Professional Documents
Culture Documents
2002 Cameron Replacement Parts Catalog
2002 Cameron Replacement Parts Catalog
29101501 A
Sara
Revision History
Change Description
Revision Change Description
A First Issue
BOP Control System
Revision A
Page iii of iv
Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Chapter 3: Installation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Accumulator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Drill Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Illustration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
iii
Sara
BOP Control System
Revision A
Page iv of iv
Table of Contents
Chapter 4: Operation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accumulator Unit Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Air pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electric Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hydraulic Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Air Remote Control Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Chapter 5: Maintenance
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Accumulator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Air Operated Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Electric Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
1 " TR Pressure Reducing and Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . 5-7
1" AMKR Pressure Reducing and Regulating Valve. . . . . . . . . . . . . . . . . . . . . . 5-11
Gallon 3000 PSI Accumulator Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Hydraullic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Model TD60 Triplex Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
iv
Sara
BOP Control System
Revision A
Page 1-1 of 4
General Information
This manual is intended for use by field engineering, installation, operation, and
repair personnel. Every effort has been made to ensure the accuracy of the
information contained herein. NOV SARA will not be held liable for errors in this material,
or for consequences arising from misuse of this material.
Conventions
Note:
i
The note symbol indicates that additional
information is provided about the current topics.
Caution:
Warning:
ning
War
1-1
Sara
BOP Control System
1 General Information Revision A
Page 1-2 of 4
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or
screen snapshots for use in identifying parts or establishing nomenclature, and may or
may not be drawn to scale.
For component information specific to your rig configuration, see the technical drawings
included with your NOV SARA documentation.
Safety Requirements
NOV SARA equipment is installed and operated in a controlled drilling rig environment involving hazardous
situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in NOV
SARA manuals are the recommended methods of performing operations and maintenance.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.
Contact the NOV SARA Equipment training department for more information
about equipment operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
described. NOV SARA recommends that only those tools specified be used when stated. Ensure
that personnel and equipment safety are not jeopardized when following service
procedures or using tools not specifically recommended by NOV SARA.
1-2
Sara
BOP Control System
Revision A
Page 1-3 of 4
General Information 1
Replacing Components
qVerify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
qReplace failed or damaged components with NOV SARA certified parts. Failure to do
so could result in equipment damage or injury to personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for
maintenance recommendations.
1-3
Sara
BOP Control System
1 General Information Revision A
Page 1-4 of 4
1-4
Sara
BOP Control System
Revision A
Page 2-1 of 17
System Description
This NOV SARA manual provides installation, operation, and maintenance information for
the NOV SARA BOP Control System. This chapter provides an overview of the system
components and their functions.
Introduction
The BOP Control System is a skid mounted pumping assembly consisting of fluid
storage tank, hydraulic pumps, control valves, regulators and various control components.
See Figure 2-1. The BOP Control System provides pressurized fluid for the BOP system
using the same electric driven hydraulic triplex pumps & Air Pumps. Hydraulic pressure from
both the pumps is stored in the accumulator bottles mounted on the skid. The accumulator
bottles have a working pressure of 3,000 psi (207 bar) dedicated to the BOP system.
In addition to the above, there is a remote control panel that remotely operate the rams,
annular and choke & kill valves on the master hydraulic control manifold on the The BOP
Control System. It should be noted the remote panel does not interfere with the manual
operation of the control valves at the The BOP Control System. The valves may be remotely
operated at the remote control panel or manually at the The BOP Control System.
2-1
Sara
BOP Control System
2 Introduction Revision A
Page 2-2 of 17
System Components
The following describes the components of the BOP control system.
Accumulator Bottles
Twenty Four 11-gallon (41.6-liter) accumulator bottles are mounted on the BOP Control System. All
have a working pressure of 3,000 psi (207 bar).
Each float accumulator bottle contains nitrogen. The nitrogen pressure in the accumulator
bottles is charged to 1,500 psi (103 bar) through the cap at the top of the bottle. The
hydraulic fluid is then pumped into the bottle cavity through the lower end and the nitrogen
is compressed until the maximum working pressure is reached.
Each header/bank is provided with a shutoff valve, a pressure gauge, and a bleeder valve.
The shutoff valves control the flow of hydraulic fluid to and from each header. In normal
operation, the shutoff valve is open and allows fluid to enter the accumulator banks and
pressurize the system. For repair operations of any equipment on the hydraulic control
manifold, the accumulator bottle rack shutoff valves are closed, thus maintaining system
pressure in the four accumulator header banks. Pressure in the manifold piping is then
bled off, and the maintenance operation is performed. After repairs to the control manifold
are completed, the shutoff valves to the pressurized accumulator banks are reopened and
the system is back on line, fully pressurized.
The bleeder valve on each header enables the pressurized fluid in the bank to be vented
into the reservoir. In normal operation, the bleeder valve is closed. Prior to maintenance
operations on an accumulator bank, the bleeder valve is opened and the fluid in the
accumulator banks is vented into the reservoir.
The pressure gauge reads the manifold supply pressure, which is normally 3,000 psi
(207 bar). Prior to starting maintenance operations, the header should be vented and the
gauge pressure should read 0 psi (0 bar).
The relief valves, set at a pressure of 3,300 psi (228 bar), relieve any over-pressure
condition.
2-2
Sara
BOP Control System
Revision A
Page 2-3 of 17
Introduction 2
Pumps
The BOP control system is provided with two independent pumping systems that are
mounted on the BOP Control System skid. Each system consists of a 60 HP electric
motor/Triplex pump assembly. Either pump system is capable of supplying fluid to the
accumulators at full operating pressure.
The electrically operated hydraulic pumps pressurize the system accumulator bottle racks.
The triplex pumps are complete with 480/380 VAC, 3-phase, 60HZ/ 50 Hz explosion-proof
motors.The triplex pumps generate hydraulic pressure for the BOP control system (see
Figure 2-2).
Each pump is fitted with an ON/OFF pressure switch assembly. One pump is set to turn on
when the system pressure falls below 2,800 psi (193 bar), and turn off when the system
pressure reaches 3,000 psi (207 bar). The other pump is set to turn on when the system
pressure falls below 2,750 psi (190 bar), and turn off when the system pressure is greater
than 2,900 psi (200 bar). This lead/lag design minimizes pump duty cycles for maximum
pump life.
60 Hp Motor
RESERVOIR
Triplex Pump
Assemby
Control Manifold
The master hydraulic control manifold is integral with the BOP Control System. See Figure 2-3
on page 2-4. The hydraulic control manifold should be located 100 to 150 feet from the well
bore and controlled by a panel near the driller. If a blowout occurs, controls on the drill floor
might be destroyed or become inaccessible. The hydraulic control manifold should be located
within the recommended distance so that the well can be closed in quickly. The control system
has separate hydraulic supply manifolds for the BOP Ram and Annular circuits. The first
manifold supplies hydraulic pressure to the 4-way control valves that operate the ram-type
preventers and stack mounted gate valves. The other manifold supplies hydraulic pressure to
the 4-way valve that operates the annular preventer. A MKR pressure regulator is installed
upstream of the BOP Ram control manifold. This regulator is factory preset at 1,500 psi (103
bar), the hydraulic operator’s normal working
2-3
Sara
BOP Control System
2 Introduction Revision A
Page 2-4 of 17
pressure for the BOP Ram preventers. A quick-opening regulator bypass valve, capable of being
remotely operated, is fitted to allow the full 3,000 psi (207 bar) accumulator pressure to the ram
preventers for fast, positive closure in emergency situations. A high-pressure strainer is installed
upstream of the regulator and 4-way valves to reduce the possibility of foreign matter affecting the
sealing capacity of the valves.
A remotely controlled, hydraulic pressure HMKR regulator is also provided upstream of the 4-way
valve controlling the annular preventer. It is capable of regulating and maintaining pressures from
500 psi (73 bar) to 1,500 psi (130 bar). It is also capable of relieving pressures in excess of its set
operating pressure to minimize buildup in the annular preventer during stripping. A high-pressure
strainer is also located upstream of the annular preventer regulator and 4-way valve.Clearly marked
nameplates on the control manifold indicate which Ram preventer or hydraulic valve each 4-way
control valve operates and indicates the position. During drilling operations, valves should be left in
either “open” or “close” position – never in the center (block) position.
Regulator Bypass
Reservoir capacity equals approximately twice the usable fluid capacity of the accumulator
system. Access ports of 4"ID (102 mm) are at each end of the reservoir to allow detection
of any leaking components on the manifold. Internal baffles in the reservoir restrict fluid
movement should the unit be transported.
Where pollution due to accidental spillage of hydraulic fluid is a problem, use environment
safe water-based fluid or pre-mixed fluids.
2-4
Sara
BOP Control System
Revision A
Page 2-5 of 17
Introduction 2
i
To prevent freezing at temperatures below 35°F (2°C),
ethylene glycol without any additives is recommended.
Reservoir
The reservoir capacity of 350 gallons (1325 liters) equals approximately twice the usable
fluid capacity of the accumulator system. Access ports of 4? ID are placed at each end of
the reservoir for visual inspection of the inside of the reservoir, and to allow detection of
any leaking components on the manifold. Internal baffles in the reservoir restrict fluid
movement when the unit transported.
Junction Box
The BOP Control System is provided with a junction box mounted on the BOP Control System
skid (see Figure 2-6 on page 2-12). Behind the junction box are the solenoid valves for remote
operation of the Annular AMKR valve and 4-way control valves. The AMKR valve has two
solenoids, one for the increase function and one for the decrease function. Each 4-way control
valve has two solenoids, one for each operating position (e.g. close, open).
The junction box houses the pressure switches which operate the indicator lights on the remote
control panel. The junction box also contains pressure transmitters which convert the fluid
pressure at the HPU gauges to electrical signals to register the pressures on the electric meters
on the Driller and Toolpusher’s control panel.
The HPU Junction Box has the following alarm indicators and buttons installed on the front
cover of the junction box:
2-5
Sara
BOP Control System
2 Introduction Revision A
Page 2-6 of 17
Gauges
The BOP Control System is fitted with a number of gauges for monitoring of critical parameters. The
BOP Control System gauge panel has the following indicators:
Annular Pressure
q
Bypass Valve
The BOP Control System hydraulic control manifold Bypass Valve (see Figure 2-11) is intended for
emergency use only. The bypass valve can be operated at the BOP control system control panel or
remotely from the Driller or Toolpusher’s control panel. During the drilling operation, it remains in the
normal position. In an emergency, this valve can be moved to the bypass position, which allows the
full 3,000 psi (207 bar) accumulator pressure to flow to all functions in the hydraulic control manifold.
Low High
In addition to the above, the accumulator bottles may be isolated and the electric pumps used to
pump the rams closed.
2-6
Sara
BOP Control System
Revision A
Page 2-7 of 17
Introduction 2
The remote control panel is a steel junction box with buttons mounted on the front doors of the panel
arranged as a mimic of the BOP and Diverter systems.
The Driller's remote panel are acceptable for installation in a Zone 1 hazardous area.
Another safety feature of the remote panels are the acrylic covers mounted over certain critical BOP
stack functions. These covers must be lifted before the function buttons can be operated. The covers
prevent accidental activation of any of the critical BOP functions.
i
The Lamp Test button does not require the Push And
Hold button to be activated.
Pressure Indicators
There are two pressure indicators on the remote control panel:
q Accumulator Pressure
q Annular Pressure
The indicating lamp at the control panel is activated by the use of (normally open) pressure switches
connected to the regulated hydraulic fluid sent to close the upper annular. In this instance the green lamp
was illuminated for the upper annular open function. However, when the upper annular “close” function
was activated, this vented the pilot signal for the upper annular “open” function, which allowed the
pressure switch to return to its normally open position breaking the electric circuit to turn off the green
lamp. Conversely, the pilot signal for the upper annular “close” also closes the pressure switch for that
function. This completes the electric circuit, which turns the red lamp on for the upper annular close
function.
In the event the rig electric power supply is unavailable, the emergency battery backup system supplies
24VDC power to the hydraulic power unit PLC junction box, and the remote control panels. In this
manner the BOP control system will remain operational until the electric power stored in the battery
backup system is depleted, before this occurs the rig electric power supply must be restored or the
blowout preventers closed.
i
The emergency battery backup system does not supply
power to run the triplex pumps.
2-8
Sara
BOP Control System
Revision A
Page 2-9 of 17
Introduction 2
For more information on the emergency battery backup system see the Vendor Documentation in this
manual.
1. Customer Air Supply (1) – Normal air supply is at 100 psi (7 bar). Higher air pressure may
require an air regulator.
5. Poppet Valve – Air pilot operated valve controlling supply air pressure to the air pumps. Valve
controlled by a pressure switch set at 2,900 psi.
6. Suction Strainer – Located in each suction line of the air pumps. Clean every 30 days.
8. Electric Motor Driven Triplex Pump Assembly – Primary pressure source. Horse power rating
can vary.
9. Check Valve – High pressure fluid.
10. Automatic Pressure Switch – Pressure switch is set at 3,000 psi (207 bar) cutout and 300-400
psi (21-28 bar) cut-in differential. Adjustable.
11. Electric Motor Starter (Automatic) – Automatically starts or stops the electric motor driving the
triplex pump. Works in conjunction with the automatic pressure switch and has a manual
on/off/auto switch.
12. 4-Way Valves – With air or hydraulic cylinder actuators for remote operation from the control
panels. Keep in standard operating mode (‘Open’ or ‘Close’)—never in the center position.
13. Bypass Valve – With air or hydraulic cylinder actuators for remote operation from the control
panels. In ‘Low’ position, 1,500 psi (103 bar), it allows regulated pressure on control valve
manifold, and in ‘High’ position, 3,000 psi (207 bar), it allows full accumulator pressure on the
control valve manifold. Keep in ‘Low’ position, 1,500 psi (103 bar), unless 3,000 psi (207 bar) or
more is required on ram-type BOPs.
14. Alternate Hydraulic Supply – Connection point for supply of fluid from other source.
15. Accumulators – Check nitrogen precharge in accumulator system every 30 days. Precharge
should be 1,500 psi (83 bar) ±10%. Size and configuration may change per order specification.
i
Use nitrogen when adding to precharge. Other gases
and air may cause fire and/or explosion.
2-9
Sara
BOP Control System
2 Introduction Revision A
Page 2-10 of 17
16. Pressure Reducing and Regulating Valve – Manually operated. Adjust to the required
continuous operating pressure of ram type BOPs. Typically 1,500 psi (130 bar).
17. Pressure Reducing and Regulating Valve, Air Operated – Reduces the accumulator pressure
to the required annular BOP operating pressure. Pressure can be varied for stripping operations.
Maximum recommended operating pressure of the annular preventer should not be exceeded.
18. Pressure Gauges – Panel of 6” gauges providing typical readings of: a. Annular Pressure
b. Accumulator Pressure
c. Manifold Pressure
19. Annular Increase and Decrease – Remote air control valve for increasing ordecreasing the
annular regulator (Item 17).
20. Control Valve Manifold – 3,000-psi (207 bar) W.P., 2" (5 mm).
21. Junction Box (J-Box) – Component housing for electric remote panels. Houses the system
pressure switches, pressure transmitters and solenoids.
22. Air Receiver – 30 gallon air supply for operating the air solenoids in the J-box. Systems with air
remote operated control panels have a 7 gallon air receiver.
i
This valve should be kept open when precharging the
accumulator bottles.
24. Air Shut Off Valve – Ball valve controls supply air to the air pumps.
25. Air Pressure Transmitters – Transmitters used in conjunction with air remote operated control
panels. Replaces J-Box (Item 21). Provides typical readings of:
a. Annular Pressure
b. Accumulator Pressure
c. Manifold Pressure
27. Suction Strainer – Located in the suction line of the electric pump. Clean every 30 days.
30. Bleed Valve – Bleed or drain accumulator header (Item 32) pressure.
32. Accumulator Header with Shut off Valve – Mounting point for accumulator bottles.
35. Suction Shut-off Valve – Located in the delivery line of the triplex pump.
2-10
Sara
BOP Control System
Revision A
Page 2-11 of 17
Introduction 2
36. Junction Plate (Primary) – Connection point for air hose bundle between the HPU and the
remote air operated control panel.
37. Junction Plate (Secondary) – Connection point for air hose bundle between the HPU and a
secondary remote air operated control panel.
38. Fluid Shut Off Valve - Ball valve controls fluid from reservoir to air pumps.
39. Accumulator Shut Off Valves - Valve controls high pressure fluid to accumulators.
2-11
Sara
BOP Control System
2 Introduction Revision A
Page 2-12 of 17
qDo not override or tamper with electrical or mechanical interlocks and safety
devices.
qBefore attempting any corrective action on the electrical circuit, verify that all
electric power sources have been removed from the circuit. Ensure that all
electrical switches are set to “Off” and the appropriate breakers are set to “Open”.
qDo not service or adjust the electrical circuits alone. Always verify that a qualified
person is present who can render aid in case of accident and who is familiar
with emergency shutdown procedures.
qWear suitable protective clothing while working within 4 ft. of exposed electrical
equipment. Do not wear rings, wrist watches or clothing with exposed metal
buttons, zippers or fasteners.
2-14
Sara
BOP Control System
Revision A
Page 2-15 of 17
Introduction 2
Ensure that the pneumatic power source is supplied at adequate pressure and volume to enable
q
safe and proper operation of equipment. Maximum system air pressure is 125 psi (9 bar).
Ensure that the air is filtered to prevent any dirt or debris from entering the Pneumatic circuit.
q
Ensure that air is dried and lubricated before it pilots or operates any motor (hydraulic pump);
q
moisture can damage components and result in unit failure.
Should there be a rupture or break in the pneumatic circuit (when pressurized), do not place
q
hands, face, or any part of the body over the escaping air. Severe bodily injury may result.
Before attempting any corrective action on the pneumatic circuit, verify that the pneumatic power
q
source is cut off and that all pneumatic pressure is completely vented. Verify that all pneumatic
pressure gauges read 0 psi (0 bar).
Mop
q up spilled hydraulic fluid immediately. Immediately investigate and correct the because of any
leakage of hydraulic fluid.
If clothing
q becomes drenched with hydraulic fluid, change immediately to dry clothing. The fluid is
severely irritating to eyes and skin. Prolonged contact with hydraulic fluid may cause dermatitis,
which may progress to allergic sensitization.
Ensure that only correct hydraulic fluid is supplied and used for safe and correct operation of the
q
control systems unit.
Hydraulic fluid must be filtered to prevent any dirt or debris from entering the hydraulic circuit.
q
Ensure that the pressure relief valves are in working condition, and that the valves are set to
q
relieve at their designated pressure levels.
Should there be a rupture or break in the hydraulic circuit (when pressurized), do not place hands,
q
face, or any part of the body over the escaping jet stream of fluid. Severe bodily injury will result.
Never
q torque leaking connections or fittings while lines are pressurized. Application of torque to
fitting or connections while lines are pressurized may cause lines to rupture and result in
injury to personnel.
Before attempting any corrective action on the hydraulic circuit, verify that:
q
2-15
Sara
BOP Control System
2 Introduction Revision A
Page 2-16 of 17
All hydraulic pressure is completely vented. Verify that all hydraulic gauges read
q
0 psi (0 bar).
When precharging accumulators, use only dry nitrogen gas. The use of another gas
q
may cause unit failure or explosion.
Welding or acetylene cutting must not be done near unprotected cables or hoses, as this may result
q
in damage to cables or hoses.
Consideration must always be given to the prescribed minimum bend radius for cables and hoses.
q
Twisting or bending cables or hoses beyond the minimum bend radius can damage the insulation,
conductors, or reinforcing wire shield
2-16
Sara
BOP Control System
Revision A
Page 2-17 of 17
Introduction 2
If any flammable materials are located or are spilled within or in proximity to the
q
work area, the hazardous material must be removed and cleaned from the work
area. Flammable materials include but are not limited to those listed below:
Should any condition, situation, or circumstance occur that may pose serious hazard(s),
appropriate action must be taken to correct or remove the hazard(s) from the work area and to
return to a safe working environment.
Many Koomey system components are specially manufactured to system design and
specifications, although apparently similar to commercial available hardware. To avoid
possible hazardous failures, use only NOV SARA replacement parts, components, and
assemblies.
2-17
Sara
BOP Control System
Revision A
Page 3-1 of 9
Installation
General
The following instructions explain how to hookup and checkout a standard Sara BOP
Control Unit. These guidelines will ensure that all the equipment is operational so that
drilling operations may begin safely.
Located in the Specifications and Spare Parts Section of this manual are drawings containing
information necessary to properly install the equipment. Also, in order to identify
specific component parts referenced in the Operation Manual, it may be necessary to
review the assembly drawings and material lists also located in the parts Section.
While reviewing the instructions, particular attention is called to all notes and cautions
as these are important to ensure safety during all phases of equipment use.
There are two major steps that must be performed during all phases of equipment use.
Wherever the following instructions are given, refer to these steps :-
Stop Pumps
a. Close air supply valves.
Start Pumps
Accumulator Unit
Set Up Location
1, The distance recommended to provide maximum protection of the accumulator
unit during a blowout or other emergencies is approximately 150 feet from the
well bore.
a. Accessibility
b. Illumination
c. Ventilation
3-1
Sara
BOP Control System
3 Installation Revision A
Page 3-2 of 9
Inspect Reservoir
1. Open the 4" inspection/fill ports on the sides of the fluid reservoir and make
sure the tank is free of any debris that could contaminate the system. A clean
reservoir reduces maintenance costs. For reservoir cleaning see Maintenance
Section .
Fill Reservoir
1. Fill with a high quality SAE 10 hydraulic oil to 8" from the top of the reservoir.
3. Remove the guard from the valve stern of the accumulator and attach a
Charging and Gauging Assembly (P/N 0902-0100).
3-2
Sara
BOP Control System
Revision A
Page 3-3 of 9
Installation 3
(2) Slowly open the nitrogen bottle valve until the precharge pressure
reaches 1500 psi.
(3) Close the nitrogen bottle valve and verify that the gauge reading is still
1500 psi.
(1) Open the charging and gauging assembly bleeder valve until the
precharge drops to 1500 psi.
(2) Close the bleeder valve and verify that the gauge reading is still 1500 psi.
i
Keep A Charging And Gauging Assembly Accessible To
The Accumulator Unit..
4. Purge a 1" airline from the main rig air supply line and connect it to the customer
air supply connection on the accumulator unit.
2. Turn the triplex pump motor starter switch to the OFF position.
4. Check the resistance, voltage, and current of the power lines to be connected.
For electrical power requirements see the Installation Data .
6. Check that the triplex pump crankcase is full of oil (weight will vary with the
ambient temperature). For crankcase oil specifications see Maintenance
.
3-3
Sara
BOP Control System
3 Installation Revision A
Page 3-4 of 9
3. 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.
7. Pumps should continue running until accumulator pressure reaches 3000 psi. If
problems occur during initial start-up, consult the Troubleshooting Section.
Interconnect Piping
1. Lay interconnect piping of sufficient size and pressure rating from the
accumulator unit to the connections on the Blowout Preventer stack.
2. Connect Piping to the function outlets on the back of the accumulator unit. DO
NOT connect to BOP stack.
1. Place all four-way control valves on the hydraulic manifold in the CENTER
position.
5. Check that the air pressure switch bypass valve is closed (if so equipped).
Verify Gauges
1. All gauges on the hydraulic manifold should read 0 psi.
3-4
Sara
BOP Control System
Revision A
Page 3-5 of 9
Installation 3
Start Pumps
1. 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.
1. After the system pressure has reached 3000 psi and the pumps have stopped,
open the manifold bleeder valve.
3. Close manifold bleeder valve and recharge the system to 3000 psi.
2. Manifold pressure gauge should read 1500 psi i.e. the pressure setting of the
manifold regulator. To adjust the manifold regulator set ting see Operation Section
A. Alternately decrease and increase the setting of the manifold regulator and
verify the correct response on the manifold pressure gauge.
B. Move the manifold bypass/internal override valve into the HIGH pressure
(handle right) position and verify that the manifold pressure gauge increases to
3000 psi.
7. Check that the chain guard is filled with oil. For chain guard oil specifications see
Maintenance Section
9. Check the rotation of the motor by turning the triplex pump motor starter switch to
AUTO and then OFF. If the rotation is backwards from arrow indication on chain
guard, swap any two-phase terminal connections to reverse the motor rotation.
10. Use a sealing compound with a melting point of at least 200°F and pour the
electrical conduit seal. Seal should be at least 5/8" thick.
3-5
Sara
BOP Control System
3 Installation Revision A
Page 3-6 of 9
2. Stop pumps.
4. Make sure swivel-joint and hammer union connections on function outlets are tight
and secure.
5. Start pumps.
6. Open each four-way control valve to flush the Open function line.
7. Close each four-way control valve to flush the Close function line.
9. Open the 4" inspection/fill ports and check the control valves for leaks.
10. Connect but do not tighten each swivel-joint assembly to its correct inlet on
the BOP stack.
11. Operate each function to ensure correct function operation and to purge
BOP stack. Make sure a joint of drill pipe is in the hole to prevent damage
to rubber element of the annular preventer.
13. Securely tighten the swivel-joint assemblies and hammer union connections
at the BOP stack.
15. Open the manifold bleeder valve and relieve all system pressure.
3-6
Sara
BOP Control System
Revision A
Page 3-7 of 9
Installation 3
Refill Reservoir
1. Check the fluid level of the reservoir after line flushing.
Remote Panel
Set Up Location
1. Install the remote panels securely on firm foundation, mounting taking into
consideration the following:
b. Illuminated areas.
c. Unobstructed ventilation.
2. The driller's panel should be installed on the drill floor at or near the driller's
position.
Panel Preparation
1. Refer separate PLC panel manual.
3-7
Sara
BOP Control System
3 Installation Revision A
Page 3-8 of 9
Drill Ahead
The following list identifies the normal operating position of the shut-off valves and
control valves of the BOP Control System.
1. Shutoff Valves
2. Control Valves
a. Annular - OPEN.
3-8
Sara
BOP Control System
Revision A
Page 3-9 of 9
Installation 3
3-9
Sara
BOP Control System
Revision A
Page 4-1 of 11
Operation
General
The BOP Control System provides the hydraulic power and controls necessary to
operate the Blowout Preventers during drilling operations. It consists of the
accumulator unit assembly, remote control panels and interconnect assemblies. The
accumulator unit assembly consists of the accumulator unit module, air and electric
pump assemblies, hydraulic control manifold and remote control interface assembly.
While reviewing the instructions, particular attention is called to all NOTES and
CAUTIONS, as these are important to ensure safety during all phases of equipment
use.
Accumulator Unit Module
The accumulator unit module provides the accumulators for storage of the high
pressure control fluid, a reservoir for storage of the atmospheric fluid, supply for the air
and electric pump assemblies, accumulator piping and a master skid for all
components of the accumulator unit assembly.
Accumulators provide the means for storage of large volumes of high-pressure fluid
necessary to control the BOP stack. These ASME coded pressure vessels have a
working pressure of 3000 psi and can be field repaired without destroying their stamp
of approval. These bladder type accumulators are precharged to 1000 psi + 100 psi of
nitrogen.
When there is a demand for fluid to operate a preventer, the high-pressure fluid
contained in the accumulator is forced out by the nitrogen. The port assembly contains
a poppet valve, which prevents the bladder from extruding through the port as the fluid
is discharged. The precharge of each accumulator should be checked during
installation (see Installation Section) as a loss of precharge pressure means a loss of
available operational fluid. The precharge should also be checked periodically during
normal operation to ensure a proper precharge being maintained. Always keep a
charging and gauging assembly readily accessible. If adjustments are necessary, see
the Maintenance Section.
4-1
Sara
BOP Control System
Revision A Operation 4
Page 4-2 of 11
Accumulator Piping
The accumulators are mounted in banks (Item 42 Fig. 4-1) to minimize leaks and line restrictions.
These banks contain isolator valves (Item 2 Fig. 4-1), which should be open during normal
operation, and bleeder valves (Item 3 Fig. 4-1), which should be closed during normal operation. If it
is known an accumulator is faulty, that bank may be isolated until it can be serviced.
Since the accumulators are 3000-psi working pressure, the accumulator piping includes a 3300-psi
relief valve (Item 4 Fig. 4-1) to protect them against higher pressures. A plug should never be
substituted for this valve. If the valve is faulty, it should be repaired and replaced or a new valve
should be installed:
4-2
Sara
BOP Control System
4 Operation Revision A
Page 4-3 of 11
and volume to operate them (see Installation Section). The air pump assembly
consists of air supply manifold, fluid suction manifold, air pumps, and air pressure
switch.
This filter removes contaminants in the air supply which may damage the air pumps.
This filter must be cleaned periodically to maintain maximum air flow (see Maintenance
Section).
This device impregnates the air with oil to lubricate the pumps during operation. This
lubricator should also be serviced periodically to replenish the oil (see Maintenance
Section).
A 0-300 psi gauge is mounted in the air supply manifold for monitoring of the air supply
pressure at the unit.
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 operation, these valves should be closed.
This valve is used to isolate the pumps during servicing. During normal operation, it
should remain open at all times.
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 to prevent clogging which could damage the
pumps by running them dry (see Maintenance Section).
4-3
Sara
BOP Control System
Revision A Operation 4
Page 5-4 of 11
2. Move the manifold regulator bypass/internal override valve (Item Fig. ) to the
high-pressure position.
This will produce pressures up to 3300 psi, which is the setting of the manifold relief
valve.
4-4
Sara
BOP Control System
4 Operation Revision A
Page 4-5 of 11
The electric pump assembly is a primary, or additional, high-pressure pump source used on the
accumulator unit. This assembly requires a customer furnished power supply (Item15 Fig. 4-1).
The amount of current required depends on the horsepower of the electric motor (see Installation
Section). The pump output remains constant up to the maximum pressure of 3000 psi,
independent of the system backpressure. This pump assembly is very important to the overall
performance of the accumulator unit. Therefore it is necessary to understand its function and
operation. The electric pump assembly consists of fluid suction manifold, triplex pump, electric
moto and drive assembly which includes chain, sprocket, chain guard and pressure switch.
1. Suction Valve (Item19 Fig.4-1) - This valve should remain open at all times in normal
operation; but should be closed to isolate the pump during servicing.
2. Suction Strainer (Item20 Fig.4-1) - This strainer helps to remove impurities that have
entered the system with the vented fluid from the preventers. It should be serviced
periodically (see Maintenance Section) to prevent damaging the pump by running it dry.
4-5
Sara
BOP/Diverter Control System
Revision A Operation 4
Page 4-6 of 11
1. Sprockets - The pump and motor sprockets are sized to reduce the speed of the motor
to the operating limits of the pump.
2. Chain complete with oil-bath-type chain guard - This assembly is used in place of belts
to eliminate slippage and prolong service life. The oil level in the chain guard should be
periodically inspected. For procedures and oil specifications, see Maintenance Section.
3. Motor Starter (Item 18 Fig. 4-1) - The motor starter controls the power to the electric
motor and is housed in an explosion-proof enclosure. The starter control switch should
always be in the AUTO position during normal operation.
4. Electric Pressure Switch (Item 17 Fig. 4-1) - This switch stops the electric motor when
discharge pressure reaches 3000 psi and automatically restarts the motor when
discharge pressure reaches 2700 psi. This protects the pump from over pressuring
which can damage the packing or the power frame. Pressure switch settings have a
tendency to drift and require periodic calibration. This is especially true when the
equipment has been moved to a different location. To adjust the pressure switch
setting, see Maintenance Section.
The control manifold directs the flow of the high-pressure fluid stored in the accumulators to
operate the preventers and gate valves. Most preventers operate at a maximum of 1500 psi,
however the accumulator pressure is 3000 psi. Therefore, regulators are required to reduce the
operating pressure from 3000 psi to 1500 psi.
Annular (Bag Type) preventers require different operating pressures from the other functions on
the BOP stack, so all control manifolds use the double manifold design. The control manifold
consists of: (1) control valves, (2) cylinders, (3) regulators, (4) gauges, and (5) manifold piping
which includes a supply header, high pressure strainer, relief valve and bleeder valve.
4-6
Sara
BOP/Diverter Control System
4 Operation Revision A
Page 4-7 of 11
Pausing will cause the valve to interflow, thus venting some of the supply fluid and delaying
function operation. The CENTER position could be used to block further pressure drop of the system
if caused by regulator malfunction while operating a preventer. The control valves should be serviced
periodically to ensure proper operation (See Maintenance Section).
Regulators
The double manifold, designed to accommodate variable pressure requirements, consists of
a manifold regulator assembly, a bypass valve assembly, and an annular 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; pressures greater than 1500 psi cannot be regulated.
The pressure setting of this regulator must be manually adjusted; to do this:
1. Loosen the locknut on the adjustment handle and hold with one hand.
3. Read manifold pressure gauge for the pressure setting of the regulator. Set at desired
pressure.
To operate with pressures up to 3000 psi, the manifold regulator assembly is fitted with a
quick opening bypass/internal override valve that can shut off the supply through the
manifold regulator and supply direct accumulator fluid pressure to the ram preventers and
gate valves.
4-7
Sara
BOP/Diverter Control System
Revision A Operation 4
Page 4-8 of 11
The Regulator can be fitted with an internal override assembly that when operated will allow
the full accumulator pressure supply to flow through the manifold regulator. In normal
operation the bypass/ internal override valve should be in the regulated or LOW-pressure
position. For pressures up to 3000 psi, the valve must be in the HIGHpressure position. For
remote operation of the bypass valve an air cylinder can be fitted to the valve.
The annular regulator controls the operating pressure settings for the annular preventer.
Since the annular preventer requires different operating pressures for stripping and well
control it is necessary to consult the annular preventer manufacturer's recommendation for
optimum pressure settings to prolong the life of the element. Regulators are available for
regulation up to 3000 psi and in 1" and 1-1/2"sizes.
The regulation of the annular operating pressure is adjusted at the accumulator unit by
operation of the manual adjustment handle on top of the regulator. It is adjusted in the same
manner as the manifold regulator (See Section ). Annular regulators fitted with air motor
operators include two (2) quick release valves to reduce air motor "run-on". For instructions
on remote regulation of the annular operating pressure, (See Section)
Gauges
The gauges on the hydraulic manifold are 6" face, glycerin-filled, panel mount type gauges which
connect to the pressure pick-up points with stainless steel tubing or mud pump type, glycerin-
filled gauges which mount in-line. Three (3) gauges are provided to monitor:
Manifold Piping
The manifold piping consists of a supply pressure header, a high-pressure strainer, a bleeder
valve, and a relief valve.
Supply Pressure Header (Item 43 Fig. 4-1) - A 2" header provides a common pressure to the ram
preventer and gate valve control valves to maximize flow and minimize leaks.
4-8
Sara
BOP/Diverter Control System
4 Operation Revision A
Page 4-9 of 11
High Pressure Strainer (Item 22 Fig. 4-1) - This strainer helps to remove debris from the control
fluid that could damage the regulators and control valves. It should be serviced Periodically to
ensure proper operation (See Maintenance Section).Manifold Bleeder Valve (Item 27 Fig 4-1) -
This valve is used to bleed off the system pressure for servicing. In normal operation it should be
in the closed position.
Manifold Relief Valve (Item 41 Fig. 4-1) - This valve is set to relieve excess system pressures to
prevent component or system failure. For systems with an air pressure switch bypass valve, it is
set at 5500 psi and for systems without an air pressure switch valve it is set at 3300 psi.
4-9
Sara
BOP/Diverter Control System
Revision A Operation 4
Page 4-10 of 11
TABLE 4-1
LEGEND - TYPICAL ACCUMULATOR UNIT ASSEMBLY
ITEM CUSTOMER LOCATIONS
A Customer Air Supply Connection
B Customer Motor Starter Power Connection
C 4" Fill/Inspection Port
4-10
Sara
BOP/Diverter Control System
4 Operation Revision A
Page 4-11 of 11
4-11
Sara
BOP Control System
Revision A
Page 5-1 of 39
Maintenance
General
A regularly scheduled maintenance program must be developed to sufficiently maintain the BOP Control
System. The operator must develop an appropriate program based on the operating, testing and drilling
programs. The entire system should be tested a minimum of once a week. This may involve simply
operating all functions and noting gauge readings. When performing routine maintenance and/or major
service and repair around high pressure and electrical equipment, care should be taken to ensure the safety
of all personnel. Remove and verify line pressure is released before attempting to disconnect pressure
lines.
Accumulators
Precharging Instructions
1. Relieve system pressure.
2. Remove the valve guard and secondary valve cap from the accumulator and attach a charging and
gauging assembly part number 0902-0100 . Screw down T-handle (6) and observe reading on
gauge. It should read 1000 psi. If pressure is high, open bleeder valve (9) until pressure drops to
1000 psi. If pressure is low, attach the charging line (7) to a nitrogen bottle.
Gradually open valve (8) to slowly increase precharge to 1000 psi. Then close valve. If pressure
does not increase, the bladder is faulty and should be replaced.
3. Remove charging and gauging assembly and Check valve core for leaks.
5. Pressurize system.
5-1
Sara
BOP Control System
5 Maintenance Revision A
Page 5-2 of 39
Accumulator Unit
Fluid Reservoir
1. The fluid reservoir should be checked regularly, drained and cleaned to eliminate sludge build-
up. The control fluid should be kept clean and free of debris. A high quality SAE 10W hydraulic
oil or suitable lightweight oil should be used in the system.
i
NEVER USE FUEL OIL, KEROSENE OR SALT WATER IN
THE RESERVOIR.
Relief Valves
Check the high-pressure relief valves for leaks. Open the 4" inspection ports on the side of the
reservoir and check the vent lines from the relief valves for leakage,
Piping
Visually check all fluid lines and connections for possible leaks.
Air Lubricator
1. Check the air lubricator to make sure it is full of SAE 10W lubricating oil.
5-2
Sara
BOP Control System
Revision A
Page 5-3 of 39
Maintenance 5
Open the petcock of lubricator to drain moisture that may have accumulated.
Check that drip setting flows 6 drops per minute. To adjust setting see Troubleshooting Section.
Filters
Drain and flush accumulated moisture. Open the manual drain on the filter housing, as pumps are
running.
Clean elements.
a. Stop pumps.
b. Unscrew housing and lift out o-ring and louver.
c. Remove filter elements and wash in warm water or kerosene.
d. Dry elements and check that bowl gasket is in good condition.
e. Replace parts and housing.
Strainers
1. Clean Y-type strainers. Ensure lines are free of pressure before attempting maintenance.
a. Stop pumps.
b. Close pump suction valves.
c. Remove Y-type strainer plugs.
d. Remove strainer elements.
e. Open pump section valves to flush piping, then close valves.
f. Clean strainer elements in warm water or kerosene.
g. Replace elements and Y-type strainer plugs.
h. Open pump suction valves.
i. Startpumps.
Pump Packing
The pump packing is spring loaded and spring adjusted. No maintenance is required.
Air Exhaust
Clean sludge build-up.
5-3
Sara
BOP Control System
5 Maintenance Revision A
Page 5-4 of 39
Electric Pumps
Hydro-electric Pressure Switch
1. To adjust the pressure setting for:
a. Pump Start-up
5-4
Sara
BOP Control System
Revision A
Page 5-5 of 39
Maintenance 5
Crankcase.
1. Check the pump crankcase to make sure it is full of good, clean engine oil.
Eight will vary depending on the ambient temperature (See Table ),
3000-2100
3000-3100 4
3001-3100
3001-4100
5-1/2
3001-5100 SAE 20 @40°F-115°F
SAE 10 @0°F-60°F
3002-2100 7
3003-1100 9
3001-3200
3001-5200 2 SAE 30
Chain Guard
1. Remove the lower drain plug and check for water or sludge build-up.
2. Check the oil level in the oil bath chain guard. It should be filled up to the spill plug.
(1) Horizontal drives should be installed with initial sag equal 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.
5-5
Sara
BOP Control System
5 Maintenance Revision A
Page 5-6 of 39
Motor Bearings
1. Disassemble motor and lubricate bearings.
Pump Packing
1. The packing glands should be tight enough to eliminate leaking and loose enough to
lubricate the plungers with a fine oily film. Over tightening the packing will damage the
motors.
Strainers
1. Clean Y-type strainers. Ensure lines are free of pressure before attempting maintenance.
a. Stop pumps.
b. Close pump suction valves.
c. Remove Y-type strainer plugs.
d. Remove strainer elements,
e. Open pump suction valves to flush piping, then close valves.
f. Clean strainer elements in warm water or kerosene.
g. Replace elements and Y-type strainer plugs.
h. Open pump suction valves.
i. Startpumps.
Hydraulic Manifold
Cylinders
1. Clean piston rods of corrosion by wiping with an emery cloth.
2. Lubricate the piston rods on the cylinders with a good quality silicone based lubricant.
5-6
Sara
BOP Control System
Revision A
Page 5-7 of 39
Maintenance 5
Filters
1. Drain and flush accumulated moisture. Open the manual drain on the filter housing as
pumps are running.
2. Clean elements.
a. Stop pumps.
b. Unscrew housing, lift out o-ring and louvre.
c. Remove filter elements and wash in warm water or kerosene.
d. Dry elements and check that bowl gasket is in good condition.
e. Replace parts and housing.
Gauges
1. Check that system pressures are maintained at proper levels,
2. When there is no pressure in system ensure that gauges are properly zeroed. If gauges are
not properly zeroed see Troubleshooting Section.
3. When system is pressurized ensure that gauges on the control manifold match gauges on
the remote control panel(s),
5-7
Sara
BOP Control System
5 Maintenance Revision A
Page 5-8 of 39
18. Extract seats and springs from seal container. Note location of backup rings, inboard on vent
seats, outboard on primary seats.
5-8
Sara
BOP Control System
Revision A
Page 5-9 of 39
Maintenance 5
Major Minor
Item # Description P/N Qty.
Kit Kit
5-9
Sara
BOP Control System
5 Maintenance Revision A
Page 5-10 of 39
Risassembly
Use replacement parts from seal kit (P/N 1110-3197), and/or repair kit (P/N 1110-3199). Item numbers
in the text refer to Figure 4-34.
1. Install new O-rings (31, 32) and Backup ring (33) into grooves of piston guide (30).
2. Push piston guide into top opening of body (1).
3. Install an O-ring (11) and two backup rings (12) on each seal plug (10), and insert one seal plug
into each flow plate (16).
4. Install an O-ring (11) and two backup rings (12) on seal plug (10), and insert seal plug into port
plate (5).
5. Install two O-rings (6) and O-ring (7) in port plate (5) and mount to flow plate (16).
6. Install two O-rings (6) and O-ring (7) in flange (17) and mount to flow plate (16).
7. Secure flow plates (16) to port plate (5) and flange (17) with two screws (15) each. Use 5/32? hex
key and torque to 40 in-lb.
8. Install O-rings (13) and backup rings (14) on port plate, flange (17) and flange (28). Note location
of backup rings.
9. Install O-rings (8, 9 and two item 25) on port plate. Check that three seal plugs are installed and
pipe plug (19) is installed in flange (17).
10. Inspect flow plate for nicks and burrs by gently sliding a seat over the sealing surface.
11. Install O-rings (21) and backup rings (22) onto seal container (34) and hydraseats (20). Install O-
rings (25) and backup rings (26) to hydraseats (24). Note position of backup rings on seats,
outboard on primary and inboard on vent.
12. Install seats into seal container from one side and springs (23, 27) and remaining
seats from the other side.
13. When installed, seats should extend equally from each side with O-rings and
backup rings confined.
14. To install flow and port plate assembly into body, line up retaining screw holes.
15. Push flow and port plate assembly into body by hand. Install retaining screw (4) with
3/16? hex key. Tighten to 90 in-lb torque.
16. Insert piston at top of seal container assembly into piston guide while holding lower
seats above flow plate to avoid nicking seats.
17. Align dowel pin with dowel hole and push side flange assembly into body by hand.
Note seal plugs and orifice plug.
18. Secure side flange to body using six screws (18) with 3/8? hex key, and tighten to
100 ft-lb.
19. To ensure proper assembly, stroke seal container assembly by hand. It should take
15–20 pounds force.
20. Align holes in bottom flange with tapped holes in body, and push flange into body by
hand. Secure with six screws (18) using 3/8? hex key and tighten to 100 ft-lb torque.
Do not use a metal object to push the seal rings into the seal
container. The seal rings are manufactured to very specific
tolerances. These tolerances would be damaged by contact
with metal tools. Use fingers, preferably protected with clean
gloves. Avoid contacting the beveled edges of the seal rings
directly with the fingers. The beveled edges are sealing
surfaces, which will corrode if contacted by the natural acids
on fingers. If it is necessary to push the seal rings in with the
fingers, apply a coating of oil to the seal rings. The oil acts as
a barrier between the acids and the metal
i
It may be necessary to lubricate the inside of the flanges with
a lightweight lubricant prior to reassembly.
5-10
Sara
BOP Control System
Revision A
Page 5-11 of 39
Maintenance 5
The numbers in parentheses correspond to the item numbers shown in Figure 4-6 and the associated
parts table. The table also provides the assembly and kit part numbers. Do not attempt to disassemble
this regulator valve without the correct repair kit or seal kit. Use the proper tools and work in a clean,
dry atmosphere.
5-11
Sara
BOP Control System
5 Maintenance Revision A
Page 5-12 of 39
Figure 5-4. 1"AMKR Pressure Reducing and Regulating Valve(P/N 10-00539), Exploded View
5-12
Sara
BOP Control System
Revision A
Page 5-13 of 39
Maintenance 5
Major Minor
Item # Description P/N Qty.
Kit Kit
5-13
Sara
BOP Control System
5 Maintenance Revision A
Page 5-14 of 39
31 üO-Ring 5001019 4
32 ü Seal Ring 1000134 4
34 ü Seal Ring 1000143 2
35 üBackup Ring, 13/16” X 11/16” 5020017 2
36 üO-Ring 5001016 2
37 Flange 1000142 1
38 Seal Container 1000203 1
39 üO-Ring 5001154 1
40 ü Wave Spring 1000147 1
41 ü Compression Spring 1000138 2
42 Spring Pin 1000551 1
43 Plunger 1000555 1
44 üO-Ring 5001017 1
These items, along with the following O-rings and backup rings (31, 30, 36, 35), are provided in the
repair kit. Apply a generous amount of Dow Corning #44 or other equivalent seal lubricant to the O-
rings prior to the replacement. Install the seal rings wth the beveled edges facing outward toward the
surface of the seal container.
5-14
Sara
BOP Control System
Revision A
Page 5-15 of 39
Maintenance 5
i
It may be necessary to lubricate the inside of the flanges
with a SAE 10W lightweight lubricant prior to assembly.
2. Install the new O-ring (28) and backup rings (27) on the plunger (43).
3. Gently replace the seal container assembly back into the body (18) with the indentations in the
upper end of the seal cartridge facing toward the inlet flange (14). (See Figure 4-7.)
4. Install a new O-ring (39) onto the bottom flange (37). Mount the bottom flange onto the body
(18). Install and tighten the eight socket head cap screws (12).
5. Replace the O-ring (17), the plate (22), and the two socket head cap screws (13) on the flange
(23). Reassemble the new plate to the flange using the new socket head cap screws.
7. Replace the O-rings (15, 17, 39, 44), the socket head cap screws (13), and the flow port (5) on the
inlet flange (14). Reassemble the new flow port to the inlet flange using the new socket head cap
screws.
i
Do not use any metal object to push the seal ring into the seal
container. The seal rings are manufactured to a very specific
tolerance. These tolerances would be damaged by contact
with metal tools. Use fingers, preferably protected with clean
gloves. Avoid contacting the beveled edges of the seal rings
directly with the fingers. The beveled edges of the seal rings
are sealing surfaces which will corrode if contacted by the
natural acids on fingers. If it is necessary to push the seal rings
in with the fingers, apply a sufficient coating of oil to the seal
rings. The oil acts as a barrier between the acids and the
metal.
5-15
Sara
BOP Control System
5 Maintenance Revision A
Page 5-16 of 39
8. Mount the inlet flange onto the body. Align the ''on the flange with the ''on the body. (See Figure 4-
8.) Install and tighten the eight socket head cap screws (12).
9. Replace the O-ring (24) on the outlet flange (25). Mount the outlet flange onto the body (18). Install
and tighten the six socket head cap screws (26).
10. Replace the O-rings (21) on the plunger guide (20). Place the plunger guide (20) onto the plunger
(43), which protrudes from the top of the body (18).
11. Set the adjustment head assembly (11) down over the plunger guide and onto the top of the body.
Align the four holes for the socket head cap screws.
12. Remove the ball handle (1) down to its original position and set the lock nut (4). The valve is now
ready for operation.
5-16
Sara
BOP Control System
Revision A
Page 5-17 of 39
Maintenance 5
Required Tools
ning
War
Replacing the accumulator bladder requires all hydraulic pressure to be vented from the
accumulator in accordance with the following steps:
q
Isolate the accumulator bottles from the main hydraulic supply by closing the appropriate
ball valve.
q
Vent the residual nitrogen precharge pressure from the bottle to atmosphere using the
charging and gauging assembly.
q
Drain the fluid from the accumulator by opening the 1/2 inch ball valve.
Removal
1. Remove the gas protective cap and valve cap from accumulator.
2. Install the proper charging and gauging assembly on the gas valve stem. Attach the air
chuck to the accumulator bladder gas valve by hand tightening the swivel hex connection.
3. Open the valve by turning the air chuck T-handle clockwise until it stops. This opens the
valve core.
ning
War
5-17
Sara
BOP Control System
5 Maintenance Revision A
Page 5-18 of 39
4. Bleed off all nitrogen gas pressure by opening the bleed valve completely. Open the gas
valve fully and then remove the gas valve.
8. Remove the lock nut from the bottom of unit using a spanner wrench.
10. Push the plug assembly into the accumulator and through the anti-extrusion ring.
11. Remove the anti-extrusion ring by folding it and pulling it through the hole.
12. Remove the plug assembly and pull the old bladder out from the bottom of the
accumulator.
Installation
1. Remove the valve core from the new bladder and squeeze all air from the bladder.
Replace the valve core.
4. Attach a bladder pull rod to the bladder by carefully threading over the Schrader
connection. Insert the rod through the accumulator (bottom to top). Pull the bladder into
the shell. Do not allow the bladder to bind or kink.
5. Attach the name plate and hex jam nut to the exposed gas valve stem and hand-tighten.
Remove the pull rod.
ning
War
6.. Push the plug assembly and then the anti-extrusion ring into the shell.
7. Pull the plug assembly through the anti-extrusion ring. Seat the ring in the hole, metal
side up.
8. Install a new metal back-up ring and a new O-ring, making sure not to pinch the O-ing.
Install a new rubber backup ring, spacer, and lock nut. Hand-tighten the lockut.
9. Precharge the accumulator (see the section titled “Precharging Accumulator Bottles”
10. Tighten the hex jam nut, making sure the gas valve stem does not rotate.
5-19
Sara
BOP Control System
5 Maintenance Revision A
Page 5-20 of 39
5 Shell 1000-9401 1
8 Poppet 1000-4103 1
18 Plug 1/4” - 1
* Parts may be ordered by referencing the item number, description, accumulator size,
accumulator pressure rating and accumulator bottle part number.
5-20
Sara
BOP Control System
Revision A
Page 5-21 of 39
Maintenance 5
Hydraulic Pump
The hydraulic pump assembly (3324000) is an integrated pump assembly consisting of a close-
coupled, 73/8" air-driven motor (3324057) and a 60:1 ratio hydraulic pump (3324056). This section
outlines the corrective maintenance procedures for the 60:1 ratio hydraulic pump. The hydraulic pump
operates when air pressure applied to the air motor forces hydraulic fluid through the pump.
The numbers in parentheses correspond to the item numbers shown in Figure 5-7 and the associated
table. For assembly and kit part numbers, see the table titled "Parts List, Hydraulic Pump".
2. Hold piston rod of motor with wrench and unthread coupling nut (2).
3. Remove connecting rod (1), coupling nut (2), and jam nut (3) from plunger (11).
Then pull plunger through lower cavity of pump block (4).
4. Remove pump cylinder gasket (8), packing spring (7), and packing set (6).
5. Hold plunger rod (11) in vise by the flats at top of plunger and remove piston
seat (16) with wrench while holding plunger horizontal with wooden support if
necessary. Remove piston ball (15), packing set (14), lower packing spring (13), and
spring retainer (12).
6. Secure foot valve (20) in vise and unthread pump cylinder (9).
7. Remove ball stop cage (18), both pump cylinder gaskets (17) and foot valve
ball (19). Remove O-ring (10) from pump cylinder (9).
5-21
Sara
BOP Control System
5 Maintenance Revision A
Page 5-22 of 39
2. Place foot valve ball (19) in foot valve (20) and install ball stop cage (18) between
the two pump cylinder gaskets (17).
4. Place packing set (14) over piston seat (16). Place piston ball (15) on piston seat
(16), follow with lower packing spring (13) and spring retainer (12). Thread plunger
rod (11) onto piston seat (16) tightly using loctite.
5. Insert packing set (6) into pump block (4). Place upper packing spring (7) and pump
cylinder gasket (8) into the lower cavity of pump block (4) behind upper packing set
(6).
7. Pump cylinder (9) over packings and connect to pump block (4).
5-22
Sara
BOP Control System
Revision A
Page 5-23 of 39
Maintenance 5
8. Insert connecting rod (1) through coupling nut (2). Thread jam nut (3) into
connecting rod. Connecting rod should then be screwed into plunger (11).
5-23
Sara
BOP Control System
5 Maintenance Revision A
Page 5-24 of 39
1
2
2a
3
11
12
13
6
7 14
8
15
16
17
18
17
19
10 20
5-24
Sara WWW.NOV.COM
BOP Control System
Revision A
Page 5-25 of 39
Maintenance 5
10 ü ü 3324048 O-Ring 1
Hydraulic Pump
The hydraulic pump assembly (3324063) is an integrated pump assembly consisting of a close-coupled,
73/8" air-driven motor (3324057) and a 300:1 ratio hydraulic pump (3151000). This section outlines the
corrective maintenance procedures for the 300:1 ratio hydraulic pump. The hydraulic pump operates
when air pressure applied to the air motor forces hydraulic fluid through the pump.
5-25
WWW.NOV.COM Sara
BOP Control System
5 Maintenance Revision A
Page 5-26 of 39
The numbers in parentheses correspond to the item numbers shown in Figure 5-8 and the
associated table. For assembly and kit part numbers, see the table titled "Parts List, Hydraulic
Pump" .
3. Loosen the packing gland nut (3). Then pull the rod (2) through upper cavity of the
pump block (1).
5. Hold pump block (1) in vise and remove cover nut (8) with wrench.
6. Remove the packing set (5) and rod sleeve (6) from the pump block.
ning
War
5-26
Sara
BOP Control System
Revision A
Page 5-27 of 39
Maintenance 5
5-27
Sara
BOP Control System
5 Maintenance Revision A
Page 5-28 of 39
Assembly
7 ü 5001142 O-Ring 1
2. Install the packing set (5) and rod sleeve (6) into the pump block (1) (see Figure 4-3
on page 4-8 for correct installation) of packing set.
3. Install the cover nut (8) into the pump block (1) and tighten with wrench.
4. Install the gland nut (3), finger tight, onto the pump block.
5. Lubricate the packing (5) and Pump rod (2) with SAE 10W oil and install pump rod
through packing into rod sleeve (6).
8. Start pump and adjust gland nut to allow slight leakage for rod to packing
lubrication.
Air-Driven Motor
The hydraulic pump assemblies (3324000 and 3324063) are integrated pump assemblies consisting of a
close-coupled, 73/8" air-driven motor (3324057) and either a 60:1 or 300:1 ratio hydraulic pump (3324056
or 3151000). This section outlines the corrective maintenance procedures for the 73/8" air-driven motor.
The hydraulic pump operates when air pressure applied to the air motor forces hydraulic fluid through the
pump.
5-28
Sara
BOP Control System
Revision A
Page 5-29 of 39
Maintenance 5
The numbers in parentheses correspond to the item numbers shown in Figure 4-4 on page 4-10
and the associated table. For assembly and kit part numbers, see the table titled "Parts List, 7-3/8"
Air-Driven Motor" on page 4-12.
i
Peak of V-packing must point up toward gland nut.
Use teflon tape on all threaded pipe connections.
5-29
Sara
BOP Control System
5 Maintenance Revision A
Page 5-30 of 39
i
The air motor should be supplied with moisture-free
air. For use under very cold and humid air conditions,
coupled with high speed and high operating pressure,
a moisture separator and an automatic oiler may be
necessary to avoid icing.
2. Remove locking bolts and nuts (24, 23), trip spring retainers (6), O-ring (5), trip
springs (4), and balls (3) from both sides of cylinder head (25).Disconnect air
line (26) from adaptors (28), top and bottom.
3. Disconnect air line (26) from adapters (28), top and bottom.
5. With piston (33) in down position, place wrench on flats of piston rod (36) and
disconnect piston rod from pump connecting rod.
6. With piston (33) at top of stroke, raise cylinder head (25) and remove retainer (20).
Lift off the cylinder head (25). The valve sleeve (10) may pull out of cylinder head; lift
sleeve off separately.
8. Remove air valve (14), followed by lower valve keeper (16) and bushing (17).
9. If valve sleeve (10) is still in cylinder head, leave it there unless it is necessary to
change O-rings. To remove, insert head of bolt (2) into large hole in valve
sleeve (10) and pull it out very carefully.
11. Remove piston rod (36) and piston (33) from motor base (39).
12. Secure piston (33) in vise and remove piston nut (21) and piston washer (22).
13. Remove valve rod assembly (32) and valve trip collar (35).
16. Remove O-rings (18, 19) from bushing (17) and O-ring (37) from motor base (39).
5-30
Sara
BOP Control System
Revision A
Page 5-31 of 39
Maintenance 5
Assembly
2 3324009 Bolt 6
5 ü ü 3324004 O-Ring 2
7 3324012 Nut 2
9 3324010 Adapter 2
14 ü 3324017 Valve 1
17 3324021 Bushing 1
18 ü ü 3324014 O-Ring 1
19 ü ü 3324020 O-Ring 1
20 3324022 Retainer 1
23 3324002 Nut 2
5-31
Sara
BOP Control System
5 Maintenance Revision A
Page 5-32 of 39
24 3324008 Bolt 2
28 3324001 Adapter 2
29 ü ü 3324023 Gasket 1
30 3324024 Cylinder 1
31 ü ü 3324022 Gasket 1
33 3324028 Piston 1
37 3324032 O-Ring 1
38 33254012 Nut 6
Wash all replaceable parts thoroughly with kerosene and lubricate with lubri-plate or similar non-water soluble
grease. For routine servicing, use the air motor seal kit. For major overhaul, replace all parts contained in the air
motor repair kit. Inspect all other parts for abnormal wear or damage and replace, if necessary.
1. Install new O-ring (37) into motor base (39) and new O-rings (18, 19) into bushing (17). Do not damage
O-rings and make sure they are properly seated in the O-ring grooves.
2. Place valve trip collar (35) into piston rod (36), followed by valve rod assembly (32).
3. Screw piston rod (36) into piston (33). Replace piston nut and washer (21, 22).
6. Place piston assembly (33, 36) into motor base (39). Do not damage O-ring (37).
5-32
Sara
BOP Control System
Revision A
Page 5-33 of 39
Maintenance 5
8. Mount air valve assembly onto valve rod (32) by placing bushing (17) over valve rod,
followed by keeper (16), which should be threaded down on air valve hand tight and
then loosened approximately 1/4 turn. Place wrench on flats of valve rod and hold to
prevent valve rod from turning. Thread stop nut (12) down on valve rod to lock upper
valve keeper (13) in position. Be sure upper valve keeper (13) does not change
position.
9. Grease inside of cylinder (30) and work cylinder down over piston gently in order to
avoid damaging piston O-ring (34).
10. Install new O-rings (11) on valve sleeve (10). Grease valve sleeve and install into
cylinder head (25) so large holes in sleeve line up with trip retainer holes in cylinder
head. Put one trip retainer (6) with O-ring (5) into cylinder head without ball (3) or
spring (4) and hold in position temporarily with locking bolt (24) and nut (23).
11. Place new gasket (29) into position in cylinder head (25) and hold with gasket
cement or grease.
12. Carefully position air valve assembly up into cylinder head (25).
13. Push bushing (17) up into bottom of cylinder head (25) sufficiently to permit
installation of retainer (20).
14. To install trip spring retainer, be sure one of the detents of valve (14) is properly
lined up with hole in cylinder head (25). Place trip spring retainer O-ring (5) onto
remaining trip spring retainer (6). Install ball (3), followed by trip spring (4) and trip
spring retainer, into hole in cylinder head. Lock into position with bolt (24) and
nut (23).
15. Remove opposite trip spring retainer (6) and repeat Step 14.
16. Connect air line (27) to adapters (26), top and bottom.
17. Replace bolts (2) and nuts (38). Always tighten nuts 180≡apart in order to obtain
proper and even compression. Do not over tighten.
18. Place wrench on flats of piston rod (36) and connect pump connecting rod.
5-33
Sara
BOP Control System
5 Maintenance Revision A
Page 5-34 of 39
Design Ratings:
Continuous Duty – 61.0 HP (45.49 kW) input at 400 RPM, pressures to 10,000 psig (703
q
kg/cm2g), capacities to 72.6 U.S. GPM (16.48 M3/Hour)
Maximum Plunger (Frame) Loading for Continuous Service: 5,700 pounds (25,355 Newtons).
q
Construction - Power Frame - A48 Class 30 Cast Iron construction designed with rigidity and
q
ease of maintenance as objectives. Full cylindrical crosshead bores are cast with sufficient extra
thickness to allow for over-boring and installation of liners in case the bores become damaged.
This model pump has the following component features:
Power Pump Lubrication - Used on Union Pump power pumps for decades, the simple and
q
sure splash / gravity feed system serves the Power Frame to provide positive lubrication to the
crossheads and bearings. The crankcase is a generous oil reservoir with provisions for adding
an oil heater and thermostat when required. An option external electric driven positive
lubrication system is available for crankshaft speed below 50 RPM or for use during pump idle
periods to enable the pump to be started under discharge pressure loads without loss of
lubrication to crossheads and bearings.
Crankshaft - One-piece SAE 4140-4145 heat treated steel for toughness and high endurance
q
limit. Reversible in Power Frame for drive input from either side of pump.
5-34
Sara
BOP Control System
Revision A
Page 5-35 of 39
Maintenance 5
mMain Crankshaft Bearings - The crankshaft has two anti-friction taper roller bearings
designed for a minimum L10 life of 30,000 hours (3.4 years); an average life of 150,000
hours.
Connecting Rods and Bearings - Carry loads in compression only. The connecting rods are
m
heavy duty with separate bolted caps at the crankshaft end to simplify assembly and bearing
insert replacement. Crankshaft end connecting rod bearings are split, replaceable, precision
type babbitt lined steel. Crosshead pin bearings are oil-impregnated bronze. These bearings
provide a smooth-running unit with excellent longevity and adjustment-free bearing life.
mCrossheads - Large diameter full piston type that are extra long for maximum support and
large bearing area. Each Crosshead operates in a full cylindrical bore in the power frame with
the entire cylindrical surface is lubricated; which in combination with the large bearing area
reduces wear to negligible proportions.
mCrosshead Wrist Pins - Crosshead wrist pins are alloy steel, carburized, hardened and
accurately ground. They slip into the crosshead and are positively locked with two (2)
setscrews.
m
Crosshead Extensions - Threaded into the crosshead providing excellent alignment with the
steel for corrosion resistance and increased wiper seal life.
m
Crosshead Extension Seals - Are spring loaded lip type that press fit into the Crosshead
Stub Seal Cap.
mCrosshead Extension Deflectors - Are made of neoprene rubber and are located in grooves
in the crosshead extensions.
m
Crossheads, Crosshead Wrist Pins Crosshead Extensions, Crosshead Extension Seals, and
Crosshead Extension Deflectors are interchangeable with those in the TD90 and QD100
models.
q
Drive Methods:
q
Pump-mounted (bolt-on) “Gear-Pac” speed reducer made by Union Pump with 3.82:1, 4.80:1,
5.00:1; 6.32:1 and 8.00:1available. See page 42070-1001 for “Gear-Pac” features.
m
Separate speed reducer.
m
Gear-head motor.
m
Top mounted “V” belt drive (standard). Provides most compact and economical drive
m
arrangement.
m
Rear mounted “V” belt drive (non-standard).
m
Variable speed drivers.
Driver Types: – Electric motor, air motor, turbine or engine may be used with any drive
q
method,except the Top mounted “V” belt drive arrangement that will not accept and engine.
q
Liquid Cylinder - Four (4) standard vertical valves and one (1) straight line (“SL”) suction valve
designs with low internal clearance volumes maximizes volumetric efficiency. Liquid Cylinder
designsare available to accept plunger diameters from 0.750” (19.05 mm) to 2.500” (63.5 mm).
Both suction and discharge connections are standard NPT Pipe taps at both ends of the
m
liquid cylinder.
5-35
Sara
BOP Control System
5 Maintenance Revision A
Page 5-36 of 39
5-36
Sara
BOP Control System
Revision A
Page 5-37 of 39
Maintenance 5
Main Crankshaft Bearings - The crankshaft has two anti-friction taper roller bearings
Optional flanged suction and discharge connections in appropriate flange facings and ratings
m
are available for all liquid cylinders.
Standard Liquid Cylinders are available in steel, nickel-aluminum bronze, 18-8 stainless steel
m
and duplex stainless steel.
Liquid Cylinder Connections - Each liquid cylinder is standard with two (2) suction and two (2)
q
discharge NPT pipe tapped connections. Optional flanged suction and discharge connections in
appropriate flange facings and ratings are available for all liquid cylinders, consult factory.
Stuffing Boxes - Standard stuffing boxes are gland design for manually adjusting plunger
q
packing. Spring loaded self-adjusting plunger packing design stuffing boxes are optional.
Stuffing boxes are readily removable for ease of maintenance by bench replacement of
m
plungers, packing and other stuffing box internal parts.
Each stuffing box is designed for a range of plunger sizes, with several stuffing boxes
m
available to cover the entire range of plungers within each liquid cylinder size. This design
then enables changes in Plunger sizes as necessary to accommodate changes in pump
operating conditions with minimal parts required for the conversion.
A wide range of stuffing box configurations are available, including lantern ring lubrication
m
designs, Union Pump Uni-Lok® double packed leakage control designs.
Stuffing Boxes are interchangeable with those within the same size Liquid End as the TD90
m
and QD100 models.
Plungers - Plungers are threaded to the crosshead extensions outside the power frame housing
q
to simplify assembly and to keep plungers replacement cost low.
A 60 RC nickel-base alloy (#6 Colmonoy®) is fused to the plunger packing wear surface,
m
then ground to an 8 RMS micro inch mirror finish for long packing and plunger life. Other
plunger base materials and hard face coatings in the packing wear area are available to
meet application requirements.
Plunger sizes are available in standard 0.125” (3.18 mm) increments, starting at 0.750”
m
(19.05 mm). Non-standard Plungers are available in 0.063” (1.59 mm) increments – consult
factory for further details.
mPlungers are interchangeable with those within the same size Liquid End as the TD90 and
QD100 models.
Valve Assemblies – The liquid cylinder valves are a standard wing guided design, which are
q
quiet and quick acting.
Are of a wing guided design with beveled seating surface between the Valve and Valve Seat
m
for effective sealing and provides for maximum wear life.
Both the Valve and Valve Seat are made of hardened stainless steel for long wear life.
m
The Valve Seats are straight press fit into the Liquid Cylinder.
m
Suction and discharge valves assemblies within the same liquid cylinder are
m
interchangeable.
Valve Assemblies are interchangeable with those within the same size Liquid End as the
m
TD90 and QD100 models.
Optional “Abrasion Resistant” or “Ball” type Valve designs are available at extra cost as
m
operating conditions warrant their use.
5-37
Sara
BOP Control System
5 Maintenance Revision A
Page 5-38 of 39
5-38
Sara
BOP Control System
Revision A
Page 5-39 of 39
Maintenance 5
26 103 Crankshaft
5-39
Sara
BOP Control System
Revision A
Page 6-1 of 25
Troubleshooting Instructions
6.1 General
The purpose of the Troubleshooting Section is to enable the operator to quickly identify and correct each
malfunction. The action taken will result in minimum downtime and prevention of additional damage.
Although the information in this section is comprehensive, other problems may arise which are not
listed. As these are solved, either locally or with the aid of a Sara representative, all steps taken should
be documented and inserted into this manual. Some repairs may void the Sara. Warranty on certain
components. Before such repairs are contemplated, contact Sara or it's nearest service representative.
The Troubleshooting Charts contain information presented in three vertical columns. The first column
identifies the problem or symptom, the second column lists probable causes and the third column
describes corrective action. In preparing these Troubleshooting Charts, it is assumed that normal
preventative maintenance procedures have been followed.
It may be necessary to consult other sections of the manual to become familiar with the BOP Control
System. The Operation Section includes a more detailed description of the system operation. To make
repairs, first locate the faulty component. Use the drawings and material lists located in the Parts
Section to determine the part number of the component. Many components are field repairable. Refer to
the Parts Section for repair instructions and available repair parts. Always order replacement parts by
part number.
Pay particular attention to notes, cautions and bold type words as these are added to ensure safety
during all phases of equipment use. The following instructions are major steps that must be performed
during the maintenance and troubleshooting procedures.
1. Stop Pumps
2. Start Pumps
i
THE TROUBLESHOOTING PROCEDURES SHOULD BE
PERFORMED ONLY AT TIMES THAT WILL NOT AFFECT
THE SAFETY OF DRILLING OPERATIONS. REMEMBER
TO REPLENISH THE FLUID SUPPLY AFTER FLUSHING
LINES.
6-1
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-2 of 25
6-2
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-3 of 25
6-3
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-4 of 25
6.3.3 Air Operated Moisture In Rig 1. Make sure unit is being sup-plied
Pumps IcingOver Air Supply with clean , dry air.
Orfreezing 2. Cut off main air supply to unit.
3. Close accumulator isolator valves.
4. Turn motor starter to OFF position.
5. Open petcock at bottom of air
lubrication bowl.
6. Remove plug from Y-type strainer.
7. Open main air supply valve to the
unit.
8. Open manifold bleeder valve.
9. Run air pumps at full capacity until
all moisture has been removed.
6-4
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-5 of 25
6.3.3 (Continued) Moisture In RigAir 10. Close air supply valves to stop
Supply (Continued) pumps.
11. Cut off main air supply to unit.
12. Replace plug in Y-type strainer.
13. Open main air supply to unit.
14. Close manifold bleeder valve.
15. Open accumulator isolator valves.
16. Open air supply valves.
17. Turn motor starter to AUTO position.
6.4.1 Pumps Run Air pump pressure 1. Close the bypass valve tightly
Excessively switch by pass 2. Reset automatic pressure
valve is open or switch(See Maintenance Section) to.
faulty shut off air pumps at:
a. 2900 psi for units with air
and electric pumps.
b. 3000 psi for units with air
pumps only.
3. If air pumps continue operating,
bypass valve may be defective.
a. Loosen tubing connector
downstream from air bypass
valve.
b. If air is escaping,replace the
bypass valve.
c. Close bypass valve tightly.
4. Check pump shutoff pressure.
6-5
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-6 of 25
6-7
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-8 of 25
6-8
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-9 of 25
6-9
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-10 of 25
6.4.3 (Continued) Faulty Check Valve In 3. Open bleeder valve and bleed off
Air Pump(s) manifold pressure.
(Continued) 4. Remove suspected air pump,
5. Clean, repair, or replace as
Necessary.
6. Install pump.
7. Start air pump and operate with
bleeder valve open to make sure
that the pump is properly primed.
8. Close bleeder valve.
9. Open isolator valves.
10. Start pumps and. pressure up
system.
6-10
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-11 of 25
6-11
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-12 of 25
6.4.5 Pumps Leaking Plunger packingIs on the older style pumps (Model
worn ordamaged on no. 88550):
airpump(s).
1. Tighten packing nut.
2. If leak stops: Check for proper
plunger lubrication. The plunger
should be coated with a thin film of
hydraulic fluid.
3. If leak persists: Remove pumps
and replace.
6-12
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-13 of 25
6.5.1 Motor Fails To Pressure switch faulty 1. Turn motor starter to OFF position
start. 2. Turn off power at rig main
generator panel.
3. Remove pressure switch
explosion -proof cover.
4. Disconnect leads from electrical
pressure switch to starter.
5. Check resistance across terminals
of pressure switch with an
ohmmeter. If resistance to
observed, the switch is working
properly.
6. If no resistance Ls found , replace
the limit switch or, if time is limited,
replace the entire pressure switch
assembly (See Section 7.0).
7. Replace the leads from starter to
pressure switch (See Starter
Wiring Diagram in Equipment
Section).
8. Turn on power at rig main
generator panel.
9. Turn motor starter to AUTO
position.
10. Check for proper adjustment of
settings (See Maintenance
Section) .
11. Replace pressure switch
explosion-proof housing cover.
6-13
Sara
BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-14 of 25
6.5.1 (Continued) Loss Of Power supply 1. Turn motor starter to OFF position
2. Check voltage of power supply to
scarcer at rig main generator
panel.
3. Restore power supply from rig
main generator panel.
4. Turn motor starter to AUTO
position.
6-14
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-15 of 25
6.5.2 (Continued) Pressure switch Span 8. After pump stops, check results to
is out of Adjustment. make sure that proper set ting has
been obtained.
9. Replace pressure switch cover.
10. Open air supply valves.
6-15
Sara
BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-16 of 25
6-17
Sara
BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-18 of 25
6.7.2 Responds Slowly Supply line or snubber is When gauge responds slowly or in an
clogged (Accumulator erratic manner during operation:
Pressure ) 1. Stop pumps.
2. Close accumulator isolator valves.
3. Open manifold bleeder valve to
relieve system pressure.
4. Disconnect gauge supply line. If
pressure gauge is installed with
snubber:
a. Remove snubber from gauge
and connect to gauge supply
line.
b. Start air operated pump,
c. Slowly close bleeder valve.
d. If fluid does not pass through
snubber it is blocked and
should be replaced.
1) Stop pump.
2) Open the manifold bleeder
valve.
3) Remove snubber and install a
new one on the gauge.
5. Purge supply line with hydraulic
fluid by starting one air operated
pump only.
6. Reconnect supply line to gauge
assembly.
7. Close bleeder valve.
8. Open accumulator isolator valves.
9. Operate air pump.
10. If gauge is still sluggish or erratic,
replace the gauge.
6-18
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-19 of 25
5.7.2 (Continued) Supply line or Snubber 3. Remove tubing and snubber from
is Clogged (Manifold
gauge.
and annular Pressure).
(Continued) 4. If gauge indicates pressure,
recalibrate to zero,
5. While hydraulic tubing is
disconnected from gauge,
increase Pressure from regulator.
If:
a. Fluid flows freely from open
tube:
1) Reduce pressure back to
zero.
2) Attach snubber to-the
hydraulic. Tubing.
3) Increase pressure.
b. No fluid escapes, the snubber
is blocked and should be
replaced.
6. Reassembly tubing, snubber,
and gauge.
7. Cycle regulated fluid pressure
to 1000 psi and back down again
to zero.
8. Check chat gauge indicates zero.
If it does not, replace gauge with a
workable unit,
5.8.1 Regulator will not Smaller adjust-ment 1. Check spring for length. For
adjust to zero spring (1"Diameter) in disassembly instructions see
pressure. the Spring control Maintenance Section.
Head is too long. 2. 1" diameter spring specifica--
tions:
a. TR-1500 - 5-1/2" Long (Blue)
b. TR-3000 - 5" Long (Red)
6-19
Sara
BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-20 of 25
5.8.2 Regulator will not Positive stop is set too 1. Remove adjusting actuator
adjust to maximum set high. (Manual handle and lock or power
pressure: drive unit) by turning handle
counterclockwise.
2. Loosen lock nut, set stop nut
TR-1500: 1600 psi lower and tighten Lock nut.
TR-3000: 3100 psi
6-21
Sara
BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-22 of 25
5.8.6 External Damaged o-ring seal Replace with new o-ring seal and
leakage from on control piston.
back-up rings from seal kit. See
venthole
( 1 / 8 " dia. ) in Maintenance Section for
spring control disassembly instructions and the
head. Parts Section for reference
drawings.
6-22
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-23 of 25
5.8.7 External leakage Damaged o-ring Replace with new o-ring seal and
from vent hole seal or seals on back-up rings from seal kit. See
(1/8"dia.) in override plunger. Maintenance Section for disassembly
Internal override instructions and the Parts Section for
housing. reference drawings.
5.8.8 Excessive and Seal plug missing Remove bottom flange and check
continuous from TR-5 valve that brass plugs are installed. If not,
exhaust flow from flow plate.
the regulator must be disassembled
secondary
( Regulated ) and part.no.0150-1143 plugs installed.
pressure out vent See Maintenance Section for
pore of TR-5 valve disassembly instructions and the Parts
only. Section for reference drawing.
5.8.9 Excessive and Seal carrier 1. Remove flange from side opposite
continuous flow Installed sub plate.
from primary Incorrectly . 2. Remove bottom flange from end
(Accumulator) Primary and vent opposite spring control head.
pressure to both hydra seats do not
3. Extract seal carrier, rotate 180 °
secondary and line up with their
and re-install.
vent ports of the respective ports
4. Re-install side and bottom flanges.
TR-4 valve on1y.
NOTE: See Maintenance Section
for detailed Instructions and
Parts
Section for reference
drawings.
6-23
Sara
BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-24 of 25
5.8.10 (Continued) Motor drive shaft key is Disengage drive motor from gearbox
not engaged in worm and check drive key. A snug fit of key
keyway thus neither in keyway facilitates proper insertion
the drive hub nor the into worm bore keyway.
adjustment handle and
lock, lever turns while
the motor is running.
5.8.12 Air driver will Airsupply pressure is Set air regulator to 60 psi minimum.
not drive o too low,
maximum set
pressure. Smaller adjustment
spring (1" diameter) in See Troubleshooting Section 6.8.1
the spring control
head is too long.
6-24
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-25 of 25
5.8.14 Hydraulic driver Hydraulic motor scored Disassemble motor, inspect, clean,
motor won't run when or jammed with foreign remove burrs or interference and
disengaged from Particles. assemble. Motor should turn freely
gearbox. by hand.
Missing or damaged
seal plug o-ring in Extract port plate and replace oring
flange of port plate to seal and back-up rings from seal kit.
seal cross-drilled vent See Maintenance Section for
passage. disassembly instructions and Parts
Section for reference drawings.
6-25
Sara
Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
3032-0102 STANCHION 2
01-1823-4A
3033-0109 LOWER PACKING SPRING 1
01-0279-4.1C
3033-0104 WASHER PISTON 1
01-0283-4.2A
3033-0101 PLUNGER ROD 1
01-0289-4F
3032-0119 NUT HEX JAM, 5/8"-11 UNC 1
x 3/8" THICK
3032-0120 COUPLING NUT 1
01-0288-4
3032-0118 CONNECTING ROD 1
01-0287-4A
3032-0101 STANCHION WASHER 6
01-1822-4A
2250-0113 ROD 1
01-0105-3B
2250-0115 FLUID INLET BODY 1
01-0107-4C
2250-0114 SPRING RETAINER 1
Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-0108-4A
2250-0111 SLEEVE 1
01-0110-3B
2250-0110 ADJUSTMENT NUT 1
01-0111-4B
2250-0109 STOPPER 1
01-0112-4B
2250-0116 MALE THREADED INSERT 1
01-0113-4B
2250-0108 INLET BODY 1
01-0114-4C
2250-0107 SPACER 1
01-0115-4A
2250-0106 SLEEVE 1
01-0117-4B
2250-0103 RETAINER 1
01-0119-4B
2250-0105 OUT LET BODY 1
01-0122-4C
8717-2111 'O ' RING (VD266) 1
01-0103-4A
8841-2111 BACKUP RING TEFLON 1
01-0104-4B
8717-2012 'O ' RING 1
01-0106-4A
8718-2012-1 'O' RING 'VITON' 1
01-0116-4.2B
2250-0101 SEAL (VD263) 1
01-0118-4A
8575-1100 WASHER LOCK, CAD PLATED, 1
1/4"
8506-0012 CAP SCREW HEX SOCKET HEAD 1
1/4" 20 UNC x 3/4"
8717-2225 'O ' RING (VD312) 1
01-0121-4B
2250-0104 CAP SCREW HEX SOCKET HEAD 4
3/8"-13 UNC X 1"LONG
2250-0112 SPRING FOR HYD. PNEUMATIC 1
PRESSURE SWITCH, 3000 PSI
7 2000-1100 CYLINDER,AIR,2POS,3"BORE, 7
01-1201-3 2-1/8"STROKE, 200 PSI,
8 0150-1576 MANUAL,ADJUSTMENT,HANDLE 1
AND LOCK LEVER ASSY,
******items reqd for each Assly.***
013164 L - SUPPORT 2
01-3164-4
013158 TOP PLATE,SHEAR RAM GRAD 1
01-3158-3
HINGE SINGLE ACTION 1
1700-8908 POPPET 1
01-0098-4C
1700-8905 SPRING REST,RELIEF VALVE 1
01-0095-4A
1700-8902 ADJUSTING SCREW,RELIEF 1
01-0094-4C VALVE
1700-8903 LOCK NUT,RELIEF VALVE 1
01-0093-5
8717-2112 O-RING 1
01-0235-4.1A
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100
94 VALVE ASSY,MTR-5/PTR-5 1
REGULATOR FOR 1-1/2"
******items reqd for each Assly.***
3 8100-0101 CONNECTOR,MALE,1/4" T x 7
Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1/4 MPT STEAL
4 8100-2101 CONNECTOR,FEMALE,1/4" Tx 7
1/4 FPT STEAL
5 8004-0600 CROSS, 1", M.I 1
59 UNION,2 1/2",M.I,NPT 2