Professional Documents
Culture Documents
Chapter 7
77
78
78
79
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CHAPTER 7
7-1
CHAPTER 7
7-2
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:
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.
CHAPTER 7
7-3
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
CHAPTER 7
7-4
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,
CHAPTER 7
7-5
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.
CHAPTER 7
7-6
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)
2)
CHAPTER 7
7-7
3)
4)
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.
CHAPTER 7
7-8
CHAPTER 7
7-9
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.
CHAPTER 7
7-10
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.
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.
CHAPTER 7
7-11
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.
2.
3.
4.
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.
CHAPTER 7
7-12
CHAPTER 7
7-13
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
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.
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
CHAPTER 7
7-16
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
CHAPTER 7
7-17
Figure 80
ADJUSTING
SCREW
A
B
C
D
E
F
ETHYLENE
GLYCOL
TANK
Can be unit or
individually skid
mounted to provide
mixed fluid for
temperatures to
-50F (-46C)
CHAPTER 7
7-18
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.
31.
32.
33.
34.
35.
36.
37.
38.
CHAPTER 7
7-19
Figure 82
CHAPTER 7
7-20
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
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
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
STACK MOUNTED
ACCUMULATORS
CHAPTER 7
7-22
Figure 85
3LVE
ACCUMULATOR
HOSE
TOUGH
POLYURETHANE
JACKET
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
YOKE
CONTROL
PANEL
RBO
JUNCTION
BOX
HANGER
FRAME
ROLLER
BOLT
NUT
CHAPTER 7
7-24
Figure 87
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 POD
JUNCTION
BOX
SPM
VALVE
SHUTTLE
VALVE
HYDRAULIC
REGULATOR
OPEN
BLUE POD
CLOSE
FROM
YELLOW
POD
FROM
YELLOW
POD
CHAPTER 7
7-26
Figure 89
HOSE RADIUS
GUARD
JUNCTION
BOX COVER &
HOSE CLAMP
POD COVER
SANDBLASTED
AND DEMETCOTED
PATENTED
PACKER SEALS
POD LATCH
LUGS FOR
MOUNTING
OR LOWER
MARINE RISE
ELECTROLESS
NICKEL-COATED
MALE
GUIDE PIN
MOLYBDENUM
DISULFIDE-COATED
UPPER FEMALE
CHAPTER 7
7-27
Figure 90
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
CHAPTER 7
7-28
Figure 91
GUIDE
FRAME
88!/2
69
LATCHED
73%/16
UNLATCHED
61#/4
RISER
PLATE
7!/4
STACK
PLATE
22#/4
LATCHED
UNLATCHED
Section A
Section B
CHAPTER 7
7-29
Figure 92
39!/2 (DIAMETER REFERENCE TO CLEAR MOUNTING LUGS)
1!/8 (DIAMETER
HOLE REFERENCE)
7 PLACES
EQUALLY SPACED
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
Description
Upper female finish & inspection
Seal retainer
Seal
Plug
"O" Ring
Pipe plug #/4"
Pipe plug !/2"
Pipe plug 1"
Pipe plug #/4"
CHAPTER 7
7-30
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
CHAPTER 7
7-31
Figure 94
REGULATOR
CONTROL VALVE
VENT
SURFACE PILOT PRESSURE
FROM STACK
ACCUMULATORS
MALE
SECTION
FEMALE
SECTION
CHAPTER 7
7-32
Figure 95
AIR
REGULATOR
Air
Supply
Discharge
RELIEF TO
RESERVIOR
Output
Input
HIGH
PRESSURE
REGULATED
PRESSURE
CHAPTER 7
7-33
Figure 96
PRESSURE TRANSDUCER
AIR OPERATED
REGULATOR
SUPPLY TO POWER UNIT
DUMP TO RESERVIOR
CHAPTER 7
7-34
Figure 97
JUMPER HOSES (TO HOSE REELS)
PRESSURE GAUGE
PRESSURE TRANDUCER
SHUTTLE VALVE
CHAPTER 7
7-35
Figure 98
POWER FLUID
OUT SUBSEA VENT
UPPER SEAT
SEAWATER
HYDROSTATIC
PRESSURE
POWER
FLUID
BLOCKED
LOWER SEAT
SPM Valve
CHAPTER 7
7-36
Figure 99
SEAWATER
HYDROSTATIC
PRESSURE
PILOT
FLUID IN
UPPER SEAT
POWER FLUID
VENT HYDROSTATIC
PRESSURE
POWER
FLUID IN
LOWER SEAT
SPM Valve
CHAPTER 7
7-37
Figure 100
CHAPTER 7
7-38
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
CHAPTER 7
7-39
Figure 102
CHAPTER 7
7-40
Figure 103
CHAPTER 7
7-41
Figure 104
AIR SUPPLY
SOLENOID
OPEN
!/4" AIR SHUTTLE VALVE
BLOCK
PRESSURE
SWITCH
CLOSE
VENT
BLUE
YELLOW
QUICK
DISCONNECT
JUNCTION
BOX
NOTE:
SHUTTLE VALVE
FROM YELLOW POD
CLOSE
OPEN
RAM-TYPE B.O.P.
CHAPTER 7
7-42
Three-Position
Function Schematic
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
QUICK
DISCONNECT
JUNCTION BOX
BLUE POD
SPM
VALVE
CONTROL
FLUID
SUPPLY
SHUTTLE VALVE
FROM YELLOW POD
FAILSAFE VALVE
OPERATOR
SHOWING SPRING
HOUSING AND
GATE
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%
380.3 gallons
VR
P3
P2
P3
P1
Where:
P1
P2
P3
V1
V2
V3
VR
Therefore:
V3
380.3
1000
1200
760.6 Gallons
1000
3000
CHAPTER 7
7-44
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
CHAPTER 7
7-45
Figure 107b
3000
1200
1000
SURFACE USABLE
FLUID
1000 X 10
3000
1000 X 10
1200
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
3.63 GALLONS
FLUID
GRADIENT = .5PSI/FT
CHAPTER 7
7-46
Figure 107c
3000
1200
1000
SURFACE USABLE
FLUID
1000 X 10
3000
1000 X 10
1200
THEREFORE USABLE
FLUID ON SURFACE = 6.7 1.7
=
5 GALLONS
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
4.73 GALLONS
CHAPTER 7
7-47
Figure 108
CHAPTER 7
7-48