Operation and Maintenance

Manual

FY-50Y BOP Handling System

Baoji Engineering Hydraulic Components Plant

Address: 2 Jiangtan Rd, Baoji, Shaanxi, China (721008)
President: Chen zhao-quan (Mobil: 13909175290)
Phone: 0917-3390710, 3397021
Fax: 0917-3397020
 (ISO9001 Certified Enterprise)

Address: 2 Jiangtan Rd, Baoji, Shaanxi, China (721008)

President: Chen zhao-quan (Mobil: 13909175290)
Phone: 0917-3390710, 3397021
Fax: 0917-3397020
 Brief
Baoji Engineering Hydraulic Components Plant is a specialized manufacturer in hydraulic
products and a scientific type enterprise in northwest of China. The plant was founded in 1993.
From then on, in order to meet the customer’s requirement, it has developed various standard
or non-standard hydraulic and pneumatic cylinders, and various hydraulic systems from middle-
low to super-high pressure, and various hydraulic stations, hydraulic machines and hydraulic
test benches. It can also design and manufacture various hydraulic components, hydraulic
systems and hydraulic machinery special needed by customer. The nine hydraulic products for
Huizhou Offshore Rig Module Project of BOMCO have gotten good reputation by ABS. The
quality system of plant is approved with ISO9001 certificates by China Import and Export
Commodities Quality Certificate Center.

The plant now has a staff of more than 190, and more than one third among these are senior
and semi-senior technicians with rich experience in specialized work. It has 110 sets main
equipment and various special equipment to make hydraulic products, such as extended
horizontal lathe, extended horizontal grinder, oilstone grinder, hydraulic machine and test
devices. It has a capacity to design and manufacture hydraulic cylinders which maximum bore
diameter is 680mm, maximum stroke is 4m, maximum working pressure 35MPa. Also we can
design and manufacture various pressure and displacement hydraulic power station, cylinder
and hydraulic system according to the customer’s requirement. The advance automatic
machining, refined quality system can ensure the products quality in every process.

For many years, the various products of plant have been widely used in the areas of oilfield,
college factories, railway, mining, metallurgy, coal and machine tool. They also completed with
products of many enterprises like oil drilling rig, single crystal furnace, rolling machine,
engineering truck, forklift and export hydraulic equipment. Its stable quality and reliability are
accepted by customers. It is certificated by “High and New Technology Enterprises” and
received ten patent certifications.

Warmly welcome to cooperate with us in any forms.

Address: 2 Jiangtan Rd, Baoji, Shaanxi, China (721008)

President: Chen zhao-quan (Mobil: 13909175290)
Phone: 0917-3390710, 3397021
Fax: 0917-3397020
 Manual of FY-50Y

I. Profile
FY-50Y BOP Handling System is designed to meet requirement of installing and
removing BOP stacks. The system is full-hydraulic control and can be used for
heavy and medium duty drilling equipment. The main function of system is to lift
and install single BOP or BOP stacks. The system features with explosion-proof,
easier operation, better reliability, and safety. It consists of left and right BOP
moving device (each hung on one guide rail below drill floor), hydraulic control
box, pipelines, and hose hangers. Controlled by hydraulic operating box, the
system can achieve the movement of rising, lowering, moving forward and
backward synchronously, or moving forward and backward asynchronously,
rising and lowering with limited separation distance (less than 1m). It is
convenient for installing and removing BOP stacks.

II. Type and Specifications

1. FY-50Y BOP Handling System mainly consists of left / right handling devices
and hydraulic system.
2. FY-50Y BOP Handling System is powered by hydraulic power station for floor
mechanical tools (i.e. power tongs) of drilling rig.
3. FY-50Y BOP Handling System is easier to assemble and disassemble. All
hydraulic hoses adopt snap joints (completed with dust-proof plugs or caps) as
connections. It not only makes it easier to assemble and disassemble system
but also keep inner hoses clean.
4. Technical Specifications
a. Max. Lifting Capacity: 2x250=500kN
b. Max. Lifting Height: 4.0m
c. Max. Lifting Speed (Two sides): 3.39m/min
d. Max. Lifting Speed (One side): 6.78m/min
e. Max. Lowering Speed (Two sides): 6.51m/min
f. Max. Lowering Speed (One side): 13.02m/min
g. Max. Horizontal Moving Speed (Dual Direction): 12m/min
h. Max. W.P. Hydraulic System: 16MPa
i. Max. Flow Hydraulic System: 120L/min
j. Wire Line Diameter: 28mm

III. Structure and Features

1. FY-50Y BOP Handling System is combined by two single lifting devices which
each hung on guide rail below the drill floor. One device can lift maximum
250kN load and 500kN for two.

2. The system adopts 3 times stroke scale-up structure which features with
shorter cylinder stroke, bigger lifting height. Compared with other same lifting

1/7
 Manual of FY-50Y

height BOP handling system, it has lighter weight and compact volume.

3. The system is full hydraulic control. Each lifting device consists of following
parts:
 Running mechanism (powered by hydraulic motor)
 Lifting cylinder
 Wire rope and pulley block
 Main frame connecting running mechanism and cylinder
 Hydraulic control system.

4. Operator can operate and control system by hydraulic control box to achieve
the following actions:
 Rising and lowering synchronously
 Moving forward and backward synchronously
 Moving forward and backward asynchronously
 Rising and lowering synchronously with limited separation distance (less than 1m)

5. By full hydraulic control, it features higher performance on explosion-proof.

6. Easy operating valves on hydraulic control box make it easy to control the
speed of rising, lowering, moving forward and backward.

7. FY-50Y BOP Handling System is easy to install and transport. All hydraulic
hoses used to connect or disconnect on installation or dismounting adopt snap
joints as connections. It not only makes it easy to install and dismount system
but also keep inner hoses clean.

IV. Installation and Test

1. Infix two lifting devices separately from the ends of guide rails below the
drilling floor (see Figure 2 for installing direction), and mount stop pins on the
end of the guide rails to prevent lifting devices from sliding out of the guide
rails.

2. Weld backing plate of pipe hanger matched with wed plates on the middle of
guide rails and mount pipe hanger (see Figure 2).

3. According to the matching codes stamped on the snap joints, connect all
hydraulic hoses with two lifting devices.

4. According to the matching codes stamped on the snap joints, connect all
hydraulic hoses with hydraulic control box and lifting devices, and fix the
middle of hoses on the pipe hanger.

2/7
 Manual of FY-50Y

Note: The length of hoses between pipe hanger and lifting device
should meet the requirement of lifting devices on moving forward and
backward.

5. Connect oil inlets and outlets on the hydraulic control box with oil inlets and
outlets on the hydraulic station of power tongs on the drilling floor.

6. Ensure all pipe connections in good condition, start hydraulic station to provide
FY-50Y BOP Handling System with 16MPa hydraulic oil.

7. Push handles of control valves according to the direction marked on the

nameplates of the control box and check if all actions are right. Only after all
actions must be checked with no any mistakes, then the system can be put into
operation.

!!! Caution !!!

On the operation of moving forward and backward asynchronously,
the distance between two lifting devices must be less than one meter,
otherwise it will cause serious accident.

V. Operation, Maintenance and Safety

1. Watch the manometer on the hydraulic control box to check if oil-feeding
pressure meets the requirement (16MPa).

2. According to the directions marked on the nameplates of hydraulic control box,

operate two lifting devices to rise, lower, move forward and backward.

2.1 Synchronously control valve No. 1 and 2 to make system move synchronously.
2.2 Asynchronously control valve No. 1 and 2 to make system move asynchronously.

!!!Caution!!!
On the operation of moving forward and backward asynchronously,
the distance between two lifting devices must be less than one meter,
otherwise it will cause serious accident.

2.3 Synchronously control valve No. 3 and 4 to make system lift synchronously.
2.4 Asynchronously control valve No. 3 and 4 to make system lift asynchronously.

3. Maintenance is the needed procedure before installation of two lifting devices.

There are 8 lubrication ports on the lifting device each, 6 for pulleys and 2 for
driving gears. All lubrication ports should be fed by lithium base grease.

4. Before each lifting operation, operator should check if all cables are in good

3/7
 Manual of FY-50Y

conditions. All cables should be reliable connection before operation. On lifting

operation, workers should be far away from the goods to avoid accidents.
VI. Spare Parts List
Item Code Description Qty. Components
1 FY50-01.04.02 Cupper Bushing 24 Pulley
2 FY50-09.02 Lift Cable Φ28 2 BOP Handling System
3 GB276-82 Bearing 306 4 Gear Reducer
4 GB278-82 Bearing 60307 4 Gear Reducer
5 GB276-82 Bearing 106 1 Pipe hanger
6 GB301-84 Bearing 8205 1 Pipe hanger
7 GB276-82 Bearing 312 20 Drive / driven Wheel
8 604-1114 J2K-160 Cycloid Motor 4 Hydraulic System
9 DB10-2-30/315 Overflow Valve 2 Hydraulic System
10 RVP10-10 Check Valve 8 Hydraulic System
11 FD12FA12/B30 Compensation Valve 2 Hydraulic System
12 GB1235-76 O-ring 12x1.9 36 Hydraulic System
13 GB1235-76 O-ring 16x2.4 4 Hydraulic System
14 GB1235-76 O-ring 20x2.4 13 Hydraulic System
15 GB1235-76 O-ring 24x2.4 2 Hydraulic System
16 GB1235-76 O-ring 30x3.1 2 Hydraulic System
17 JB982-77 Combined Gasket 22 18 Hydraulic System
18 JB982-77 Combined Gasket 18 6 Hydraulic System
19 JB982-77 Combined Gasket 14 18 Hydraulic System

VII. Attached Drawings

1. Fig.1: Lift Diagrammatic Sketch
2. Fig.2: Structure of FY-50Y BOP Handling System
3. Fig.3: Hydraulic Principle of FY-50Y BOP Handling System

4/7
 Manual of FY-50Y

≥ 1 300

T e c h n i ca l S p e c i f i ca t i o n s
1 . M a x. L i f t i n g Ca p a c i t y : 2 x 25 0 = 5 0 0 k N
2 . M a x. L i f t i n g He i g h t : 4 . 0 m
3 . M a x. L i f t i n g Sp e e d ( T w o si d e s ) :
3 . 39 m / m i n
4 . M a x. L i f t i n g Sp e e d ( O n e si d e ) : 6 . 7 8 m/ m i n
5 . M a x. L o w e r i n g S p e e d ( T w o s i d e s ) :
6 . 51 m / m i n
6 . M a x. L o w e r i n g S p e e d ( O n e s i d e ) :
1 3 . 02 m / m i n
7 . M a x. H o r i z o n t al M o v i n g S pe e d ( D u a l
D i r ec t i o n ) : 1 2 m /m i n
8 . M a x. W . P . H y d r a ul i c S y s t e m :1 6 M P a
9 . M a x. F l o w H y d ra u l i c S y s t em : 1 2 0 L / m i n
115 0

1 0 . W ir e L i n e D ia m e t e r : 2 8 m m
75 00

p o w e r t o n gs
11 50

T o oi l r e t u r n po r t of hy d. s t a t i o n of
45 40

p ow er t o ng s
T o o i l - i n p or t o f hy d . s ta t i o n o f
9 10

H y d . c o nt r o l b ox
680
65 0

9 50
24 00

F ig .1 : L iftin g In s tr u ctio n

5/7
 Manual of FY-50Y

A s s o c ia t e D r il l e r 's S i d e A s so c i a t e D r i l l e r 's S i d e
G ear Reducer M o vable B lock
13 00-2000 D r i l le r 's S id e H ose H anger
D riv in g W h ee ls

R un ning M otor
(7 65) 12 20 6 4 8 . 5 ～ 1 9 8 3 .5 1 1 4

5 60
574
M i n . D i st a n c e a ft er l i ft i n g

M a x . D i s t a n c e a f te r l o w e r i n g
737
40

154 5
(17 01)

(2 6 4 5 ) ～ (3 9 8 0 )

M a x . S tr o k e
W ire R o p e

44 5 H y d r a u l i c C o n tr o l B o x

Ram p W ellhead

T o o i l r e t u r n p o r t o f h y d . s t a ti o n o f p o w e r t o n g s

T o o i l- in p o r t o f h y d . s t a t i o n o f p o w e r t o n g s

F ig .2 : S tr u c tu r e o f F Y -5 0 Y B O P H a n d lin g S y s te m
6/7
 Manual of FY-50Y

0-25M Pa

16M Pa

P T

F ig .3 : H y d r au lic P rin c ip le o f F Y -5 0 Y B O P H an d lin g S y s tem

7/7