Air pump - Reset automatic pressure switch to shut off air
excessively pressure switch pumps at 2900 psi for units with air and electric
NOTE: Problems Bypass valve open pumps (3000 psi for units with pumps only).
involving or faulty
accumulator - If air pumps continue operating, bypass valve
precharge, leaking may be partially open or defective.
valves or leaks in the - Close the bypass valve tightly.
fluid system usually - Loosen tubing connector downstream from air
cause excessive pump bypass valve.
running
- If air is escaping, replace the bypass valve.
2. Hydraulic seals in - Stop pumps, shut off air supply, bleed off
automatic manifold pressure and remove automatic pressure
pressure switch switch for inspection and repair.
are leaking - See instructions elsewhere in this section for
repair procedure.
3. Bleeder valve - Bleeder valve open or other valves venting.
leaking - Close bleeder valve.
- Check for leakage by looking through inspection
ports located at each end of the reservoir.
- If valve is leaking, repair it.

84
4. Four-way valve - Open inspection ports located at each end of
leaking reservoir.
- Observe which valve is leaking and manipulate
manually several times.
- If leaking persists – repair faulty valve.
5. Faulty precharge - Shut off pumps and open bleeder valve on
valve. (bladder manifold.
type separator) - Check precharge pressure on each accumulator
and record.
- Tighten each precharge valve assembly by using
valve core tool.
- Precharge each accumulator with 1000 psi of
nitrogen. Accumulator with highest recorded
pressure should be precharged first. This will
conserve nitrogen.
- Check al precharge valves for gas leaking by
placing drops of saliva across tops of valves (light
oil may also be used).
- If no bubbles appear, accumulators are ready for
service.

85
6. Leaks in fluid - Visually inspect all piping and connections on the
system accumulator unit including all connecting lines to
B.O.P. stack.
- Repair all fluid leaks.
7. Loss of precharge - Bleed fluid system pressure slowly through
pressure bleeder valve.
- If poppet valve does not close at precharge
pressure and pressure continues to drop to zero, at
least one accumulator has lost its precharge.
- Check and record precharge pressures on each
accumulator.
- Those with zero precharge may have faulty
bladders.
- To check this, tighten valve cores snugly with
vale core tool, and precharge with 200 psi of
nitrogen.
- If pressure does not decrease, recharge with 1000
psi of nitrogen.
- If an accumulator does not sustain 200 psi
precharge the bladder is ruptured and must be
replaced.

86
Pumps shut down at 1. Air pump - Turn off power to electrically driven pump.
wrong pressure pressure switch - Close accumulator isolator valves.
out of adjustment
- Close air by-pass valve.
- Start air operated pumps.
- To increase cut off pressure setting, rotate
adjustment nut counter clockwise until pump
stops running when desired fluid pressure has
been reached.
- Bleed off manifold pressure through bleeder
valve and repeat procedure to check accuracy of
setting.
2. Electric pressure - Pressure switch settings have a tendency to drift
switch out of and require periodic calibration. This especially
adjustment true when the equipment has been moved to a
different location.
- If pump stops before reaching desired pressure,
the setting must be readjusted.
- Remove protective screw in housing to expose
fluid pressure.
- This will trigger the pressure switch and pump
will start.

87
 - Insert thin screwdriver blade in adjustment screw
slot and rotate screw counter clockwise for
approximately 1/8 turn.
- If pump still stops before reaching desired
pressure, repeat above procedure until required
setting has been obtained.
- Replace protective screw in housing.
- If pump runs past desired pressure follow
instructions in preceding paragraph except rotate
adjustment screw in clockwise direction to reduce
top limit setting.
Pumps problems – 1. Fluid - Close accumulator isolator valves if pressured up.
No pressure contamination - Shut off air to air pumps.
- Open bleeder valve, start air operated pumps and
observe fluid flow through inspection ports.
- If slight or no fluid flow is observed, stop pumps.
- Close pump suction valve(s).
- Remove “Y” strainer plug and remove strainer.
- Open suction supply valve and flush out debris
from piping.
- Close valve and replace strainer and plug. Start
88
 pump and observe fluid flow.
- Repeat procedure until system is clean.
2. Loss of pump - To restore fluid level, isolate accumulator
prime due to low manifolds if pressured up.
fluid level - Bleed system by opening manifold bleeder valve.
- Add fluid to within twelve inches above pump
suction lines.
- Start one pump and operate at full air pressure.
- Observe fluid flow through inspection ports.
Pumps cannot reach Faulty check valve in - If pump discharge pressure reaches a certain
full pressure pump discharge line pressure and pump still continues to run, the
check valve in the discharge line is stuck in open
position or has been damaged.
- Stop pumps, isolate pressured up accumulators
and bleed off manifold pressure.
- Remove suspected check valve and disassemble.
- Clean, repair or replace as necessary.
- After reinstallation operate pump with bleeder
valve open to make sure that the pump is properly
primed.

89
Pumps leaking 1. Plunger packing is - On the older style pumps tighten packing nut.
worn or damaged - If leak stops, check for proper plunger
– air pumps lubrication.
- The plunger should be coated with thin film of
hydraulic fluid.
- If leaks persist, remove pump and repair. See
pump maintenance.
2. Worn packing – - Replace packing per instructions in the parts
electric driven section.
pumps
3. Damaged valve - Turn off pump motor switch.
cover gasket or - Close suction valve.
loose cover plate –
electric driven - Remove and inspect valve cover gaskets.
pump - Replace gaskets if they appear to be distorted,
washed out, or compressed excessively.
- If the gaskets appear to be good, invert and
reinstall.
- Replace cover plate and tighten bolts.
- Open suction valve, start pump and check for
new leaks.

90
Regulator problems 1. Damaged seals or - When hydraulic fluid pressure remains stable and
– air pilot operated debris on sealing regulator continues to vent to reservoir, place
regulator surfaces of air function control valves on control manifold in
operated pressure block position.
regulating valve - Locate air regulator which supplies pilot pressure
to the fluid pressure regulating valve.
- Turn pilot air regulator handle from closed to full
open.
- Repeat this procedure several times.
- If venting of air controlled pressure regulating
valve continues, the valve should be repaired or
replaced.
2. Air pilot regulator - There are two air regulators which affect the
leaking performance of the air operated hydraulic
pressure.
- One is located on top of the hydraulic manifold
next to the manual-remote selector lever. The
other is located on the remote panel.
- Determine which air regulator is faulty by
isolating and individually checking each.
- Regulate air pressure up and down from zero to
maximum and observe which regulation produces
91
 the erratic response.
- Replace faulty air regulator.
3. Air operated on - This condition may be caused by damaged or
pressure loose gasket in the air operator chamber.
regulating valve is - Close accumulator isolator valves.
leaking air
- Stop all pumps.
- Relieve manifold pressure through bleeder valve.
- Reduce pilot air pressure to zero.
- Remove upper half of operator chamber.
- Remove and inspect gasket. Replace gasket if
damaged.
- If no damage is evident, replace gasket and
reassemble.
- Tighten bolts evenly around the air operator
flange.
- Reattach air pilot pressure.
- Check all connection for potential air leaks.
4. Damaged seals or - See corrective procedure for air operated valve
debris in sealing with as similar problem.
surfaces
92
Regulator problems 1. Internal parts not - If the regulator has not been in use over a long
– manually operated moving properly period of time the seals may be preventing the
regulator due to extended regulator from returning to its original setting.
inactivity - Place function valves in central or “block”
position.
- Adjust regulator from zero to full pressure several
times.
- This action will establish a new seat and also will
flush out any debris from the seal area.
2. Seals are damaged - Place valves in center or “block” position.
or washed out. - Cycle manual adjustment from zero to full open
Debris in seal area several times.
- Observe venting through inspection ports.
- If venting persists, repair or replace the regulator.
- To remove, isolate accumulator manifolds.
- Vent hydraulic system manifold.
A pneumatic Shock to remote - The transmitter is a reliable but delicate
transmitter out of gauge during instrument which is easily affected by rough
adjustment shipment treatment.
- To correct adjustment, reduce hydraulic pressure

93
 on the corresponding gauge to zero.
- Remove transmitter cover.
- Use a thin screwdriver to adjust valve setting
until air receiver gauge on remote panel indicates
zero pressure.
- Increase hydraulic pressure in system to 1000 psi.
- Adjust receiver gauge on remote panel to
corresponding setting.
- Increase hydraulic pressure by 1000 psi
increments until 3000 psi maximum has been
reached.
- Make adjustments to obtain corresponding
pressure reading.
- Use manifold bleeder valve to reduce pressure in
500 psi increments until pressure drops to zero.
- Make final adjustment to receiver gauge on
remote panel.
CAUTION
Do not change setting of air regulator to transmitter.
Maximum pressure shall not exceed 18 psi. Higher
pressures may cause damage to piping inside the
transmitter.
94
Pneumatic receiver Small hoses inside - Remove cover from transmitter.
gauge indicates low the transmitter are
or no pressure clogged, have burst - Make sure air is flowing through the small
or become internal lines. Sometimes lines are clogged
disconnected. causing malfunction of transmitter.
- Listen for escaping air. Locate damaged or
disconnected hose and repair. Re-calibrate gauge
by following steps outlined previously. Observe
pressure limit caution.

95
Glossary
Accumulator
A device used in a hydraulic system to store energy or, in some applications, dampen pressure
fluctuations. Energy is stored by compressing a precharged gas bladder with hydraulic fluid from
the operating or charging system. Depending on the fluid volume and precharge pressure of the
accumulator, a limited amount of hydraulic energy is then available independent of any other
power source. Well pressure−control systems typically incorporate sufficient accumulator
capacity to enable the blowout preventer to be operated with all other power shut down.
Accumulator Bank
An assemblage of multiple accumulators sharing a common manifold.
Accumulator Precharge
An initial nitrogen charge in an accumulator which is further compressed when the hydraulic
fluid is pumped into the accumulator storing potential energy.
Air Pump (Air Powered Pump)
Air driven hydraulic piston pump.
Annular BOP (Blowout Preventer)
A large valve used to control wellbore fluids. In this type of valve, the sealing element resembles
a large rubber doughnut that is mechanically squeezed inward to seal on either pipe (drill collar,
drill pipe, casing, or tubing) or the open hole. The ability to seal on a variety of pipe sizes is one
advantage the annular blowout preventer has over the ram blowout preventer. Most blowout
preventer (BOP) stacks contain at least one annular BOP at the top of the BOP stack, and one or
more ram−type preventers below. While not considered as reliable in sealing over the open hole
as around tubulars, the elastomeric sealing doughnut is required by API specifications to seal
adequately over the open hole as part of its certification process.
Bleeder Valve
A device for removal of pressurized fluid. Used to bleed air from system.
Blind Ram BOP
A thick, heavy steel component of a conventional ram blowout preventer. In a normal pipe ram,
the two blocks of steel that meet in the center of the wellbore to seal the well have a hole
(one−half of the hole on each piece) through which the pipe fits. The blind ram has no space for
pipe and is instead blanked off in order to be able to close over a well that does not contain a drill
string. It may be loosely thought of as the sliding gate on a gate valve.
Blind Ram - Shear
An item of pressure−control equipment often fitted to the wellhead during well−intervention
operations on live wells. Most commonly associated with coiled tubing operations, the
shear−seal BOP is a ram−type preventer that performs the dual functions of shearing or cutting
the tubing string and then fully closing to provide isolation or sealing of the wellbore. Shear−seal
BOPs are most commonly used in offshore or high−pressure applications where an additional
contingency pressure barrier is required.

96
Block Position
The center position of a three position control valve where pressure is blocked on the Open and
Closed Side of the valve.
Blowout
An uncontrolled flow of reservoir fluids into the wellbore, and sometimes catastrophically to the
surface. A blowout may consist of salt water, oil, gas or a mixture of these. Blowouts occur in all
types of exploration and production operations, not just during drilling operations. If reservoir
fluids flow into another formation and do not flow to the surface, the result is called an
underground blowout. If the well experiencing a blowout has significant open hole intervals, it is
possible that the well will bridge over (or seal itself with rock fragments from collapsing
formations) downhole and intervention efforts will be averted.
Blowout Preventer
A large valve at the top of a well that may be closed if the drilling crew loses control of
formation fluids. By closing this valve (usually operated remotely via hydraulic actuators), the
drilling crew usually regains control of the reservoir, and procedures can then be initiated to
increase the mud density until it is possible to open the BOP and retain pressure control of the
formation. BOPs come in a variety of styles, sizes and pressure ratings. Some can effectively
close over an open wellbore, some are designed to seal around tubular components in the well
(drill pipe, casing or tubing) and others are fitted with hardened steel shearing surfaces that can
actually cut through drill pipe. Since BOPs are critically important to the safety of the crew, the
rig and the wellbore itself, BOPs are inspected, tested and refurbished at regular intervals
determined by a combination of risk assessment, local practice, well type and legal requirements.
BOP tests vary from daily function testing on critical wells to monthly or less frequent testing on
wells thought to have low probability of well control problems
BOP Closing Ratio (Ram BOP)
A dimensionless factor equal to the area of the piston operator divided by area of the ram shaft.
BOP Control System
The system of pumps, valves, lines, accumulators, fluid storage and mixing equipment, manifold,
piping, control panels and other items necessary to hydraulically operate the BOP equipment.
BOP Stack
A set of two or more BOPs used to ensure pressure control of a well. A typical stack might
consist of one to six ram−type preventers and, optionally, one or two annular−type preventers. A
typical stack configuration has the ram preventers on the bottom and the annular preventers at
the top. The configuration of the stack preventers is optimized to provide maximum pressure
integrity, safety and flexibility in the event of a well control incident. For example, in a multiple
ram configuration, one set of rams might be fitted to close on 5−in. diameter drill pipe, another
set configured for 4 1/2−in. drill pipe, a third fitted with blind rams to close on the open hole and
a fourth fitted with a shear ram that can cut and hang−off the drill pipe as a last resort. It is
common to have an annular preventer or two on the top of the stack since annular preventers can
be closed over a wide range of tubular sizes and the open hole, but are typically not rated for
pressures as high as ram preventers. The BOP stack also includes various spools, adapters and
piping outlets to permit the circulation of wellbore fluids under pressure in the event of a well
control incident.

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BOP Stack Maximum Rated Working Pressure
The pressure containment rating of the ram BOP’s in a stack. In the event that the rams are rated
at different pressures, the BOP Stack Maximum Rated Working Pressure is considered equal to
the lowest rated ram BOP pressure. In stacks which do not contain any ram BOP, the BOP stack
maximum rated wellbore pressure is considered equal to the lowest rated BOP pressure.
Bumpless Transfer
The transfer from main electrical supply power to an alternate electrical power supply without
losing signal and/or memory circuit normally associated with power interruption.
Cavitation
A circumstance that occurs in pumps when existing space is not filled by available fluid.
Cavitation will deteriorate the hydraulic oil and cause erosion of the inlet metal.
Check Valve
A mechanical device that permits fluid to flow or pressure to act in one direction only. Check
valves are used in a variety of oil and gas industry applications as control or safety devices.
Check valve designs are tailored to specific fluid types and operating conditions. Some designs
are less tolerant of debris, while others may obstruct the bore of the conduit or tubing in which
the check valve is fitted.
Choke Line
A high−pressure pipe leading from an outlet on the BOP stack to the backpressure choke and
associated manifold. During well−control operations, the fluid under pressure in the wellbore
flows out of the well through the choke line to the choke, reducing the fluid pressure to
atmospheric pressure. In floating offshore operations, the choke and kill lines exit the subsea
BOP stack and then run along the outside of the drilling riser to the surface. The volumetric and
frictional effects of these long choke and kill lines must be considered to control the well
properly.
Choke Manifold
A set of high−pressure valves and associated piping that usually includes at least two adjustable
chokes, arranged such that one adjustable choke may be isolated and taken out of service for
repair and refurbishment while well flow is directed through the other one.
Closed Loop Circuit
A hydraulic control circuit in which spent fluid is returned to the reservoir.
Closing Unit (Closing System)
See BOP Control System.
Contaminant
Any material or substance which is unwanted or adversely affects the fluid power system or
components, or both.
Control Fluid
Hydraulic oil or water based fluid which, under pressure, pilots the operation of control valves or
directly operates functions.
Control Hose Bundle
A group of pilot and/or supply and/or control hoses assembled into a bundle usually covered
with an outer protective sheath.

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Control Line
A small−diameter hydraulic line used to operate downhole completion equipment such as the
surface controlled subsurface safety valve (SCSSV). Most systems operated by control line
operate on a fail−safe basis. In this mode, the control line remains pressurized at all times. Any
leak or failure results in loss of control line pressure, acting to close the safety valve and render
the well safe.
Control Manifold
The assemblage of valves, regulators, gages and piping used to regulate pressures and control the
flow of hydraulic power fluid to operate system functions.
Control Panel
An enclosure displaying an array of switches, push buttons, lights and/or valves and various
pressure gages or meters to control or monitor functions. Control panel types include: diverter
panel; driller’s panel; master panel; and mini or auxiliary remote panel. All of these panels are
remote from the main hydraulic manifold and can be pneumatic, electric or hydraulic powered.
(a) Diverter Panel – A panel that is dedicated to the diverter and flow line system functions.
(b) Drillers Panel – The BOP control panel mounted near the driller’s position on the rig floor.
(c) Master Panel (Hydraulic or Electric) – The panel mounted in close proximity to the main
accumulator unit. All control functions are operable from this panel including all regulators
and gages.
(d) Mini or Auxiliary Remote Panel – A limited function panel mounted in a remote location for
use as an emergency backup. On an offshore rig it is normally located in the tool pusher’s
office, and on a land rig, at least 100 feet from the well center on the leeward side of the
prevailing wind.
Control Valves
The ways you can harness the power of a hydraulic system is through the use of control valves.
The three basic types of control valves are the tandem center type, the open center (motoring
spool) type, and the closed center type. Both the tandem center and the closed center types are
available in a three way or four way valve. Opening or closing valves, allows control of how
much or in what direction a hydraulic piston moves. Valves can also control many pistons
working with each other at the same time.
Control Valve (Surface Control System)
A valve mounted on the hydraulic manifold which directs hydraulic power fluid to the selected
function (such as annular BOP close) while simultaneously venting the opposite function
(annular BOP open).
Diverter
A device attached to the wellhead or marine riser to close the vertical flow path and direct flow
(typically shallow gas) into a vent line away from the rig.
Electric Pump
An electrically driven hydraulic pump, usually a 3 piston (triplex) positive displacement pump.
Electro Hydraulic (EH) System
A control system that uses an electrical signal to activate a solenoid piloted hydraulic valve to
operate a function or to operate a control valve which in turn operates a function.

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Filter
A device incorporated into a hydraulic system to remove contaminants from the oil.
Function
Operation of a BOP, choke or kill valve or other component, in one direction (example, closing
the blind rams is a function, opening the blind rams is separate function).
HAZ
Heat Affected Zone (pertains to welding).
Hydraulic Power Unit
Any device used to create kinetic energy within a hydraulic system. Motors and manual energy
are both sources of power in hydraulic power units.
Junction Box (J−Box) (Electrical)
An enclosure used to house the termination points of electrical cables and components. May also
contain electrical components required for system operation.
Junction Box (J−Box) (Hydraulic or Pneumatic)
A bolt−on plate having multiple stab−type terminal fittings used for quick connection of the
multi−hose bundle to a pod, hose reel or manifold.
Kill Line
A high−pressure pipe leading from an outlet on the BOP stack to the high−pressure rig pumps.
During normal well control operations, kill fluid is pumped through the drill string and annular
fluid is taken out of the well through the choke line to the choke, which drops the fluid pressure
to atmospheric pressure. If the drill pipe is inaccessible, it may be necessary to pump heavy
drilling fluid in the top of the well, wait for the fluid to fall under the force of gravity, and then
remove fluid from the annulus. In such an operation, while one high pressure line would suffice,
it is more convenient to have two. In addition, this provides a measure of redundancy for the
operation. In floating offshore operations, the choke and kill lines exit the subsea BOP stack and
run along the outside of the riser to the surface. The volumetric and frictional effects of these
long choke and kill lines must be taken into account to properly control the well.
Limit Switch
A hydraulic pneumatic or electrical switch that indicates the motion or position of a device.
Manifold
An assemblage of pipe, valves, and fittings by which fluid from one or more sources is
selectively directed to various systems or components.
Manipulator Valve
A three position directional control valve that has the pressure inlet port blocked and the operator
ports vented in the center position.
Multiplex
A system that uses electronic signals that are coded and transmitted through a conductor pair.
This eliminates the requirement of a dedicated conductor pair for each required signal.

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Pipe Ram BOP
A type of sealing element in high−pressure split seal blowout preventers that is
manufactured with a half−circle hole on the edge (to mate with another horizontally opposed
pipe ram) sized to fit around drill pipe. Most pipe rams fit only one size or a small range of drill
pipe sizes and do not close properly around drill pipe tool joints or drill collars. A relatively new
style is the variable bore ram, which is designed and manufactured to properly seal on a wider
range of pipe sizes.
Power Fluid
Pressurized fluid dedicated to the direct operation of functions.
Pressure Vessel
For BOP Control Systems, a pressure vessel is a container for the containment of internal fluid
pressure.
Ram Preventer
A classification of blowout preventer in which the pressure−control functions are achieved
through the operation of hydraulically operated ram sets. Each ram set is configured as an
opposing pair and, depending on function, are designed to close within the bore of the preventer.
Ram preventers are commonly available in single−, double−, triple− and quad−ram
configurations.
Readback
An indication of a remote condition.
Regulator (Pressure)
A hydraulic device that reduces upstream supply pressure to desired (regulated) pressure. It may
be manual or remotely operated and, once set, will automatically maintain the regulated output
pressure unless reset to a different pressure.
Relief Valve
A device that is built into a hydraulic or pneumatic system to relieve (dump) any excess pressure.
Remote Panel
(See Control Panel)
Reservoir
A storage tank for the BOP control system fluid.
Response Time
The time elapsed between activation of a function at any control panel and complete operation of
the function.
Selector Valve
A three position directional control valve that has the pressure inlet port blocked and the operator
ports blocked in the center position.

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Shear Ram BOP (Blowout Preventer)
A blowout preventer (BOP) closing element fitted with hardened tool steel blades designed to cut
the drill pipe when the BOP is closed. A shear ram is normally used as a last resort to regain
pressure control of a well that is flowing. Once the drill pipe is cut (or sheared) by the shear
rams, it is usually left hanging in the BOP stack, and kill operations become more difficult. The
joint of drill pipe is destroyed in the process, but the rest of the drill string is unharmed by the
operation of shear rams.
Sheave
A wheel or rollers with a cross−section designed to allow a specific size of rope, cable, wire line
belt or hose bundle to be routed around it at a fixed bend radius. Normally used to change the
direction of, and support a line or for driving an electric motor/pump assembly.
Shutoff Valve
A valve with two or more supply pressure ports and only one outlet port. When fluid is flowing
through one of the supply ports the internal shuttle seals off the other inlet port and allows flow
to the outlet port only.
Solenoid Valve
An electrical coil operated valve which controls a hydraulic or pneumatic function or signal.
Spent Fluid
Hydraulic control fluid that is vented from a function control port when the opposite function is
operated.
Stored Hydraulic Fluid Volume
The fluid volume recoverable from the accumulator system between the maximum designed
accumulator operating pressure and the precharge pressure.
Usable Hydraulic Fluid
The hydraulic fluid volume recoverable from the accumulator system between the maximum
designed accumulator operating pressure and the minimum operating pressure.
Water Based Hydraulic Fluid
A control liquid mixture composed mainly of water with additives to provide lubricity,
anti−foaming, anti−freeze, anticorrosion and anti−bacterial characteristics.

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