User Manual Modular BOP System (Dual)
Contents
1. DETAIL EQUALISATION BLOCK SET UP ASSEMBLY INSTRUCTIONS FOR 6 3 8 DUAL MODULAR DWG No 3653 OPS 3653 Rev A User Manual Phuel Modular BOP System Dual COMPLETE ASSEMBLY INSTRUCTIONS FOR 6 3 8 DUAL MODULAR DWG No 3653 OPS 3653 Rev Phuel User Manual Modular BOP System Dual 5 7 Maintenance Record Sheet Date Performed Maintenance Type of Performed By Verified By Comments OPS 3653 Rev A Table 2 Maintenance Record 19 User Manual Phuel Modular BOP System Dual OIL TOOLS 6 Testing All testing is to be carried out in the designated test area and by suitably qualified and competent personnel WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous It has enough stored energy to separate parts with considerable force 6 1 Prepare BOP for pressure testing Check the pressure rating for test equipment is sufficient to allow testing to be carried out Check replace o ring on the pin part of the BOP Ensure BOP is placed in an area suitable for pressure testing Fit the BOP to the test stump Makeup BOP collar on test stump by turning the collar all the way down and then back off 1 4 turn2. 12 5 6 Modular 12 5 6 1 Splitting the Connection 12 5 6 2 Re Making the Connection sees 13 5 7 Maintenance Record 19 RE EE ert 20 61 Prepare BOP for pressure 20 6 2 Body area 20 6 3 Wireline Ram Seal Test Between the 21 6 4 Post Test Procedure a a 21 7 Pans List Drawings e 22 8 lt gt ut 34 OPS 3653 Rev User Manual Phuel Modular BOP System Dual OIL TOOLS Table 4 Technical Data eag agawa gae ea Ek aan 3 Table 2 Maintenance 19 Table 3 193 3568 HV0 Parts List eee 22 Table 4 Modular Body 196 3145 HV0 25 Table 5 Actuator Assembly 190 2476 0 27 Table 6 Wireline Ram Assy 190 3863 29 Table 7 Equalisatloh ASSY bes aaa a REEERE at 30 Table 8 Bolted Collar Parts List 196 3497 0 31 Table 180919 VD 7A KA AA 32 Table 10 190 317
3. Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen 23 8JW User Manual Modular BOP System This Manual Covers the Following Part Numbers 193 3653 HVO OPS 3653 Rev User Manual QPhuel Modular BOP System Dual OIL TOOLS Table of Contents Revision History RE sci EE EE RER RE iv 1 e cn EEUU 1 c r 1 1 2 Product Identification eio ctae anana aane enn 1 2 Technical Speed 3 3 Technical Description 5 31 Basic Description Me 5 EET 6 41 Operating the u uu 6 4 1 1 Hydraulic Operation T 6 Al Manual Operation EO EO 6 4 1 3 Locking the TROIS cc uu u a 6 42 Equalising across the 7 4 37 Job Planing 2 ER 8 4 3 1 Before the Job MEME 8 4 3 2 During the Tc 8 4 3 3 After the Job Lee 8 S Maintenance RET E 9 5 1 sr PEER ERE RE 9 52 PE AA 9 5 2 1 Pre amp Post ojo OR ee eee 9 522 gt RAY 9 5 2 3 Five NEA del 9 2 NG 9 Re 10 55 Ram Seal Redress dekoder 10 5 5 1 Access EE KA 10 5 5 2 Ram Removal not required to redress ram seals 11 5 5 3 Ram Seal Redress 11 5 5 4 Re attach to BOP Body ende
4. seer 33 Table 11 BOP Redress Kit 3653 34 Table 12 Actuator Redress Kit RDK 2476 HH0 34 Table 13 Wireline Ram Redress Kit RDK 3863 HH0 34 Table 14 Equalisation Isolation Redress Kit 2806 34 Figure 1 Section through BOP rams closed position 5 Figure 2 Accessing the 11 Figure 3 BOP Wireline REPE e Coda ANG 11 Figure 4 Example of Single bolted collar and lock block 13 Figure 5 Modular 192 3653 0 24 Figure 6 Modular Body rer 26 Figure 7 6 3 8 Actuator Part No 190 2476 HV0 28 Figure 8 Wireline Ram Assy 190 3863 0 29 Figure 9 Equalisation ASSY aaa KA 30 Figure 10 Bolted Collar Assembly 196 3497 0 31 OPS 3653 Rev A ii Phuel User Manual Modular BOP System Dual Revision History Issue Release Date Description Rev A 03 Mar 11 Initial Issue OPS 3653 Rev User Manual Phuel Modular BOP System Dual OIL TOOLS Safety WARNING Trapped air requires considerable time to compress and when it is compressed is hi
5. Fill the BOP with test fluid to above the Upper Ram Close the Upper Ram by setting Ram to 2700 psi by activating the valves on the BCU to close position Pump test medium thru the equalizing Block 1C to see fluid is rising above the upper ram Close equalizing valve 1C 2A 2D 3A 3B Open equalizing valve 1A 1B 1D Put up safety barrier in the workshop Pressure up to 300 psi in 5 minutes and observe for leaks Bleed off to zero Press up to MWP for bop according to documentation for current bop for 15 min Bleed pressure to zero Open the rams open lower first and then the upper ram 4 Post Test Procedure Disconnect All Hoses Remove Test Cap Remove BOP from Test Stump Grease end connections and fit oiled thread protectors OPS 3653 Rev A 21 Phuel User Manual Modular BOP System Dual 7 Parts List and Drawings Item Number Part Number Quantity Description 1 196 3145 2 6 3 8 MULTILINE BODY ASSY 3 196 3497 HSO 3 CONNECTING COLLAR ASSY 4 196 3151 HSO 1 11 1 2 QU TOP SUB ASSY 5 196 3152 HVO 1 11 1 2 QU BOTTOM ASSY 7 190 3997 480 1 RIGHT ANGLED PORT 10K 8 190 2821 316 2 PORT BLANK END 9 190 3998 HVO 1 EQUALISING CHECK VALVE 10K 10 190 3170 HVO 1 SAVER INJECTION ASSY 11 190 3171 HVO 1 BLANK SAVER ASSY 13 190 3324 316 1 EXTENSION BAR 12 625 P C D 14 801 0110 V80 5 O Ring B S Size 110 15 950 2558 316 2 1 4 S
6. is normally used to operate the BOP in an offshore environment Refer to the relevant manual for that equipment for details of operation and connection An alternative pump pack may be used for onshore maintenance work but the operation of this equipment is out with the scope of this manual IT IS IMPERATIVE THAT BOTH THE RAMS ARE CLOSED SIMULTANEOUSLY WHEN CLOSING AROUND THE WIRE Failure to follow this procedure may result in cutting or damage to the wire 4 1 2 Manual Operation The rams can be closed manually but not opened again by turning the hand wheel in a clockwise direction some 30 40 turns providing that the hydraulic fluid from the other side open port is allowed to escape The hydraulic connections must still therefore be made up to the WCU even when intending to operate the rams manually When closing around the wire IT IS IMPERATIVE THAT THE UPPER GUIDED RAM AND THEN THE LOWER GUIDED RAM IS FULLY CLOSED BEFORE CLOSING THE UPPER NON GUIDED RAM AND THEN THE LOWER NON GUIDED RAM Failure to follow this procedure may result in cutting or damage to the wire The non guided rams can be identified by the restrictor valve block attached to the return hose for the actuator This side must be closed last Once the rams have been closed using the manual method it is not possible to open them again without hydraulic pressure The Hand wheel however must still be turned in an anti clockwise direction until it stops to allow the pisto
7. 190 2823 PEK 4 VALVE SEAT 10 190 1758 416 2 AFO Plug PLAA3124010A 11 801 0108 V90 4 O Ring B S Size 108 12 801 0110 80 1 O Ring B S Size 110 13 01 0113 90 2 O Ring B S Size 113 20 SHC 0555 HTS 6 SOC HD SCREW 3 8 UNC X 3 0 LONG 21 SBC 0543 304 4 Button Hd Screw Size 3 8 Length 0 625 in 22 WNL 0540 304 10 Nord Lock Washer Size 3 8 23 190 3328 316 1 VALVE PLATE EQUALISATION BLOCK Table 7 Equalisation Assy OPS 3653 Rev Figure 9 Equalisation Assy 30 User Manual Phuel Modular BOP System Dual OIL TOOLS Number Part Number Quantity Description 196 3496 411 1 BOLTED COLLAR SHC 0673 AL7 Soc Hd Cap 3 4 UNC x 3 5 Long WNL 0660 316 WASHER NORDLOCK M12 2 5 190 2791 316 1 LOCK BLOCK 5 1 SHC 0507 HTS Soc Hd Cap Size 1 4 Length 1 in 1907804304 SPIROLROLLPINT A DIAX i Table 8 Bolted Collar Parts List 196 3497 HSO Po Figure 10 Bolted Collar Assembly 196 3497 HSO OPS 3653 Rev A 31 User Manual Phuel Modular BOP System Dual Item Part Number Quantity Description 1 190 3997 480 1 RIGHT ANGLED PORT 10K 2 100 2114 PEK 1 CHECK VALVE SEAL 3 145 2185 STL 1 COMP SPRING D22120 1 4 801 0110 80 O Ring B S Size 110 100 910 2186 N66 1 2in SHIPPING CAP PLUG Table 9 190 3159 HVO OPS 3653 Rev A 32 User
8. BOP before disconnecting the Lubricator e Hydraulic Hose ends should never be allowed to drop in to dirt or grit or otherwise become contaminated with foreign matter Any dirt or grit introduced into the BOP is very injurious to the equipment If end connections become dirty they should be cleaned thoroughly with solvent and dried e Only clean Hydraulic fluid should be used Shell Tellus 22 is recommended to operate the BOP The use of mixed types dirty or very old fluid of unknown origin is not recommended When one of these conditions is known or suspected the hydraulic system should be flushed and the hydraulic fluid replaced 4 3 3 After the Job After each job the BOP should be thoroughly cleaned repaired as may be required and redressed OPS 3653 Rev A 8 User Manual Phuel Modular BOP System Dual OIL TOOLS 5 Maintenance All maintenance to be carried out by suitably qualified and competent personnel 5 1 Introduction Regular maintenance of the equipment using Phuel redress kits or approved spares is essential to its continued safe operation Ensure that the pre and post job operating procedures are followed and that maintenance records are kept 5 2 Schedule The maintenance schedule may be governed by international or company standards and the following is considered to be the minimum requirements 5 21 Pre amp Post Job Refer to Section 4 3 1 and Section 4 3 3 for details 5 2 2 Yearly e Dis
9. Manual Phuel Modular BOP System Dual OIL TOOLS Part Number w Quantity Description 1 205 2105 480 1 BLANK TEST PORT 5 801 0119 90 1 O Ring B S Size 119 10 SHC 0583 3A4 2 Soc Hd Cap Size 1 2 Length 0 75 in 11 WNL 0580 304 2 WASHER NORDLOCK M12 Table 10 190 3171 HVO OPS 3653 Rev 33 User Manual QPhuel Modular BOP System Dual OIL TOOLS 8 Spares Use only spares supplied or approved by Phuel Oil Tools Ltd is recommended that sufficient quantities of the following spares be maintained to ensure that the equipment is always available when required Elastomeric spares are supplied in Viton material as standard Other materials are available please specify when ordering Part Number Quantity Description Comment RDK 2476 HVO Actuator Redress Kit RDK 2806 HVO Equalisation Isolation Redress Kit 801 0110 V80 O Ring BS 110 801 0119 V90 O Ring BS 119 801 0443 V90 O Ring BS 443 Bottom Sub 00 o 802 2921 V80 7 642 T SEAL WITH BACK UPS Table 11 BOP Redress Kit RDK 3653 HVO Part Number Quantity Description Comment 801 0345 V90 O Ring B S Size 345 801 0342 V90 O Ring B S Size 342 801 0344 V90 O Ring B S Size 344 801 0439 V90 O Ring B S Size 439 802 2505 H85 ROD T SEAL 0 825 DIA 802 2162 H85 ROD T SEAL 1 625 802 2161 H85 PISTON T SEAL 4 000 802 1699 H85 Rod T seal Assy TR004
10. Table 12 Actuator Redress Kit RDK 2476 HHO a Part Number Quantity Description Comment 190 1715 H70 4 Outer Seal 6 3 8 190 2998 H90 4 Inner Seal 6 3 8 6 5 K only 190 3689 H90 4 Inner Seal 6 3 8 10K only Table 13 Wireline Ram Redress Kit RDK 3863 HHO Part Number Quantity Description Comment 801 0108 V90 4 O Ring BS 108 801 0110 V80 2 O Ring BS 110 801 0113 V90 2 O Ring BS 113 Table 14 Equalisation Isolation Redress Kit RDK 2806 HVO Individual seals and parts may be ordered as required See the parts list in the previous section for part numbers OPS 3653 Rev A 34
11. 004 31 802 2505 H85 1 ROD T SEAL 0 825 DIA 1 1 1 i 40 190 2491 STL EXTERNAL CIRCLIP SH 75 0 750 DIA 41 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 42 SHC 0503 HTS 4 Soc Hd Cap Size 1 4 Length 0 5 in 43 SDU 0582 HTS 3 Set Screw Dog Point 1 2 UNC X 0 625 in 44 SHC 0581 HTS 4 Hd Cap Size 1 2 Length 0 5 in 45 WNL 0580 316 46 SDU 0503 HTS Set Screw Dog Point Size 1 4 Length 0 5 in 47 100 2179 STL GREASE NIPPLE 1 8 NPT Table 5 Actuator Assembly 190 2476 0 WASHER NORDLOCK M12 k OPS 3653 Rev 27 User Manual Phuel Modular BOP System Dual Y oP MIN f 4 e 077777777 Le S L o ki N im Figure 7 6 3 8 Actuator No 190 2476 HVO OPS 3653 Rev A 28 User Manual Phuel Modular BOP System Dual TOOLS Part Number Quantity Description 1 190 3705 480 1 GUIDE RAM 6 3 8 2 190 3706 480 1 SINGLE GUIDE RAM 6 3 8 3 190 1715H70 2 Outer Seal 4 190 2998 90 2 RAM INNER SEAL SIZE 7 00 Table 6 Wireline Ram Assy 190 3863 Figure 8 Wireline Ram Assy 190 3863 HHO OPS 3653 Rev A 29 User Manual Modular BOP System Dual Item Part Number Quantity Description 1 190 2813 480 1 EQUALISATION BLOCK 2 110 2979 316 4 4
12. 316 4 CONNECTOR 3 8 BSPP X 3 8 NPT 1252 06 06 14 950 3169 316 4 CONNECTOR 1 4 BSPP X 1 4 NPT 1252 04 04 20 CS1 0585 3A4 4 CSink Soc Size 1 2 Length 1 in 21 196 3164 304 2 DOWEL PIN 6MM X 32MM LONG Table 4 Modular Body 196 3145 OPS 3653 Rev A 25 ga User Manual Phuel Modular BOP System Dual OIL TOOLS Figure 6 Modular Body OPS 3653 Rev A 26 User Manual Phuel Modular BOP System Dual OIL TOOLS Item Part Number Quantity Description 1 32 801 0345 90 33 802 2161 85 34 801 0344 90 35 802 2162 85 36 801 0342 90 37 801 0439 90 O Ring B S Size 345 PISTON T SEAL 4 000 O Ring B S Size 344 ROD T SEAL 1 625 O Ring B S Size 342 O Ring B S Size 439 190 2927 480 1 ROTATE CYLINDER CAP 2 190 2772 480 1 DRIVE ROD 3 190 1726 480 1 DRIVE SLEEVE 4 190 1645 316 1 INDICATOR ROD 5 190 1649 480 1 COLLAR 6 190 1773 STL 1 DRIVE KEY PLATE CAST 7 190 2926 480 1 HOUSING 8 190 1929 480 1 PISTON 9 190 3233 STL 1 MODULAR ACTUATOR BRACKET 10 190 1612 480 1 Piston Seal Sub 11 190 2863 480 1 ACTUATOR COLLAR 12 190 2838 480 1 REWORKED RAM KEY PLATE 13 190 1774 STL 1 TEE 20 190 1696 STL 1 Thrust Bearing FAG 812 06 21 190 1702 STL 1 Hand Wheel 22 190 1704 STL 1 lAcorn Nut 1 2 13 23 190 1608 STL 2 Slide TK 25 UU 30 802 1699 H85 1 Rod T Seal Assy TR
13. Allen Key s 7 32 5 16 amp 3 8 long version for removing Actuators from the BOP External Circlip Pliers 14 20 UNC Socket Head Cap Screw x 1 Long Pair of Long Nose Pliers Large Flat ended Screwdriver Hide or Rubber Mallet Seal Grease Oil spillage cleaning kits 5K Hydraulic pump and Gauge to operate Actuators Lifting equipment Aids as required 5 5 Ram Seal Redress Note If rams are required to be removed ensure they have been pumped forward until only 2 of the indicator rod is visible 5 5 1 Access Rams This procedure results in the removal of the actuator assembly from the BOP body in order to gain access to the rams e Ensure Rams are fully opened e Back off the Actuator from the BOP using the extended 3 8 Allen Key in the Cap Screw heads on the Locking Sleeve Do not loosen the cap screws during this process e Once the thread is fully disengaged pull the Actuator fully back to the End Stops OPS 3653 Rev A 10 User Manual Phuel Modular BOP System Dual OIL TOOLS Figure 2 Accessing the rams 5 5 2 Ram Removal not required to redress ram seals Remove Ram from Actuator by sliding the Ram off the Ram Tee 5 5 3 Seal Redress e The Inner Ram Seals can be removed by simply sliding the seal out to either side e The Outer Seal can be removed by levering out one end with a suitable instrument and simply pulling off e The Ram is now completely stripped dow
14. Fill BOP with test fluid Connect the hydraulic hoses from the BCU to to operate the rams Check all connections hoses that they are secured with safety wire before use Vent BOP Rams by hydraulic operation of the Rams On completion of venting the Rams fit test cap ensuring the valve is in the open position to allow air to vent and top up the BOP with Test Fluid Once all air is expelled close valve is now prepared for testing 6 2 Body Test Ensure that all the rams in the open position Close equalizing valve 1A all other equalizing valves to be open Disconnect pipe on the grease injection and the chemical injection connector plate to test check valves Fit the pressure test hose with security link Put up safety barrier in the workshop Pump slowly up to 300 psi and observe for leaks Hold Time 5 min Bleed the pressure to zero Pressurize to MWP of BOP and observe for leaks Hold Time 15 min Bleed of pressure to zero and drain BOP OPS 3653 Rev A 20 User Manual Phuel Modular BOP System Dual OIL TOOLS 6 3 Wireline Ram Seal Test Between the ram Ensure Test is not fitted Ensure all Rams are in open position Open the equalizer valve between the respective rams to be tested Connect the test hose in the 1A on equalizing block gauge port Close the Middle Ram Open Snaptite connector on the test stump for verification of leakage on the lower ram
15. NAPTITE COUPLER PT NO SVHC44FV 16 950 2559 316 2 1 4 SNAPTITE NIPPLE PT NO SVHN44FV 17 950 3716 316 4 1 4 45 Degree Street Elbow 18 950 3717 316 4 3 8 NPT x 1 4 Connector 100 910 3621 N66 1 DW FEMALE PROTECTOR 11 1 2 101 910 3620 N66 1 DW MALE PROTECTOR 11 1 2 Table 3 193 3568 HVO Parts List OPS 3653 Rev 22 User Manual Phuel Modular BOP System Dual to ch dab Sp RAM SET UP AYAN ew HI HEE LI m 35 02 O E 7 um i Ca Nel AM TL IL a m BR ol i 11111 OPS 3653 Rev pi User Manual Modular BOP System Dual Phuel DETAIL Figure 5 Modular BOP 192 3653 HVO 24 OPS 3653 Rev User Manual __ Phuel Modular BOP System Dual OIL TOOLS Item Number Part Number Quantity Description 1 196 3318 480 1 MODULAR BOP BODY 10K 2 190 2476 HVO 2 ACTUATOR ASSEMBLY V2 3 190 3863 HHO 1 6 3 8 WIRELINE RAM ASSEMBLY V2 4 190 2806 HVO 1 EQUALISATION BLOCK ASSEMBLY 6 190 2413 X90 4 SLIDER ROD 21 5 LONG 8 190 1537 316 4 END STOP 10 802 2921 V80 1 7 642 T SEAL WITH BACK UPS 11 196 2918 316 2 BOP HOSE OPEN 12 196 2919 316 2 HOSE CLOSE 13 950 3168
16. alize the pressure across closed rams inject chemicals above or below any of the rams or a combination of both There are two isolated external ports that allow the connection of a pressure gauge and drain hose if required OPS 3653 Rev A 7 User Manual Phuel Modular BOP System Dual OIL TOOLS 4 3 Job Planning 4 3 1 Before the Job e Check that the certification is within date and that the scheduled maintenance is up to date e Examine the BOP Assembly to make sure that it is good operating order and assembled with the Rams in the correct orientation for the desired operation e Functioning of the Rams may be checked by running both Rams to the closed position Do not exceed the maximum operating pressure when closing the Rams Pressure test the rams from the direction of the well or applied pressure that is expected during the operation This also verifies that the rams are in the correct orientation 4 3 2 During the Job Special care should be taken that the Rams are fully open when passing any equipment through them The impact of a collar hitting a Ram may damage the Ram to such an extent that the Ram may no longer Seal or prevents it from fully opening e Only lift the BOP using suitable lift caps Do not sling or attach lifting equipment to the crash frame to lift the BOP assembly Care should be taken to completely remove any residual pressure or accumulated pressure existing on Lubricator equipment above the
17. assemble e Clean and degrease all components e Inspect the condition of sealing surfaces and surface coatings repair replace as necessary e Re coat threads and sealing surfaces if necessary Contact Phuel if in doubt Replace all elastomeric seals Re assemble BOP Pressure Test to 300 psi and to maximum working pressure Inspect paintwork and repair where necessary 5 2 3 Five Yearly e Yearly maintenance plus the following e Carry out surface NDE on all component threads and damaged surfaces e Pressure Test to 300 psi and maximum test pressure per API 6A PSL3 Witnessed by certifying authority 5 3 Safety e This product contains high pressures when in operation Failure of any part may cause injury Welding corrosion rough handling or other abuse may affect the Integrity of this product e Many of the components are heavy and should not be lifted without lifting aids e Wear appropriate personal protective equipment OPS 3653 Rev A 9 User Manual Phuel Modular BOP System Dual OIL TOOLS Do not over exert yourself while using torque wrenches Use appropriate mechanical advantages when available e Ensure that all tools and equipment are in good condition and are suitable for intended use 5 4 Tools The following tools are required Non marking Memac Chain Wrench Other pipe wrenches may be used but will mark equipment e Piston Seal Sub Assembly Tool Part No 900 1577 400
18. d wire line as a leak tight seal cannot be obtained due to the construction of the wire The high viscosity of the grease allows the pressure to be maintained even though a small leak of grease still exists Onder Sud Inner Seal Indicator Rod Pressure Figure 1 Section through BOP rams closed position The rams are driven by a hydraulic actuator which consists of a piston with an indicator rod to provide visual confirmation of the position of the rams A manual locking mechanism is also provided to ensure that when the BOP is closed hydraulically during operations it cannot be opened again until the mechanism is deliberately withdrawn Each of the actuators assemblies are identical on the Phuel BOP and so can be positioned in any ram bore This provides excellent flexibility for maintenance and redress of the equipment OPS 3653 Rev A 5 User Manual Phuel Modular BOP System Dual OIL TOOLS 4 Operation 4 1 Operating the Rams Note Always ensure that the pressure across the rams has been equalised before opening 411 Hydraulic Operation The BOP has been provided with flexible armoured piping to offer the required fire protection level Two connections are required for each ram set for open and close It is important that both connections are connected as the fluid displaced by the movement of the piston must be allowed to pass through the valve system back to the reservoir A Well Control Unit WCU
19. e actuator ensuring that the ram does not hang up on the actuator front face When fully back remove the hydraulic pump Note It is still possible to assemble the actuator to the BOP without pumping back the rams but more effort may be required to allow the thread to make up e Apply a generous coating of grease to the inner and outer seals e Push the Actuator back into BOP Body taking care that the edges of the guide pass into the seal bore and make up the thread using a 3 8 hex key in the cap head screws to provide the torque Making up the thread will drive the actuator assembly fully home e The Ram Assembly is now fully made up Repeat this procedure for each ram seal that need to be replaced 5 6 Modular Connection The Modular BOP allows modules to be separated and re configured to suit operation needs Follow this procedure to split and re make the modules as required Note This must be carried out in a workshop environment with pressure testing facilities by suitably qualified personnel 5 6 1 Splitting the Connection e Locate and remove lock block equalisation blocks may need to be removed to allow access e Remove the bolts that hold the Collar together There are two design options one with two bolts on each half and one with a single bolt Split the Bolted collar using a cold chisel if required The two assemblies can now be pulled apart Inspect the T Seal and replace if necessary Inspect the Pins to mak
20. e sure they are not damaged Replace if necessary OPS 3653 Rev A 12 User Manual Phuel Modular BOP System Dual OIL TOOLS 5 6 2 Re Making the Connection Note Take note of new body serial number to allow update of traceability e Ensure that the Pins and T Seals are in good condition e Lower the upper module down to locate the pins in the holes then push down to engage the seal Drive down with a weight or blows with a soft face hammer if required The end faces should be almost flush within 1mm e Fit Bolted collars ensuring that the gap between the two halves is completely closed rotate the collar tighten until it bottoms out then back it off to line up the holes for the Lock Block e Fit lock block to hold collar in place e Assemble bolts and washers Two Bolts Torque to 150Nm large bolt and 100Nm small bolt Single Bolt Torque to 150Nm Carry out pressure testing to maximum working pressure see Test Procedure below e Update paperwork with new numbers for traceability Figure 4 Example of Single bolted collar and lock block OPS 3653 Rev 13 User Manual Phuel Modular BOP System Dual OIL TOOLS OPS 3653 Rev User Manual Modular BOP System Dual OPS 3653 Rev A User Manual Phuel Modular BOP System Dual
21. ghly dangerous It has enough stored energy to separate parts with considerable force This product contains high pressures when in operation Failure of any part may cause injury Welding corrosion rough handling or other abuse may affect the Integrity of this product All pressure equipment has a particular pressure rating and care must be taken to ensure that no item is used in a situation that may cause its working pressure to be exceeded All personnel involved in pressure testing must be formally trained competent and utilise the appropriate PPE Ensure the identification plate is fitted and is displaying the correct information This equipment and the equipment it is attached to is heavy never position yourself below a suspended load OPS 3653 Rev A iv User Manual QPhuel Modular BOP System Dual OIL TOOLS 1 Introduction 1 1 General The Modular Blow out Preventer BOP provides essential safety barriers against well pressure during wireline operations It is located directly above the wellhead flange The BOP has two or more sets of wireline rams for sealing against slick line and then sealing against the well pressure The ram consists of hydraulic piston that can be extended or retracted to energise or retract the ram The ram has a set of inner and horse shoe seals that when compressed against the opposite ram forms continuous seal that is further energised by the application of pressure in one directi
22. n Clean and inspect all parts for evidence of damage or excessive wear Check the seals and replace if required Repair or replace any damaged or worn parts If the seals are to be redressed use the parts from the specified redress kit e Assemble Outer Seals by pushing the tab into the slot in the ram and working it around the radius of the ram Tap home using a rubber or hide mallet and if required use a screwdriver to lever the second tab over the edge of the slot Take care not to significantly damage Seal during assembly but expect that some slithers of rubber will be produced as the corners of the rubber seals are removed by the assembly operation Tap all around the circumference of the seal to ensure that it is bedded into the groove and that the seal is not protruding above the ram diameter e Slide the Inner Seals into Ram taking care not to dislodge the outerseal in the process Figure 3 BOP Wireline Rams OPS 3653 Rev A 11 User Manual Phuel Modular BOP System Dual OIL TOOLS 5 5 4 Re attach to BOP Body e fthe rams were removed from the actuator Section 5 5 2 then slide the ram back onto the Tee taking careful note of the orientation of the rams depending on its intended use for the BOP assembly i e if pressure is to be held from below then the outer seal must be on top otherwise it must be on the bottom Attach a hydraulic pump to the open port of the actuator and pump the rams back into the recess in th
23. n to move fully back 41 3 Locking the Rams After closing with hydraulic pressure the piston can be mechanically locked by winding in the manual mechanism Turning the hand wheel in a clockwise direction will advance the locking mechanism by 3mm per turn It is therefore necessary to turn the hand wheel 30 40 turns to lock in the piston Continue to OPS 3653 Rev A 6 User Manual Phuel Modular BOP System Dual turn until the hand wheel stops indicating that the piston is now against the back up lock For safety reasons and to reduce the mechanical effort required Phuel recommends that the hydraulic pressure be removed or reduced while closing the mechanical back up This reduces the risk of injury caused by the failure of a seal under hydraulic pressure and decreases the time required to implement the back up feature It is important to remember that the manual lock must be fully withdrawn before the rams can be opened No damage to the mechanism will occur if pressure is reversed with the lock in place providing that the maximum operating pressure is not exceeded 4 2 Equalising across the rams Each ram has a dedicated equalising valve block and these blocks are connected together to allow single point chemical injection pressure measurement and dump facility There are four valves on each block two are for equalising and two are for isolation By opening and closing the appropriate valves it is possible to either equ
24. on The ram consequently can be arranged so that it holds pressure from below the BOP or from above Across the rams there is an equalisation valve assembly This is used to equalise pressure across the rams so that the rams can be withdrawn to open up the well bore The equalisation valve assembly consists of cone seal set on screw Unwinding the screw opens the valve and allows equalisation across the rams Tightening the screw closes the seal and prevents pressure from passing through the valve assembly There is also circuit to allow the injection of chemicals into the well or across the equalisation valves and can be used to prevent the valves freezing while bleeding down gas injecting glycol for example Between each of the ram pairs it is possible to inject grease through the injection port For braided line operations or in cases where an effective seal cannot be achieved the injection port can be used to inject grease at pressures greater than the well head pressure The injection port has check valve to prevent well pressure entering the injection system The BOP is mounted to a crash frame assembly that provides forklift pockets protection during transport The crash frame has foldable platforms for the operators to stand on when operating the BOP and stabbing in the lubricator not shown in diagrams below This user manual serves as an introduction to the equipment and contains the relevant specifications operation
25. planning and maintenance instructions parts list and drawings 1 2 Product Identification Phuel products are identified by unique serial number that facilitates full product traceability Each product is supplied with documentation pack that OPS 3653 Rev A 1 User Manual Phuel Modular BOP System Dual OIL TOOLS contains product certification and material inspection reports The serial number is always etched on the surface of the product but can sometimes be difficult to find or read after painting A customer identification number is also included to allow the customer to track the asset in their system A stainless steel band secures the nameplate tag that is stamped with the information shown below This tag should be located in the first instance to ensure that this manual refers to the correct equipment PHUEL OIL TOOLS LTD DESCRIPTION amp SIZE CUSTOMER ID No PHUEL ID No YY XXX XX MWP amp SERVICE TEST DATE OPS 3653 Rev A Phuel 2 Technical Specification User Manual Modular BOP System Dual Top Connection 11 5 4 ACME Quick Union Box Bottom Connection 11 5 4 ACME Quick Union Pin Collar Height 49 55 1 26 Width 70 9 1 80 m Working Pressure 10 000 PSI 690 Bar Test Pressure 15 000 PSI 1034 Bar Service H2S Hydraulic Pressure 3 000 psi 200 Bar Max Standard Actuators Stroke Volume Standard Act 52 cu in
26. to close 48 cu in to open Total 107 cu in 1 64 litres Stroke Volume Shear Act 52 cu in to close 48 cu in to open Total 107 cu in 1 64 litres Weight 2448 lbs 1110 kg Hydraulic Connections Wireline Rams 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Actuators 14 x 3 8 Tube Grease Injection 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Chemical Injection Port 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Gauge Port 12 10 000 psi max WP OPS 3653 Rev A Table 1 Technical Data User Manual Phuel Modular BOP System Dual OPS 3653 Rev User Manual Phuel Modular BOP System Dual 3 Technical Description 3 1 Basic Description The Phuel BOP provides a positive barrier against well pressure while performing intervention operations The equipment consists of three sets of hydraulically operated rams that can be individually pumped closed to form a seal against pressure The orientation of the ram outer seal determines whether the rams hold pressure from above or below By opposing adjacent ram sets it is possible to apply pressure between the rams through a grease injection port normally at a pressure greater than the well pressure and thus form a positive protection barrier This technique is particularly effective when sealing against braide
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