CHAPTER SEVEN

B.O.P. Control Systems

Pages
73
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74
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75
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76
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76

Chapter 7

SURFACE ACCUMULATOR UNIT ................................................................................

Fluid Mixing System ................................................................................
Fluid Filtering ...........................................................................................
Electric Triplex Pumps .............................................................................
Accumulator Bottles ................................................................................
Accumulator Isolator ...............................................................................
Pilot Control Valves and Regulators ......................................................
Pod Select .................................................................................................
Gauges .......................................................................................................
Electrical Junction Boxes .......................................................................
Solenoid valves ........................................................................................
Pressure switches ....................................................................................
Pressure Transducers ..............................................................................

JUMPER HOSES, HOSE BUNDLES AND REELS ....................................................... 76

Hydraulic Junction Boxes ....................................................................... 76
Hose Reel Control Panel .......................................................................... 77
CONTROL PODS ...........................................................................................................
Pod Latch Mechanism .............................................................................
Subsea Control Pod Regulators ..............................................................
Regulated Pressure Read-back ...............................................................
S.P.M. Valves .............................................................................................
Shuttle valves ...........................................................................................

77
78
78
79
79
79

REMOTE ELECTRIC PANELS ..................................................................................... 710

THREE POSITION FUNCTION ..................................................................................... 710
Open Position .......................................................................................... 710
Close Position .......................................................................................... 711
Block Position .......................................................................................... 711
TWO POSITION FUNCTION ......................................................................................... 711
Open Position ........................................................................................... 711
Vent Position ............................................................................................. 712

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STRAIGHT THROUGH FUNCTION .............................................................................. 712

FUNCTION TESTING .................................................................................................... 712
ACCUMULATOR SIZING ............................................................................................... 712
Norwegian Petroleum Directorate ............................................................ 713
Subsea Accumulators .............................................................................. 713
CONTROL SYSTEM TROUBLE SHOOTING ................................................................ 713
Hydraulic Circuit ....................................................................................... 713
Electrical Circuit ....................................................................................... 715
HYDRAULIC SCHEMATICS .......................................................................................... 716
FIGURES 78 THRU 108 ................................................................................. 717 thru 748
HYDRIL MUX OVERVIEW link ..................................................................................... 7-49

CAMERON MUX SYSTEM link ..................................................................................... 7-49

HYDRIL VIDEO link ..................................................................................................... 7-49

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SUBSEA EQUIPMENT TRAINING MANUAL

B.O.P. Control Systems

very component in a B.O.P. assembly is hydraulically operated, therefore the function of the
control system is to deliver, on command, hydraulic fluid at the correct pressure, to the appropriate side of the components operator and also provide a means for fluid in the opposing side of
the operator to be vented.
The B.O.P. control systems in use today, for subsea installations, are the pilot operated (indirect)
type, which use hydraulic pilot signals, sent from the surface accumulator unit to operate subsea
pod mounted valves and regulators, which in turn direct the power fluid, at the correct pressure, to
the B.O.P. components. There are therefore two separate hydraulic systems within the control
system, and they are the pilot system and the power fluid system.
The control system to be discussed in the following text is manufactured by the Koomey division
of N.L. Shaffer. For the purposes of this course, the control system can be separated into four
sections, these being:

The surface accumulator unit

The hose bundle, reels, and reel control panel

The control pods

The remote electric control panels

Each of these sections will be broken down into the individual components for discussion. Figure
78 shows an overall view of a typical B.O.P. control system.

SURFACE ACCUMULATOR UNIT

The Koomey accumulator unit contains the fluid reservoirs, pumping systems, filtering systems,
accumulator bottles, gauges, pilot control fluid system, power fluid system, explosion proof electrical junction boxes etc. and is shown in Figure 79.
Fluid Mixing System
The fluid used today in subsea B.O.P. control systems is a concentrate made up of various components which has to be mixed with fresh water at a 100-1 ratio, that is 100 parts fresh water to 1
part concentrate. The concentrate is formulated specifically for subsea systems where venting
subsea is required, and consists of: fresh water which acts as a carrier, mono-ethylene glycol
which gives freeze protection in the drum, a lubricity agent which lubricates the moving parts, a
corrosion inhibitor which prevents corrosion, a biocide to combat bacterial growth and a dye to
allow leak detection.
The fluid mixing system automatically mixes the fluid as required by means of a float switch in the
mixed fluid reservoir.

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The float switch or valve has an air supply which is piped to the reservoir fresh water supply shut
off valve and to an air operated pump in the concentrate reservoir. As the fluid level in the reservoir drops, the float switch drops allowing air pressure to open the fresh water supply shut off
valve and operate the concentrate pump simultaneously. The fresh water flow rate and concentrate pump output are regulated to ensure the correct mixture strength.
Since the fluid used affects the entire B.O.P. and control system it is vitally important to ensure
that the fluid mixture strength is correct. This can be done on the rig on a daily or weekly basis
using the fluid manufacturers test kit. The fluid should also be sent to the manufacturer on a
monthly basis for full bacterial analysis. Figure 80 shows the fluid mixing system.
Fluid Filtering
The fluid is strained and filtered at the surface unit prior to it entering the accumulator bottles. The
strainers are placed between the reservoir and the pumps and the high pressure filters are placed
between the pumps and the accumulators. These filters and strainers MUST be cleaned on a regular
basis to ensure that any material which could cause damage to the system components is removed.
Electric Triplex Pumps
The primary pressure pumps for the control system are electrically driven triplex pumps which
should be installed in such a way that, when the accumulator pressure drops to 90% of the
maximum system pressure, a pressure switch opens and automatically turns the pumps on. The
pressure switch also turns the pumps off at the maximum system pressure of 3,000 P.S.I. Figure
81 shows a triplex pump. Figure 82 shows the output capacity of the Koomey Triplex pump.
Secondary air-driven pumps provide additional output capacity and also act as a backup should
the electric power fail. The combination of electric and air-driven pumps should be capable of
charging the entire accumulator system, from the pre-charge pressure to the maximum system
pressure, in 15 minutes or less. This requirement is used to determine the number of pumps
required in each system.
Accumulator Bottles
The banks of accumulator bottles located at the accumulator unit are separator/bladder type
accumulators which serve to store hydraulic energy, which is used to operate the B.O.P. components at the desired closing rate. They supply the fluid to the B.O.P. at rates much higher than the
pump capability and can achieve faster B.O.P. actuation than if using the pumps alone.
The Koomey bladder/separator type accumulator has a rubber bladder separating the nitrogen
pre-charge pressure from the hydraulic fluid. The bladder is pre-charged with nitrogen to 1,000
P.S.I. and this pre-charge acts as expulsive energy to deliver the fluid as required.
When the fluid pressure from the pumps reaches the nitrogen pre-charge pressure, the poppet valve
is lifted and fluid enters the accumulator. As the fluid pressure increases the gas in the bladder is
compressed. When fluid is required from the accumulator, the compressed gas supplies expulsive

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SUBSEA EQUIPMENT TRAINING MANUAL

energy to deliver the fluid. The poppet valve prevents bladder extrusion as the fluid is expelled.
Figure 83 shows a separator/bladder type accumulator.
Accumulator Isolator
An accumulator isolator circuit is provided, which allows isolation of the surface and subsea accumulator bottles. The surface accumulator isolator valve is a two position, hydraulic double pilot
operated valve which, when closed, isolates the surface accumulators from the pump supply.
When this valve is closed the pump output is directed to the pod selector and not to the accumulators. This valve should only be closed in the event of a major accumulator leak. Figure 84 shows
the accumulator isolator circuit.
Pilot Control Valves and Regulators
The pilot signal control valves are !/4", three position, four way, manipulator type valves which are
mounted on the front panel of the accumulator unit. The pilot control valves can be operated
manually at the unit or remotely from the remote electric panels. An air cylinder is attached to the
valve handle which, when an air signal is received moves the valve to the desired position.
The inlet ports of the valves are manifolded together and supplied with 3,000 P.S.I. fluid pressure
direct from the main accumulators, through a check valve. The check valve prevents pressure drops
occurring in the pilot circuit which could be caused by pressure fluctuations in the main accumulators.
There are normally two five gallon pilot accumulators in the system which provide sufficient volume to pilot as many functions as the main accumulators can operate.
The pilot regulators are air pilot operated and have an air pilot to output fluid pressure ratio of 30:1.
This ratio indicates that a 50 P.S.I. air pilot signal is required to achieve an output pressure of 1500
P.S.I. The pilot air signal to the pilot regulators can be adjusted manually at the unit or remotely
from the remote panels.
These regulators are used to send pilot signals of varying pressures to the subsea pod mounted
regulators which are hydraulically piloted with a hydraulic pilot to output pressure ratio of 1:1. This
ratio means that a 1500 P.S.I. pilot signal is required to achieve an output pressure of 1500 P.S.I.
Pod Select
The power fluid at 3000 P.S.I., is directed from the main accumulators, through a flowmeter, to the
desired subsea control pod by a 1 inch, 3 position, 4 way, manipulator type valve, which simultaneously vents the pressure from the other pod. While the block or vent position is selected the
accumulator pressure is blocked at the valve and both pods are vented.
Gauges
The accumulator unit has all the necessary gauges required to monitor the system pressures mounted
on the front panel and they include, accumulator pressure, pilot pressure, B.O.P. manifold pressure,

B.O.P. CONTROL SYSTEMS

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B.O.P. manifold readback pressure, annular pressure, annular readback pressure, ball joint pressure, rig air supply pressure and failsafe regulator pressure.
These pressures also tee off at the unit to supply the pressure transducers, which convert the
pressures to a voltage to give a corresponding reading on the remote panel meters.
Electrical Junction Boxes
Explosion-proof electrical junction boxes provide the interface between the remote electric control panels and the accumulator unit. The left hand junction box houses the pressure switches,
and transducers, which convert hydraulic pressure to a voltage and transmit these to the remote
panel meters and indicator lights.
The right hand junction box houses the solenoid valves which direct air pressure to the air operators
of the !/4 inch pilot control valves, the 1 inch pod selector valve and to the !/4 inch pilot control regulators.
Solenoid valves
The solenoid valves housed in the right hand junction box are two position, three way valves
which have a rig air supply to the inlet ports. When energized from the remote panels, the solenoid valves open allowing the rig air to flow to the appropriate pilot valve operator. The solenoids
are also used to control the surface pilot regulators by either increasing or decreasing the air
pressure on the diaphragm.
Pressure switches
The pressure switches housed in the left hand junction box are activated by pilot pressure and are
used to activate the function position indicator lights on the remote panels.
Pressure Transducers
The pressure transducers are supplied, through a voltage regulator, with 5 volts input. The transducers convert the varying hydraulic pressures, which have to be monitored, into varying output
voltages, up to 5 volts maximum. These voltages are sent to the meters on the remote panels,
which are calibrated in P.S.I. For every pressure gauge on the accumulator unit front panel there
will be a corresponding transducer and meter.

JUMPER HOSES, HOSE BUNDLES AND REELS

The pilot control signals and power fluid are distributed through hydraulic umbilicals which extend
from the surface accumulator unit, to the hose reels, and from the hose reels to the subsea pods.
The umbilicals consist of one 1 inch I.D. power hose which supplies the power fluid to the pod,
and up to sixty four #/16 inch hoses which supply pilot signals to the pod S.P.M. valves and regulators. All the hoses are contained within an outer polyurethane covering which protects the individual hoses against damage from roller sheaves, clamps etc. Figures 85 and 86 show a typical
hose bundle and reel.

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The actuation times required to operate the pod S.P.M. valves depend, to a great extent, on the
size and rating of the pilot hoses; this is due to volumetric expansion. Figure 87 shows the actuation time versus hose length for a 1" S.P.M. valve for both !/8" and #/16" hoses of different types.
Hydraulic Junction Boxes
Hydraulic junction boxes (R.B.Q. plates) are required to allow removal of the jumper hose from
the hose reels while running or pulling the B.O.P. stack. The male junction plate contains the male
section of the quick-connect check valves to which the pilot hoses are terminated.
The female plate contains the female section of the quick connects to which the reel pilot hoses
are terminated. When the plates are bolted together the quick connect check valves are automatically opened and sealed allowing fluid flow. An alignment pin is provided which prevents misalignment during connection.
All of the hydraulic pilot signals to the pods pass through the junction boxes except for the pod
lock supply which has to be maintained at all times even when the junction boxes are disconnected. The pod lock supply therefore passes through a high pressure swivel on the reel centre
shaft where it is then connected to the pod lock pilot hose inside the reel.
The main power fluid 1 inch supply must also be maintained while the junction boxes are removed
from the reels and therefore passes through a high pressure swivel on the reel centre shaft where
it is then connected to the 1 inch power fluid supply hose inside the reel.
The hose bundle terminates to the control pod top plate through a junction box known as a kidney
plate. From the kidney plate the fluid is carried through stainless steel tubing to the various S.P.M.
valve and regulator ports.
Hose Reel Control Panel
Control of a number of B.O.P. stack functions is required while the B.O.P. stack is being run or
pulled with the jumper hose from the accumulator unit disconnected from the reel.
To allow this control, a panel containing the necessary regulators and selector type valves is
mounted on the side of each reel. The valves on the reel panel are !/4", three position, four way,
manually operated selector type valves, which have different internal porting to the manipulator
type used at the accumulator unit. Figure 88 shows a typical hose reel control panel.

CONTROL PODS
Two independent identical control pods, normally designated yellow and blue for identification,
are situated on the LMRP and provide the necessary regulators and valves to operate all the
B.O.P. functions. Some of the requirements of the control pods are:
1)

Capable of being run and retrieved independently.

2)

Capable of being run and retrieved with the LMRP.

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3)
4)

All seals are on the retrievable sections of the pod.

All functions go to the vent position if communication with the surface is lost.

The Koomey double female pod meets the above requirements and consists of a male section
which houses all the S.P.M. valves, regulators and pod lock mechanism and is located in the
upper female.
An upper female section which is bolted to the LMRP frame and is basically a ported block
which directs the fluid flow from the male section of the pod to the LMRP functions through high
pressure hoses or to the lower female section.
The lower female section is also a ported block and is bolted, in a spring housing, to the B.O.P. frame
and directs the fluid flow from the upper female to the B.O.P. functions through high pressure hoses.
This double female arrangement allows the male section of the pod to be retrieved on its own by
means of a wire line attachment, or the upper female and male sections can be retrieved with the
LMRP. Koomeys double female pod is shown in Figures 89, 90, 91 and 92.
Pod Latch Mechanism
The pod latch mechanism is a hydraulally operated latching system which mechanically locks the
male section of the pod to the upper female section. Hydraulic pressure applied to the latch rod
forces the latching segments to pivot under the upper female base plate and pre-load the male
section to the upper female section.
To release the pod latch, the hydraulic pressure is vented and a straight upward pull of 3000 lbs.
is applied to the retrieving line which is attached to the latch rod. Figure 93 shows the pod latch
mechanism.
Subsea Control Pod Regulators
Power fluid is supplied at system pressure, 3,000 P.S.I. to the control pod and the stack mounted
accumulators through the 1 inch umbilical hose from the pod selector on the surface accumulator
unit. Since the B.O.P. equipment normally operates at pressures below 3,000 P.S.I. the power fluid
passes through pod mounted regulators which regulate and maintain the lower pressure.
Two regulators are normally used, one for the B.O.P. rams, choke and kill valves and connectors
and one for the annular preventers. Regulators serve two purposes. Firstly they reduce the supply
pressure to a pre-set lower pressure and secondly, they regulate the pre-set pressure when outside forces attempt to increase or decrease that pressure.
The selected preset pressure is controlled by a pilot signal sent from the surface accumulator unit
through an umbilical pilot hose. The output side, or regulated pressure side, of the regulator is
connected to the appropriate S.P.M. valve manifold within the pod. Figure 94 is a simplified diagram of the fluid flow path within the control pod. Figure 95 shows the operating sequence of a
regulator valve. Figure 96 shows a regulator control schematic.

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SUBSEA EQUIPMENT TRAINING MANUAL

Regulated Pressure Read-back

The regulated power fluid pressure which is supplied through the pod mounted regulators to the
S.P.M. valves may, due to a malfunction, differ from the pilot signal pressure sent to the pilot side
of the regulator. For this reason a pressure read-back system is provided which gives an accumulator unit gauge reading of the actual pressure being supplied to the S.P.M. valves and therefore,
the pressure being applied the B.O.P. components.
One of the pilot hoses in the umbilical is utilized to send the readback signal back to a shuttle
valve at the accumulator unit. The shuttle valve isolates the hoses in the active and inactive pod
umbilicals and delivers the signal to the corresponding read-back gauge. A separate read-back
system is required for each regulator in use on the control pods. Figure 97 shows a schematic of
a typical read-back system.
S.P.M. Valves
The Koomey S.P.M. control valves direct the power fluid from the subsea regulator to the desired
side of the B.O.P. component and vent the fluid on the opposite side of the component. The valves
are pilot operated from the surface through the pilot hoses in the umbilical. Two S.P.M. valves are
required to operate each three position function.
The valves which are two position, three way, normally closed, pilot operated and spring return
are available in three sizes; 1!/2 inch, 1 inch and #/4 inch. The 1!/2 inch valves are generally used to
operate the annular preventers which require large fluid volumes. The 1 inch valves are generally
used to operate the ram type preventers and the #/4 inch valves are used to operate the choke and
kill valves and some connectors. Figures 98 and 99 show the S.P.M. valves.
Shuttle valves
After passing through the S.P.M. valve in the control pod, the regulated power fluid, which operates the function, exits the pod and flows to the B.O.P. component shuttle valve through a high
pressure flexible hose.
The shuttle valve has two inlet ports and one outlet port, which allows two separate supplies to be
directed to a single function, as is the case with the two pod system. If the yellow pod is selected,
fluid will flow to the shuttle valve and the shuttle valve piston will be forced across the valve to seal
off the blue pod inlet port, and vice versa. The shuttle valve is therefore an integral part of the
redundant two-pod design. Figure 100 shows a Koomey shuttle valve. Figure 101 shows the fluid
flow path through the shuttle valve.

REMOTE ELECTRIC PANELS

Direct current (120 v) is used to operate all the components of the electrical remote panels. This
power is provided by 10 x 12 volt batteries connected in series. The battery power is maintained
by using a battery charger and a step down transformer.

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Remote operation of the B.O.P. stack functions can be carried out through two electrically operated control panels. The Drillers panel is located at a convenient position on the drill floor and the
Mini panel is usually installed in the drilling office.
The Drillers panel contains the pushbutton switches/indicator lights required to operate and
indicate the position of all the B.O.P. functions. Electrical meters for reading the various system
pressures, fluid flowmeter gallon count and increase/decrease pushbuttons are provided for the
control of the surface regulators.
The Mini panel is normally located in the rig office inside the accommodation and contains all
the pushbutton switches/indicator lights to operate the functions but does not normally provide
control of the surface regulators and does not have any pressure gauges. The Mini panel houses
the memory circuit board which, through the use of relays, will indicate a functions position, prior
to that function being moved to the vent or block position. Figures 102 and 103 show typical
Drillers and Mini panels.

THREE POSITION FUNCTION

A typical three position function would be a set of pipe rams or an annular preventer, the three
positions of which would be: open, closed or block. A three position function require two control
pod S.P.M. valves to operate. The surface !/4 inch pilot control valves determine the function position by sending a pilot signal to the control pod S.P.M. valves.
Open Position
When opening a function, the !/4 inch pilot control valve is moved to the open position, either
manually or remotely. The 3,000 P.S.I. pilot signal flows through the valve and the hose reel to the
open side S.P.M. valve in the control pod, while simultaneously venting the pilot signal to the
close side S.P.M. valve.
The 3,000 P.S.I. pilot signal opens the open side S.P.M. valve allowing power fluid from the
regulator to flow through the pod to the open side of the function. The fluid in the close side of the
function is allowed to vent to atmosphere through the close side S.P.M. valve. The !/4 inch pilot
valve must remain in this position to retain opening pressure on the function.
Close Position
When closing a function, the !/4 inch pilot control valve is moved to the close position, either
manually or remotely. The 3,000 P.S.I. pilot signal flows through the valve and the hose reel to the
close side S.P.M. valve in the control pod, while simultaneously venting the pilot signal to the
open side S.P.M. valve.
The 3,000 P.S.I. pilot signal opens the close side S.P.M. valve allowing power fluid from the
regulator to flow through the pod to the close side of the function. The fluid in the open side of the
function is allowed to vent to atmosphere through the open side S.P.M. valve. The !/4 inch pilot
valve must remain in this position to retain closing pressure on the function

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SUBSEA EQUIPMENT TRAINING MANUAL

Block Position
When blocking a function, the !/4 inch pilot control valve is moved to the block or centre position,
either manually or remotely. The 3,000 P.S.I. pilot signal is vented back through the hose reel and
valve from both the close side and open side S.P.M. valves in the control pod.
Both the close side and open side S.P.M. valves in the control pod move to the closed position
allowing the power fluid to vent from both sides of the preventer. Figure 104 shows a three position function schematic.

TWO POSITION FUNCTION

A typical two position function would be a subsea choke line valve which requires a single hydraulic line to open and is vented to close. The two positions would be; open and vent. A two position
function will require only one control pod S.P.M. valve to operate.
Open Position
When opening a two position function, the !/4 inch pilot control valve is moved to the open position, either manually or remotely. The 3,000 P.S.I. pilot signal flows through the valve and the hose
reel to the open side S.P.M. valve in the control pod.
The 3,000 P.S.I. pilot signal opens the open side S.P.M. valve allowing power fluid from the
regulator to flow through the pod to the open side of the function. The !/4 inch pilot valve must
remain in this position to retain opening pressure on the function.
Vent Position
When closing a two position function, the !/4 inch pilot control valve is moved to the vent position,
either manually or remotely. The 3,000 P.S.I. pilot signal vents back through the hose reel and the
valve allowing the open side S.P.M. valve in the control pod to close and vent the power fluid to
atmosphere. The spring force would then close the choke line valve. Figure 105 shows a two
position function schematic.

STRAIGHT THROUGH FUNCTION

Certain very low volume functions such as the pod latch and ball joint pressure, use pilot pressure
at the function, which removes the need for a control pod S.P.M. valve for that function. In this
case the pilot fluid flows from the surface unit to the pod through the hose reel and then flows
straight through a port in the male section of the pod to the function.

FUNCTION TESTING
Function testing of the control system is required to confirm the system is operating correctly. With the
B.O.P. on deck the function test can firstly be carried out manually from the accumulator unit. This will
confirm the hydraulic circuits between the unit, the control pods and the B.O.P. components.

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Each function should be visually checked for hydraulic leaks during this test at the !/4 inch pilot
valve, at the jumper hose connections and RBQ plates, at the hose reel RBQ plates, at the pod
kidney plates, at the S.P.M. valves, at the B.O.P. hoses and at the B.O.P. component.
During the function test a record should be made of all the operating pressures, the amount of
fluid used on each function and the time taken for each function to operate fully. Any abnormalities
should be investigated and repairs carried out as required.
The remote panels can be tested independently to confirm the electrical circuits between the
panels and the accumulator unit junction boxes.

ACCUMULATOR SIZING
There are various requirements relating to accumulator fluid volumes for any given subsea B.O.P.
control system. The requirement adhered to depends to a large extent on the geographical area
in which the rig is operating. Some of these accumulator requirements are listed below:
1.

API RP 53 First Edition, revised 1978.

2.
3.

API RP 53 Second Edition, published 1984.

API RP 16E, issued 1990.

4.

Norwegian Petroleum Directorate.

The UK D.EN. recognises API RP 53, first edition only, which states that;
As a minimum requirement, closing units of subsea installations should be equipped with
accumulator bottles with sufficient volumetric capacity to provide the usable fluid volume
(with pumps inoperative) to open and close the ram preventers and one annular preventer
and retain a 50% reserve.

Usable fluid volume is defined as the volume of fluid recoverable between the accumulator operating pressure and 200 P.S.I. above the pre-charge pressure.
API RP 16E which at this time is not recognised by the UK D. EN. states that: the hydraulic control
system for a subsea B.O.P. stack should have a minimum total stored hydraulic fluid volume, with
pumps inoperative, to satisfy the greater of the two following requirements:
1.

Open and close, at zero wellbore pressure, all of the ram type B.O.P.s and one annular
preventer in the B.O.P. stack, with a 50% reserve.

2.

The pressure of the remaining stored accumulator volume after 1 above, should exceed the calculated minimum system operating pressure. The calculated minimum system operating pressure should exceed the greater of the following minimum stack
component operating pressures:
A. The minimum calculated operating pressure required to close any ram B.O.P.
at the maximum rated wellbore pressure of the stack.
B. The minimum calculated operating pressure required to open and hold open
any choke or kill valve in the stack at the maximum rated wellbore pressure.

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SUBSEA EQUIPMENT TRAINING MANUAL

Nowegian Petroleum Directorate

The NPD has a minimum requirement, where closing units of subsea installations should be
equipped with accumulator bottles with sufficient volumetric capacity to provide the usable fluid
volume (with pumps inoperative) to close, open and close again all rams and annulars and have
25% of the total close volume in reserve. Figure 106 shows a sample accumulator volume calculation using Boyles Law.
Subsea Accumulators
When calculating usable fluid volumes for subsea mounted accumulators, the effects of hydrostatic pressure have to be considered. If hydrostatic pressure is not compensated for, the amount
of usable fluid available will be reduced. Figure 107 shows a sample calculation.

CONTROL SYSTEM TROUBLE SHOOTING

Hydraulic Circuit
One of the most common problems associated with the hydraulic circuits of the control system is
fluid leakage. The most obvious indication of a leak having developed is that the system pumps
cut in and out frequently, without any functions having been operated.
If there are no obvious surface leaks, check if a fluid flow is registering at the flowmeter. If the
flowmeter is registering a fluid flow then the leak is most likely to be in the power fluid circuit and
could be any one of the following :
Pod selector valve
Umbilical 1" supply hose
S.P.M. valve
Pod regulator
High pressure hose at the B.O.P. component
Shuttle valve
B.O.P. component operating chamber
Subsea accumulators
Each component of the B.O.P. stack can be considered to have its own hydraulic circuit for the
purpose of troubleshooting and, therefore, by venting the pressure from each component in turn,
and at the same time checking the flowmeter, it can be determined quite easily, which component
is leaking.
For example, the flowmeter is registering a fluid flow and when the upper rams !/4 inch control
valve is moved to the centre block position the flowmeter stops registering a fluid flow, then you
have established that it is this function which contains the leak.
At this point you have also established that the umbilical 1" hose, the pod regulators and the
subsea accumulators are not leaking.

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It must now be determined whether or not the leak is common to both control pods by selecting
the other pod and pressurising the leaking function again.
If the leak reappears when the pod selection is changed and the function is pressurised, then the
problem is likely to be the B.O.P. component, the high pressure hose or the shuttle valve.
If the leak does not reappear, then it will most likely be the original pods S.P.M. valve and that pod
will have to be pulled for repair.
When a system leak is evident, but the flowmeter is not registering a fluid flow and again there are
no obvious surface leaks, then the problem will most likely be in the pilot system, a !/4 inch pilot
valve, a surface regulator or a system relief valve.
The pilot control valves, surface regulators and relief valve vents are all manifolded back to the
mixed fluid reservoir. Check the tank entry and, if fluid is flowing into the reservoir, the vent port on
each of the !/4 inch control valves, the surface regulators and relief valves should be checked for
fluid escaping and the faulty component replaced. If there is no fluid returning to the tank then the
leak will most likely be in one of the umbilical pilot signal hoses, or at the pilot piston of one of the
S.P.M. valve on the pods.
Tracing hydraulic leaks while functioning the B.O.P. is more straight forward than when the system
is idle as in the cases mentioned. An example of this would be that whilst operating a set of rams
the flowmeter continues registering a fluid flow after the normal amount of fluid has been used,
thus indicating a leak in that functions circuit.
When tracing the system for obvious surface leaks it has to be remembered that in most cases
the diverter panel, although remote from the accumulator unit, receives hydraulic supply from the
control system pumps and could therefore be a source of system leaks.
Electrical Circuit
Electrical problems have to be traced in the same methodical manner as that of the hydraulic
circuits. Prior to operating any functions from the electric panels ensure that all the indicator lights
are working correctly as this will avoid any confusion.
If while operating a function from the Drillers panel the pushbutton is depressed, but the function
does not operate i.e. the indicator light does not change and there is no flow registered on the
flowmeter, go to the mini panel and operate the function from there. If the function operates
correctly from the mini panel, then the problem is at the Drillers panel pushbutton.
If the function does not work from either panel then the problem will be the corresponding solenoid valve, located in the right hand junction box at the accumulator unit.
If while operating a function from the Drillers panel the push button is depressed and the function
operates correctly, but the indicator light does not illuminate, go to the mini panel and check the
corresponding light. If this has not come on, then the problem will be the corresponding pressure

CHAPTER 7
7-14

SUBSEA EQUIPMENT TRAINING MANUAL

switch located in the left hand junction box. If the mini panel light has come on, the problem will be
the Drillers panel lamp holder or its wiring.
When moving a function to the centre block position the memory circuit should cause the indicator light from the functions previous position to stay on. If this does not happen then the problem
will be the corresponding memory relay located in the mini panel.
The Drillers panel electric gauges or meters are supplied with varying voltage by the pressure
transducers located in the left hand junction box. If one meter fails to register the same pressure
as that of the corresponding hydraulic gauge the problem will be the transducer or the meter.
Firstly check the output voltage of the transducer, if this is not correct change the transducer. If
this voltage is correct check the meter and interconnecting cable. If all the Drillers panel meters
are reading incorrectly either high or low the problem will most likely be the voltage regulator
located in the accumulator unit left hand junction box.

HYDRAULIC SCHEMATICS
The ability to read and understand hydraulic schematics is vital to understanding, troubleshooting
and repairing B.O.P. control systems. Every B.O.P. control system component has a schematic
number, which is particularly useful when a component has malfunctioned, as by checking the
schematic drawing the components location can be identified immediately by its number.
When any changes or modifications are made to a control system, they must be documented on
the appropriate schematic drawing to avoid future confusion. Figure 108 shows schematic symbols which represent various components used in B.O.P. control systems.

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-15

Figure 78

Equipment List
1. Hydraulic power unit with pumps
2. Hydraulic jumper hose bundles
3. Subsea hose reels
(with manual control manifold)
4. Subsea hydraulic hose bundles
5. Subsea control pods
6. Subsea accumulators
7. Retrieving frame for subsea pods
8. Electric control power supply cable
9. Electric power pack
10. Electric power cable to control system
11. Central hydraulic control manifold
12. Air winches for running subsea pods
13. Master electric panel control cable
14. Master electric panel
15. Electric mini-panel control cable
16. Electric mini-panel
17. Shelves for subsea hose bundles
18. Wire lines to subsea pods
19. Shelves for wire lines to subsea pods

Typical B.O.P. Control System

CHAPTER 7
7-16

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 79
QUICK-DISCONNECT
HYDRAULIC
JUNCTION BOXES
FLOWMETER
READOUT
IN 10THS OF
A GALLONS

EXPLOSION-PROOF
BOX FOR PRESSURE
SWITCHES

DUAL
DISCHARGE
FILTERS

REMOTELY
OPERATED
ACCUMULATOR
ISOLATOR
VALVE

EXPLOSION-PROOF
BOX FOR
SOLENOIDS

DUAL TRIIPLEX
PUMPS PROVIDE
LARGE GPM
OUTPUT AND
SAFETY

LARGE SIX-INCH
DUAL FACE
GAUGES

LARGE
THREE-INCH
SUCTION
FILTERS

CHAIN &
SPROCKET
DRIVE WITH
OIL BATH

EXPLOSIONPROOF
ELECTRIC
STARTERS

DUAL AIR
PUMPS WITH
AUTOMATIC
PRESSURE
SWITCHES

Koomey Accumulator Unit

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-17

Figure 80
ADJUSTING
SCREW

THIS FLOAT TURNS

SYSTEM ON & OFF
AS REQUIRED
100 P.S.I. FILTERED
& REGULATED AIR
FROM MANIFOLD

MIXED FLUID TANK

K-50
TANK
TO AIR
PRESSURE SWITCH
FOR LOW FLUID
LEVEL ALARM

A
B
C
D
E
F

ETHYLENE
GLYCOL
TANK

Water rate valve (adjustable orifice)

Water pressure
Water pressure regulator
Water flow rate indicator
Air-operated pump
Customer connection wash water supply

Can be unit or
individually skid
mounted to provide
mixed fluid for
temperatures to
-50F (-46C)

Fluid Mixing System

CHAPTER 7
7-18

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 81

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Power frame
Crankshaft
Crankshaft bearing
Connecting rod
Connecting rod bearing (pairs)
Crosshead
Crosshead stub
Crosshead stub spring pin
Crosshead pin
Crosshead pin bearing
Crosshead stub deflector
Crankshaft frame cap out board
Crankshaft frame cap inboard
Crosshead stub seal cap
Crankcase cover

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Crankcase cover gasket

Cross stub seal cap gasket
Crankcase oil seal
Crankcase breather
Crosshead stub seal
Fluid cylinder
Discharge valve cover
Cylinder head
Suction & discharge valve
Suction & discharge valve seat
Suction & discharge valve spring
Stuffing box flange
Discharge valve stop
Discharge valve gasket
Stuffing box gasket

31.
32.
33.
34.
35.
36.
37.
38.

Cylinder head extension

Cylinder head gasket
Stuffing box
Stuffing box gland
Stuffing box throat bushing
Plunger
Gland follower
Plunger packing

Electric Triplex Pump

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-19

Performance Characteristics of Series T-360 Pump

Figure 82

CHAPTER 7
7-20

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 83
NO THREADS ON ACCUMULATOR SHELL
TO BE DAMAGED AND PREVENT REPAIR
OF ACCUMULATOR
U.S. DEPARTMENT OF
TRANSPORTATION APPROVED

GAS CHARGING
VALVE MOLDED INTO
THE BLADDER
REDUCES CHANCE
OF PRECHARGE LOSS

ASME CODED VESSEL

(USCG OR DNV
APPROVED ON
REQUEST)
SEAMLESS,
HOMOGENEOUS
CHROMEMOLYBDENUM
SHELL WITH 4-TO-1
SAFETY FACTOR
STANDARD BLADDER
RESISTS AROMATICS
AND OPERATES FROM
-38F (-39.4C) TO
185F (85C)

NO PLEATS OR STRESS
AREAS IN BLADDER
DESIGN
POSITIVE GAS
AND FLUID
SEPARATION

HIGH VOLUMETRIC
EFFICIENCY

INSENSITIVE TO FLUID
CONTAMINATION

POSITIVE SHUT-DOWN
AT MINIMUM (PRECHARGE) PRESSURE WITHOUT LOSS
OF PRECHARGE
INTEGRAL SAFETY
RELIEF

ENGINEERED SPRING
DESIGN COMPRESSES
EASILY TO MINIMIZE WEAR
WHEN BLADDER
CONTACTS POPPET;
YET IS STRONG ENOUGH
TO PREVENT
PRECLOSURE DURING
OUTRUSH OF FLUID.
PORT ASSEMBLY
HELD IN PLACE MECHANICALLY SO THAT IT CANNT
BE DISASSEMBLED
UNDER PRECHARGE
PRESSURE. DOES NOT
RELY ON SMALL VENT
HOLES, SHICH CAN
BECOME PLUGGED.

LARGE FLOW
PORTS

Separator/Bladder Type Accumulator

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-21

Figure 84

FLUID
SYSTEM
MIXING

ACCUMULATORS
PRE-CHARGED TO
1000 P.S.I.
ACCUMULATOR
ISOLATOR VALVE

ACCUMULATOR
ISOLATOR
VALVE
(PILOT)

WATER
SUPPLY
WATER
SOLUBLE
CONCENTRATE

MIXED
FLUID
RESERVOIR
PRESSURE
SWITCH SET
AT 3000 P.S.I.

FLOW METER

PILOT
SUPPLY

POD SELECTOR
VALVE

HYDRAULIC
MANIFOLD

QUICK DISCONNECT
JUNCTION BOX
BLUE

YELLOW

TO YELLOW
HOSE REEL

QUICK DISCONNECT
JUNCTION BOX
BLUE HOSE
REEL
HYDRAULIC
REGULATORS

BLUE POD

POD MOUNTED
ACCUMULATOR
ISOLATOR VALVE

CONTROL
FLUID
TO SPM
VALVES
FROM YELLOW POD

!/4" SHUTTLE
VALVE
1!/2"
SHUTTLE
VALVE

FROM YELLOW POD

STACK MOUNTED
ACCUMULATOR
ISOLATOR VALVE

STACK MOUNTED
ACCUMULATORS

Accumulator Isolator Circuit

CHAPTER 7
7-22

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 85

3LVE
ACCUMULATOR
HOSE
TOUGH
POLYURETHANE
JACKET

Typical Hose Bundle

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-23

Figure 86
HOSE REEL
CONTROL PANEL

HOSE REEL
DRUM

DISC BRAKE
BRAKE
HANDLE

LIFTING
EYELIT

THROTTLE

AIR MOTOR

SKID
LOCK
PIN

Diagram of a hose reel showing the component parts.

YOKE
CONTROL
PANEL

RBO
JUNCTION
BOX

HANGER
FRAME

ROLLER
BOLT
NUT

The hose reel viewd from the manifold.

CHAPTER 7
7-24

Roller sheaves with component

parts called out.

SUBSEA EQUIPMENT TRAINING MANUAL

VALVE OPENING (SECS.)

Figure 87

PILOT HOSE LENGTH (FT)

Koomey 1" SPM Valve with 925 PSI Shifting Pressure

and 1500 PSI Power Fluid Pressure

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-25

Figure 88
MAIN HYDRAULIC
SUPPLY THROUGH
1" SWIVEL-JOINT

HOSE REEL
MANIFOLD
SUPPLY VALVE

TO OTHER HOSE
REEL MANIFOLD
FUNCTIONS

MANIFOLD
REGULATOR

JUMPER HOSE
BUNDLE FROM
HYDRAULIC
MANIFOLD

!/4" SELECTOR
VALVE

REGULATOR
SHUT OFF
VALVE

QUICK DISCONNECT
CHECK VALVES

HOSE BUNDLE
ON BLUE
HOSE REEL

BLUE HOSE REEL

BLUE POD
JUNCTION
BOX

SPM
VALVE
SHUTTLE
VALVE
HYDRAULIC
REGULATOR
OPEN

BLUE POD

CLOSE

FROM
YELLOW
POD

FROM
YELLOW
POD

Typical Hose Reel Control Panel

CHAPTER 7
7-26

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 89

HOSE RADIUS
GUARD

JUNCTION
BOX COVER &
HOSE CLAMP
POD COVER
SANDBLASTED
AND DEMETCOTED

STAINLESS STEEL TUBING,

PIPING, &
FITTINGS

PATENTED
PACKER SEALS

POD LATCH
LUGS FOR
MOUNTING
OR LOWER
MARINE RISE

ELECTROLESS
NICKEL-COATED
MALE

GUIDE PIN

MOLYBDENUM
DISULFIDE-COATED
UPPER FEMALE

LOWER FEMALE AND

SPRING HOUSING

Koomey's Double Female B.O.P. Control Pod

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-27

Figure 90

JUNCTION BOX AND

HOSE GUARD ASSEMBLY

LATCH ROD

RETRIEVABLE
MALE POD
BODY
POD COVER

PACKER SEALS

UPPER FEMALE
(mounted on LMRP)

LMRP Spider

LOWER FEMALE
(mounted on B.O.P. Stack)

B.O.P. Stack
Upper Spider

Double Female Pod

CHAPTER 7
7-28

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 91

GUIDE
FRAME

88!/2
69
LATCHED
73%/16
UNLATCHED

61#/4

RISER
PLATE

7!/4
STACK
PLATE
22#/4
LATCHED
UNLATCHED

34!/4" DIA. HOLE IN RISER PLATE

41#/4" 00 SPRING HOUSING
42" DIA. HOLE IN STACK PLATE
43!/2" B.C.
45!/4" 00 SPRING HOUSING MOUNTING RING
Item
Description
1
Male body
2
Side plate
3
Top plate
4
Junction plate
6
Latch assembly
14
Upper female assembly
15
#/4" S.S. Allen socket head plug
16
!/2" S.S. Allen socket head plug
17
Lower female assembly
Section APacker seal (female to female)
Section BPacker seal (male to male)

Section A

Section B

Koomey Standard Subsea Pod Locking Mechanism

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-29

Figure 92
39!/2 (DIAMETER REFERENCE TO CLEAR MOUNTING LUGS)
1!/8 (DIAMETER
HOLE REFERENCE)
7 PLACES
EQUALLY SPACED

36!/2 !/32 (DIAMETER B.C. REFERENCE)

30!/2 (DIAMETER REFERENCE)
25!/4 (DIAMETER B.C. REFERENCE)

11!/2 (REF.)
13#/4 (REF.)

2 MAX THICKNESS
OF RISER PLATE
1-8UNC 2B THREADS
7 PLACES EQUALLY
SPACED
34!/2 !/16 (DIAMETER OPENING IN RISER PLATE)

Item
1
2
3
4
5
6
7
8
9

Detail B

Detail C

Pocket assembly typical

when pockets are used
for stack functions
(female to female)

Pocket assembly typical

when pockets are used
for riser functions
(female to female)

Description
Upper female finish & inspection
Seal retainer
Seal
Plug
"O" Ring
Pipe plug #/4"
Pipe plug !/2"
Pipe plug 1"
Pipe plug #/4"

Double Female Pod

CHAPTER 7
7-30

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 93
Order Numbers for
Pod Latch Assembly and Parts
ITEM
NO.

IN
SEAL
KIT

ASS'Y
1
2
3
4
5
6
7
8
9
10
11
12
KIT

Latch Unlocked

PART DESCRIPTION
POT LATCH ASSEMBLY
(less latch rod)
LATCH ROD (see parts list
furnished with subsea pod)
O RING, PISTON
BACKUP RING, PISTON (not
shown)
DOG PIN (with 2 retaining rings)
LINK PIN
LATCH DOG
DOG LINK, MALE
DOG LINK, FEMALE
LATCH BODY
PISTON STOP
LATCH NOSE
O RING, LATCH BODY
SEAL KIT

PART
NO.

QTY.

18 00002

50 01244
50 20212

2
2

18 00003
18 00004
18 00005
18 00006
18 00007
18 00008
18 00009
18 00010
50 01310
99 18001

2
3
2
1
1
1
1
1
1
1

Latch Locked

Koomey Stary Subsea Pod Locking Mechanism

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-31

Figure 94

POWER FLUID FROM SURFACE

SURFACE PILOT PRESSURE

REGULATOR

CONTROL VALVE
VENT
SURFACE PILOT PRESSURE

FROM STACK
ACCUMULATORS

MALE
SECTION

FEMALE
SECTION

Fluid Flow Path within the Control Pod

CHAPTER 7
7-32

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 95

AIR
REGULATOR
Air
Supply

Discharge

RELIEF TO
RESERVIOR

Output

3. In the third position, the input

port is closed and the regulated
output relieves pressure through
the discharge port.

Input

HIGH
PRESSURE

REGULATED
PRESSURE

1. With the slide valve to its limit

by the diaphragm, the input
and regulated output ports are
opened.

2. In the intermediate, pressurebalanced position, all three

ports are closed. Variation in the
regulated output port pressure
will instantly open either the
relief discharge port or the input
to output port.

Operating Sequence of a Regulator Valve

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-33

Figure 96

JUMPER HOSES (TO HOSE REELS)

PRESSURE TRANSDUCER

AIR PILOT LINE

AIR OPERATED
REGULATOR
SUPPLY TO POWER UNIT

DUMP TO RESERVIOR

Regulator Control Schematic

CHAPTER 7
7-34

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 97
JUMPER HOSES (TO HOSE REELS)

PRESSURE GAUGE

PRESSURE TRANDUCER

SHUTTLE VALVE

Schematic of a Typical Read-back System

Schem

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-35

Figure 98

POWER FLUID
OUT SUBSEA VENT
UPPER SEAT

SEAWATER
HYDROSTATIC
PRESSURE

PILOT FLUID OUT

SURFACE VENT

POWER
FLUID
BLOCKED

LOWER SEAT

SPM Valve

CHAPTER 7
7-36

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 99

SEAWATER
HYDROSTATIC
PRESSURE

PILOT
FLUID IN
UPPER SEAT

POWER FLUID
VENT HYDROSTATIC
PRESSURE

POWER
FLUID IN

LOWER SEAT

SPM Valve

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-37

Figure 100

Koomey Shuttle Valve

CHAPTER 7
7-38

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 101
SURFACE POD SELECTOR VALVE
INACTIVE POD

ACTIVE POD

POWER FLUID
VENT

VENT
VALVE A

VALVE B

VALVE A1

VALVE B1

PILOT PRESSURE

POWER FLUID

VENT

INACTIVE POD

Fluid Flow Path Through Shuttle Valve

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-39

Figure 102

Driller's Electric Panel

CHAPTER 7
7-40

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 103

Mini Remote Electric Panel

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-41

Figure 104

HYDRAULIC PILOT SUPPLY

AIR SUPPLY

SOLENOID

OPEN
!/4" AIR SHUTTLE VALVE
BLOCK

!/4" MANIPULATOR VALVE

PRESSURE
SWITCH

CLOSE

VENT
BLUE

YELLOW

QUICK
DISCONNECT
JUNCTION
BOX

TO YELLOW HOSE REEL

NOTE:

Three Solenoid Valves

can be used for critical
functions, such as shear
rams.

BLUE HOSE REEL

QUICK
DISCONNECT
JUNCTION
BOX

CONTROL FLUID SUPPLY

SPM
VALVE
BLUE POD

FROM YELLOW POD

SHUTTLE VALVE
FROM YELLOW POD
CLOSE
OPEN
RAM-TYPE B.O.P.

CHAPTER 7
7-42

Three-Position
Function Schematic

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 105

SOLENOID
HYDRAULIC PILOT SUPPLY
OPEN

AIR SUPPLY

VENT
VENT
!/4" MANIPULATOR VALVE OR
SELECTOR VALVE WITH
2 POSTION AIR CYLINDER
PRESSURE SWITCH
QUICK DISCONNECT
JUNCTION BOX
HYDRAULIC MANIFOD
BLUE

YELLOW

QUICK
DISCONNECT
JUNCTION BOX

TO YELLOW HOSE REEL

BLUE HOSE REEL

QUICK
DISCONNECT
JUNCTION BOX

BLUE POD
SPM
VALVE

CONTROL
FLUID
SUPPLY

SHUTTLE VALVE
FROM YELLOW POD

FAILSAFE VALVE
OPERATOR
SHOWING SPRING
HOUSING AND
GATE

B.O.P. CONTROL SYSTEMS

OPEN

Two-Position
Function Schematic

CHAPTER 7
7-43

Figure 106
Using a Hydril Ram B.O.P. and a Shaffer Annular, the total usuable fluid requirement for this
example using API RP 53 is 380.3 gallons, where:
Close vol.

Open vol.

No.

Total

Hydril Rams

19.4

16.7

144.4

Shaffer Annular

61.37

47.76

109.13

253.53 + 50%

Total required usuable fluid volume

380.3 gallons

Boyles law, P1 V1 = P2 V2 derived to

V3

VR
P3

P2

P3

P1

Where:
P1

Maximum operating pressure (3000 psi)

P2

Minimum operating pressure (1200 psi)

P3

Nitrogen pre-charge pressure (1000 psi)

V1

Volume of nitrogen at maximum pressure (3000 psi)

V2

Volume of nitrogen at minimum pressure (1200 psi)

V3

Total accumulator volume (nitrogen and fluid)

VR

Total usable fluid required

Therefore:

V3

380.3
1000

1200

760.6 Gallons

1000

3000

The number of bottles required therefore = 760.6/10 = 76.6 = 77.

Accumulator Volume Calculation using Boyles Law

CHAPTER 7
7-44

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 107a

1000 PSI

3000 PSI

1200 PSI

V1

V2

V3

PRE-CHARGE
PRESSURE
P1 = 1000 PSI

MAXIMUM FLUID
CHARGE PRESSURE
P2 = 3000 PSI

MINIMUM OPERATING
PRESSURE
P3 = 1200 PSI

V1 = 10 GALLONS

P1 X V1

P1 X V1
=

V2

P2

1000 X 10

V3

P3

= 3.33 GALS.

3000

1000 X 10

= 8.33 GALS.

1200

THEREFORE THE TOTAL AMOUNT OF USABLE FLUID OPERATING BETWEEN THE MAXIMUM AND MINIMUM WILL BE:
V2 V3 = 8.33 3.33 = 5 GALLONS

Sample Calculation of Usable Fluid Volumes for Subsea Mounted Accumulators

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-45

Figure 107b

3000

1200

1000
SURFACE USABLE
FLUID
1000 X 10

3000

1000 X 10

1200

3.3 GALLONS GAS

6.7 GALLONS FLUID

8.3 GALLONS GAS

1.7 GALLONS FLUID

THEREFORE USABLE
FLUID ON SURFACE = 6.7 1.7
=

3300
DEPTH = 500'

1500

5 GALLONS

1000
USABLE FLUID ON SEABED WITH SAME
PRE-CHARGE =
1000 X 10

3300

1000 X 10

1500

3.03 GALLONS GAS

6.97 GALLONS FLUID

6.66 GALLONS GAS

3.34 GALLONS FLUID

THEREFORE USABLE FLUID

ON SEABED = 6.97 3.34
=

3.63 GALLONS

FLUID
GRADIENT = .5PSI/FT

Sample Calculation of Usable Fluid Volumes for Subsea Mounted Accumulators

CHAPTER 7
7-46

SUBSEA EQUIPMENT TRAINING MANUAL

Figure 107c

3000

1200

1000

SURFACE USABLE
FLUID
1000 X 10

3000

1000 X 10

1200

3.3 GALLONS GAS

6.7 GALLONS FLUID

8.3 GALLONS GAS

1.7 GALLONS FLUID

THEREFORE USABLE
FLUID ON SURFACE = 6.7 1.7
=

5 GALLONS

HYDROSTATIC = .5 X 600 = 300 PSI

3300
DEPTH = 600'

1500

1000
USABLE FLUID ON SEABED WITH SAME
PRE-CHARGE = 1300

1300 X 10

3300
10 3.93

1300 X 10

1500
10 8.66

3.93 GALLONS GAS

6.07 GALLONS FLUID

8.66 GALLONS GAS

=

1.34 GALLONS FLUID

THEREFORE USABLE FLUID

ON SEABED = 6.07 1.34
=

4.73 GALLONS

FLUID GRADIENT = .5PSI/FT

Sample Calculation of Usable Fluid Volumes for Subsea Mounted Accumulators

B.O.P. CONTROL SYSTEMS

CHAPTER 7
7-47

Figure 108

Schematic Symbols Representing Various Components of B.O.P. Control Systems

CHAPTER 7
7-48

SUBSEA EQUIPMENT TRAINING MANUAL

Hydril MUX Overview

Cameron MUX System

Hydril MUX Presentation

by Jeff Boughton- TSF SSE
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