BOP control systems for land rigs, platform and jack up rigs

a) Basis Accumulator pump unit.

a) Basic accumulator pump unit

Normally there are one or two electric driven triplex hydraulic pumps present and two or
three air operated hydraulic pumps to charge the accumulator bottles
The total amount of pump capacity present should be able to charge the complete
hydraulic circuit from 0 psi to 3,000 psi within 15 minutes (API)
The air operated pumps should be able to reach their maximum working pressure with
only 75 psi rig air pressure.
The accumulator unit is connected with the driller’s panel and an auxiliary remote control
panel, which is either electrical or air operated.
In the second chapter we will look into this panel in great detail.
b) The driller’s console panel
The drillers console panel should be able to control all the hydraulic functions which are
installed on the basic accumulator unit also alarms and pressure indications should be
installed.
At land rigs no valve position indication is required, but on all offshore installation valve
position indication is required by API 16D rules.

typical Jack up driller’s panel

Fig xx typical land rig driller’s panel

typical land rig driller’s panel

The difference between the land rig panel and the jack up panel are the following:

Land rig panel Offshore rig panel surface BOP’s

a) Air operated valves
b) No valve position indication
c) No alarm indication installed
d) No pressure indication
e) No flow meter
1. Electric push buttons
2. Valve Position indication by lights
3. Alarms lights installed
4. Three pressure gauges present
5. Some panels have a flow meter

Several items on this old fashion land rig panel should be installed to comply with the
API 16D rules.
Sometimes we find this “land-rig” panel on older jack-ups and this is not acceptable (API
16D)
Even land rigs some times change to the electric control panels to increase safety

c) The auxiliary panel

This panel is normally installed close to the company/tool pushers caravan on the land
rigs and inside the tool pushers office on offshore rigs.
air operated auxiliary panel electric auxiliary panel

1. Customer air supply, normal air supply is 100-120 psi

An air regulator might be installed (maximum air pressure TR regulators is only 100 psi)

2. Air lubricator, located in the air inlet tot he air operated pumps. SAE 10 lubricated to
be used

3. Air by-pass valve, this by passes the hydro-pneumatic pressure switch. Ensure this
valve is closed during our survey, otherwise the right operation of the hydro-pneumatic
switch can not be tested.

4. Automatic Hydro-pneumatic pressure switch, this pressure switch is normally set at

2700 psi cut out and 2400 psi cut-in. With the adjustable spring the pressure range of the
switch can be altered.
The name for this switch comes from Shaffer/Koomey; Cameron calls this identical piece
of equipment a pump governor
 Hydro-pneumatic switch

5. Air shut off valves, manually operated, these valves should be open during normal
drilling operations
When the hydro-pneumatic switch is faulty than of the crew closes this valves during
drilling operations (not too smart though). Be aware of this when testing the unit.

6. Air operated hydraulic pumps

Shaffer/Koomey pump (FA-42) . Cameron C-7 series

The air operated hydraulic pumps are normally installed with either two or three pumps
Some systems have more than one hydro-pneumatic switch installed, which is the better
option to have redundancy to perform maintenance during drilling operations.
During pumping the air section often has ice on the outside even in tropical climates, this
is harmless and a normal event.
The most common problems with these pumps are the seals either at the stem of at the
pistons which wear rapidly creating malfunction
All pumps should pump at the same speed, if one pump is pumping much faster then
most likely are the piston seals of the pump history and it the pump not putting out fluid
but is the fluid by-passed in the pump liner. The average life of the piston and rod seals is
between 6-12 months thus regular inspection is required by the crews.
The output of the Shaffer air pumps (model FA-41) is approximate 6 gallons/minute for
each pump at 125 psi air input.
The out put of the Cameron air pump (model C-7-50G) is approximate 3 gallons/minute
for each pump with 120 psi air input.

7. Suction shut-off valve, manually operated, each pump should have its own suction
valve. These valves should be normally open. As these valves are not used often is it
recommended to inspect the operation of the valves.

8. Suction strainer. One for each air operated hydraulic pump suction line. Sometimes
the filters are either missing in action or completely deteriorated, so we inspect this
during our survey.

9. Check valve; one for each air operated hydraulic valve to prevent that hydraulic
pressure is bled down through the pumps back to the tank.

10. Electric driven triplex pumps; most surface BOP units have only one hydraulic
triplex pump, on the subsea units two or three triplex pumps are installed.
The triplex pumps have a larger capacity than the air operated pump and do not suffer
from rapid wear like the air operated pump as there are no piston seals installed, just
plungers operating inside the liners.
The triplex pumps are mostly chain driven (Shaffer and Koomey)or sometimes belt
driven (Cameron).
The chain case is partly filled with oil, during our survey the chain, the drive sprocket and
the pump sprocket need to be inspected.
The pumps should not create too much noise when operating.
The plungers should not create excessive heat at the plunger bushing, we must be able to
keep our hands on the plunger housing during operation of the pumps.
When too much heat is created a bent plunger might be the cause or the nuts of the
plunger seal bushings are tightened too much, this can even cause to burn the packing
elements in the plunger bushings.
 The valve and valve seats require regular maintenance, worn seats and valves might be
indicated not only by prolonged operation sequences but also by very noisy pumps.
When the pumps have been disconnected it is very important to vent the air out of the
discharge side of the pumps.

Cameron triplex pump Shaffer triplex pump

Capacity Shaffer duplex and triplex pumps

(model with D in the number is duplex) Capacity Cameron triplex pumps

Model Overall GPM Model Overall GPM

D25-3-3 1.14 10 H.P. 4.3
D25-5-3 2.19 20 H.P. 8.8
D25-7-1/2-3 2.50 30 H.P. 14.8
T315-10-3 4.55 40 H.P 20.8
T315-15-3 6.40 50 H.P. 23.8
T315-20-3 8.70
T315-25-3 11.40
T330-30-3 14.20
T360-40-3 2020
T360-50-3 25.20
T360-60-3 30.00

11. The automatic hydro-electric pressure switch

This switch starts and stops the electric motor driving the triplex pumps. Each triplex
pump should have its own dedicated pressure switch installed.
The triplex pump should stop at 3,000 psi and start at approximate 2700 psi.
“If two triplex pumps are present then one pump should be the “lead pump” adjusted to
stop at 3,000 psi and one need to be set as the “slave pump” which is normally adjusted
200 psi lower than the lead pump.
The automatic pressure switch can be adjusted to each desired pressure value.
Ensure to inspect that the electrical condition of this switch is conform API 500.
The hydraulic piping of the sensor should have an adequate length if very thin tubing is
used, if this tubing is very thin and short it can cause “hunting” of the triplex pumps.

12. Electric starter (automatic)

This starts and stops the electric motor driving the triplex pump and works in conjunction
with the automatic hydro-electric pressure switch and has an manual over-riding on/off
switch installed.
Ensure the electrical connections are corresponding to the API 500 rules.

13. Suction shut off valve. Manually operated, normally open valve. Located in the
suction line of the hydraulic triplex pump. To be checked in the same manner as the other
suction valves on the manifold.

14. Suction strainer, located in the suction line of the electric pump, to be cleaned every
30 days.

15. Check valve, located in the discharge side of the triplex pump. The 1” check valves
of the triplex pumps are vulnerable and should be replaced regularly.

16. Electrical power. Customer connections ensure explosion proof appliances are used
in the proper manner

17. Accumulators, the pre-charge is normally 1,000 psi.

Ensure only Nitrogen is used and that a test program for the content of the Nitrogen
bottles is in place. (Introduce a method to use portable gas detectors to check the content
of the Nitrogen bottles especially at third world countries which have a dubious infra-
structure.) If accidentally Oxygen is used in an accumulator system then it is possible that
the accumulators bottles explode ! (Colombia; Lasmo rig 1997).

The following type of accumulators are present

a) Cylindrical accumulators with a bag (Koomey/Shaffer)
b) Cylindrical accumulators with a float (Cameron)
c) Spherical accumulators with a small float (Koomey/Shaffer)
d) Spherical accumulators with a large float (Cameron)
More detail explanation will be found in the separate accumulator chapter (chapter 26)

18. Accumulator relief valve.

Valve set to relief at 110% of the MWP or 3,300 psi, ensure the relief valves are certified
at regular intervals (bi-annually).
Sometimes are the hydraulic units were used to test the BOP and are 10,000 psi relief
valves installed, ensure these are replaced for 3,300 psi relief valves.
Ensure the relief valves can not be isolated by a ball valve from the main system.

19. Inlet high pressure strainer.

Located either at the inlet of the accumulator bottles or straight after the triplex pumps.
These fine mesh strainers (10 –15 micron) are to be cleaned every 30 days .

20. Manually operated reducing and regulating valve (MKR)

Manually operated regulator which is normally set at 1500 psi and supplies the manifold
pressure, which delivers hydraulic pressure to the rams and gate valves on the BOP.
The manual operated valve can not be controlled from the drill floor or the auxiliary
panel.

21. Main valve header,

This is normally a 1-1/2” – 2” all welded header with a working pressure of 5,000 psi.
On the main header the Ram BOP functions and the gate valve functions are connected.

22. 4-Way valves.

Connected to air cylinder operator for remote operation from the control panels
These valves are to be set in operation mode (open or close) and not to be left in the
center or block position as fluid can leak through these valves back to the tank when the
valves are left in block position.
23. By-pass valve.
With the air cylinder for remote operation from the control panels.
In “Low “ position the valve puts the regulated pressure from the HKR
(normally 1500 psi) on the main header.
In “High “ position it will supply the pressure from the accumulator bottles
(normally 3,000 psi) directly to the main header.
During normal drilling operations is the by-pass valve set in the Low position.

24. Accumulator bank isolation valves

These are normally manually operated globe valves which should be normally open.
It is recommended to have the accumulator bottles racks to be divided in two or four
equal sized sections. If bottles are missing ensure that both bottle racks have the same
amount of bottles installed.

25. Hydraulic Bleeder valve.

Manually operated, normally closed. This valve needs to be opened when the
accumulator bottles are getting pre-charged with Nitrogen.

26. Panel unit selector.

This is a manual 3-way valve. This valve is used to apply pilot air pressure to the air
operated pressure reducing and regulating valve (AKR) which is connected to the annular
preventer operating system, either from the air regulators on the unit or from the air
regulator on the remote control panel.

27. Pressure reducing and regulating valve- air operated.

Reduces the accumulator pressure to the required annular BOP operating pressure, The
pressure can be altered for stripping operations. The maximum operating pressure of the
annular preventer should not be exceeded.
(A better option would be the installation of the TR regulator, which will be explained in
chapter 27)

28. Accumulator pressure gauge.

The minimum face size of this pressure gauge is 4”. An engraved sign should be
installed next to the gauge.

29. Manifold pressure gauge

The minimum face size of this pressure gauge is 4”., An engraved sign should be
installed next to the gauge.

30. Annular preventer gauge.

The minimum face size of this pressure gauge is 4”., An engraved sign should be
installed next to the gauge.

32. Pneumatic transmitter for the manifold pressure

For the indication of the manifold pressure on the driller’s panel and auxiliary panel

33. Pneumatic transmitter for the annular preventer operating pressure

For the indication of the manifold pressure on the driller’s panel and auxiliary panel

34. Air filter

Located in the supply line going to the air regulators

35. Air regulator for pressure reducing and regulating valve- air operated

36. Air regulator for pneumatic transmitter (33) for annular pressure

37. Air regulator for pneumatic transmitter (31) for accumulator pressure

38. Air regulator for pneumatic transmitter (32) for manifold pressure
The air regulator which controls the pneumatic transmitters is normally set at 15 psi.
Increase or decrease air pressure in order to calibrate the panel gauges to hydraulic
pressure gauge on the unit.
39. Air junction box
To connect the air lines on the unit tot he air lines coming from the remote control panles
through the air hose bundle.

Junction box model RB-24

Junction box model JB-16

40. Storage or mixture tank (not drawn on fig )

The storage or mixture tank contains either hydraulic oil or a water/soluble oil mixture.
The tank size should be 1.5 times or greater than the maximum accumulator volume.
We inspect the condition of the tank for the presence of debris, rust or fungus
contamination. Especially above the maximum fluid level and against the top of the tank
inspection is required.
Most of the times is a “low level” alarm installed on the tank.
At frequent intervals should the storage tank be drained and cleaned.
The tank should have adequate vents installed to prevent pressure build up from
hydraulic fluid which returns from the BOP functions when operated.
The covers on the tank should be tightened to prevent dust and debris to enter the system.
A clear sight glass should supply the level indication of the tank.
Accumulator bottles and volume calculations
Accumulator bottles are used to store hydraulic fluid.To ensure that the “last drop” out of
the accumulator has a pressure which is useful for the components are the accumulators
pre-charged with Nitrogen.
Very often is the minimum pressure required to remain in the accumulators related to the
close ratio of the BOP and that pressure can be as high as 1428 psi for 10M BOP’s .
The volume of the fluid present at full charge minus the remaining fluid at the close ratio
pressure is called the useable fluid.

The rule of thumb is that the pre-charge pressure is approximate 1/3 of the maximum
operating pressure of the system.
At surface BOP’s is the accumulator pre-charge normally 1,000 psi.

The Nitrogen is compressed when the system is charged.

The nitrogen is separated from the BOP fluid by either a bag (Koomey and Shaffer) or
with a float (Shaffer and Camaron)

There are cylindrical and spherical accumulators.

The spherical accumulators are normally 80 gallon accumulators and are installed on
older systems.

The cylindrical bag type accumulators are normally found on surface installations.
The most common used bag type accumulator are the 10 and 12 gallon accumulators.
The volume of the bags inside these accumulators is approximate 1 gallon.

The cylindrical float type accumulators made by Cameron are commonly used on subsea
installations but sometimes appear at surface installations.
The most common float type accumulator are the 20 and 27 gallon accumulators.
Cameron does not supply information about the volume of the float but from the
performance curve charts of Cameron charts it is possible to ascertain the right useable
fluid.
1.Cylindrical accumulators with a bag (Koomey/Shaffer)
With this type of accumulators it is vital that no debris in the hydraulic fluid is present as
this debris will puncture the bladders when pressure is applied.
Ensure that the Nitrogen valve located on the top is adequately protected as these valves
are easily damaged and can also eject the valve stem if the valve is damaged.

Shaffer bag type accumulator

2. Cylindrical accumulators with a float (Cameron)
The volume of the floats is not known, we have to check the tables supplied by Cameron
to establish the useable volume of these accumulator bottles. (see fig xx)

Nitrogen

BOP fluid

Float type accumulator.

 Cameron accumulator performance curves.

3. Spherical accumulators with a small float (Koomey/Shaffer)

This are 80 gallon accumulators, the volume of the small float is approximate 2 gallon.

4. Spherical accumulators with a large float (Cameron)

Nominal volume is 80 gallon
The useable volume of the accumulator is to be found in the 85 accumulator chart from
fig
CALCULATING ACCUMULATOR SIZE FOR TYPICAL BOP STACK
(ACCORDING API Spec 16D)

(Example Three 13-5/8” 10M Shaffer Ram BOP’s and one 13-5/8” 5M Shaffer Annular
preventer)

Required volume:
Three rams open: 3x10.52= 30.56 US gallon
Three rams close 3x10.58= 11.74 US gallon
Annular preventer close = 23.58 US gallon
Annular preventer open = 17.41 US gallon
------------+
Total volume 83.29 US gallon

Useable volume required according API16D is:

a) Total volume to open and close all ram preventers and one annular preventer x 1.5
This means 83.29 x 1.5 = 125 US gallon

b) The second method is to open and close the ram preventers and the annular preventer
and then the remaining pressure should be equal or higher than the closing ratio of the
ram preventers.
The closing ratio of the 10M Shaffer BOP is 7:11:1 which results in
10.000:7.11=1406 psi.

3000 psi accumulator system

How to calculate the useable fluid for the 11 gallon bag type accumulator bottle

We use the Boyle rule P1V1=P2V2=P3V3=P4V4

P1= Pressure of the Nitrogen at the pre-charge stage in absolute units

(gauge reading +15 psi= 1000+15=1015 psi)
V1=Volume of the Nitrogen at pre-charge stage (10 gallon)
The volume stored in each 11-gallon accumulator is 10 gallons nominal capacity.

P2=Pressure of the Nitrogen at fully charged condition

(gauge reading +15 psi=3000+15=3015 psi)
V2=Volume of the Nitrogen at fully charged condition

P3= Pressure of the Nitrogen at discharge condition

(pre-charge +200 psi=1000+200+15=1215psi)
V3=Volume of the Nitrogen at discharged condition

P4= Pressure of the Nitrogen at closing ratio

(1406+15=1421psi)
V4= Volume of the Nitrogen at closing ratio

P1V1=P2V2=P3V3=P4V4
1015x10=3015xV2=1215xV3=1421xV4
V2=3.4 gallon of Nitrogen, so 10-3.4=6.6 gallon fluid is left in each accumulator
V3=8.4 gallon of Nitrogen, so 10-8.4=1.6 gallon fluid is left in each accumulator
V4=7.1 gallon of Nitrogen, so 10-7.1=2.9 gallon fluid is left in each accumulator

A) Therefore subtracting the remaining control fluid from the stored fluid is
6.6-1.6=5 gallons of useable fluid for each accumulator bottle.

B) If we are using the closing ratio than the remaining control fluid is
6.6-2.9=3.7 gallons of useable fluid for each accumulator bottle.

In case A the amount of required accumulator bottles is 125 :5 =25 bottles of 11 gallon
In case B the amount of required accumulator bottles is 83.29 :3.7=23 bottles of 11 gallon