The Control System for Surface

Mounted BOP Stacks

Operation Manual

FeUing Petroleum Machinery Co.

2009,2
 Following standards:
o API Spec 16D 2nd Edition (Specification for Control Systems for
Drilling Well Control Equipment and Control Systems for Diverter
Equipment)
o SY/T 5A53.2-2007 (Specification for control systems for drilling well
control equipment and control systems for diverter equipment) (Apl
Spec 16D: 2004, IDT)
o Q/JS J070101-2007 (Ex-works Testing Method of the Control System
for Surface Mounted BOP Stacks)

No. Of License of APt 16D: 1OD-0016

G
Quality Management System Certification:
o No. of APIQR !SO9001 :0770
o No. of API Specification Q1:Q1-0513
o No. of API ISO /TS 29001:TS-0330

No. of Production License of National lndustriar product:

xK14-001-00016

,f*"6r$#tfi,r
BEIJING PETROLEUM MACHINERY CO.

Address: No.41 ,Zhixin Road, Haidian District, Beijing, 100083

P.R.China
Phone: (8610) 83597657 (sates) (8610) 83597692 (Technotogy)
Fax: (8610) 62311837
Netaddress: wvvw.bpmc.com.cn
E-mail: sales@bpmf. com. cn;
bpm.sales@vio. 1 63.com
 IM PORTANT I NSTRU GTIONS

The man who operates or repairs the Control System for Surface
Mounted BOP Stacks must accept a technical training, qualified to
have the certificate of operating and maintenance. The operator
should know the potential danger of pressure vessel and pipetine
clearly and do some precaution to protect from harming.

Read this Operational Manual thoroughly before you operate or repair

the control system, and correctly install, use and repair it according to
,C the manual.

The accumulator bank is the major source of pressure for the normal
operation of the system. The user should make regular checks on the
nitrogen pressure pre-charged in the accumulators to see if there are
such malfunctions as damaged bladder or lack of nitrogen pressure.

The accumulator bottle should be pre-charged with nitrogen only. It is

not allowed to pre-charge the bottle with oxygen, compressed air or
other flammable gases, in order to avoid equipment damage and
personnel injury. During long distance transport, the accumulators
should have proper nitrogen pressure around 1MPa.

The oil tank should be full filled with hydraulic oil according to
regulations in case the accumulator is not filled with oil. The hydraulic
oil must be changed in time to keep clean, to prevent damage the
hydraulic component. No oil supplementation to the oil tank is allowed
after the accumulator is filled with oil and is pressurized.

No fuel oil like diesel or kerosene is allowed to fill into the tank.

After using the control system, you must examine and maintenance in
time. calibrate and check the relief valve and other pressure
 CONTENTS

l.lntroduction ............1
2.Model lllustration...... ................1
3.Main Technical Parameters... ...............1
4.Features and Structure ....,2
4.1 Remote control panel ...........3
4.2 Driller's panel ........ ...........4
4.3 Air cable .............s
4.4 Hydraulic cable
ii
C .........:5
4.5 Alarm device ............... .......: ......8
4.6 Nitrogen backup system..... .....".g
4.7 Pressure compensation unit. .........g
4.8 Auxiliary control panel ............g
S.Working Principles and Operation lnstruction. ..........11
5.1 control of starting and stopping of Electric oil pump ..........11
5.2 Control principles of Hydraulic System .......12
5.3 Control of Auxiliary Pump ... g 1

6. lnstallation and Test Run. .........20

6.1 lnstallation ..........2A

fi Lubrication... .,.......
7. Use, Maintenance and ......27
operation
7.1 Notice of .....27
7 .2 Maintenance ......29
lubrication
7.3 Notice of .........30

9. Instruction of Order. .......36

Appendix A: Exchange between Engrish Unit and Metric Unit .. ...3g
Appendix B: Recommended Hydraulic Oil .......3g
Appendix c: Technical Parameters of the control system ..........3g
 EPX Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

1. lntroduction
The control system for surface mounted BOP stacks (hereinafter
called control system for short) is important equipment for controlling
wellhead BOP stacks, choke valve and kill valve, and is an indispensable
device for the prevention of well blow out during drilling and workover
operations.
This manual does not stipulate the reparation and discarding of the
control system, but it does not mean the unlimited use of the system. The
user and maintenance personnel should judge if the maintenance,
overhaul or discarding is required for the system. i

2. Model lllustration
The symbols of the models of the control system for surface
mounted BOP stacks are shown AS below (take FKQ400-58 as an
example):

Serial number of design change

Objects controlled (5 in this example)

Total volume of the accumulator (400L in this example)

Mode of remote control (Q means the mode of air controlling

the liquid, no remote control in void position)
Product code for the control system for surface mounted BOp stacks

3. Main Technical Parameters:

Nominal working pressure: 21MPa 3000psi
Max. working pressure: 34.5MPa 5000psi
Range of pressure regulating: 0-14MPa 0-2000psi
Nitrogen pressure of the accumulator:
7 x0.7MPa 1000 t 100psi
Page 1
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

Range of pressure controller regulation:

19- 21MPa 2700 - 3000psi
Range of Iiquid switch regulation:
17.85 - 21MPa 2580 - 3000psi
Pressure of air supply: 0.65 - 0.8MPa 93 - 115psi
Power supply: 380 t 19 V/50H2
Environmental temperature: -13 - 40C 8.6"F -1 04'F

GAUTION: Special order is needed when beyond the above

technical parameters.

4. Features and Structure

f'
The control system for surface mounted BOP stacks of the FKQ
series basically consists of the following components:
1. Remote control panel (including the protective house)
2. Driller's panel
3. Air cable
4. Hydraulic pipeline (flexible pipeline or rigid pipeline like pipe rack
and closed bent pipe should be specified when ordering)
The control system for surface mounted BOP stacks of the FK series
basically consists of the following components:
f
1. Remote control panel (including the protective house)
2. Hydraulic pipeline (flexible pipeline or rigid pipeline like pipe rack
and clcised bent pipe should be specified when makirtg order)

CAUTION: The customers should specify when making order if they

require a house with thermal insulation, air conditioning, etc.

According to customers' requirement, following functions may be

added for some models:

Page2
 9PM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

1. Alarm device
2. Nitrogen backup system
3. Pressure compensation unit
4. Auxiliary control panel

Layout and connection of the control system for surface mounted

BOP stacks are as shown in Figure 1.

Closed bent
pipe
Triple-bent
pipe
!r Flexible
hose

Figure 1 Layout and connection of the control system for surface

mounted BOP stacks

CAUTION: Composition of the control system for surface mounted

BoP stacks is subject to the range of customers, order.

4.1 Remote control panel

The remote control panel consists of chassls, oil tank, pump unit,
accumulator bank, manifold, various valves; instrument, power control
box, etc. The remote control panel is mainly used to control generating of
high-pressure oil by the oil pump and the storage of the high-pressure oil
in the accumulator bank. When there is a need to open or close the
preventers, high-pressure oil will go from the accumulator via the
3-position 4-way control valve of the control manifold into each control
objects (preventers).

Remote control panel is featured in:

Page 3
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

1. lt is equipped with two different pump systems. The FKQ series

has an electrical oil pump and an air-operated oil pump, while the FK
series has an electrical oil pump and a hand-operated oil pump.
Therefore, in case of power failure, you may keep the system in normal
operation.
2. The accumulator bank has high-pressure liquid reserved enough
to meet the control requirement of closing all BOP stacks and opening
choke valVe. ln case of the failure of any accumulator, the loss caused by
the accumulator against the total quantity of the liquid is less than z|ok,
which complies with the requirement of Apl.
3. The electrical oil pump and the air-operated oil pump are both
equipped with the pressure switch to start and/or stop the pumps
automatically. Even when the automatic control device goes wrong in
normal operation, the relief valve may quickly open to avoid overload.
4. Each preventer is under the control of a relative 3-position 4-way
control valve in order to open or close it. For the FKQ series, you may
operate the control valves directly by hand or by air-operated remote
control. For the FK series, you may only operate the control valve by
hand.
5. Control manifold of remote control panel,is equipped with interface
of backup pressure source. When required you may introduce pressure
source, like nitrogen backup system, etc.
6. The pressure of annular preventer circuit in FKQ series control
system may be conducted by remote air-operated regulation. ln case of
a sudden failure of air supply, the pressure could be recovered
automatically to initial set value.

4.2 Driller's panel

FKQ series control system may be equipped with driller's control
Page 4
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

panel, which is currently installed at the drilling rig floor and thus, the
driller may conveniently control the remote control panel.
The features of the driller's panel include:
1. compressed air is used as the working medium, which may
guarantee the safety in operation.
2. The valve core of each air-operated valve is y type, which may be
automatically reset and will not influence the operation of prevention unit
in remote panel in any cases.
3. The function of operation memory. Each control valve is
connected with a display cylinder. Therefore, when the valve comes to
positions of "OPEN" or "closE", the Ietter of "opEN" oi "closE" wilt
appear in the display window simultaneously. After the reset of the valve
handle, the window display does not change, thus make the operator
know previous operation status in driller's panel.
4. ln order to guarantee the reliability of the operation, the valve on
the driller's panel is handled in a two-step procedure, i.e., first to turn the
air supply valve to connect the air supply and in the meantime, turn other
valves to activate relevant control objects.

4.3 Air cable

The air cable is used to connect the air circuits between the remote
control panel and the driller's panel. The air cable consists of the sleeve,
a number of core pipes, and connecting flanges on both ends. The two
ends ottne air cable are connected with the remote control panel and the
driller's panel respectively. For each connection, rubber-sealing washers
are used.

4.4 Hydraulic pipeline

ln general the distance between remote control panel and wellhead

Page 5
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

BOP stacks is 30 meters and a group of hydraulic pipeline is needed to

link them. Rigid and flexible pipeline may be used for the connection.
Rigid pipeline includes pipe rack, closed bent pipe, triple-bent pipe,
etc. It is safe and reliable to connect with rigid pipeline but the installation
is inconvenient.
It is simple and convenient to connect with flexible pipeline but the
safety should be taken into account when using it.
Based on the circumstance of the work site, the flexible and rigid
pipeline may be used together in order to make a full use of both
advantages. For example, for long and straight pipeline, pipe rack is
used and flexible pipeline is used for the connection of two bnds.
Pipe rack is specially designed for the protection of high-pressure
control fluid pipeline. Pipe rack is equipped with high-pressure oil tube
according to the number of control objects, which is used for the
connection between remote control panel and BOP stacks. The oil pipes
between pipe racks are linked up with the quick unions or high-pressure
self-seal pipe joints which may be easily tightened by hammering. There
is a baffle on each end of the pipe racks in order to protect the quick
unions or high-pressure self-seal pipe joints from damage during the
transportation. t

The closed bent pipe (Figure 2) may extend to 2,3 or 4 meters long.
Flexible elbows are used to connect each oil pipes and they turn flexibly
and much easy for installation on site.
The triple-bent pipe (Figure 3) may be either connected with the
body of the preventer, or used to connect the outlet of the remote control
pane! and the pipe racks.
The two ends of flexible pipeline (Figure 4) have setf-sealed quick
union, in substitution for rigid piperines of pipe rack, closed bent pipe,
etc., to link up control system and preventer.
Page 6
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

The connection screw thread of the two ends of pipeline is 1 Lp

(Petroleum line thread GB/T 92s3.2-1ggg, equivalent to NpT1,
GB/T1 2716-1999). Quick exchange union or fast union is generally used
for the connection between pipelines.

,@ Figure 2 Closed bent pipe

Figure 3 Triple-bend pipe

Figure 4 Flexible hose

Page 7
 BPM Beijing petroleum Machinery
Co. The Control System for Surface
Mounted BOp Stacks
4.5 Alarm device
Remote control panel may be equipped
with alarm device to monitor
the pressure of accumurator bank, air suppry pressure,
the riquid rever of
oil tank and the running of electric purnp.
when the above parameters
exceed the alarm limits, the signal
of sound and light will be given
on the
remote control panel and driller's
controt panel, indicating the operator
to
take proper measures' operators
should use the information provided
by
the alarm device and other instruments
and make an overall analysis of
equipment operation status in
order to ensure the reliable work
of the
control system of surface mounted
BOp stacks.
The functions of the ararm device
are as foilows:
) Ararm for rower pressure of accumurator
bank
) Alarm for tower pressure of air
supply
) Alarm for lower liquid level of oil tank
) lndicating of the running of electric pump
4.6 Nitrogen backup system
Nitrogen backup system consists
of a number of high_pressure
nitrogen cytinders connected with
control manifold and used for
supplying emergent auxitiary energy
to control manifotd. Nitrogen backup
system is linked up with control
manifold via isolate valve, check
vatve
and high-pressure ball valve. lf accumulator
and /or pump unit ;annot
provide the.contror maniford
with enough power fruid, nitrogen
backup
system may be used to provide high-pressure
fluid for the manifold in
order to close the preventer.
Pressure fruid can be prevented
from entering nitrogen backup
system by means of linking up nitrogen
backup system and manifold and
entry of nitrogen to accumulator
circuit should be avoided in operation.
Nitrogen backup circuit is designed
with exhaust valve to control the
Page 8
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

exhaust of high-pressure nitrogen preventing it from entering fluid tank.

Nitrogen backup system may be used to charge accumulators.

4.7 Pressure compensation unit

Pressure compensation unit is auxiliary equipment of control system
of surface mounted BOp stacks.
During drilling process, pressure fluctuation may occur in hydraulic
system whe:, drilling pipe connector passes through annular-preventer.
This unit is installed in the pipeline of controlling annular-preventer. The

.G pressure fluctuation in the pipeline can be absorbed immediately so

reduce the wear against the rubber core of the preventer,- meanwhile to
as to

make the rubber core rapidly reset after passing through the connector,
as a result the drilling safety is guaranteed.

Pressure compensation unit is installed in the control pipeline of

annular-preventer in control system of surface mounted BOp stacks. To
ensure the effect of utilizalion, this device should be installed in the
closed oil circuit rather near the annular-preventer.

4.8 Auxiliary control panel

In order to control the remote control panel, FKQ series control
system may be also equipped with auxiliary control panel. Air-operated
control is adopted in the auxiliary control panel. Via the connection
between air cable and remote control panel, the remote control panel
may be iontrol by both driller's control panel and auxiliary control panel.
Auxiliary control panel may have the foilowing functions: :

F Accumulator pressure display (manometer)

Manifold pressure display (manometer)

Air supply pressure display (manometer)

Annular pressure display (manometer)
Page 9
 BPt Beijing Petroleum Machinery Co.
The Contuol
lystem for Surface Mounted BOp Stacks

F Alarm function (optional)

Auxiliary control panel is small in size and easy to

be placed

Page 10
 BPM BeUing Pefroleum Machinery Co.
The Control System for Surface Mounted BOp
Stacks
5. working Principles and operation lnstruction
5.1 start and stop controt of electric-operated
oir pump
Turn the main switch in power switch box (Fig.
5) to ,,AUTO, position,
thus the complete equipment is under the position
of automatic control.
Now if system pressure is rower than l gMpa (2700psi),
pressure switch
will. automatically start etectric-operated oil pump. pressure
oil is fed to
accumulator bank through non-return valve (The
isolate valve of
accumulator bank must be opened previousry).
when system pressure

),4 reaches 21MPa (3000psi), pressure controtler automatically

power supply making electric-operated oil pump
turns off
stop feeding oil. when
system pressure drops down to lgMpa (2TOOp.si),
erectric-operated oir
pump will be automatically restarted to work.

PE N L1 L2L3

Figure 5 Erectric diagram of contror system

(Power switch box)

The system is under the position of "AUTO", pressure switch

allows
the pressure of accumulator bank being always kept in 19
21Mpa -
(2700- 3000psi), available for opening and ctosing preventer
all the time.
Page 11
 BPM BeUing petroleum Machinery Co.

GAUTION: when main switch is under ,,AUTO,,

,*r*
electric-operated oil pump will start to
work automatically. The
operator must pay attention to avoid being
hurt by the motor.
when the main switch is turned to "MANUAL" position, press
"srART" button, erectric-operated
oir pump wiil start to work. When
system pressure goes up to 2IMpa (3000psi),
the ,,srop, button should
be pressed to stop the pump.

cAUTloN: when main switch is under ,,MANUAL,,

position,
electric'operated oir pump cannot stop
automaticaily. The operator
should cautiousry observe system pressure,
and manuaily stop the
electric-operated pump when nequired.

5.2 Gontrol principles of Hydraulic

System
see attached diagram for the principles
of hydraulic system of control
system of surface mounted BOp stacks.
The pressure oil in the accumulators goes
through the isolate valve
(high-pressure ball valve) of the accumulator
bank, the filter, and the
reducing 3-position 4-way control valve.
ln the meantime, the pressure
oil goes from the accumulators, through the
filter, irito ihe reducing and
regulating valve, which contrors the annurar
preventer. By pushing the
or *closE,, the preventer.
handle of the contro! varves you can "opEN"
The contror varve may be operated through
the driiler,s paner. First,
turn on the air supply valve to the "oPEN" position,
which controts the air
supply operation on the driller's panel,
and then turn on the related air
valves to operate the contror vatve. Then,
compressed air goes to the
remote control panel through the air
cable, into relevant air cytinders,
push the handle of the control vatve
to change direction. while the air

Page 12
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

valve changes direction on the driller's panel, compressed air pushes the
piston of the display cylinder, and you will see the letters of "opEN,, or
"CLOSE" from the hole on the top of each air valve on the driller's panel.
The letters of "OPEN" or "closE" indicate the preventer is in the
.OPEN"
or "CLOSE" position.

cAUTloN: on the driller's panel, the valve was operated in a 2-step

mode. Before turning the valve of each control object, you must
turn the air supply valve to open simultaneously. Due to long
pipeline of control system, turn the valve and hold it for more than 3
,Q, seconds, in order to guarantee the proper direction change of the
valve on the remote control panel.

The adjustment of the outlet pressure of the reducing and regulating

valve in the control manifold ranges from 0 to 14Upa (2000psi), with
10.5MPa (1500psi) being most often used. When the bypass valve is in
"OPEN" position, the reducing and regutating valve will not work,
and the
pressure of the control manifold is the same as the system.

The reducing and regulating valve controlling annular preventer can

be operated either manuaily or air-operated. ln case of
manually/air-operated system, the output pre3suie of this valve can be
regulated by air operation either in remote control panet or driller's control
panel. The position of air-operated pressure regulation is determined by
distribution valve in remote control panel. There are two positions on the
distribution valve: "remote control panel" and "driller's control panel,,.

When regulated manually, turn the hand wheel on the reducing and
regulating valve, the output pressure may be regulated to set pressure.
Turning down to increase output pressure and turning up to decrease it.

Page 13
 ?L o6ed

-T-l

ax
(-/)
(D
:.
(D
a
w
O
-U
-r-l
\r-x-
^
L'
J-U ii^{
-{ ,F
=Et s
{'#
,^E1L
v) -&
+iE
(D iEiti
-=
f-l
-,\
xo
O?
o)i
.N L_J
C)l
l-{
'i6
\] Fr
Til€
s
--EI ,

,-n U
C
C)

FTI
C)
r
z
a

-
C)

&xo r@ 5@
*m gF TE
zE
m
C
-o a
a
s)|cels dog polunoht ecetns roJ rxolslstorx.6a€ql
'oC Irountcef1 unatoJled-6[[tog
t t1f,A
 BPI Bdjing ffir,m llacfrineryCo. The Control System for Surface Mounted BOp Stacks
Serial l

r Name
No.
'! Airtreafrnent 5126990110
2 Pressure gfl{;e 0-2.5MPa ( 350psi)
Afu ftessure regulator
F!*ogneurnatic pressure
9161500000
5 Akshut<fivalve

check valve
I 1'Suction strainer wu-160X100
g Ballvatve
10 Explosion-proof electric motor
3101030040
't1 Tr
12 Ballvalve
13 1 1/2"Suction strainer
14 ; YTK series 9170100000
15 check valve
16 ballvalve QI rNS-31.5
17 Relief valve
'!8 Double
19 controlvalve
n Pressure reducing and
valve
2'l valve 91 61 000000
n NXQ/model bladder
acqrmulator
n Vibrati:n-proof pressu re ga u ge
21 Retrief valve
Shut-ofi valve
Akoperated pressure
26
fryrsducer
C n Air+rated pressure
trartsduoer
n ballvalve
x
Ai, ard valve
31
Aifnad operde regulating
rd€ | 9161400000

3Q
M! ?h openated valve
refue
3[l Akte*neril 5126990't00
3* hessue
35 Fressue
s vahre 9163100000
3i7 affiy:f ryenaEd rrahre 9163100000
3E [he

Page 15
 BPM Beijingpetroteum Mdchinery Co. The Control System for Surface Mounted BOp
Stacks

FK series Bop controt system FK12s-3 Hydraulic Mechanism

No. Name otv Type Order No. Remark
1 Ballvalve 1
44U3U00020 Dg15
2 irI ter
DU 1 wu-63X20n 9162500000
3 Manual pump 1
9160800000
4 Check valve 1 A.-:/1,E 9'162200000
5 YTK series pressure switch 1 Y IK-OzE 3802000600
6 Explosion-proof electric rnotor Q-aOMPa(6000psi)
1 YB16OM4 31 01 03001 0 11 kW
7 Ballvalve 1
4403000050 Dg40
I Suction strainer 1
91 62800000
I Ballvalve 1 4403000040 Dg25
10 Triplex pump i QB-21 40 9'160300000
11 Straight check valve 1
9162400000
'12 Relief valve 1
9162000000
13 Fluid strainer 2 9162700000
14
Pressure reducing and relief
valve 1 JYS-21,25 9161200000
15 3-way valve 1
91 61 000000
16 High-pressure ball valve 1
4401000040
17 High-pressure ball valve 5 4401000050
18
NXQ/model - btad--der
Ps25
accumulator 5 NXQ_125 4807100010
19 Vibration-proof pressure gauge 2 YTN_1OO 3802000340 0-40MPa(6000psi)
20 3-position 4-way control valve 3 34ZS-21,25 9160900000
21 Suction shut-off valve 1 J15W-320P 4401000010 Dg15
Page 16
 FKQ32O-4G
?€ E+ fr ffi *a fl,)*4.8 & )t
1. 5126990110 Air treatment nffirt4fl+ 1 AC5000-10
2. 3802000060 Pressure gauge Eht{ 2 Y-10027 0-2.5MPa ( 350psi )

3. 5'126990080 Air pressure regulator ndtfrEW 2 Qry-18

Hydro-pneumatic pressure
4. 9161500000
switch
fr.<** 1 QKY-21,25

5. 4403000030 Air shut-ofivalve &rtl4 2 D920

6. 9165200000 Air pump <4jfrf, 1 QYB4O, 165L
7. 9162300000 Straight check valve EJE+F1E 1 A--40,15
XEffiE only used as
8. 9163100000 4-way air operated valve ='fiEiE-1*tE 1 34ZR6Y-18
two-way control valve

9. 9163000000 Double acting rylinder LX+FHEEi,I,*I 5 GS2-F24X30

10. 3101030020 Explosion proof electric motor ffiEE,AfL 1 YB160L-4 15Kw380V/50H2
11. 4403000040 Ball valve SE 2 Dg25
12. 9160400000 Triplex pump & ftti*fi 1 3GB.OOB
! 4 13. 4403000050 Ball valve ,tE 1 Dg40

I 14. 9162800000 Suction strainer 1 1/2 *r'&# 1 wu--400x400

t 15. 9170100000 YTK series pressure switch EhEH# 1 YTK_O2E 0-a0MPa(6000psi)
16. 9162400000 Straight check valve EjE+t"ltE 1 A-32,25
17. 4401000040 High-pressure ball valve EE$IE 2 QItNS-31.5-25
18. 9162000000 Relief valve ,trfi8 1 PY.00(B)
19. 9162900000 Double acting rylinder nffnfiX*.n+tr 5 GS2-275 X 58
20. 9160900000 4-way valve =.fiEiE*E 4 34ZS-21,25
21. 9162700000 Fluid strainer 1"x*# 4 wu-160x100
Pressure reducing and ,|
22. 9161200000 fr,EshtE JYS-21,25
regulating valve
23. 9161000000 3-way valve 1 23ZS-21,25D
-.fn=iEftm
24. 4807100020 NXQ/model bladder accumulator A*JiB6E# I 40L
25. 3802000201 Mbration-proof pressure gauge ffi$EE.r!* 2 YTN_1OO e-4oMPa(6000psi)
26_ 9161900000 Relief vafue #fi,t4 1 PY.00(A)^r-40,20
27. 21401000030 High-pressure ball valve EESH 8 YQz-32H Dg32
i 28. 3808000041 Air-operated pressure transducer <drEh tit# 2 YPQ4OOB 0-40MPa(6000psi)
29. 3808000011 Air-operated pressure transducer nCrEh tjtIF ,|
YPO25OB 0-25MPa(3500psi)

a
30. 4401000010 Suction shut-offvalve &rH 1 J13W-320P Dg15
31. 3808000030 Air filtering and reducing valve A^1dffi#.i,EFl 1 QFH-261 0-0.6MPa(85psi)
32. 3802000190 Vibration-proof pressure gauge ffiH.Ehf{ 1 YTN_IOO 0-25MPa(3500psi)
33_ 9161400000 Air/manual operate regulating n+affiEw 1 JYSQ.21,25B
4-way air operated ={tEiE-1+tlfr
v. 9163200000
(
1 34ZR6Y-L8A
valve(Distribution valve) aErhn )
35. 9163100000 4-way air operated valve =.fiEiE<4tE 5 34ZR6Y-18
36_ 5126990100 Air treatment <fr-Ag)r'W 1 AC4O1H4
Y-10027 t^fr\
37- 3802000080 Pressure gauge Ehfi 2
40MPa
0-0.2 MPa (29psi)

Y-1002r t^fr\
38. 3802mOO70 Pressure gauge Ehf,. 1 0-0.2 MPa (29psi)
25MPa
 !H
&

- -
=*'
H'xl-
=l =<{
I

t
t
lt
I
L
I

=.
 II BefrrE Pefoleum Machinery Co. The Control System for Surface Mounted BOP Stacks

The use instruction for air-operated pressure regulation is as follows:

When the air pressure is zero, firstly regulate manually the
tr.
pressure to 10.5MPa (1500psi) or desired set pressure, then lock
regukating rod.
2. Turn handle of distribution valve to the position of "Driller's panel",
h,um'r the regulating knob to regulate the control pressure of annular
pn'eventer. Clockwise turning is to decrease control pressure.

3. Turn handle of distribution valve to the position of "Remote control

paunel- turn the regulating knob to regulate the control pressure of annular
tsneuenter. Clockwise turning is to decrease control pressure

CAUTION: When air operated function fails (e.9., zero air pressure
due to air cable explosion), the control pressure for the' annular
peventer will be automatically reset to the initially set value
[10.5]rlPa or 1500psi), in order to guarantee safety.

GAUTION: In case of air-operated pressure regulating conducted in

driller's control panel, the long air control circuit may result in the
sNlight lagging of pressure change at the outlet of the reducing and
regulating valve. Therefore, it is advisable to pay much attention
and handle it slowly.

On the remote contro! panel, the 3-position 4-way control valve

be*ongs Jo the "O" mode category. When its handle sits in the "middle"
positbn, one cavity is not open to the other. When the handle is at the
'Orpen' position or the "Close" position, pressure oil may enter one end of
fp oil rylinder, while oil in the other end may go back to the oil tank via
UrB 3fosition 4-way control valve. The valve handle should be always
frrgfi at the "Open" position or the "Close" position.
orr1 the driller's panel, al! the 4-way air operate valve may be
Page 17
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

automatically reset ("middle" position)

5.3 Gontrol of auxiliary pump

A group of pumps is available to work with the control system,

air-operated oil pump is for FKQ series and hand-operated oil pump is
for FK series. ln case power is failure or power is not available, the
pressure required by the system mqy be supplied by air-operated oil
pump or hand-operated oil pump

5.3.1 Control of air-operated oil pump

For the control systems with air-operated oil pump, opgn air supply
valve, close bypass valve' of the hydro-pneumatic pressure switch,
compressed air entering hydro-pneumatic pressure switch via air supply
processing components. lf the pressure of manifold is Iower than 17.85
MPa (2580psi), hydro-pneumatic pressure switch will open automaticallr
Compressed air enters air-operated oil pump via hydro-pneumatic
pressure switch, make it work. The pressure oil exhausted enters
manifold via chock valve. When system pressure rises to about 21MPa
(3000psi), under the effect of pressure oil, hydro-pneumatic pressure
switch is automatically closed, air supply is cut off and air-operated oil
pump stops working. '-

ln special cases, it is needed to work with overpressure under

pressure oil of more than 21MPa (3000psi). Air-operated oil pump is the
only wayto feed oil. At this moment you should close isotate valve of
accumulator bank on the pipeline first to make pressure fluid not enter
accumulator bank, meanwhile turn the bypass valve of reducing and
regulating valve from "closE" to "oPEN" position, open the bypass
valve of hydro-pneumatic pressure switch and make it ineffective. As a
result, compressed air goes into air-operated oil pump directly and make

Page 18
 BPt Beiiing Petroleum Machinery Co. The Control System for Surface Mornt"i l9I J99!o

it work.

GAUTION: When using air-operated oil pump, normal operation of

rcgulating valve of manifold should be confirmed. Prior test should
be done if required to ensure it fully open and overflow at 34'5MPa
(5000psi).

GAUTION: When the pressure of manifold is more than 21MPa

(3000psi), isolate valve (ball valve) of accumulator bank on the

pipeline must be closed, otherwise the equipment and personal
safety would be imPaired.

5.3.zApplication of hand-operated oil pump

For the contro! system with hand-operated oil pump, the system is
fed with pressure oil only by turning the handle of the pump. lt should be
noted that at low system pressure, the cut-off valve in hand-operated oil
pump should be closed, making it work with double cylinders and
increasing fluid volume expelled. At high system pressure, it is very
difficult to turn the handle, in this case the cut-off valve in hand-operated
oil pump should be opened, making it work with single cylinder and
decreasing the load'to push the handle' "

Page 19
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

6. lnstallation and Test-run

l

6.1 lnstallation
l

1' ln the hoist of installing remote control panel with protective l

house, l

4 pieces of steel rope must be used to each one of four corner l

of the I
l
base for the smooth hoist. When hoisting driller's panet
or pipe rack, the
steel rope must pass through or hook the rifting ring.
2'The remote control panet should be installed no less than
30
meters from the wellhead (refer to relevant standard and
specification),
while the driller's panet should be placed near the driller
on the rig floor.
3. Connection of oil pipes
When connecting the oil pipes, it is recommended to connect
the
preventer body first, and then connect the pipes in
succession. ln doing
so, you place the pipes in good order, which will facilitate direction
changes, and save labor. Besides, all the oil pipes or air cable
shoutd be
blown clean with compressed air before installation. lt is necessary
to
pay full attention to this.
On the upper side of the hind channel section steel of the base
of the
remote control panel, welded letter of ,o,, or "C, is shown
a
corresponding to each oil pipe, with "o" meaning "open and *c,
meaning "Close". The pipes connected should'not only in accordance
with the instruction (blind ram, pipe ram, annular, choke, etc) of the brand
plate on the remote control panel, but also in accordance with
the
marked letters of "O" and *C", so that the pipes may be correctty
connected with the "open" or,,close,, function.

GAUTIoN: The wrong connection of pipes or wrong connection of

switch directions may lead to wrong operations. Therefore, care is
needed for the identification of pipes before connection.

Page 20
 BPI Beijing Petoleum Machinery Co. The Control System for Surface Mounted BOP Stacks

GAUTION: No clogging or Ieakage is allowed for the pipe

connectors. There should be no dirt in the pipe, or otherwise the
operation of the system may be unfavorably affected.

4. Connection of air pipes

Air supply pipe and air cable should be connected to FKQ series
control system. When connecting air cable, attention should be paid to
the direction of connection flange, the seal washer should be place
between the surface of flange and the screws are fastened evenly.

),G . Flexible hose..with 32mm (1,26") and 16mm (0.63") diameter are
used to connect air supply of remote control panel and driller's panel
respectively. The point joining flexible hose and connector must be
tastened with hoops to avoid being loosened. The flexible hose should be
free of defects, such as aging, crack, etc. in order to avoid its explosion.

CAUTION: When connecting air cable, take care and prevent dead
bends. The pipes should be closely connected with the connectors,
so as to prevent troubles like pipe explosion and disconnection.

lf the seal washer is not in the correct position or the

l i GAUTION:
ll

il connecting bolts are not properly tightened, the conn6ction of the

{ , flanges at the two ends of the air cable may lead to air leak, thus

j resulting in failure.

5. Connection of power supply

The AC power at 380V and 50Hz is used. The ground lead must be
earhed securely to avoid personal damage according to relevant electric
regulations.
Tum the main power order switch on the power switch box to the
Sp' position before connecting power, in order to avoid starting the
Page 21
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks
motor abruptly and causing accidents.
It is recommended that to sirpply the power cable
for control system
should pursuant to the fotlowing form. ln the following
form, there is the
power cable's diameter for singte electric
motor. When using the duplex
electric motor, the degree of the power cabre,s diameter
need enhance a
level. I
I

Electric mofor Pnr,vor Cable Lenoth Power cable Diametor

18.skw {30m )6mm2
{80m 21Omm2
>80m 716mm2
11- 1 skw {50m 26mm2
)50m 21Omm2

cAUTloN: Prior to switch on, it must be confirmed that

the power
switch in power switch box is turned off to avoid accidents.
Before
the power is on, make sure that the controiling equipment
has been
securely earthed.

when equipment instaltation is completed, it is necessary to 1""n""t

each of the pipelines, make sure all connections are proper.
Considering
the transportation and other causes, the flexible connection
and other
union parts might toosen, so please do make sure each part
is in place
before testing operation.

6.2 Test ruir

The preparatory work for the test run is carried out according
to the
following procedures.
1' Pre-charge or check the nitrogen pressure in each accumulator,
the pressure should be Tt}.TMpa (1000r100psi), and fill
nitrogen when
pressure is not enough.

Page22
 til;miliilunmq m*mrumum !Ws::- ne-. Co The Control System for Surface Mounted BOP Stacks

J. ffiift fie ei iank. Make sure the oil lever reaches its upper limit.
&\mmnu,nm6 :1t.e :rr f," [ne oil tank weekly. To check the oil after an operation
effi,M, r ffie :nr s r"rddy. it is necessary to change the oil.
illflfrfr*E- ar*ient temperature is above 0C, use D.T.E24(MOBH)

nrurm"a.ll,c :r] 3" any proper substitute oil.

*rilrrmrn*er arb ert tempeiature is below 0"c, use D.T.E13(MOBH)
(m El*tr,ffirL"e hydraulic oil or any proper substitute oil.
I l;r. r*-i ,-3i-cation according to this operationar manuar.
.,ru, llr:ra-rrn;, :ne isolate valve of the accumulator bank. opening the
lmHEtru$sl- ,uBrr€ :':re ccntrol manifoid. Push the handle of each 3-position
ilt-f,irr rE',8 to the middle position and push the by-pass valve to
"llll4ffiffilrril*

lftrw -:L:ts=- :€E t rn.

i -.r rE r€'r,rer switch to the "MANUAL" position, the electrical oil

ffin r AorK. ln the mean time, check and see if the motor
Jmutu$rllNr|tlm mmiilil

Tr',m r t-e se-f,,e direction as is indicated by the arrow on top of the

tilNllllffilrlr ffi,n€t- lre'*"tse. you should change the phases of the power line.
*TE
]E5',t'-l- 3,'Eitogd U res :

* -,rffi -n *emrc-operated oil pump

Jr* t-e:'ry,',er switch to the "AUTO" position. After the
-fliffimtt[rlllm*:Err=ilts: s- sLJmp rotates without any load for 10 rninutes. close
lmm mr *B'*€ :, Lhe control manifold to increase the pressure. When
tmim romm-l'= r:€ arcumulator rises to 21MPa (3000psi), the pump wili
*,'m, muforrmmai', 'Ctf-lerutise, turn the power switch to the "STOP BY
iritlusuffirrTln'
lE$imcn I SMr the purnp.)
;mm*all11 itr€- Te bleeder vaive to reduce the pressure of the
ffiMlrm ilillfirh-f',,- tr : "essure drops to around l gMpa (2700psi), the
ffiilMmflrrr -:Iar?r:: : : --:B should be able to start automatically.

^' -'r,* ii:: : :-::.s"s, check and adjust the pressure switch until the
Page 23
 BPM Beijing pekoleum Machinery Co. The Control System for Surface Mounted
BOp Stacks
electrical oil pump stops and starts automati",
is any oil leak in the connectors on the remote
control panel while the
pressure is going up.

2. Tests on the air-operated oil pump

when using the air-operated oir pump, you
shourd crose the by_pass
valve of the hydro-pneumatic pressure
switch, and open the air suppry
valve to start the air-operated oir pump.
when the pressure of the
accumulator rises to 21Mpa (3000psi),
check and see if the
hydro-pneumatic pressure switch can
cut off the air supply and stop the
air-operated oil pump.
Gradually open the bleeder valve on the
a
control manifold to let the
system unroad srowry. when oir pressure
drops to around 17.g5Mpa
(2580psi), the air-operated oil pump
should be able to start automatically.
ln the above process, check and adjust the hydro_pneumatic
pressure switch untir the air-operated
oir pump stops and starts
automatically. Check and see if there is
any oil leak on the remote control
panel, while the pressure is going
up.

3. Test on hand-operated oil pump

When using the hand-operated oil pump, close
the isolate valve of
the accumulator bank on the circuit, open the
by-pass valve of the control
manifold, swing the handre of the hand-operated
pump and see if the
pressure of the contror maniford goes
up. when the handre of the
hand-operated pump is difficurr to swing, ptease
open the varve rod of
check valve on the hand-operated pump, in order to keep the
hand-operated pump working with a single cylinder and to continue
pressure increase.

4. Test on pressure reducing and regulating valve

ln the process of pressure increase, check and see if the ouflet
Page 24
 II Befrg Felroler.rm Machinery Co. The Control System for Surface Mounted BOP Stacks

pressure of the reducing and regulating valve equals 10.5MPa (1500psi),

rd rnake adjustment if it does not.

5. Opening/Closing tests
lffien the pressure of the accumulators goes up to 21MPa (3000psi),
[rn the by-pass valve of the contro! manifold to the "CLOSE" position.
@rate the 3-position 4-way control valve for direction change on the
remote control panel. Check and see if the functions of the control valve
colrrcide with those of the preventer or the choke/kill valve. On the
drilbr's panel, turn the air valve "OPEN" or "CLOSE", and check and see
) if the functions of the air valve coincide with those of the control objects.
Offierwise, you should check and see if the circuit is connected properly.

6. Tests on the overflow valve

Tests on low pressure overflow valve: close the isolate valve of the
accumulator bank on the circuit, and turn the 3-position 4-way control
valve to the middle position. Push the power switch to the "MANUAL"
pmition to start the electrical oil pump, and the pressure of the manifold
goes up to around 23MPa (3300psi). Check and see if the overflow valve
at the outlet of the electrical oil pump opens for full relief. Then, stop the

I tr mp by tum off the power switch, check and see if the overflow valve
tfioroughly opened. After compete open and orierflow, push the power
switch to the "STOP" position to stop the electrical oil pump, Overflow
nalve should be completely closed at the pressure not less than 19MPa
(27oopsi).
Tests on high pressure overflow valve: close the isolate valve of the
mrnulator bank on the circuit, turn the by-pass valve on the manifold to
fr IOPEN' position. Open the air supply valve and by-pass valve to
Wer# the airoperated oil pump, oil pressure in the manifold goes up to
nurd 34-5MPa (5000psi). Check and see if the overflow valve opens

Page25
 .t

BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

for full overflow. After full open and complete overflow, stop the pump by
shutting off air supply, overflow valve should be completely closed on the
pressure not less than 29MPa (4200psi).
You may adjust the overflow pressure of the overflow valve if required.

CAUTION: When testing and adjusting the overflow valve, the

isolate valve of the accumulator bank must be closed to avoid
pressure increase in accumulators and result in accidents.
7. Tests on air-operated pressure adjustment of the annular-preventer.
Rotate downwards the hand wheel of the airlmanual operated
reducing and regulating valve of the annular-preventer, to set the outlet ?
pressure of the value to 10.5MPa (1500psi).
Turn the handle of the distribution valve on the remote control panel
to the "driller's panel" position, and then, adjust the hand wheel on the
driller's panel for air-operated pressure adjustment. Check and see if the
pressure gauge of the annular preventer on the driller's panel changes in
reading, and see if this reading coincides with that of the pressure gauge
on the remote control panel.
Turn the handle of the distribution valve to the "remote control panel"
position, and adjust the hand wheel for air-operated pressure regulation. o
Check the readings on the pressure gauge of the annular preventer.

8. Check on the oil level in the oil tank

lf the oil Ievel in the oil tank is too low due to oil Ieak in the process
of adjustment should refill oil p'operly. lf there is too much of oil, overflow
may occur when the accumulator drops its pressure and all the oil
returns to the oil tank.

7. Use, Maintenance and Lubrication

The control system of surface mounted BOP stacks is important
Page 26

E.
 BPI Beijing Petloleum Machinery Co. The Control System for Surface Mounted BOP Stacks

equipment of "armies are to be maintained for years but used on a single

daf. Therefore in order to ensure the control system of BOP stacks
efiective, reliable and quick when used to control well blowout, relevant
stafis must receive technical training, making the personnel to manage
and operate the system well understand principle, and conduct
installation, operation, maintenance and trouble shooting.
Operation personnel should well know the regulations stipulated in
the following standards (and relevant information involved).
SY5225- 1994 Fire-proof, explosion-proof production safety
Management regulations on well drilling, development, store and
transportation of petroleum and natural gas.
5Y5742-1995 Management regulation on technical check on
drilling and well control safety of petroleum and natural gas.
SY/T596 4-1994 Specification of drilling and well control

equipment mating and composition.

SY/T5697-1994 lnstallation, test run and maintenance of drilling
and well control equiPment.
SY/T6203-1996 Fire extinguish measure of oil and gas well
blowout
O Sy/T6283-1gg7 Guide of management system on health, safety

and environment of petroleum and natural ga$ Oritling.

SY/T6426-1999 Specification of drilling and well control

technique.

7.1 ilotice of oPeration

1. Under normal drilling operation, the positions of each valves on
tre remote control panel are: the preventers are in "OPEN" position; the
drokeftill valve is in "CLOSE" position; and the bypass valve is in

UOSE'position.
Page 27
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

2. The valve in drill's pane! belongs to two-handed operation. Air

supply valve should be operated first, meanwhjle relevant control valves
are operated. As air cable is a'long and fine cable and it needs a time
period for response, 3 seconds are needed to stop after operating valve
handle in order to ensure completing corresponding operation on
relevant valves on remote control panel.
3. Vehicles are prohibited from going across the pipe racks and other
oil pipes, which are protected from damage.
4. Under normal operation, conduct inspection each shift to see:

hydro-pneumatic switch are correct and reliable;

relevant safety regulations.

5. The customers should establish operation and maintenance
record and make records on operation, malfun0tion and maintenance at
all time. All the documents and record should be placed along with the
equipment.

7.2 Maintenance
1. Remove and check the oil strainer and filter screens of the intake
on the top of the oil tank monthly. Take the screens out and wash them
carefully in order to protect them from being blocked by dirt.
2, To the water-trap in the air treatment unit: Open the water
discharge valve at its lower end and drain dirty water out of the cup daily.

Page 28
 ltl B€ng Peffieum MachineryCo. The Control System for Surface Mounted BOP Stacks

Remove and wash the filter cup and the water cup once every two weeks.
ytash them with gasoline or other mineral oils, and dry them with
oqnpressed air. Do not use acetone or toluene to wash them avoiding
damage.
3. To the oil mist filter of the air treatment unit: Check the oil level in
the cup daily. Refill and replace Iubricant (N32 hydraulic oil or other
proper oil). Dismount and wash the filter promptly when the oil does drip
srnoothly
4. check the pressure of the pre-charged nitrogen in the
i amrmulator periodically. During the beginning period, check nitrogen
pessure weekly, and thereafter, during normal operation, check it
nronthly. Recharge nitrogen at once when its pressure is below 6.3MPa
(900psi). Check nitrogen pressure only after the accumulator releases
pressure thoroughly. The pressure may be released by the ball valve on
the bottom of accumulator.
5. For long distance transport of the control system, decrease
pressure of nitrogen in the accumulator to about lMPa (140psi), so as to
guarantee safety during transportation.
6. Check oil level in the oil tank at all time. Open the plug on the
T n bofrom of the oil tank to drain water periodically. Observe if there is any
ilnpurity on the bottom, and clean the bottom if necessary.
the seal packs in the crankshaft plunger pump, the
7. Check
ak-operated hydraulic pump or the hand-operated oil pump. Do not
over{ighten the packing only adequate if no oil leakage is found.
Replace the damaged packing in time.
8. When removing the quick connectors, take care not to lose the
U rirqs in quick- change union. Put the removed "O" rings together and
bep in good condition.
9- Often wipe and clean the surface of the remote control panel and
Page 29
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks
the driller's panel, and keep nameplates in places.
10. Once finishing drilling a well, inspect and calibrate the
pressure gauges.

7.3 Notice of lubrication

1. Use the lubricator and refill adequate lubricant into the two oil
nozzles in each air cylinder weekty.
2. Check the lubricant in the oil mist filter. Refill N32 hydraulic oil or
other proper oil if the oil level is low.
3. check the level of lubricant in the crankcase of
"the
electric-operated oil pump monthly. Refill N32 hydraulic oil or other
proper oil if the oil levet is tow.
4. Remove the chain cover monthly, and check lubrication. Refill N32
hydraulic oil or other proper oil if the oil tevel is tow.

Page 30

L-
 l"I tsei;5ng Petrobum Machinery Co. The Control System for Surface Mounted BOP Stacks

S.Trouble Shooting
(1). Noise from the system
Cause: there is gas contained in the system oil
Remedy: running the system without any load, exhausting the gas
repeatedly. Check if the capsule of the accumulator is
broken and make a prompt change.
Cause: the chain ;s too loose or isn't in a straight line. The
concentricity of the pump shaft and the motor shaft is
above the degree.
Remedy: regulate the chain; re-regulate and tighten the screw
Cause: low oil temperature or high viscosity.
Remedy: heating the oil tank. Replace the suitable oil liquid.
Cause: the oil pump sucks air or the oil level is too low in the oil
tank.
Remedy: when the accumulator has no pressure, fills oil in the oil
tank.
Cause: if there is any dirt in the oil inlet of pump or in the filter
screen.
Remedy: wash the filter screen.
+tr
"i'-
(2). Electrical motor failed to start.
Cause: the electric power parameters do not comply with the
requirement, voltage is low.
Remddy: repair electric circuit.
C,ause: electric components in power switch box are damaged or
out of order.
Remedy: repair power switch-box.
t3)- Ttle system pressure doesn't raising or raising slowly after starting
electric-operated oil pump and there is abnormal noi.se during the

Page 31
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

pump operation
Cause: the oil level is too low in the oil tank, the oil pump sucks air.
Remedy: refill oil.
Cause: the valve for the oil suction orifice is closed or the oil filter is
blocked.
Remedy: check pipe line, open valve and wash oil filter.
Cause: the bleeder valve on the control manifold is not closed
Remedy: close the bleeder valve.
Cause: malfunction of electric-operated oil pump.
Remedy: check and repair oil pump.
Cause: "V" sealing ring wears out.
Remedy: Replace the sealing ring.
Cause: sealing surface wears out or is blocked.
-
Remedy: replace the valve core and the valve seat, or regulate the
position between them.
(4) The electric pump doesn't stop automatically.
Cause: oil pipe or oil connector of pressure controller is blocked or
Ieaks.
Remedy: check pipeline of the pressure controller.
Cause: pressure controller does not work. ."

Remedy: adjust or change pressure controller.

(5) After adjusted the pressure controller, start and stop spot fluctuated.
Cause: pressure controller is damaged.
Remedy: replace the pressure controller.
(6) The pressure in outlet of reducing and regulating valve is too high or
fluctuated.
Cause: dirt exists in sealing surface of seal ring inside the valve.
Remedy: turn pressure-adjusting hand wheel and make seal be
moving up and down for several times in order to facilitate
Page32
 BPH Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

the elimination of dirt.

cause: pressure reducing sealing ring's sealing belt is damaged.
Remedy: replace the reducing sealing ring.
Cause: there is any leakage in the system.
Remedy: check if the 4-way valve and the bteeder valve is closed.
(7)The preventer cannot be opened or closed in driller's panel or relevant
actions do not coincide with each other.
Cause: pipe core is wrongly connected, is broken or.is blocked.
seal washers connecting flanges make air pass through.
Remedy: check air cable.
18) The pressure of the system is drop quickly
cause: the connection of the remote control panel, pipe rack or
flexible hose has breakthrough.
Remedy: check every connection, and open the inspection port on
the oil tank to see the leakage of every valve. lf
needed ,replace the broken parts
(ts| Though there isn't a leak in the system, the system pressure can not
ffidy going at 21MPa (3000psi) . The system pressure descent
continuously and the motor run up frequenfly.
o Came: the capsule of the accumulator is broken.
Rernedy: replace the capsule.
Carse: there is gas contained in the system oil
Rerrrcdy: exhausting the gas repeatedly.
Cause: the check valve which is at the outlet of the electrical pump
is broken.
mrreAf replace the check valve.
mmni'Wenated oil pump cannot stop automatically
Carse: the sealer of hydro-pneumatic pressure switch is out of
mcrk.
Page 33

)
 BPM Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp Stacks

Remedy: replace the sealer.

(11)Air operated oil pump's working pressure can not reach the normat
quantity or the piston of the piston of the pump commutate slowly.
Remedy: replace the V-Seal.
Cause: the V-Seal is damaged.
(12)Though having air supply, the air operated oil pump can not work.
Cause: didn't use for a long time so that reversing structure rusted
and couldn't move.
Remedy: need to wash and grind the dismantled accessory of the
reversing structure. lf didn't use for a short time, inject oil
from top of the pump head to act as a lubricant. After one
day, try to start the air pump again. lt is suggest that start
air operated oil pump regularly.
Cause: pressure of air supply is low.
Remedy: increase the pressure of air supply.
cause: the reversing structure of air pump is located dead spot.
Remedy: as the QYB.O0F air operated oil pump, screw off the oil pipe
of the air pump's admission air port, use the overbolt flick
downward the valve core sleeve, or use the long wrench
pry upward or downward the nut of."the piston rod Iightly,
when hear a bang, restart air pump. As the eyB.OOA air
operated oil pump, may be because the connecting rod
. occurs jam of slider with casing. At this moment, need to
dismantle the accessory and grind the connecting rod.
(13) OYB.0OF air operated oil pump has a blow-by phenomenon.
Cause: the poffurethane o-ring which is on the core rod is broken.
Remedy: replace the polyurethane o-ring.
Cause: o-ring which is on the piston wore out.
Remedy: replace the O-ring which is on the piston.
Page 34

L.
 Co. The Control System for Surface Mounted BOP Stacks

the admission air pipe of two sides is Ioose.

: screw down the admission air pipe of two sides.

Page35
 BPill Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOp
Stacks

9. lnstruction of order
Technicat parameter of the control system
of surface mounted BOp
stacks is rather complicated and a large variety
of structure and models
are avairabre for this product. rn order to herp
customers make right
choice and a
proper order, and make its configuration
compry with
national standard and API specification,
customers are kindly requested
to provide technical data and operation requirements
as detailed as
possible. These data and requirements
incrude:'
1. Number of contror objects and their modets

Open volume (L) Closing volume (L)

2. Range of order
lf the follow optional parts are needed:
tr Driller's panel
tr Air cable
tr Pipe lines (tr pipe racks, fr ctose bent pipe, fr hoseE others_)
tr Others:
3.Special requirements
when there are speciar requirements on products or parts,
users
should specify in detail. Those without special
requirements will be

Page 36

U
 e.rr- The Control System for Surface Mounted BOP Stacks

ffnffi**ance \ilith national and enterprise standards.

Wlllmnr device
hckup system
compensation device
control pangl
house

Eq:oating and decorations (painting and appearance)

Cormections
OOrcrs:
wfiol system for surface mounted BOP stacks produced in"our
with national and enterprise standard an'd can satisfy
requirement in ordinary conditions. The special
proposed by customers may influence the term of delivery
of the product.

1S
,t?
ii$

Page 37
 BPt Beijing Petroleum Machinery Co. The Control System for Surface Mounted BOP Stacks

Appendix A: Exchange between English Unit and Metric Unit

1. Weight
1 kg = 2'2lbs'
1 lbs. = 0.454 kg

2. Volume
1 L = 0.264 US gal = 61 cu. in
I US gal = 3.785 L= 231 cu. in
3. Pressure
lMPa = 145psi
l psi = 0.0069MPa

4. Length {

1m=3.28ft=39.37in
1ft=0.305m
5. Temperature
1C= 5/9("F-32)
1T= 1.8X"C+32
6. Power
1kW = 1.34 HP
.1 HP = 0.746 kW

Appendix B: Recommended hydraulic oil of the control system

(lt is suitable for all parts which need hydraulic oil.)
Types of hydraulic oil

Ambient temperature is above 0C Ambient temperature is below 0C

GB. L-HM32 L-HS32

rso 32 32

MOBH D.T.E24 D.T.E13

Shell: Tellus 32 Tellus T32

[Note]:When the temperature of hydraulic oil is 50C, its kinematic

viscosity is 17-33 mm'/s.

Page 38

L.
 6ta6ed

-n -tl 'n -ft -tl -n.'Tt 'r'!

'n 'n 'n 'n 'n
x rlx
-n 'n
x xrx x Tt
.TI 'n -Tt -Tt -Tl -Tt -Tt -Tt .Tt
x ox 1]
'Tt TI -11

x ox ox o x ox ox ox ox ox ox ox ox ox ox o ox ox o
x o xox oxo
o o
@ o, @ @ @ @ @ @ @ (o
o @ @ (o
o PPqq=
\)L)vL)v=- , D
D
o 5 o oo o
o o o o
o oo o o
o 5 N N N 5 N N 5 o)@ic--:lJ
(/)
o c) o No N
o o, @ N o N
o O) o N
@ @ @ o 5 @ @ 5 so)c:\:s:
o o o o OCCS=EY
o, { { { !.Tt ! { { { \t o o @ @ @ o o o o
I I I I I I I I I I I

o
a

I o m C- o @ { { I I r
@
t
@ @ @ @ (o
c) (D
I I

o o N 5 \ii!!YY
sj
I I I I I I

== =
-l
@,
a,l3
J =,
-:= -
--A ft
LJ
i8?

(, (, (, 5 (, (, s (, 5 l
g a-1
q) G' o) O) (.) CD (l) (/) (f,) OJ 5 OJ (^) E 5 q) ww9u
:
j
--=EI Ea
N) N N N l\) N) l\) f\) N N N N) t\) (, o) (r) u) N N) (, (, N 5 { N c,:lN s cc
= 3=
,*
i-d
:q

!q 0
N N { 19 ,i- - r: D
=!

5 5 5 5 5 5 5 A s o, @ o, s (') O) o, @ @ @ o) @ @ @ O) 5 <D
ox ox ox ox ox ox ox ox ox ox ox Ox Ox Ox ox c)x ox ox Ox c)x ox ox ox ox ox AA!\:\:-=&a
ox @ i'X;i-=: |l
N o N N N N N N l\) N N) N N
o o o o O o o O 5 O o) l\) N N
N o s o) o O) O) o, o @ (,) C') s OJ ocJcs 5- a
t
5 5 5 s 5 s sO 5o s@ o)o O)s o)o) 5o Al\) sOo o, (')
c') !
o t\) o) o) o) s,s o, r ^ 5; l
838=_==>3
-.1
o
o
O)
N)o c) o
o (f, o o
o
o o
o o o o o o io o o o
O)
O
<)
so O)
5
o A 5 5 N N
c) c) o o o O o
f,fi:

I .-= -o
tt
o)N OJ (, (, (, o)OJ OJ CD 5 s(o E (, N o) s s s 5 5 (,l 5 s (,r N
o 0)'(, s st\: =-= = -
o 5o N) o o O) N (o (r) N (o (o (o N (tl (o (o (,l (ji(,) : 1{
N)
o No No o N
N) T\)
O o N s No O) N o .r O) o O) o) o) O o OJ o, s o) o)'o Nl
C=-==-o- =
i 56 -
=
t*
-t
o @ a a. ll @ a @ a a U, a ll a a a o (f, @ (t 1l a. a. a 1l 1l -UllE
=
-
=A o
d d o- o d d d d d d
o o o o o o o o
o d d d o o- d o o ooo; 5 =
!
o o o o U' o o o o o CN o o o CNa, 999
E o o E o o a o rc o 1, 1f
o o o o o o o o
o
o o o IJ E o rf o
o o 1'o oo o PE= E3 -r
o o o
@ o @
o
(, a 9.. a o 9.. 9.. 9.. 9.. a a a o o o o
a a 9.. 9.. 9.. o oa o@ 9.. 9..
CJ) dili
0 0-q =g
a
d;
6' 6' 6' 6'
5 =
6' 6' 6' 6' =
= =
o =
d.
o o = o 6' 6' 6' 6' 6' = o =
o =. o 6' 6' 6' =
J
o =-o o' o ===
)i)=!
o
= = J = = = = = = =

N t\) N N N) IO N N t$NN
i. ) @
t
O) O) (,l @ N (,t N) (,r O) o(', (,l O) o, O) o) o) N) l\) O) N) 5
N)
(I) o, N -:3i D
o (, (Jt O o (tl O (, OI
c)
o o @ O (,l o
o o
o o
o o
o o O (Jl o
o o ooc
c
O (Jl O
o c) o o O O o O O o o c) o O o o o o O)
o O oo3-=== -=t
-{
t!
o _ a- C!
o
(, -=- -==
90 P 90 @ 90 90 P co @ @ @ @
90 90 P @ @ @ @ 90 9o (Jl (Jl (rl (Jl 90 90 (Jt (Jr ir' i, (, i, i,x Ln iJr iJ! @
90
(,r (,r(rr
9D
(,r (, (Jr (, irt Ltr i.n i"n (,
x x x x ('l (,r x x x X x x x x x iJ' x X X X ==a
-=n d
N) N N N N N N l\) N) l\) N l\) N N N) N)tJt\: --:
o
5 5O) 5 5 A s s s s s A so) so) S 5 s 5 -NS.\,:>-=
t
o \T
s
O)
5 o)
o) x x
so) s s s
o) o, o,
5
o)
O)
x
O) o) O)
x x x o)
5
O)
O) O) O)
x x x
O)
x x
o) o) o)
O)
x x x x x
5 AAA^==-
O) x,x x x :- - o,
N) N) N l\) l\) N N) N) N) N) N) N N) N) N N I$'N N N + = :
@
! o
!
r I - >=' !
d!
o)
J
O) c') o)ox o) o) OJ O) O) O) o, O) O) o) O) O) O) o, O) O) o) o) O) o) o) o) v)lw)lv) D
(Jt (,l (,t (,1 ot (,l (Jr (Jr (,t (Jr (Jr (,r (, (,l ('r ot (,l (Jr (Jt (,l (, (tI (,l(,i(, !) a r
(Jt (,l (,l ir - - CI
x x x 5 x x (, x x x x x x x x x x x x x x x x x x x x xix x x =
-l ==:
3 -
N) N) N) N) N) (, N) N) N) N) l\) (, N (,) (, N) N (, N rr:irul<,: c.: + =
N N) N N N ,e
a=="<
= = !-
-+a

<a=
= -4
:E:_
5= 3
J=;

-===
?3 =-<
N N N) N) N) N) N) N) N N t\) N) N N) N) N) N) N) N t\) N N) N) N N N N N N-! I\C
uea=
JJII =E=,

slcels doE palunoy\,| ecelJns.lol uels^s loJluoc eql 'oO fueur+3eH uJrGaF-@# 6+Ueg II
 The Control System for Surface Mounted B!fg'"kt
BPM Beijing Petroleum Machinery Co'

Page 40
 L? ased

slcels dog peunoN me#ns rcJ ruels^s prluoS eql !SftntH|GFRt