accumulator - copia

MAILING ADDRESS: 6828 - 52 AVENUE, RED DEER, AB. T4N 4L1 SERVICE FACILITY: BLACKFALDS, AB, Ph: (403) 885-2677 Fax: (403) 885-0392

OPERATORS MANUAL

ENSIGN

WO# 31129

PO # 2-35319PO RIG # PU#22

6-STATION 300 GALLON

E/H BOP CONTROL SYSTEM-API 16D 2ND

EDITION

API OPERATORS MANUAL

TABLE OF CONTENTS

1. OPERATORS MANUAL

2. TWO YEAR SPARE PARTS LIST

3. DESIGN SUMMARY

4. FACTORY ACCEPTANCE TESTING

5. CONTROL SYSTEM CERTIFICATION & CHARTS

6. BILL OF MATERIALS

7. DRAWINGS

8. PARTS RECORDS

9. CERTIFICATE OF COMPLIANCE

OPERATIONS MANUAL

BOP CONTROL SYSTEM OPERATION MANUAL

TABLE OF CONTENTS

CHAPTER ONE.SYSTEM DESCRIPTION

CHAPTER TWO....SYSTEM OEPRATION

CHAPTER THREE...SYSTEM TROUBLESHOOTING

CHAPTER FOUR....SYSTEM MAINTENANCE

CHAPTER FIVE........COMPONENT MAINTENANCE

CHAPTER SIX...PARTS LIST

CHAPTER SEVEN...SCHEMATICS

CHAPTER ONE SYSTEM DESCRIPTION

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Control Technology Inc. (CTI) is a manufacturer of B.O.P Control Systems for use in a wide range of applications. Systems are typically custom-tailored for each customers requirements, including wire line, coil tubing, well servicing, land-based drilling and offshore drilling operations. Although each CTI BOP Control System is matched to each customers differing requirements, all CTI BOP Control System include a selection of standard features and components. Review the following descriptions of features and components to identify these items in your CTI BOP Control System. Skid or Frame All systems include a skid(s) or frame(s) for mounting the components utilized within the system.

Fill Port

Fluid Reservoir The fluid reservoir is for storage of system operating fluid. Each fluid reservoir will include, as a minimum, the following features:

Vent Port Drain/Clean-out Port(s) Interior Baffles Fluid Level Sight Gauge Pump Suction Port(s) Fluid Return Port(s)

The standard CTI fluid reservoir is manufactured by welding 3-16 plate steel sections, each being formed on all corners to provide a 1 lap on all welded seams. Following the installation of all reservoir porting, each reservoir is then liquid penetrant inspected to ensure the integrity of all welds. Hydraulic Pump Each BOP Control System incorporates one or more pumps to provide system hydraulic pressure. The fluid reservoir suction port is connected to the pump suction port, and the pump discharged port is connected to the Accumulator Manifold. When the pump is operating, hydraulic fluid is displaced from the fluid reservoir to the Accumulator Manifold.


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Pump type and design is subject to the system application. Each system may include one or more of the following types of hydraulic pumps:

PTO-Driven gear pump typically engine-mounted when used in wire line, coil tubing and well servicing applications. When installed this pump is considered to be the primary pump.

Electric or gasoline motor-driven gear pump a direct-drive installation for small to medium volumetric applications. When installed, the pump is considered to be the primary pump.

Electric or gasoline motor-driven triplex plunger pump a reduction-drive installation for medium and large volumetric requirements. Types of speed reduction drives include a v-belt drive, a poly-chain drive, or a chain drive. Gasoline engine drives may also incorporate a drive clutch. When installed, this pump is considered to be the primary pump.

Air motor-driven plunger pump a reciprocating plunger pump installation that may be incorporated in small, medium and large volumetric applications. Depending on the application, the air motor-driven pump(s) may be considered the primary or secondary pump.

Hand-operated plunger pump a reciprocating plunger pump that is operated manually, and is intended for small volumetric applications. Depending on the application, the hand-operated pump may be considered the primary or secondary pump.

Pump Discharge Check Valve(s) each pump discharge is equipped with a check valve to prevent displaced fluid from returning to the reservoir through the pump.

Accumulator Manifold The Accumulator Manifold maintains system operating pressure to 3000 PSI/21000 KPA. The manifold will include the following features:

Accumulator(s) a pressure vessel for storage of nitrogen precharge and pressurized hydraulic fluid. Accumulator type and sizing is subject to the application. Accumulator types may include the following:

- Separator - type accumulator, bottom-loading. Sizes: 1-

quart; -gallon; 1-gallon; 2 -gallon; 5-gallon; 10-gallon; 11-gallon; 15-gallon.

- Separator-type, top loading. Sizes: 11-gallon; 15 gallon. - Guided-float sphere. Sizes: 80-gallon. - All sizes shown in US Gallons.


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Accumulator Isolation Valve one or more valves incorporated into the Accumulator Manifold piping to provide isolation of individual accumulators or provide isolation of complete accumulator manifolds.

Automatic Pump Control each pump is equipped with automatic pump

control to stop the pump when system pressure is reached, and to restart the pump when system pressure drops below a predetermined pressure. An automatic pump typically incorporates a pressure switch to the Accumulator Manifold to detect the system pressure, and a motor control circuit (air, hydraulic or electric).

PTO-driven gear pumps incorporate an unloader to divert displaced fluid from the pump to the fluid reservoir when full system pressure is achieved, and to direct the displaced fluid to the Accumulator Manifold when system pressure drops below a predetermined pressure. The unloader is piloted by system pressure from an Accumulator Manifold source that is located downstream from the unloader, and isolated from the unloader with a check valve. When the unloader is in the pressuring position, the check valve allows displaced fluid from the pump to flow to the Accumulator Manifold. When the unloader is in the divert position, the check valve prevents system pressure from the Accumulator Manifold to the fluid reservoir via the unloader.

Electric motor-driven triplex plunger pumps use an electro-hydraulic pressure switch to interrupt the motor starter control circuit when full system pressure is achieved, and to complete the motor starter control circuit when system pressure drops below a predetermined pressure.

Gasoline motor-driven triplex plunger pumps use an electro-hydraulic pressure switch to interrupt the engines ignition control circuit when full system pressure is achieved. Once stopped, the gasoline engine must be restarted manually to operate the pump again. Air motor-driven plunger pumps use a hydro-pneumatic pressure switch to shut off the pump air supply when full system pressure is achieved, and to open the pump air supply when system pressure drops below a predetermined pressure.


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The set points for pump shut-off and re-start are subject to system application. The variance between full system pressure and the pump re-start pressure is called differential, and is usually expressed as a percentage of full system pressure. An example would be a triplex pump that operates a 3000 PSI/21000KPA working pressure system with 10% differential. This indicates the pump will shut off at 3000PSI/21000KPA and will restart at 2700PSI/18900KPA.

Accumulator Pressure Gauge a liquid-filled hydraulic gauge

connected to the Accumulator Manifold, to indicate Accumulator Pressure in the manifold. Units having electric remote functions may also incorporate an electro-hydraulic Accumulator Pressure transducer to indicate Accumulator Pressure on an electric meter in the Remote Panel.

Control Manifold Inlet Strainer a high-pressure strainer that is the first component installed in the Control Manifold supply piping. The inlet strainer is intended to trap contaminants in the operating fluid as the fluid flows from the Accumulator Manifold to the Control Manifold.

Control Manifold The Control Manifold is intended to use system hydraulic pressure to operate the blowout preventers and BOP stack valves. Using pressure regulators and control valves, the Control Manifold will provide hydraulic fluid, at a controlled pressure, to the Open or Close of each annular-type BOP, ram-type BOP, and HCR valve in the stack. Typical CTI Control Manifold configurations include the following components:

Control Manifold Inlet Check Valve a check valve installed in the Control Manifold supply piping immediately downstream of the inlet strainer. This check valve is intended to automatically prevent any reverse flow from the Control Manifold to the Accumulator Manifold.

Control Manifold Nitrogen Inlet a port provided downstream from the control manifold inlet check valve to allow for the introduction of nitrogen into the Control Manifold as a control medium. See Nitrogen Back-Up Operation for more information.

Control Manifold Pressure Safety Valve (PSV) a reservoir-vented pressure relief valve that is intended to protect the Control Manifold from over-pressurization. This valve is adjusted to open at


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3300PSI/23100KPA and vent excess pressure to the fluid reservoir. This valve is self-resetting when Control Manifold pressure decreases below 3000PSI/21000KPA.

Manifold Regulator a hydraulic pressure reducing and regulating valve intended to reduce Accumulator Pressure to Manifold Pressure, and to regulate the Manifold Pressure at the desired setting. Manifold Pressure is typically adjusted to 1500PSI/10500KPA, and is piped to a series of BOP Control Valves for the control and operation of ram-type BOPs and HCR valves. Manifold regulators may incorporate a manually-operated adjustment, an air-operated failsafe adjustment with manual override, or a hydraulic-operated failsafe adjustment with manual override.

Manifold Pressure Gauge a liquid-filled hydraulic gauge connected to the piping manifold that supplies the ram-type BOP and HCR control valves, to indicate Manifold Pressure in the manifold. Units having electric remote functions may also incorporate an electro-hydraulic Manifold Pressure transducer to indicate Manifold Pressure on an electric meter in the Remote Panel.

Annular Regulator a hydraulic pressure reducing and regulating valve intended to reduce Accumulator Pressure to Annular Pressure, and to regulate the Annular Pressure at eh desired setting. Annular Pressure is adjusted to a pressure required to operate the annular BOP, as specified by the annular manufacturer. Annular pressure is piped to a BOP Control Valve for the control and operation of an annular-type BOP. Annular regulators may incorporate a manually-operated adjustment, an air-operated failsafe adjustment with manual override, or a hydraulic-operated failsafe adjustment with manual override.

Annular Pressure Gauge a liquid-filled hydraulic gauge connected to the piping manifold that supplies the annular-type BOP control valve, to indicate Annular Pressure in the manifold. Units having electric remote functions may also incorporate an electro-hydraulic Annular Pressure transducer to indicate Annular Pressure on an electric meter in the Remote Panel.

Control Manifold Bleed Valve a rough-service needle valve connected to the Control Manifold that is for venting system pressure to the reservoir.

Manifold Regulator Bypass Valve a 3-position valve installed in the Control Manifold that is intended to select either Manifold


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Pressure (typical operation) or Accumulator Pressure (emergency operation) to be supplied to the ram-type BOP and HCR control valves.

Regulator Isolation/Bypass Valves manually-operated ball or needle valves incorporated into the Control Manifold piping such that they enable the operator to both isolate and bypass a regulator valve.

Remote Manifold (Optional) Most BOP Control Systems incorporate a Remote Manifold to provide varying degrees of system operation from an auxiliary or remote location. There are three main types of Remote systems: Air-over-Hydraulic (A/H); Hydraulic-over-Hydraulic (H/H); and Electric-over-Hydraulic (E/H).

Utilizes a clean, dry air source, an air panel, interconnect hoses and air actuators to provide remote function of BOP/HCR control valves and/or pressure regulators.

Air-over-Hydraulic (A/H)

The Air Remote Station will include a panel frame, an air filter/lubricator assembly, a master supply valve, and the required number of remote function (manipulator) valves for each BOP/HCR control valves and air-operated regulator adjustment in the Control Manifold. This panel may also include hydraulic gauges to provide indication for Accumulator, Manifold and/or Annular Pressures.

Each BOP/HCR control valves in the Control Manifold will include an air-operated actuator to provide remote function of each control valve.

One or both pressure regulating valves may include an air-operated failsafe adjustment for remote adjustment of the pressure regulator(s).

Utilizes a regulated hydraulic pressure source (taken directly from the manifold pressure regulator), a hydraulic remote valve manifold, interconnect hoses and hydraulic actuators to provide remote function of the BOP/HCR control valves and/or pressure regulators in the Control Manifold.

Hydraulic-over-Hydraulic (H/H)

The Hydraulic Remote Station will include a master supply valve and the required number of remote function (manipulator) valves for each


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BOP/HCR control valve and hydraulic-operated failsafe regulator adjustment in the Control Manifold. This remote system may also include gauges to provide indication for Accumulator, Manifold and/or Annular Pressures.

Each BOP/HCR control valve in the Control Manifold will include a hydraulic-operated actuator to provide remote function of each control valve.

One or both pressure regulating valves may include a hydraulic-operated failsafe adjustment for remote adjustment of these pressure regulator(s).

E/H Remote systems utilize an electric-operated Remote (Drillers) Panel to function electro-hydraulic solenoids contained within a Main Junction Box. The solenoids in the Main Junction Box operate the hydraulic actuators mounted on the control valves and/or pressure regulator(s) in the Control Manifold. E/H Remote systems may incorporate either compressed air or regulated hydraulic pressure as an operating medium in the solenoids.

Electric-over-Hydraulic (E/H)

The E/H Remote (Drillers) Panel contains a master (hold-to-operate) pushbutton, remote function pushbuttons, valve position indicator lights, electric pressure meters and additional optional features to provide remote function of the BOP/HCR control valves and/or pressure regulators in the Control Manifold.

The E/H Junction Box contains an inlet hydraulic filter, a master supply solenoid, remote function solenoids, valve position pressure switches and electric pressure transducers.

Each BOP/HCR control valve in the Control Manifold will include a hydraulic-operated actuator to provide remote function of each control valve.

One or both pressure regulating valves in the Control Manifold may include an air-operated or hydraulic-operated failsafe actuator for remote adjustment of these pressure regulator(s).

The E/H Remote system includes a programmable logic controller PLC installation.

Electric-over-Air (E/A)


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Same general configuration as E/H systems, with the following differences; an air filter and air lubricator replace the inlet hydraulic filter at the main junction box; electro-pneumatic solenoids replace the electro-hydraulic solenoids in the main junction box; pneumatic actuators replace the hydraulic actuators.

Pressure Test Units

Utilizes a clean, dry air source, Air motor-driven plunger pumps use an air filter, regulator, lubricator supply system to shut off the pump air supply when full system pressure is achieved, and to open the pump air supply when system pressure drops below a predetermined pressure.

CHAPTER TWO SYSTEM OPERATION

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Before Start-up

1) Ensure the system bleed valve and all accumulator isolation valves are

open. Ensure all hydraulic pressure is bled from all the accumulator bottles mounted in the accumulator manifold.

2) Test the pre-charge pressure in all the accumulator bottles mounted in the accumulator manifold. Pre-charge using NITROGEN to 1000 PSI / 7000 KPA, +/- 10%. DO NOT USE OXYGEN.

3) Test the precharge in all the 1-US quart pulsation dampeners on the main unit. Precharge using NITROGEN only. DO NOT USE OXYGEN. Adjust precharge in primary dampener(s) to 1000 PSI / 7000 KPA.

4) Check the fluid level in the reservoir on the main unit. The fluid level should be 8 to 10 inches / 20-25 cm from the top of the reservoir when the B.O.P. Control System is completely bled off. The reservoir oil should be clean and free of water and dirt contamination. Fill as required using clean, light hydraulic oil.

5) Check the oil level in the pump crankcases. The oil level is visually inspected at the sight gauge on the pump. The oil level should be visible in the middle of the sight gauge. The oil should be clean and free of water and dirt contamination. Fill as required using appropriate crankcase oil. Refer to manufacture specifications.

6) Inspect and clean pump suction screens. To remove the screen, first close the pump suction valve and remove the hex cap in the pump suction Y-strainer. The screen will be accessible in the strainer housing once the hex cap is removed. Clean the screen and re-install. Open the pump suction valve.

7) Inspect and clean high pressure T-strainer. The screen will be accessible in the strainer housing once the hex cap is removed. Clean the screen and re-install.

8) Check drive belt for proper tension and belt integrity. Belt tension = 1/4 deflection of the belt between the drive and driven pulleys. Ensure


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there are no torn or frayed sections on the drive belts. Adjust or replace as required.

1) Connect all hoses and piping from the accumulator building to the BOPs.

On-Site

2) Connect the communications cable from the main unit to the EH PLC Drillers Panel.

3) Connect power source cables (if required) for main unit PLC and Drillers Panel PLC.

4) Ensure the Shear Ram Isolation valve is positioned as required. (Closed if shear ram control station is not in operation, Open if shear ram control station is in normal operation)

5) Ensure the system bleed valve on the main unit is closed.

6) Ensure the pump suction valve for each pump on the main unit is open.

7) Ensure the Nitrogen Back-Up Inlet valve on the main unit is closed.

8) Ensure all Nitrogen Back-Up cylinders are closed.

9) Ensure the Nitrogen Booster Inlet valve is closed.

10) Ensure all Nitrogen Booster cylinders are closed.

11) Ensure all accumulator isolation valves in the accumulator manifold interconnect piping are open.

TRIPLEX PUMP # 1

12) Ensure the On/Off selector switch on the motor starter enclosure is in the Off position.

13) Place the circuit breaker marked Accumulator Pump #1 in the respective electrical power source breaker panel in the On position.


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14) Place the circuit breaker marked Accumulator Remote in the respective power source breaker panel in the On position.

15) Place the On/Off selector switch on the motor starter enclosure in the On position and then immediately place the some selector switch back to the Off position. Monitor the pump drive for proper rotation (as indicated by the CCW directional arrow on the belt guard) while operating the selector switch. If required, correct the pump rotation by reversing the electrical phase sequence

16) Place the On/Off selector switch on the motor starter enclosure in the On position. Allow the pump to continue operating while the Accumulator Pressure increases to 3000 PSI/21000KPA. The pump is equipped with an automatic pump control, and the pump will turn off when the accumulator pressure reaches 3000 PSI/21000KPA. The automatic pump control will re-start the pump when the accumulator decreases below 2700 PSI/18900 KPA. Leave the On/Off selector switch on the motor starter enclosure in the On position for continuous operation.

at the electrical power source.

TRIPLEX PUMP # 2

17) Repeat Step12 through Step 16 for Pump #2

18) Check the Manifold Pressure, as indicated by the Manifold Pressure gauge in the main unit gauge panel. Typical Manifold Pressure is 1500PSI / 10500 KPA for operating ram-type BOPs and HCR-type valves. Adjust the Manifold Pressure as required by adjusting the setting on the manifold pressure regulator on the main unit. Turn the regulator adjustment screw clockwise to increase the Manifold Pressure. Turn the regulator adjustment screw counter-clock wise to decrease Manifold Pressure.

19) Check the Annular Pressure, as indicated by the Annular Pressure gauge on the main unit gauge panel. Annular model, pipe diameter, well bore pressure and ambient temperature are factors to be considered in selecting the required Annular Pressure. Typical Annular Pressure is established by maintaining 200 PSI / 1400 KPA above the annular operating pressure required to close the annular and effectively seal in the well bore. Adjust the annular pressure as required by adjusting the setting on the annular regulator on the main unit. Turn the regulator adjustment screw clockwise to increase the Annular Pressure. Turn the regulator adjustment screw counter-clock wise to decrease Annular Pressure.


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Should your annular be over 13-5/8 5000 psi, the annular regulator will be equipped with a supply limiting turn ball valve. This valve should be open in normal operation. The valve must be closed for smaller annulars to prevent damage to the Annular regulator.

20) Function each B.O.P. or HCR control valve in the B.O.P. Control Manifold by manually operating each respective B.O.P./HCR control valve handle. Using the respective control valve, close the annular on the minimum tubular diameter anticipated in the scope of work. Using the respective control valve(s), close the pipe ram(s) on the specified diameter of pipe. Do not close pipe rams on open hole.

21) Monitor system operation for the following: a. Full and complete operation of each BOP and / or HCR. b. Efficient closing times for each BOP and / or HCR. c. Efficient accumulator pumping system recharge times.

22) Compare the Accumulator, Manifold and Annular Pressure indications on the (3) meters in the EH Drillers Panel versus the pressure indicated on each respective hydraulic gauge on the main unit gauge panel. Each corresponding gauge and meter should indicate the same pressure.

23) Remote function each BOP or HCR control valve in the BOP Control Manifold by manually depressing the Hold-To-Operate pushbutton and simultaneously operating each respective BOP or HCR Open/Close pushbutton. Close the annular on the minimum tubular diameter anticipated in the scope of work. Close the pipe ram(s) on the specified diameter of pipe. Do not close annular or pipe rams on open hole. Remote function each regulator equipped with a remote actuator.

24) Monitor system operation for the following: a. Full and complete remote operation of each BOP and / or HCR b. Full and complete adjustment range of each remote-actuated

regulator. c. Efficient closing times for each BOP and / or HCR. d. Efficient accumulator pumping system recharge times.

25) Visually inspect complete BOP Control System, interconnect piping and hoses, and BOP stack for external fluid leaks.


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NITROGEN BOOSTER FOR SHEAR RAM

In Readiness

1) Ensure the Nitrogen Booster Inlet Valve is closed. 2) Ensure the Nitrogen Booster Bleed Valve is closed. 3) Open the Shear Ram Isolation Valve. The shear ram control station will

now operate using a Manifold Pressure hydraulic supply. 4) Open all nitrogen cylinders on the Nitrogen Booster manifold. 5) Use the Nitrogen Booster Regulator to adjust the shear ram boost

pressure to the required shear ram operating pressure. Do not exceed 3000 PSI maximum shear ram boost pressure. Refer to the BOP manufacturers specifications for required shear ram operating pressure.


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To Shear and Boost

1) Place the Shear Ram Control Valve in the CLOSE position. 2) Close the Shear Ram Isolation Valve. 3) Open the Nitrogen Booster Inlet Valve.

To Open Shear Ram After Boost

1) Close the Nitrogen Booster Inlet Valve. 2) Close all nitrogen cylinders on the Nitrogen Booster manifold.


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3) Open the Nitrogen Booster Bleed Valve to vent all nitrogen from the shear ram close piping. Close the bleed valve when all nitrogen is vented to the reservoir.

4) Place the Shear Ram Control Valve in the NEUTRAL position. 5) Open the Shear Ram Isolation Valve. 6) Place the Shear Ram Control Valve in the OPEN position. The shear ram

control station will now operate using a Manifold Pressure hydraulic supply.

BOP CONTROL SYSTEMS OPERATION MANUAL

Condition Possible Cause Remedy

CHAPTER THREE TROUBLESHOOTING 1/10

No electrical power to main unit. Electrical power source. Main breaker panel. Motor starter.

Power must be connected to the proper electrical power source. Power source electrical breaker marked Accumulator must be in the ON position. On/Off selector switch must be in ON position for continuous operation.

Electrical power to main unit but electric pump motor will not operate.

Motor starter overloads. On/Off selector switch. Pump electric pressure switch. Motor starter coil.

Inspect overloads for proper operation. Reset or replace as required. On/Off Selector switch must be in ON position for pump to operate. Inspect for proper operation and replace as required. The electric switch operates on the Normally Closed circuit in the switch. Inspect for switch continuity below 3000PSI/21000KPA to complete the motor control circuit. Inspect coil for proper operation. Replace as required.




Electrical power to main unit but electric pump motor will not operate.

Motor starter. Electric motor.

Inspect motor starter for proper operation. Repair or replace as required. Inspect motor for proper operation. Repair or replace as required.

Pump rotates in wrong direction. Incorrect electrical power phase sequence.

Reverse phase sequence at electrical power source.

Pump operates but system will not increase Accumulator Pressure.

Low reservoir fluid level. Pump suction valve. Pump suction strainer. System bleed valve. BOP Control valves.

Maintain reservoir fluid level as required. Pump suction valve must be open for pump to operate. Strainer must be clean and free of contamination or restriction for pump to operate. System bleed valve must be closed to operate BOP Control System. BOP Control valves must be in neutral, full-left or full-right position to operate BOP Control System.

Pump operates but system will not increase Accumulator Pressure.

Pump Pump is faulty. Repair or replace pump as required.

Pump operates but system will not increase Accumulator

Leaking valve(s) on main unit.

Open fluid reservoir inspection port on end of reservoir. Visually inspect all return piping




Pressure. External Leaks.

from each main unit valve (bleed valve, pressure relief valves, manifold regulator, annular regulator, control valves, remote manifold). All BOP Control System valves are designed for zero leakage and should not exhibit any fluid returning to the reservoir except when operating BOPs/HCR. NOTE: Disconnect BOP hoses from BOPs and repeat leak inspection prior to determining source of leak. Inspect all system components for external hydraulic fluid leaks, repair as required.

Pump increases Accumulator Pressure but does not shut off as required.

Pump pressure switch. Motor starter. Pump pressure switch snubber.

Pump pressure switch must be adjusted to shut pump off at 3000 PSI / 21000 KPA and to re-start pump at 2700 PS I / 18900 KPA. Motor starter not operating properly. Repair as required. The pump pressure switch is equipped with a snubber to protect the switch from hydraulic shock. If contaminated, the snubber may prevent pressure from entering the switch. Replace snubber as required.

Main unit will not maintain Leaking valve(s) on main unit. Open fluid reservoir inspection port on end of




Accumulator Pressure after pump shuts off.

External Leaks.

reservoir. Visually inspect all return piping from each main unit valve (bleed valve, pressure relief valves, manifold regulator, annular regulator, control valves, remote manifold). All BOP Control System valves are designed fro zero leakage and should not exhibit any fluid returning to the reservoir except when operating BOPs/HCR. NOTE: Disconnect BOP hoses from BOPs and repeat leak inspection prior to determining source of leak. Inspect all system components for external hydraulic fluid leaks and repair as required.

Main unit has Accumulator Pressure but BOP Control Manifold does not operate.

Accumulator isolation valve(s). Manifold Regulator. Annular Regulator. Manifold Regulator Isolation/Bypass Valves

Accumulator isolation valve(s) must be in Open position for proper system operation. Manifold regulator must be adjusted to supply 1500 PSI / 10500 KPA. Annular regulator must be adjusted to supply required annular operating pressure. Manifold Regulator Isolation/Bypass Valves must be in the proper position to allow




hydraulic pressure to reach the Control Manifold. Valve Color Code: Green Normally Open; Red Normally Closed.

BOP Control Manifold operates but BOP/HCR does not operate.

BOP/HCR control valve. BOP/HCR hoses. Hose Quick-connectors.

Respective BOP/HCR control valve must be in full-left position to open BOP/HCR, and must be in full-right position to close BOP/HCR. Inspect BOP hoses for proper connection at the BOP stack. Inspect BOP/HCR quick-connectors. Ensure there is no mechanical damage to each connector poppet and that connectors are fully engaged.

Manifold regulator vents fluid and/or gas into the fluid reservoir when BOP(s) are closed on well bore pressure.

Manifold regulator. BOP

Manifold regulator is faulty. Repair or replace as required. Well bore pressure in excess of the regulated Manifold Pressure may be leaking into the BOP and the manifold regulator is venting the excessive regulated pressure. Isolate and service the BOP. NOTE: To differentiate a faulty regulator from a faulty BOP, disconnect the BOP hoses from the BOP(s) and repeat leak in inspection.

Annular regulator vents fluid Annular regulator. Annular regulator is faulty. Repair or replace




and/or gas into the fluid reservoir when Annular is closed on well bore pressure.

Annular.

as required. Well bore pressure in excess of the regulated Annular Pressure is leaking into the Annular and the annular regulator is venting the excessive regulated pressure. Isolate and service the Annular. NOTE: To differentiate a faulty regulator from a faulty BOP, disconnect the BOP hoses from the BOP(s) and repeat leak inspection.

BOP control valve is venting fluid into the fluid reservoir when Ram BOPs and/or Annular are closed on well bore pressure.

BOP/HCR control valve. BOP(s).

Disconnect from BOP hoses from the BOPs and repeat leak inspection. Repair as required. Well bore pressure may leak into any non-pressured operating chamber in any BOP exposed to well bore pressure. Disconnect all BOP hoses from BOPs and repeat leak inspection. If venting stops then identify, isolate and service leaking BOP.

E/H PLC Drillers Panel will not operate.

PLC electrical power source.

Both the main unit PLC and the Drillers Panel PLC require 120VAC electrical power to operate. Ensure power cable for Drillers Panel is installed. Ensure PLC breaker switch is in the ON position.




120VAC/24DC power supply. Drillers Panel communication cable.

Inspect power supply and power supply fuses for proper operation. Repair or replace as required. Ensure communication cable is connected. Inspect communication cable and cable connectors for damage. Repair or replace as required.

BOP/HCR valves operate manually.

Master (hold-to-operate) pushbutton. Remote manifold inlet valve. Remote manifold inlet filter. Master supply solenoid. Remote function solenoid.

Inspect master (hold-to-operate) pushbutton in Drillers Panel for proper operation. Repair or replace as required. Inlet valve at main junction box must be OPEN for remote functions to operate. Inlet filter at main junction box must be clean and free of contamination for the remote functions to operate. Inspect master (hold-to-operate) supply solenoid in main junction box for proper operation. Repair or replace as required. Inspect the respective remote function solenoid in the main junction box for proper operation. Repair or replace as required.




Remote function pushbutton switch. Drillers Panel communication cable.

Inspect the respective remote function pushbutton switch in the Drillers Panel for proper operation. Repair or replace as required. Inspect communication cable and cable connectors for damage. Repair or replace as required.

BOP/HCR control valves operate manually but do not operate from Drillers Panel.

PLC. Inspect main unit PLC and Drillers Panel PLC for proper operation. Repair or replace as required.

BOP/HCR control valves operate from the Drillers Panel but the position indicator light(s) will not operate.

Position indicator light bulb. Pushbutton lamp socket. Lamp pressure switch. Lamp pressure switch snubber.

Use lamp test pushbutton to test all lights in Drillers Panel. Replace as required. Ensure lamp is secure in lamp socket. Open and Close hydraulic pressures from each control valve are tubed to respective, plunger-type pressure switches mounted in the main junction box. All switches use the normally open (NC) contacts, with the switch plunger closing the contacts when pressure is applied. Inspect for proper operation of switch contacts when pressure is applied and removed from each switch. Each lamp pressure switch is equipped with a




Circuit wiring.

snubber to reduce hydraulic shock. Inspect each snubber for contamination and replace as required. Inspect lamp circuit wiring for proper connection and mechanical damage.

BOP/HCR control valves operate from the Drillers Panel but the position indicator light(s) will not operate.

Drillers Panel Communication cable. PLC.

Inspect communication cable and cable connectors for damage. Repair or replace as required. Inspect main unit PLC and Drillers Panel PLC for proper operation. Repair or replace as required.

Electric meter(s) in Drillers Panel will not operate.

Pressure transducer isolation valve. Pressure transducer. Pressure transducer snubber.

Ensure all transducer isolation valves on the main junction box are open. Each meter circuit in the Drillers Panel incorporates a pressure transducer in the main junction box. Each transducer converts its respective hydraulic pressure to a proportionate electrical signal. Inspect each transducer for proper operation. Each transducer is equipped with a snubber to reduce hydraulic shock. Inspect each snubber for contamination and replace as required.




Electric meter. Circuit wiring.

Inspect meter for proper operation. Repair or replace as required. Inspect meter/transducer circuit wiring for proper connection and mechanical damage.

Electric meter(s) in Drillers Panel will not operate.

Drillers Panel Communication cable. PLC.

Inspect communication cable and cable connectors for damage. Repair or replace as required. Inspect main unit PLC and Drillers Panel PLC for proper operation. Repair or replace as required.

CHAPTER FOUR SYSTEM MAINTENANCE

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Reservoir Fluid The operating fluid in the reservoir requires periodic inspection and maintenance to ensure the system can be supplied with a sufficient volume of clean operating fluid to perform the required tasks. CTI recommends clean, lightweight hydraulic oil for CTI BOP Control System operating fluid. To aid in maintaining the fluid in the reservoir, the reservoir is equipped with a fluid level sight gauge, a sediment trap below the minimum pump suction level, and large clean-out ports.

The fluid level sight gauge allows the operator to visually note the volume of fluid in the reservoir. The reservoir is considered full when the fluid level is eight inches from the top of the reservoir while the system accumulator(s) has been bled off to the reservoir. DO NOT OVERFILL THE RESERVOIR. The fluid level sight gauge also allows the operator note the condition of the fluid in the reservoir. Contamination will appear in the sight gauge in the form of visible sediments (introduced through the fill port or hose connections), discolored oil (from wellbore hydrocarbons), or grey/white/cream colored oil (water contamination).


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The sediment trap is the bottom two inches of the reservoir, below the minimum pump suction level. The trap will help contain fluid contaminants such as dirt, metal shavings sludge and small amounts of water that may have been introduced into the system. If the operating fluid requires replacement, the reservoir is equipped with large clean-out ports to allow for thorough cleaning of the reservoir at that time. FLUID FILTERS AND STRAINERS CTI incorporates filters or screens within the BOP Control System piping to assist in removing sediment, dirt and other contaminants from the operating fluids. Proper operation of the BOP Control System requires that all filters and screens are clean and free of contamination to allow sufficient fluid flow as required. A dirty or contaminated pump suction filter and strainer screen will reduce the pump output, and cause pump cavitation, resulting in premature pump failure. A dirty or contaminated high-pressure T-strainer will result in slower BOP closing times. A dirty or contaminated solenoid supply filter will result in slower remote function response times. Spin-On Filter Assembly - Low-volume gear pumps (typically up to 5 GPM) use a 100-mesh spin-on filter assembly in the pump suction piping. The filter head is equipped with a 3 PSI (21Kpa) pressure differential bypass, and a vacuum gauge at the outlet port. The spin-on filter element should be changed every 30 days of continuous operation, or if the vacuum gauge indicates a pressure differential greater than 5 Hg (5 of vacuum). Replace the filter element on the pump suction line as follows:

NOTE: With care, this service can be performed while the Control System is in operation.

Turn off and lock out the electrical power source for the pump drive motor.

Close the pump suction valve. Using a strap wrench, remove the old filter element from the filter head

by rotating counter-clockwise (RH thread). Apply clean oil to the gasket on the new filter element. Install the new filter element on the filter head by rotating clockwise.

Using a strap wrench, tighten only of a turn beyond finger tight. Open the pump suction valve. Open the pump discharge bleed valve.


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Unlock and turn on the electrical power source for the pump drive motor.

Turn on the pump motor and allow the pump to operate while excess air in the pump discharge is vented through the pump discharge bleed valve.

Slowly close the pump discharge bleed valve once all air has been displaced from the pump.

The pump can now be returned to normal operations. In addition, some CTI BOP Control Systems utilize a 100-mesh spin-on filter assembly in the Control Manifold return piping. The filter head is equipped with a 40 PSI (280 Kpa) pressure differential bypass, and a 200 PSI (1400 Kpa) pressure gauge at the inlet port. The spin-on filter should be changed every 30 days of continuous operation, or if the return line pressure is in excess of 40 PSI (280 Kpa). Low Pressure Y-Strainer - High-volume plunger pumps (typically greater than 5GPM) use an oversized, low-pressure Y-strainer in the pump suction piping. The y-strainer houses a re-usable 20-mesh screen. The screen should be removed and cleaned or replaced every 30 days of continuous operation, or if the pressure gauge indicates more than 40 PSI (280 Kpa) return line pressure. Service the Y-strainer screen on the pump suction line as follows:



Close the pump suction valve. Using the proper-fitting wrench, loosen the hex cap on the Y-strainer

housing by rotating counter-clockwise. Remove the hex cap and the screen from the housing.

Clean the screen to remove all contaminants. Install the hex cap and screen in the Y-strainer housing. Ensure the

screen fits properly on the hex cap and seats properly in the Y-strainer housing. Using the proper-fitting wrench, tighten the hex cap on the Y-strainer housing by rotating clockwise.

Open the pump suction valve. Open the pump discharge bleed valve. Unlock and turn on the electrical power source for the pump drive

motor.


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Turn on the pump motor and allow the pump to operate while excess air in the pump discharge is vented through the pump discharge bleed valve.


The pump can now be returned to normal operations High Pressure T-Strainer The Manifold supply piping in the BOP Control System incorporates an oversized, high pressure T-strainer to assist in preventing contamination in the operating fluid from entering the Manifold valving. The screen should be removed and cleaned or replaced every 30 days of continuous operation, or after the rupture of any accumulator bladder. Service the T-strainer screen in the Manifold supply piping as follows:

NOTE: This service can not be performed while the BOP Control System is in operation.

Turn off and lock out the power source(s) (electric and air) for all system recharge pumps.

Open the system bleed valve and bleed the Accumulator pressure to 0 PSI (0 Kpa).

Using the proper-fitting wrench, loosen the hex cap on the T-strainer housing by rotating counter-clockwise. Remove the hex cap and the screen from the housing.

Clean the screen to remove all contaminants. Install the hex cap and screen in the T-strainer housing. Ensure the

screen fits properly on the hex cap and seats properly in the T-strainer housing. Using the proper-fitting wrench, tighten the hex cap on the T-strainer housing by rotating clockwise.

Close the system bleed valve. Unlock and turn on the power source(s) (electric and air) for all system

recharge pumps. The BOP Control System can now be returned to normal operations

High Pressure Filter BOP Control Systems that incorporate an E/H remote control package will include a high-pressure filter in the solenoid supply piping. The filter housing contains a replaceable 40-micron filter element. The element should be removed and replaced yearly or more often if required. Replace the solenoid supply filter in the solenoid supply piping as follows:


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NOTE: This service can be performed while the BOP Control System is in operation.

Close the solenoid supply isolation valve. Using the proper-fitting wrench, loosen the hex cap on the solenoid

supply filter housing by rotating counter-clockwise. Any residual hydraulic pressure in the filter housing will be vented through a safety vent. Remove the hex cap and the old filter element from the housing.

Install the new filter element and hex cap in the filter housing. Install the hex cap and screen in the T-strainer housing. Ensure the

screen fits properly on the hex cap and seats properly in the T-strainer housing.

Close the system bleed valve. Unlock and turn on the power source(s) (electric and air) for all system

recharge pumps. The BOP Control System can now be returned to normal operations.

Air Filter, Air Regulators, Air Lubricators Air pump packages installed on CTI BOP Control Systems include an air filter, an air regulator and air lubricator to respectively clean, regulate and lubricate the air supply delivered to the air motor(s). In addition, A/H remote systems include an air filter and air lubricator to clean and lubricate the air supply delivered to the remote system. Maintenance frequency of the air filter is subject operating conditions. The air filter assembly has a sediment reservoir that requires being periodically drained, removed, cleaned and re-installed. Air filters operating offshore or in humid atmospheric conditions requires more maintenance than air filters operating in dry atmospheric conditions. The air regulator is installed to provide a regulated air supply to the air motor(s) in the air pump package. Air pumps provided by CTI require a maximum 100 PSI (700 Kpa) air supply and the air regulator should be adjusted to maintain this maximum pressure setting. Air pressure in excess of the maximum will cause damage to the air motor. Maintenance frequency of the air lubricator is subject to operating frequency. The air lubricator has an air lubricant reservoir that requires being periodically filled with air lubricant. The lubricator introduces the lubricant into the airflow in controlled, minute amounts to provide lubrication for the air motor(s) and/or air cylinders.


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The lubricant flow should be adjusted to provide one drop of lubricant to the air flow every 20 seconds of full air flow. The lubricant flow is visually inspected in the small sight glass located on top of the air lubricator assembly. (See illustration below) In operations below 0C (32F), an antifreeze can be added to the air lubricant to prevent freezing of any residual moisture in the air flow. Combine one part methyl hydrate for every ten parts air lubricant, and add this mixture to the lubricant reservoir for winter use.

Pressure Snubber CTI uses pressure snubbers on the installation of all hydraulic pressure switches, hydraulic pressure gauges, and hydraulic pressure transducers to lessen fluid pulsations in the respective piping. Pressure snubbers do not require routine maintenance. However, as a media filter, pressure snubbers are subject to contamination. When contaminated, a pressure snubber may impede or prevent hydraulic pressure from reaching the intended component. Replace each snubber as required.


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PUMPS Pumps, General Each CTI BOP Control System uses one or more pumps to recharge the Accumulator (system) pressure. Each pump package is designed to provide the output volume needed to meet the intended volumetric requirements. Proper pump operation is dependant on the following:

Sufficient power (electric or air) to operate the pump under all load conditions.

A properly-operating drive motor (electric or air). A properly-operating pump control to start and stop the pump as

required. An unrestricted flow of clean, lightweight hydraulic oil delivered to

the suction port on the pump fluid end. If equipped, a properly-precharged fluid end discharge pulsation

dampener. A properly-operating fluid end discharge check valve.

General maintenance of pump systems should include routine maintenance of the power source, the drive motor, the operating fluid, the discharge pulsation dampener(s), and the discharge check valve. For specific repair maintenance information, refer to the Troubleshooting and Component Maintenance chapters in this manual. Gear Pumps CTI manufactures smaller-sized BOP Control Systems that utilize a direct-drive gear pump as an accumulator recharge pump. Periodic inspection of all pump mounting fasteners and drive hubs should be performed to ensure proper tightness. Gear pumps are non-repairable, and CTI recommends unit replacement. Cat 550, 650 Triplex Pump CTI manufacturers small to medium-sized BOP Control System that utilize either the Cat 550 or Cat 650 triplex pump as an accumulator recharge pump. Both pumps are similar in design and installation, and both are maintained in a similar manner. Daily maintenance of the Cat triplex pump is performed as follows:


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With the pump not running, visually inspect the oil level in the power end (crank case) sight glass. The oil level should be in the center of the sight glass for proper operation.

Apply one drop of light oil to each (3 total) packing gland lubrication port on the pump fluid end.

Inspect the pump for oil leaks in either the power end or fluid end. Repair as required.

Pump drive belt maintenance should be performed every 30 days as follows:


Remove the drive belt guard. Visually inspect the drive belts for excessive wear, cracks, or frayed or

damaged sections. Replace belts as required. Visually inspect the drive belts for proper tightness. There should be

1/2 deflection of the drive belt midway between the drive and drive pulley. Tighten as required.

Install the drive belt guard. Unlock and turn on the electrical power source for the pump drive

motor.

Bear BX10, BD30, BD60 Triplex Pump CTI manufactures medium to large BOP Control Systems that utilize one of the Bear BX10, BD30 or BD60 triplex


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pumps as an accumulator recharge pump. These pumps are similar in design and installation, and are maintained in a similar manner. Daily maintenance of the Bear triplex pump is performed as follows:

With the pump not running, visually inspect the oil level in the power end (crank case) sight glass. The oil level should be in the center of the sight glass for proper operation.

Inspect the pump for oil leaks in either the power end or fluid end. Repair as required.

Pump drive belt maintenance should be performed every 30 days as follows:


Remove the drive belt guard.

Visually inspect the drive belts for excessive wear, cracks, or frayed or

damaged sections. Replace belts as required. The Bear series of pumps are installed using a poly-chain drive belt configuration. When adjusting or replacing this belt, care must be taken to ensure the pump crankshaft and electric motor shaft maintain parallel axis. Failure to do so will result in poor belt tracking and premature belt wear. Alignment of the axis of both shafts is accomplished using the four (4) adjustment jacks supporting the motor mount plate.


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Visually inspect the drive belts for proper tightness. There should be 1/4 deflection of the drive belt midway between the drive and drive pulley. Move all 4 motor mount adjusters equally to ensure motor mount plate remains parallel to base plate. To operate each motor mount


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adjuster, loosen each lock nut, loosen 2 flange capscrews each, and turn adjustment nut. Tighten the drive belt tension as required.

Install the drive belt guard. Unlock and turn on the electrical power source for the pump drive

motor.

Accumulators

BOP Control Systems manufactured by CTI use accumulators that vary in design and size to meet the intended application. Irregardless of these variances, each accumulator requires routine maintenance to ensure proper operation. Routine maintenance of accumulators includes the following:

Test and adjust all accumulator and pulsation dampener precharge

pressure prior to the start of each well. Test and adjust all accumulator and pulsation dampener precharge

every 30 days of continuous operation.

NOTE: Use nitrogen only for precharging accumulators. Use of other gases may cause an explosion resulting in equipment damage, personal injury or death.


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Testing of the accumulator and pulsation dampener precharge should be performed as follows:

Turn off and lock out the power source(s) (electric and air) for all

system recharge pumps. Open the system bleed valve and bleed the Accumulator pressure to 0

PSI (0 Kpa). Remove the valve guard and valve cap from the accumulator. Connect the charging adapter and charging gauge to the gas valve.

Tighten securely to prevent gas leaks. Close the charging adapter bleed valve. Open the gas valve by rotating the valve screw in the charging adapter

clockwise (RH thread). DO NOT OVERTIGHTEN. Read the accumulator precharge pressure on the charging gauge. The

accumulator precharge pressure should be as shown the Precharge Pressure Table shown below.

Close the gas valve by rotating the valve screw in the charging adapter counter-clockwise.

Open the charging adapter bleed valve to vent nitrogen trapped in the charging adapter.

Remove the charging adapter. Test for valve core sealing integrity using a commercially-available liquid leak detector (IE: Snoop). Use compressed air to remove any excess leak detector from the valve stem following the test. Re-install the valve cap and valve guard.

Adjusting the nitrogen precharge in the accumulator should be performed as follows:

Turn off and lock out the power source(s) (electric and air) for all system recharge pumps.

Open the system bleed valve and bleed the Accumulator pressure to 0 PSI (0 Kpa).

Remove the valve guard and valve cap from the accumulator. Connect the charging adapter and charging gauge to the gas valve.

Tighten securely to prevent gas leaks. Close the charging adapter bleed valve. Connect the nitrogen fitting to an approved cylinder of compressed

nitrogen. Tighten securely to prevent gas leaks. Connect the nitrogen fill hose to both the nitrogen fitting and the

charging adapter. Tighten securely to prevent gas leaks.


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Open the gas valve by rotating the valve screw in the charging adapter clockwise (RH thread). DO NOT OVERTIGHTEN.

Slowly open the nitrogen cylinder and allow nitrogen to flow into the accumulator. Fill the accumulator precharge to the required pressure as indicated on the charging gauge. Close the nitrogen cylinder to discontinue precharging. Allow for the temperature of the precharge gas and the accumulator to return to ambient prior to making final pressure reading.

Close the gas valve by rotating the valve screw in the charging adapter counter-clockwise.

Open the charging adapter bleed valve to vent nitrogen trapped in the charging adapter and charging hose.

Remove the charging adapter. Test for valve core sealing integrity using a commercially-available liquid leak detector (IE: Snoop). Use compressed air to remove any excess leak detector from the valve stem following the test. Re-install the valve cap and valve guard.

Soft Start System Each triplex pump is equipped with a simple Soft-Start System designed to unload hydraulic pressure from the pump fluid end after the pump has stopped


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operating. This system incorporates the primary pulsation dampener and a metering valve to provide easy pump starting at high accumulator pressures. Hydraulic fluid is tubed from the pump discharge port to a metering valve inside the fluid reservoir. The metering valve is adjusted to approximately 2 turns open, and will continually vent a small amount of hydraulic fluid to the reservoir when the pump is operating. When the pump stops, the metering valve will continue venting until all discharge pressure has been vented from the pump fluid end and the primary pulsation dampener. When the pump starts again, the discharge pressure starts at Zero, increases to the precharge pressure in the primary dampener, fills the primary pulsation dampener until discharge pressure increases to the current Accumulator pressure, and then commences pumping Accumulator pressure. This gradual application of load on the pump allows the pump and electric motor to reach maximum RPM without stalling. It may be necessary to open and flush the metering valve while the pump is operating to discharge any contaminating material such as thread tape from the valve. Re-adjust the metering valve to 2 turns open. Proper adjustment is such that the primary pulsation dampener discharges fluid for 10-12 seconds after the pump stops operating. The metering valve is accessed through the 4 inspection port on the left end of the reservoir.


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COMPONENT MAINTENANCE SCHEDULE

EACH WELL DAILY

1 MONTH

1 YEAR

AS REQD

Reservoir fluid x x Clean/replace pump suction screen or filter x x Inspect triplex pump power end oil level x x Change triplex pump power end oil x Inspect triplex pump drive belt tension x x Inspect/adjust triplex pump pulsation dampener precharge

x x

Inspect triplex pump plunger packing, fluid end seals, power end seals for leaks

x x

Inspect air pump plunger packing, fluid end seals for leaks.

x x

Inspect/adjust accumulator precharge x x Clean/replace high pressure screen x x Replace high pressure filter x x Replace pressure snubber x x Drain and clean air filter x x Inspect air regulator x Inspect air lubricator x Inspect/tighten pump mounting fasteners x x Inspect/tighten all control valve actuator fasteners

x x

CHAPTER FIVE COMPONENT MAINTENANCE

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MAIN UNIT Suction Screen Assembly


- Low-volume gear pumps (typically up to 5 GPM) use a 20-mesh suction screen mounted in a y-strainer housing in the pump suction piping. The suction screen should be cleaned prior to each start-up, and every 30 days of continuous operation. Clean / replace the suction screen on the pump suction line as follows:

Lock out the pump system(s) to ensure safe maintenance conditions. Close the pump suction valve. Remove the y-strainer housing cap and then remove the screen. Clean

or replace the screen as required, and re-install in the housing. Apply clean oil to the gasket on the housing cap and install in the

housing. Tighten to 20 ft/ lbs. Open the pump suction valve. Open the pump discharge bleed valve (if so equipped). Unlock and turn on the electrical power source for the pump drive

motor. Turn on the pump motor and allow the pump to operate while excess air

in the pump discharge is vented through the pump discharge bleed valve.


The pump can now be returned to normal operations. Low Volume Gear Pumps CTI recommends unit replacement. Triplex Pumps Refer to the Manufacturers Service Manual as provided. Pump Motor Starter Inspect inside the motor starter enclosure for broken or loose components or wiring. If tripped, re-set the heaters by depressing the heater contacts fully. If motor starter repair or replacement is required, CTI recommends this service be performed by a qualified electrician. Pump Pressure Switch The pump pressure switch operates the control circuit in the pumps motor starter to start and stop the pump motor. The switch is field adjustable. If replacement is required, CTI recommends this service be performed by a qualified electrician.


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3/4 3500 PSI Pressure Relief Valve - This relief valve is set to fully open at 3500 PSI / 24500 Kpa, and is piped to direct relieving pressure to the fluid reservoir. The valve is self resetting when the pressure decreases below 3300 PSI / 23100 Kpa. In the event of valve failure CTI recommends unit replacement. 1/4 3000 Check Valve - In the event of valve failure CTI recommends unit replacement. 1/2 3000 Check Valve - In the event of valve failure CTI recommends unit replacement. 1/2 5000 Ball Valve - In the event of valve failure CTI recommends unit replacement. 1/2 5000 Needle Valve (Bleed) - In the event of valve failure CTI recommends unit replacement. 1-1/4 Return Line Filter Element CTI recommends unit replacement. ACCUMULATOR MANIFOLD

11 AND 15-US Gallon Top-Repairable Accumulator Caution must be used when preparing to service this accumulator. High pressure nitrogen and / or hydraulic oil may be trapped in the pressure vessel and must be vented prior to


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disassembly of the pressure vessel. Service of this accumulator is performed as follows:

Bleed Accumulator pressure to zero. Lock out the pump system(s) to ensure safe maintenance conditions.

Connect the accumulator charging valve to the gas valve on the top of the accumulator. Rotate the charging valve operating stem clockwise to open the gas valve. Do not over tighten. Vent all nitrogen from the accumulator.

Remove the charging valve from the accumulator. Loosen and remove the outer lock nut on the top adapter assembly. Remove the spacer, back-up ring, o-ring and metal back-up ring from the

top adapter assembly. Remove the anti-extrusion ring and top adapter assembly. The bladder will

remove with the top adapter assembly. Loosen and remove the bladder retainer nut on the top adapter of the

accumulator. Install the new bladder stem in the top adapter assembly. Install the

bladder retainer nut on the bladder stem.


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Install the bladder, top adapter assembly and anti-extrusion ring in the accumulator.

Install the metal back-up ring, o-ring, back-up ring and spacer on the top adapter assembly.

Install the outer lock not on the top adapter assembly and tighten to 30 ft. lbs.

Precharge the accumulator as required prior to returning to service. See precharge instruction contained in the SYSTEM MAINTENANCE chapter in this manual.

Accumulator Isolation Valve

Bleed Accumulator pressure to zero. Lock out the pump system(s) to ensure safe maintenance conditions.

This valve is not accessible for repair when the control system is in operation. The control system must be removed from service prior to repairing this valve. Repair is performed as follows:

Loosen and remove the gland nut from the isolation block by rotating the gland nut counter-clockwise.

Remove the valve stem from the gland nut by rotating the valve stem counter-clockwise.


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Replace the two o-rings on the gland nut and replace the stem seal on the valve stem.

Assemble the valve stem in the gland nut. Ensure the valve stem is fully threaded into the gland nut. Install the gland nut and valve stem assembly in the isolation block. Torque the gland nut to 40 ft-lb.

The accumulator isolation valve can now be returned to service. 1/4 3000 3-Position 4-Way Manipulator Valve, Spring Centered (Remote)

Bleed system pressure to zero. Lock out the pump system(s) to ensure safe maintenance conditions.

Care must be taken when repairing this valve. There are numerous internal components that require proper alignment during assembly to ensure safe valve operation. That said, the valve can typically be repaired without removing the valve from the system piping. Perform the disassembly, repair and assembly as follows:

Remove the valve handle nut, washer, handle, handle spacer, spring cover and return spring from the front housing.

Remove the snap ring and detent disc from the operating stem. Remove the four bolts, lock washers and nuts from the valve housings.

Ensure the valve sections remain fully engaged until completely unbolted. Rotate the front housing forward and downward to remove from the body.

Lightly clamp the front housing in a suitable vise with the operating stem

pointing downward. Remove the rotor, bearing assembly and operating stem. Make careful note of rotor orientation in relationship to the front housing. Visually inspect the rotor seal surface, bearing assembly, operating stem and front housing for wear and mechanical damage. Replace worn or damaged components and all seals as required.

Remove the three seal seats and wave springs from the body. Inspect the seal surfaces on the body for wear and mechanical damage. Replace worn or damaged components and all seals and wave springs as required.

Install all wave springs, seals seats and seals in the body.


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Install all seals, operating stem, bearing assembly and rotor in front

housing. Use a general-purpose grease to maintain position of loosely assembled components. Ensure rotor is installed in proper orientation.

Remove the front housing from the vice and install on the body. Rotate the front housing upwards and inwards to install on the body. This will maintain the positioning of the loosely assembled components in the front housing. Install the four bolts, nuts and lock washers. Ensure the two valve sections remain fully engaged until completely bolted. Tighten the four bolts.

Install the detent disc and snap ring on the operating stem. Install the return spring, handle spacer, spring cover, handle, washer and

nut. The valve can now be returned to service.

1/2 and 1 3-Position 4-Way BOP Control Valve - Care must be taken when repairing this valve. There are numerous internal components that require proper alignment during assembly to ensure safe valve operation. That said, the valve can typically be repaired without removing the valve from the system piping. Perform the disassembly, repair and assembly as follows:


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Bleed system pressure to zero. Lock out the pump system(s) to ensure safe maintenance conditions.

Remove the valve handle nut, washer, handle, handle spacer, hydraulic cylinder, clevis, and two valve assembly bolts nuts and lock washers, and cylinder mounting plate, from the front housing.

Remove the snap ring, detent disc, and detent ball and detent spring from the operating stem.

Remove the remaining two valve assembly bolts, lock washers and nuts from the valve housings. Ensure the valve sections remain fully engaged until completely unbolted. Rotate the front housing forward and downward to remove from the body.

Lightly clamp the front housing in a suitable vise with the operating stem pointing downward. Remove the rotor, bearing assembly and operating stem. Make careful note of rotor orientation in relationship to the front housing. Visually inspect the rotor seal surface, bearing assembly, operating stem and front housing for wear and mechanical damage. Replace worn or damaged components and all seals as required.

Remove the three seal seats and wave springs from the body. Inspect the seal surfaces on the body for wear and mechanical damage. Replace worn or damaged components and all seals and wave springs as required.

Install all wave springs, seals seats and seals in the body. Install all seals, operating stem, bearing assembly and rotor in front

housing. Use a general-purpose grease to maintain position of loosely assembled components. Ensure rotor is installed in proper orientation.

Remove the front housing from the vice and install on the body. Rotate the front housing upwards and inwards to install on the body. This will maintain the positioning of the loosely assembled components in the front housing. Install the top two valve assembly bolts, nuts and lock washers. Install the cylinder mounting plate and bottom two valve assembly bolts nuts and lock washers. Ensure the two valve sections completely until completely bolted. Tighten the four valve assembly bolts.

Install the detent disc and snap ring on the operating stem.


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Install the handle spacer, handle, cylinder spacer, hydraulic cylinder, clevis, washer and nut. Check and adjust cylinder travel as required.

The valve can now be returned to service.

Hydraulic Cylinder, 1-1/2 Bore, 2-1/4 Stroke

Lock out the remote valves on the main unit to ensure safe maintenance conditions.

Repair of this cylinder is performed as follows:

Remove the cylinder from the mounting bracket. Remove the clevis and jam nut from the piston rod.

Remove the four cylinder assembly bolts and nuts. Remove the rear end cap. Slide the front end cap off the piston rod. Slide the piston and piston rod from the cylinder. Remove the o-rings from the piston and the front end cap.

Visually inspect the piston, piston rod, cylinder bore and front end cap bore for wear and mechanical damage. Repair or replace as necessary.

Install new seals and assemble the cylinder. Take care to align both end caps during assembly. Torque the four assembly bolts evenly to 5 ft-lbs and then to 15 ft-lbs. Ensure piston rod moves freely during assembly and tightening.


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Install the jam nut and clevis on the piston rod. Install the cylinder on the mounting bracket. Adjust the clevis threaded position on the piston rod to ensure the cylinder operates the valve fully. Tighten the jam nut to lock the clevis on the piston rod.

The cylinder can now be returned to service. 1/2 and 1 3000 Pressure Regulating / Relieving Valve (Manifold and Annular Regulator)

Lock out the triplex pump and bleed system pressure to zero to ensure safe maintenance conditions.

Repair of this valve is performed as follows:

Remove the regulator from the manifold piping by loosening the piping unions.

Using die stamps, identify positioning on the valve body and all bolted flanges on the valve body to ensure proper assembly.

Remove all bolted flanges from the valve body. Inspect all internal components and elastomers for wear and/or

mechanical damage. Repair or replace as required. Assemble regulator. Ensure all internal components and external bolted

flanges are in proper orientation.


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KR75 Full-Flow Regulator (Typical)

ITEM QTY DESCRIPTION 1 1 Body 2 1 Lower Flange 3 1 Inlet/Vent Flange 4 1 Blind Flange 5 1 Outlet Flange 6 1 Manual Operator 7 1 Supply Flow Plate 8 1 Blind Flow Plate 9 1 Seal Container 10 1 Pin 11 1 Piston 12 1 Piston Guide 13 4 Capscrew 14 38 Capscrew 15 2 Vent Seal Ring 16 2 O-ring 17 2 Back-up Ring 18 1 Wave Spring 19 4 Supply Seal Ring 20 4 Back-up Ring 21 4 O-ring 22 2 Spring 23 1 O-ring 24 1 Back-up Ring 25 2 O-ring 26 2 O-ring 27 1 Pin Retainer


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ITEM QTY DESCRIPTION

1 1 Body 2 1 Lower Flange 3 1 Inlet Flange 4 1 Vent Flange 5 1 Outlet Port 6 1 Manual Operator 7 1 Supply Flow Plate 8 1 Vent Flow Plate 9 1 Seal Container 10 1 O-ring 11 1 Back-up Ring 12 1 Piston Guide 13 4 Capscrew 14 22 Capscrew 15 2 Supply Seal Ring 16 2 O-ring 17 2 Back-up Ring 18 1 Spring 19 4 Vent Seal Ring 20 4 Back-up Ring 21 4 O-ring 22 2 Spring 23 1 O-ring 24 4 O-ring 25 1 O-ring 26 2 O-ring 27 1 Back-up ring 28 1 O-ring


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Install the regulator in the manifold piping and tighten the piping unions. Remove the triplex lock-out. Close the bleed valve. Operate the triplex

pump to full system pressure. Inspect the regulator for proper operation.

E/H PLC COMPONENTS

Close the E/H Manifold Isolation valve on the lower left exterior of the E/H PLC enclosure.

E/H Manifold Supply Filter The E/H Manifold supply filter can be serviced while the BOP system is in operation. Service is performed as follows;

Push and release the Push-To-Operate pushbutton on the Drillers Remote Panel numerous times. This will vent hydraulic pressure trapped in the E/H Manifold.

Remove the hex cap on the filter housing by rotating counter-clockwise. Replace the filter element. Install and tighten. Open the E/H Manifold Isolation Valve.


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SV3 Solenoid Valve The SV3 solenoid valve is used as an E/H master valve. The SV3 prevents hydraulic flow to the E/H manifold until energized. The solenoid is energized by pushing and holding the Push-To-Operate pushbutton on the Drillers Remote Panel. The SV3 Solenoid valve is serviced using replaceable components. The valve body, the valve cartridge and valve coil are replaceable. Contact CTI for additional information. E/H Solenoid Manifold The E/H Solenoid manifold is a custom-order 8-station solenoid manifold, and must be replaced if damaged. DG4V Solenoid Valve The DG4V solenoid valve is a 3-position 4-way manipulator valve, and is used as a remote function solenoid. Each DG4V solenoid operates a specific remote function on the E/H Manifold. Energizing Coil A will cause flow out Port A, while venting Port B to the fluid reservoir. Energizing Coil B will cause flow out Port B, while venting Port A to the fluid reservoir. When both coils are de-energized, the valve will vent both Port A and Port B to the fluid reservoir. The solenoid valve and solenoid coils are both available as component-replacement parts. Pressure Transducer Pressure transducers sense hydraulic pressure and convert this to an electrical signal. The signal is used by the PLC to operate the corresponding pressure meters in the Drillers Remote panel. CTI recommends unit replacement.

Pressure switches are connected to the Open and Close piping for each of the six control stations on the control manifold. When hydraulic Open or Close pressure is applied to the switch from the respective control station piping, the

Pressure Switch E/H PLC


14 / 14

switchs plunger will close the switchs electrical circuit to the PLC. The PLC will use this electrical input to operate the corresponding light in the Drillers Remote Panel. Use electrical pins Common and Normally Open.

OFF/ON

OR'WG BY: TG DATE: Apr 14/0:3 DRVG #: n/a

CHKD BY: DATE: PAGE ___ OF

208V 30 230V /240V 30 460V I 480V 30

REV. #: n/a

SCALE: NOT TO SCALE

L3 fl2 From Motor Run 1

Auxiliary Contact

tl3 To Motor Run 2

SIZE 2 MOTOR STARTER WIRING SCHEMATIC

(DN"TRo~CHN:=aGY .. _____ .. INC .~

: L1

OFF/ON

DR'w'G BY: TG DATE: Apr 14/03 DRVG II: n/a REV. #: CHKO BY: DATE: PAGE OF SCALE:

480V 30

n/a

NOT TO SCALE

I I

: L3

SIZE 2 MOTOR STARTER WIRING SCHEMATIC

(DNTRo~CHN6aGY .. _____ .. INC.~

1 of 2

BOP Control Systems Recommended 2-year spare parts

NOTE: Please contact CTI Sales department for a quotation based on your specific unit design. All items listed below are in general terms description. Each item must be sized based on the components that have been used on that unit, for which the spare parts list is being prepared. HYDRAULIC / MECHANICAL PARTS QTY DESCRIPTION NOTE 1 Regulator Repair Kit For each size of regulator on system 1 Control Valve Repair Kit For each size of control valve on system *excluding bypass valve 1 Actuator Seal Kit Type and size as used on system 1 Relief Valve For each size and pressure of relief valve on system 1 Filter For each size and type of filter on system 1 Set Pump Packing If required, matching pump on system 1 Set (piece) Drive Belts As used on system 1 Pressure Gauge For each size and pressure used on system 2 Accumulator Bladder with Seal Kit Sized to match system accumulators *EXCLUDING PILOT ACCUMULATOR AND DAMPNERS 2 Accumulator Gas Valve To match size on system accumulators 2 Isolation Valve Seal Kit For every 12 ISO blocks on system, rounded up. (14 isolation valves require 4 seal kits).

2 of 2

ELECTRICAL PARTS NOTE: All electrical parts must be of equal class and zone rating as system. QTY DESCRIPTION NOTE 1 Pressure Meter For each size used in drillers panel *ONLY IF CTI SUPPLIED PANEL 1 Push Button Control with Terminal Block 2 Indicator Light Bulbs (clear) To match voltage of bulbs used on system 1 Set Fuses Sand Filled To match size and quantity used on system 2 Snubber Valves

PART

SE1.CTORVALVES \t \\ \J /S I , '\ ~ , ':s"\

l ACTUATOR Cvt.fNOERS, \D \L C\ L .. \\ 1 \\o(,o ')~-\')

I BYPASS VALVE I 0 '"L[) \

I REIIOTE PiLOT BOTTLE y '-\ s ~ ~ Co

..

SERIAL NUMBER I NATIONAL BOARD #-l~~eo1o 4So~\O 2 S~

IDNT:C;~ECHN~Y -----J:Nl:.~ CUSTOMER Ensign

END USER PROJECT QUOTE# 688611

CONTACT

CONTACT RIG#

BOP CONTROL SYSTEM DESIGN SUMMARY

CUSTOMER INFORMATION

Pat Mackenzie PHONE

PHONE PU#22

SALES REP Barrie Meyer

SYSTEM PRESSURES

QF-20 Rev.4 Apr6. 2011

DATE {sales) Nov.3/11 DATE {eng) Nov.3/11

0 Customer Request for Design Review (OF 09) 403.262.1361 EMAIL

EMAIL

31129

SYSTEM PRESSURE 3000 AIH SUB-SYSTEM PRESSURE H/H or EIH SUB-SYSTEM PRESSURE 1500

GOVERNING SPECIFICATIONS

API16D

EQUIPMENT LOCATIONS

HPU LCTN Combo Building R1 LCTN Dog House R2 LCTN R3LCTN R4LCTN OTHER

ENVIRONMENT

ONSHORE X INDOORS X TROPICAL MILD X COLD OFFSHORE OUTDOORS EXT. COLD POLAR CRITICAL HPUTEMP Mild R1 TEMP. Mild R2TEMP.

R3TEMP

- - - . ' .

..... -.', --:.:: .:::::-:;-,:::;.,-::;.::::-.:

CODE R2

Environment

Tropical Mild Cold

NEC

R4 TEMP. BOP TEMP.

Ambient Temperature Classification Chart

High Low

140 32 120 20 120 -4

HPU

R3

Degrees c High Low

60 0 50 50

-13 -20

Environment

Extreme Cold Polar

ELECTRICAL ZONE SPECIFICATIONS

Safe Area

FUNCTIONAL REQUIREMENTS

-23 120 -40

R1

R4

BOP MAKE MODEL SIZE + PRESSURE CLOSE VOLUME UPPER ANNULAR Shaffer Spherical 13-5/8" 10M 40.16 LOWER ANNULAR UPPER PIPE RAM Cameron u 13-5/8" 10M 5.8 BLIND RAM Cameron u 13-5/8" 10M 5.8 LOWER PIPE RAM Cameron u 13-518" 10M 5.8 UPPER HCR Cameron FLS 3-1/8" 10M 0.383 LOWERHCR

OTHER

OTHER VOLUMETRIC SPEC. VOLUMETRIC REQUIREMENT

ADD CTI10% REQUIREMENT ADDITIONAL INFORMATION: TOTAL VOL. REQUIREMENT

Pao~r cooiP.!; artlt uncontrolled. Thi5 coov valtd onlv at t:imP- of orinfino Current [email protected]$ion av;iilabl~ from OAOC..

Low

-30 -40

Safe Area

OPEN VOLUME

104 268

N/A 104.268

E:CFH~T QF-20, REV. 4. Apr 6, 2011 BOP CONTROL SYSTEM DESIGN SUMMARY DATE (sales) Nov.3/11 :tNt:. DATE (eng) Nov3/11

SKID I ENCLOSURE LENGTH 146 WIDTH 78 BEAM SIZE W6@ 15 Wide Flange Beam X-MEM. SIZE 4" x 4" X 0 25" Angle

LIFT POCKETS ~ ROLL ENDS LIFT FRAME RAIN ROOF INSULATED WALLS I HEAT A/C GEN.SET LIGHTING WlfiiDOWS

FLUID RESERVOIR

LENGTH 124 WIDTH 30 HEIGHT 44 FRAME MT. X SKIDMT. X VENT SZ 1-1 #OF BAFFLES 4 USABLE VOL 515 3 MAT'L. 1/4" Mild Steel Group 1

PUMPS

PRIMARY PUMP OiY 1 MOO~ B0-60 GF'M 24.0 I'OWF.:R REQUIREMENT 50HP 3PH SOOV TEFC Motor SECONDARY PUMP QTY 1 MODEL BD-60 GPM 24 0 POWER REQUIREMENT SOHP 3PH 600V TEFC Motor

PRESSURE SAFETY VALVES

ACC. MANIFOLD SIZE 1" CRACK PSI 3300 FULL OPEN PSI 3500 CERTIFICATION Yes

CNTRL MANIFOLD SIZE CRACK PSI FULL OPEN PSI CERTIFICATION

TEMP.COMP. SIZE CRACK PSI FULL OPEN PSI CERTIFICATION

ACCUMULATOR MANIFOLD

QTY. BANKS 2 QTY BTLS PER BANK 10 ISO PER BANK 0 GAUGE PER BANK 2 BLEED PER BANK 2 BOTTLE SIZE 15 BOTTOM LOAD TOP LOAD X HPU MOUNTED BLEED PER BTL

STAND-ALONE X TOTAL VOLUME 300 NET VOLUME 280 CONFIGURATION 00000 Back To Back

HPU MANIFOLD 0 HIH REMOTE (Note: Manifold Regulator is alwavs located on HPU) 0 OTHER REGULATOR SIZE 3i4" MANUAL X AIR FAILSAFE HYD FAILSAFE ADJ. RANGE 03000 PSI

BYPASS SIZE 1" MANUAL AIR PILOT HYO. PILOT X QUICK OPEN X

UPPER PIPE SIZE 1" MANUAL AIR PILOT HYD PILOT ~ PSI RATING 3000 PSI

BLIND RAM SIZE 1" MANUAL AIR PILOT HYD. PILOT X PSI RATING 3000 PSI LOWER PIPE SIZE 1" MANUAL AIR PILOT HYD. PILOT X PSI RATING 3000 PSI

UPPERHCR SIZE I" MANUAL AIR PILOT HYD. PILOT X PSI RATING 3000 PSI

LOWERHCR SIZE MANUAL AIR PILOT HYD PILOT PSI RATING

SHEAR SlZE MANUAL AIR PILOT HYD. PILOT PSI RATING

AUXILIARY SIZE 1" MANUAL AIR PILOT HYD. PILOT X PSI RATING 3000 PSI

READBACKS ACC X MAN PRESS X UANN PRESS X LANN PRESS RIG AIR

ANNULAR 0 H/HREMOTE 0 OTHER UREGULATOR SIZE H/2" MANUAL AIR FAILSAFE HYD FAILSAFE X ADJ. RANGE 03000 PSt

UBYPASS SIZE MANUAL AIR PILOT HYO. PILOT QUICK OPEN

UANNULAR SIZE 1-1/2" MANUAL AIR PILOT HYD. PILOT X PSI RATING 3000 PSI

LREGULATOR SIZE MANUAL AIR FAILSAFE HYD FAILSAFE ADJ. RANGE

LBYPASS SIZE MANUAL AIR PILOT HYO. PILOT QUICK OPEN

LANNULAR SIZE MANUAL AIR PILOT HYD. PILOT PSI RATING

0 REMOTE CONTROL STATIONS 0 H/H MAIN UNIT QUANTITY A/H H/H E/H E/APLC E/H PLC OTHER

FNCTNS I SIZE U.ANN L.ANN U. PIPE BLIND L. PIPE SHEAR U.HCR L. HCR MANBYP MAN. INC/DEC U ANN BYP L ANN SYP U ANN INC/DEC

L. ANN INC/DEC OTHER 1 0THER2 UNITS TOGGLE 2ND LANGUAGE

READ BACKS ACC. PRESS MAN. PRESS. U ANN PRESS L ANN PRESS RIG AIR

INDICATIONS PUMP 1 RUN P1 RUNTIME PUMP 2RUN P2 RUN TIME LAMP TEST

ALARMS ACC PRESS. FLUID LEVEL EXT PUMP 1 RUN EXT PUMP 2 RUN HMIORPB

AIC POWER LOSS UPS & VOLTAGE PLC BRAND By Customer

NITROGEN

N2 BACK-UP X QTY 6 SIZE SOL SHEAR BOOST QTY SIZE

VENDORS

HPU I CTI REMOTES Peco INSTALL Ensign

A duly authorized customer representative hereby agrees that the information provided for this inquiry is accurate to the best of their knowledge, and will form the basis of our estimate, and subsequent contract to furnish the corresponding system.

Signature: Dated:

P

CNTRCL

MAILING ADDRESS 6828 52 AVENUE RED DEER, AB. T4N 4L 1

accumulator - copia

Documents

system description chapter

system maintenance chapter

cti bop control system

storage of system

system application

system troubleshooting

system oepration chapter

bop control systemapi