User Manual 3`` Dual Monoblock BOP OPS-5481
Contents
1. Elastomeric spares are supplied in Viton material as standard Other materials are available please specify when ordering 802 4339 H85 ROD T SEAL 1 750 801 0231 V90 O Ring B S Size 231 Table 10 Hydraulic Actuator Redress Kit RDK 4289 HVO 801 0119V90 6 ORing B SSize119 Table 11 Injection Module Redress Kit RDK 5511 HVO Part Number Quantity 190 4171 H80 3 GUIDING INNER MULTI SEAL 190 4170 H80 3 POINTED INNER MULTI SEAL 190 3107 H70 BOP OUTER SEAL 3 50 Table 12 Wireline Ram Redress Kit RDK 4360 HHO Individual seals and parts may be ordered as required See the parts list in the previous section for part numbers 9 1 Supporting Equipment 950 4656 316 Piston Assembly Tool OPS 5481 Rev A 342. Phuel Unit 12 Barratt Trading Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual 3 Dual Monoblock BOP OPS 5481 This is a certified safety critical product and modifications or changes not authorised by Phuel Oil Tools may compromise the oafety Functionality and Certification of the assembly OPS 5481 Rev A User Manual Phuel 3 Dual Monoblock BOP OIL TOOLS Table of Contents Table of Contents i Fabi ON 1 ADISS a aaa i a a a a a RAMENI ji able OT FS Je ji REVISION HISTORY li STE EE C EE eee iv 1 Introduction ii 5 Hi Cilea 5 2 Pee er 6 EDEN 7 PEN 7 22 BC 7 BET ON 8 Oi ODETA ME NA ica esse eee eae eee 8 3 2 Equalising across the rams nh vn nha 9 39 Job PIANO aaa 10 4 Operational Characteristics na 12 4 1 Sealing CharacteristiCS SH s nh h u 12 12 TH TE HT TIT 12 43 Ram ACCESS SS ROTEN Neo ka 13 4 4 Shearing Performance and limitations 13 4 5 Performance of Ram Guides c 13 4 6 Temperature and Pressure Limitations 14 MAIN NO EEE 16 s MEME eee 16 SM cii ERU 16 dd 210 17 54 Ram SEA Hedl685 oreet elo i i 17 5 5 Maintenance Record Sheet ennen ek su 23 5 TESUNG c 24 6 1 Hydrauli
3. In the event that the BOP is closed against wire during an operation it is essential that the Inner seals are replaced after that job has been completed Working practice and procedures must reflect this requirement Blind shear seals should always be fitted on the shear rams They should be tested regularly to verify that they are suitable for operation If they are ever OPS 5481 Rev A 8 User Manual 3g Phuel 3 Dual Monoblock BOP OIL TOOLS closed during a live well operation they should be replaced when the operation is complete 3 1 4 Bleed Down Rate in Gas Wells To avoid explosive decompression in gas wells or oil wells were there is a large quantity of gas present it is important to control the bleed down rate of the pressure The following procedure is recommended 1 Reduce pressure from 10000 to 2000 Psi at a rate of 1000 psi per minute 2 Reduce pressure from 2000 psi to 1000 psi at a rate of 100 psi every one minute 3 Reduce pressure from 1000 Psi to zero at a rate of 20 psi per minute 3 2 Egualising across the rams There is an external port that allow the connection of a pressure gauge or dump valve if required There is also an injection port that feature a check valve There is an isolation valve for each opening into the BOP Body which allow flow to either side of the rams It is therefore possible to equalise across any ram or combination of rams NVALVE 3 mdi Figure 4 Equalisat
4. Table 4 3 Dual Monoblock BOP 192 5481 HVO OO Ni O U R O N OPS 5481 Rev A 26 a User Manual NG Phuel 3 Dual Monoblock BOP OIL TOOLS DEA Swe K RA SS Ao WAS AVON VT NS COS EN Oo I Om dre S Sos m m ES RE m Nm Ri N Sac que SN SSH ST zal NOTES WEIGHT WITH FRAME 1058lbs 480Kg WEIGHT WITHOUT FRAME 948lbs 430Kg 3 10 000 PSI WORKING PRESSURE 15 000 PSI TEST PRESSURE 2 TONNE 2 000KG SWL FIT PROTECTORS NOT SHOWN Figure 14 3 Dual Monoblock BOP 192 5481 HVO OPS 5481 Rev A 27 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS m EU 190 4277 480 NU les ter iI 3 MOD PISTON HOUSING 190 4282 480 3 MOD HYDRAULIC CYLINDER HOUSING 190 4281 480 3 MOD CYLINDER CAP 190 4198 480 3 MOD ACTUATOR COLLAR 190 4278 480 3 MOD BALANCED PISTON 190 4201 480 3 MOD SEAL RING 190 4279 480 3 MOD HYDRAULIC PISTON 190 4286 480 3 MOD DRIVE ROD 190 4287 480 3 MOD DRIVE SLEEVE To 190 4283 460 1 3 MOD KEY PLATE 11 190 4284 316 3 MOD INDICATOR ROD 12 190 4290 480 3 RAM GUIDE BAR 13 190 4202 ALU 3 MOD BEARING BRACKET 14 190 4319 PEK 3 MOD KEY BUSH 15 190 4335 316 COLLAR BOLT 3 MOD 16 801 0340 V90 1 O Ring B S Size 340 17 190 3870 H85 1 ROD SEAL 18 190 4343 PEK 1 GREASE SCRAPPER RING E 802
5. 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 Figure 1 3 Dual Monoblock BOP OPS 5481 Rev A IV User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 1 Introduction 1 1 General The Blow Out Preventer BOP provides essential safety barriers against well pressure during wireline operations It is usually located directly above the Xmas tree flange The BOP has two sets of wireline rams for sealing against well pressure on slick line and or braided line This BOP is compatible with the Phuel 3 Modular BOP system with interchangeable rams and actuators A sets of shear and seal rams can be fitted to this BOP which are capable of cutting through the wire and then sealing against the well pressure The ram is attached to a hydraulic piston that can be extended or retracted to energise or retract the ram The ram has a set of inner and horse shoe outer seals that when compressed against the opposite ram forms
6. e 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 6 1 Ram Seal Redress Note If rams are required to be removed ensure they can be moved fully forward when the time comes 6 1 1 Access Rams This procedure results in the disconnection 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 5 16 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 Figure 7 Accessing the rams Note figure shows single modular BOP Body 6 1 2 Ram Removal not required to redress ram seals e Pump the actuator forward until the back of the ram is clear of the Collar e Undo guide bar ensuring the nordlok washer remains in the actuator piston housing and slide into ram e Remove Ram from Actuator by sliding the Ram off the Piston OPS 5481 Rev A 17 User Manual 3g Phuel 3 Dual Monoblock BOP OIL TOOLS 6 1 3 Ram 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
7. 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 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 3 3 3 After the Job After each job the BOP should be thoroughly cleaned repaired as required and redressed The BOP should be protected against the effects of corrosion to ensure that the expected functionality is achieved The diagram overleaf highlights the key areas to consider OPS 5481 Rev B 10 User Manual Phuel 3 Dual Monoblock BOP OIL TOOLS Grease seal bore and threads Cover the assembly when before fitting thread protectors ie 7 Mau in long term storage With the actuators closed pump grease to all grease ports until it flows through the other port omear grease on all bars Touch up paint when it is damaged or coat damaged area with thick grease TX Grease before fitting protectors For long term storage fit test stump and fill Figure 5 Correct lubrication for storage with oll OPS 5481 Rev A User Manual Phuel Modular BOP Sys
8. or damage e Close the rams with 3 000 psi and hold for 10 minutes with no leaks allowed Open the rams with 3 000 psi and hold for 10 minutes with no leaks allowed If there are leaks then the actuators will need to be dis assembled and the seals replaced e Disconnect the actuators and inspect the rams guides and seals Replace the seals if they are worn or damaged Re assemble e Re apply grease to the balanced piston ref Figure 13 Instructions for greasing of the Piston Shaft Verify that the equalising valves are moving freely and smoothly Verify that the tie bolt nuts and all other screws are tight Remove external rust or treat using a non toxic rust remover gel or liquid Inspect the condition of quick union sealing surfaces and surface coatings repair replace as necessary e If any of the above are showing signs of wear or damage then strip down to investigate and replace parts or seals as necessary e Re assemble and then pressure test according to Section 7 e Inspect paintwork and repair where necessary 5 2 3 Five Yearly e Recertification by Phuel Oil Tools in accordance with DNV RP E101 OPS 5481 Rev A 16 User Manual Phuel 3 Dual Monoblock BOP OIL TOOLS 6 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 Wear appropriate personal protective equipment
9. way down and then back off 14 turn Fill BOP with test fluid Connect the hydraulic hoses from the BCU to BOP to operate the rams Check all connections hoses that they are secured with safety wire before use Vent BOP Rams by opening and closing the Rams a few times each On completion of venting the Rams fit test cap ensuring the test cap 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 test cap valve e The BOP is now prepared for testing OPS 5481 Rev A 24 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 7 1 2 Body Test Ensure that all the rams are in the open position Open all the egualising valves 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 7 1 3 Ram test Close the Ram this is done by activating the BCU ram seal valve to close position then pressurize up to a maximum of 3 000 psi on the ram Test fluid may be observed coming out of the Test Cap valve Close all equalising valves except the bottom valve 5 so that pressure testing is done from the underside of rams and up Put up safety barrier in the work area Observe Test Cap valve during testing for fluid leaking out under pressure e Pressurize up to 300 psi low pressure test observe if there are leaks Hold T
10. 3 4 16 MAC 765 13 801 0119 V90 6 O Ring B S Size 119 14 801 0108 V90 3 O Ring B S Size 108 15 801 0110 Vo0 3 O Ring B S Size 110 16 ISHC 0583 3A4 8 Soc Hd Cap 1 2 UNG Length 3 4 in 17 ISHC 0585 3A4 2 Soc Hd Cap Size 1 2 Length 1 in 18 WNL 0580 316 14 WASHER NORDLOCK M12 19 ISBC 0543 304 3 Button Hd Screw Size 3 8 Length 0 625 in 20 WNL 0540 316 3 Nord Lock Washer Size 3 8 21 ISHC 0586 3A4 4 Soc Hd Cap Size 1 2 UNC Length 1 25 in 22 190 2821 316 1 PORT BLANK END Table 8 192 5511 HVO Injection Module OO Ni O OMI R OINI OPS 5481 Rev A 31 User Manual a Phuel 3 Dual Monoblock BOP EQUALISING BLOCK EQUALISING END VALVE SAVERSUB Figure 18 Injection Module 192 5511 HVO OPS 5481 Rev A 32 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS tem Part Number 950 2558 316 Quang TE 1 4 SNAPTITE COUPLER PT NO SVHC44FV 2 950 2559 316 1 4 SNAPTITE NIPPLE PT NO SVHN44FV 3 950 2587 316 MALE NIPPLE 1 4in NPT 4 950 4434 316 NPT SOCKET HEAD PLUG 1 4 Table 9 Modular BOP Hydraulic Fittings 190 4433 HS1 OPS 5481 Rev A 33 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 9 Spares Use only spares supplied or approved by Phuel Oil Tools Ltd It is recommended that sufficient quantities of the following spares be maintained to ensure that the equipment is always available when required
11. 4340 H85 PISTON T SEAL 2 385 802 4339 H85 ROD T SEAL 1 750 801 0231 V90 O Ring B S Size 231 802 4341 H85 PISTON T SEAL 2 750 23 801 0235 V90 1 O Ring B S Size 235 24 802 2505 H85 1 ROD T SEAL 0 825 DIA E 802 4342 H85 1 ROD T SEAL 0 245 WNL 0540 316 Nord Lock Washer Size 3 8 SDU 0585 316 Set Screw Dog Point 1 2 UNC X 1 000 in SDU 0505 HTS Set Screw Dog Point Size 1 4 Length 0 75 in SHC 0503 HTS Soc Hd Cap Size 1 4 Length 0 5 in WNL 0500 316 2 1 4 Nordlock Washer 32 WNL 3703 316 1 NORDLOCK WASHER M4 33 100 2209 316 2 NPT SOCKET HEAD PLUG 1 8 34 190 1608 STL 2 Ball Slide TK 25 UU 35 190 4338 STL 1 Thrust Bearing FAG 811 06 36 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 37 190 2491 STL 1 EXTERNAL CIRCLIP SH 75 0 750 DIA Table 5 Modular Hydraulic Actuator Assembly 190 4289 HVO Med OPS 5481 Rev A 28 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 20 67 PISTON AREA TO OPEN 5 85 SOIN FULL STROKE VOLUME 157 CUIN 0 26 LITRE 19 PISTON AREA TO CLOSE 3 56 SOIN FULL STROKE VOLUME 9 4 CUIN 0 15 LITR ra 2 PISTON STROKE 2 53 IN T asi AMP PER GE 14 IT er Lore ORIENTATION OF VENT PORT TO BRACKET GREASE INJECTION PORT CLOSE ACTUATOR AND INJECT UNTIL GREASE IS VISABLE IN VENT PORT Figure 15 3 Modular Act
12. Operation The BOP has two pairs of connections 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 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 3 1 2 Locking the Hydraulic Rams After closing with hydraulic pressure the piston can be mechanically locked by winding in the manual mechanism Turning the drive shaft in a clockwise direction will advance the locking mechanism by 3mm per turn It is therefore necessary to turn the hand wheel 20 25 turns to lock in the piston Continue to 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 3 1 3 Proper Use
13. Ram is now completely stripped down 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 damage the 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 outer seal in the process Ensure the Guided Inner Seal is fitted to the correct ram as shown below Figure 8 BOP Wireline Rams Figure 9 BOP Shear Rams OPS 5481 Rev A 18 User Manual za Phuel 3 Dual Monoblock BOP OIL TOOLS 6 1 4 Re attach to BOP Body e lf the rams were removed from the actuator Section 6 1 2 then slide the ram back onto the actuator and guide bar out of the ram and attach the bar back to the piston housing taking careful note of the orientation of the rams depending on its intended use for the BOP assembly i e if press
14. a continuous seal that is further energised by the application of pressure in one direction 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 a cone seal set on a 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 a 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 by injecting glycol for example The injection port has a check valve to prevent well pressure entering the injection system The BOP is mounted to a crash frame assembly that provides lifting points and protection during transport This user manual serves as an introduction to the equipment and contains the relevant specifications operation planning and maintenance instructions parts list and drawings OPS 5481 Rev A a User Manual zg Phuel 3 Dual Monoblock BOP OIL TOOLS 1 2 Product Identification Phuel products are identified by a unique serial number that facilitates full product traceability Each product is supplied with a documentation pack that c
15. 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 braided 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 Figure 3 Section through BOP rams closed position 2 2 Balanced Piston The actuator is designed with a balanced hydraulic piston that eliminates the end load that can be created due to well pressure This means that the torque or closing pressure of the actuator is independent of the well pressure inside the BOP This feature has two major advantages The hydraulic volume requirements of the actuator are much less than a conventional BOP this reduces the requirements for accumulator storage and charging The BOP can be closed with the same amount of effort no matter what the well bore pressure exists in the bore This is particularly useful with a manual actuator and ensures quick and safe closure OPS 5481 Rev A 7 User Manual Phuel 3 Dual Monoblock BOP OIL TOOLS 3 Basic Operation 3 1 Operating the Rams Note Always ensure that the pressure across the rams has been equalised before opening 3 1 1 Hydraulic
16. c BOP ana 24 7 Drawings and Bills of Material aenea 26 roe AA lae ai aaa aaa 34 OPS 5481 Rev A User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS Table of Tables FET TENNE 6 Table 2 Shearing performance and limitations 13 Table 3 Maintenance Record H HH nh nh cha 23 Table 4 3 Dual Monoblock BOP 192 5481 HV0 26 Table 4 Modular Hydraulic Actuator Assembly 190 4289 HVO 28 Table 5 Wireline Ram Assy 190 4360 HHO seen 30 Table 6 Shear Ram Assy 190 4359 HHO c2 30 Table 7 192 5511 HVO Injection Module lt lt lt lt lt 31 Table 9 Modular BOP Hydraulic Fittings 190 4433 HS1 33 Table 10 Hydraulic Actuator Redress Kit RDK 4289 HVO 34 Table 11 Injection Module Redress Kit RDK 5511 HVO 34 Table 11 Wireline Ram Redress Kit RDK 4360 HH0 34 Table of Figures Figlie To PAINE dec IV Figure 2 Typical identification tag e 6 Figure 3 Section through BOP rams rnnnernneneennenennnana nene anna 7 Figure 4 Equalisation Valve MA OU istusin ueiaaibgndngtblingediolildsgbonnikiapsdioeiiieonddih 9 Figure 5 Correct lubrication for st
17. ernative to hex key an Assembly Tool Part number 950 4656 316 is available to allow use of 1 1 8 socket COMPLETE Figure 12 Hydraulic Actuator Assembly Part 2 OPS 5481 Rev A 21 OPS 5481 Rev A User Manual 3 Dual Monoblock BOP User Manual a Phuel 3 Dual Monoblock BOP 6 3 Maintenance Record Sheet Type of Performed Verified Comments Performed Maintenance By By Table 3 Maintenance Record OPS 5481 Rev A 23 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 7 Testing AIl testing is to be carried out in the designated test area and by suitably gualified and competent personnel Safety procedures must be followed 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 7 1 Hydraulic BOP Check the build configuration then test accordingly using the procedures laid out below 7 1 1 Prepare BOP for pressure testing Check the pressure rating for all 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 Fit the test hose to the Gauge port on the Equalising Block or if using the Injection Port then first remove the check valve Makeup BOP collar on test stump by turning the collar all the
18. ime 10 min E Bleed the pressure to zero e Press up to the MWP for the bop in accordance documentation maintain the pressure for 10 min without leakage e Bleed the pressure to zero Open rams on bop by enabling BCU ram seal valve to open position 7 1 4 Post Test Procedure Disconnect All Hoses Remove Test Cap Drain out test fluid and circulate with water displacing fluid or lubricating oil Re fit the gauge to the Equalising Block if required or re fit the check valve if removed earlier Remove BOP from Test Stump Grease end connections and fit oiled thread protectors OPS 5481 RevA 25 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 8 Drawings and Bills of Material 192 5501 480 1 DUAL BOP BODY 3 BX FLANGED 190 4289 HVO 4 3 MOD PISTON ACTUATOR 190 4360 HHO 2 MODULAR 3 GUIDE RAM ASSEMBLY 1 25 4945 HS0 1 3 ID X OVER 4 3 4 4 BOX X 3 1 16 BX FLG 10K 192 5511 HVO 1 la MONO DUAL INJECTION MODULE 1 90 4433 HS1 2 3 Mod Hydraulic Kit Snap Tite 190 4276 X90 8 3 MOD SLIDER ROD 25MM 190 1 672 316 8 END STOP 9 ICSU 0585 3A4 8 ICSink Soc Hd Size 1 2 UNC Length 1 in 10 900 3253 STL 1 ISEAL RING BX 154 12 125 3212 AL7 8 ISTUD 1 00 8 UN X 5 50 LONG 13 IHNC 0750 A2H 8 Hex Nut 1 00 UNC 14 1 92 5504 STL 1 3 DUAL MONOBLOCK BOP CRASHFRAME 15 ISHC 0625 HTS 12 Soc Hd Cap Size 5 8 Length 1 5 16 IWNL 0620 31 6 12 Nordlock Washer 5 8 NL16
19. ion Valve Layout note ram orientation may differ OPS 5481 Rev A User Manual Phuel 3 Dual Monoblock BOP OIL TOOLS 3 3 Job Planning 3 3 1 Before the Job Note Configuration will determine which processes are required e Check that the certification is within date and that the scheduled maintenance is up to date e All blind shear inner seals need to be inspected after 30 pressure cycles and replaced where necessary Wire line seals must be tested without the use of test rods and must always be replaced after being closed on wire during normal operations Always inspect the wireline seals for signs of wear or damage and replace if necessary 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 3 3 2 During the Job e Special care should be taken that the Rams are fully open when passing any equipment through them The impact of the tool string 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 or bars to lift the BOP assembly e Care should be taken to completely remove any residual pressure or accumulated pressure existing on Lubricator equipment above the BOP
20. k line 250 Kg 1060 psi 10 000 psi 0 125 6 Slick line 250 Kg 2120 psi 10 000 psi 0 160 Slick line 250 Kg 1670 psi 10 000 psi Table 2 Shearing performance and limitations Note The shear rams are designed to cut only once The rams must be replaced once they are used to cut wire 4 5 Performance of Ram Guides Testing has been conducted to verify that the wireline rams can centralise the cable without cutting at extreme wire positions and with applied side loadings The rams always closed without incident or damage to the cable Operational planning and set up should still attempt to minimise the expected side loading on the wire by ensuring the lubricators are vertical and that the tool string is centralized as much as possible in the well bore OPS 5481 Rev A 13 User Manual IG Phuel Modular BOP System OIL TOOLS 4 6 Temperature and Pressure Limitations Testing has been conducted to verify the performance of the BOP at extreme operating temperatures 4 6 1 General Sealing The BOP seals typically O Rings and T Seals of 90 hard Viton material with part numbers listed in this manual have been qualified for operating temperatures between 10C and 121C with no restrictions to the operating pressure 4 6 2 Blind Ram Shear Seals The shear rams using blind ram inner shear seals part number 190 4141 H80 amp 190 4142 H80 have been qualified for operation between 10C and 121C with no restrictions to the wo
21. ontains 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 The nameplate tag that is stamped with the information shown below is secured either by a stainless steel band or fixed directly onto the assembly This tag should be located in the first instance to ensure that this manual and any other paperwork refers to the correct equipment PHUEL OIL TOOLS DESCRIPTION PART NUMBER HSERIAL NUMBER CUSTOMER NUMBER API 16A API 6A PSL3 P U MWP PSI H2S Figure 2 Typical identification tag 1 3 Technical Specification 25 cu in 0 41 Litre Total Cycle Stroke Volume 15 6 cu in 0 26 Litre to Close 9 4 cu in 0 15 Litre to Open Weight 1057 Ibs 479 kg Crashframe SWL 2 Tonne 2 000 Kg Table 1 Technical Data OPS 5481 Rev A User Manual 3g Phuel 3 Dual Monoblock BOP OIL TOOLS 2 Technical Description 2 1 Basic Description The Phuel BOP provides a positive barrier against well pressure while performing intervention operations The equipment consists of one or more sets of rams operated either manually or hydraulically that can be individually closed to form a seal against pressure The orientation of the ram outer seal determines whether the rams hold pressure from
22. orage n o 11 Figure 6 Qualified Operating Envelope nene 15 Fiqure 7 Accessing TNC TAT aa a aniliini kail iii amka si 17 Figure 8 BOP Wireline RamMS essere 18 FOUG 2 OS ae ag eeu m 18 Figure 10 Hydraulic Actuator Assembly Part 1 20 Figure 11 Hydraulic Actuator Assembly Part 2 21 Figure 12 Instructions for greasing of the Piston Shaft 22 Figure 13 3 Dual Monoblock BOP 192 5481 HVO0 27 Figure 13 3 Modular Actuator Hydraulic 190 4289 HV0 29 Figure 14 Wireline Ram Assy 190 4360 HHO c 30 Figure 15 Shear Rams 190 4359 HHO S2 30 Figure 16 Injection Module 192 5511 HVO ennen kk kk t kk k ren 32 OPS 5481 Rev A ii User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS Revision History Issue Release Date Description Rev A 04 Sep 13 Initial Issue OPS 5481 Rev A lil User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS Safety 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 This product contains high pressures when in operation Failure of any part may cause injury Welding
23. replaced before this limit is exceeded If records do not exist then the seals should be changed every year as a minimum Fatigue life has not been defined on the wireline seals due to their less critical function and the fact that these are to be replaced whenever they are closed on the wire Pre job inspection to verify their condition is therefore required and replacement if they are not in good physical condition OPS 5481 Rev A 12 User Manual 733 Phuel Modular BOP System OIL TOOLS 4 3 Ram Access Testing Testing has been performed to determine the ability of the BOP to undergo repeated ram changes without affecting operating characteristics The tests have shown that the rams were accessed a total of 200 times test limit without failure of the sealing or locking mechanism Records must be maintained to ensure that the seals are replaced before this limit is exceeded If records do not exist then the seals should be changed every year as a minimum 4 4 Shearing Performance and limitations Testing has been conducted to verify the shearing and sealing capabilities of the shear rams The minimum tool string weight must be achieved either by direct weight or the combination of that and additional tension to ensure that the cutting performance is achieved Wire Size No of Wire Minimum Hydraulic Maximum dia wires Type Tool String Pressure needed Wellbore Weight to shear at zero Pressure bore pressure psi 0125 1 Slic
24. rking pressure 4 6 3 Wireline Multi Seals The wireline multi seal part number 190 4170 H80 amp 190 4171 H80 are qualified to be used within the operating envelope shown below If operations dictate that the expected surface temperatures and pressures exceed the operating envelope then wire specific inner seals must be used instead of the standard multi seal Consult Phuel Oil Tools for advice and part numbers OPS 5481 Rev A 14 Phuel Pressure bar 8 8 8 8 8 8 OPS 5481 RevA User Manual 3 Dual Monoblock BOP 3 BOP Operating Envelope Wireline seal a blind slickline TIN JR TD TSG MULTI LINE REGION TIT ID KIT TT Shearseattimis 1 Temperature C Figure 6 Qualified Operating Envelope User Manual za Phuel 3 Dual Monoblock BOP 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 2 1 Pre amp Post Job Refer to Section 3 3 1 and Section 3 3 3 for details 5 2 2 Yearly e Visually inspect the BOP for signs of wear
25. tem OIL TOOLS 4 Operational Characteristics 4 1 Sealing Characteristics 4 1 1 Minimum Hydraulic Pressure The actuator is pressure balanced and so it is possible to close the rams against any well pressure with more than 500 psi In order to ensure that the BOP seals correcily it is recommended to apply the full closing pressure of 2900 psi 200 bar In most cases the BOP will seal with pressures greater than 1 000 psi 70 bar applied 4 1 2 Opening the BOP with differential pressure It is not recommended that the BOP should be opened with differential pressure across the rams The pressure should always be equalised first using the equalising valves Even with differential pressure applied across the rams it is possible for the BOP to be opened if the opening pressure is greater than 1400 psi The manual locking feature should therefore be used when the BOP is closed to prevent accidental opening 4 2 Fatigue Testing Testing has been performed to establish the fatigue limit of the actuators and shear rams so that preventative maintenance can be scheduled to replace worn seals or parts A total of 546 close open cycles have been completed without failure including 78 pressure cycles to maximum working pressure This test simulates closing and opening the BOP once per day and testing well bore pressure at 300 psi and 10 000 psi once per week for 1 5 years of service Records must be maintained to ensure that the seals are
26. uator Hydraulic 190 4289 HVO OPS 5481 Rev A User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS m EU 190 4363 480 JU E MODULAR NO GUIDE RAM 3 00 190 4364 480 MODULAR GUIDED RAM 3 00 3 190 4171 H80 1 3 GUIDING INNER MULTI SEAL 4 190 4170 H80 1 3 POINTED INNER MULTI SEAL 5 190 3107 H70 2 BOP OUTER SEAL 3 50 Table 6 Wireline Ram Assy 190 4360 HHO Figure 16 Wireline Ram Assy 190 4360 HHO 1 EE 4362 480 MODULAR 3 GUIDING SHEAR RAM BODY 2 190 4361 480 MODULAR 3 SHEAR RAM BODY NO FINS 3 190 4141 H80 3 POINTED INNER BLINDSEAL 4 190 4142 H80 3 GUIDING INNER BLIND SEAL 190 3107 H70 BOP OUTER SEAL 3 50 Table 7 Shear Ram Assy 190 4359 HH0 for information not fitted upon supply Figure 17 Shear Rams 190 4359 HH0 for information not fitted upon supply OPS 5481 Rev A 30 User Manual a Phuel 3 Dual Monoblock BOP OIL TOOLS 190 4255 480 1 IMOD EOUALISATION BLOCK LW 190 4285 480 1 MODEQUALISING END VALVE SAVERSUB 190 4275 480 1 13 MOD CONNECTING BAR 145 2176 480 2 SAVER SUB PORT 900 3019 480 1 CHECK HOUSING 110 2979 316 3 VALVE 190 2823 PEK 3 VALVE SEAT 100 2114 PEK 1 CHECK VALVE SEAL 9 190 2786 PEK 1 CHECK CONE SEAL 10 145 2185 STL 1 COMP SPRING D22120 11 190 1749 STL 1 COMP SPRING C5515650 12 190 1703 STL 1 Hollow Lock Screw
27. ure 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 if required to the open port of the actuator and pump the rams back into the recess in the 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 5 16 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 6 2 Special Tools General workshop tools will be required to maintain and assemble and disassemble the BOP To undo and tighten the balanced piston from the hydraulic piston two hex keys are required 3 8 and 1 1 8 Phuel can supply a Hex bar to fit this piston and allowa 1 1 8 socket to be connected Figure 10 950 4656 316 Piston Assembly Tool OPS 5481 Rev A 19 User Manual 3 Dual Monoblock BOP OPS 5481 Rev A 20 User Manual 3g Phuel 3 Dual Monoblock BOP OIL TOOLS As an alt
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