User Manual Modular BOP System 6 3/8`` ID 10K
Contents
1. 23 6 6 Modular 24 6 6 1 SITING the Wel ne de EE 24 6 6 2 Re Making the Connection 24 6 7 Maintenance Record Sheet 34 Te STU WE 35 71 Prepare BOP for pressure testing 35 BOOY eo 35 7 9 Ram test 2218 21 36 7 4 Wireline Ram Seal Test Between the 36 7 7 OSE OC ia uu muu aan 37 Lis nG u u 38 GB 61 Table 1 Technical 4 Table 2 Minimum hydraulic pressure to 5 16 Table 3 Shearing performance and limitations 17 Table 4 Maintenance Record 34 Pants LISE en est eta dete olet enc stehen ee 38 Table 6 Modular Body Parts List 196 4185 41 Table 7 Modular Actuator Assembly 190 4186 43 Table 8 Wireline Ram Assy 190 3863 HH0 45 Table 9 She2. 61 Table 27 Wireline Ram Redress Kit RDK 3863 HH0 61 Table 28 Shear Ram Redress Kit RDK 3862 HHO 62 Table 29 Equalisation Isolation Redress Kit RDK 4187 HVO 62 Table 30 Triple Injection Redress Kit RDK 4192 HVO 62 Table 31 9 Bottom Sub Redress Kit RDK 4348 HVO 62 OPS 4120 Rev F Table 32 9 1 2 Bottom Sub Redress Kit RDK 4350 HVO 62 Table 33 11 1 2 Bottom Sub Redress Kit RDK 4190 HVO 62 Table 34 Optional Metal to Metal Seal 62 FOUG L BOP a V Figure 2 Typical identification tag 2 Figures leie ET cutn 3 Figure 4 Dimensional Data 193 4120 5 Figure 5 Section through rams closed position 6 Figure 6 T 9 Figure 7 Equalisation Operation 1 10 Figure 8 Equalisation Operation 2 11 Figure 9 Equalisation Operation 3 12 Figure 10 Corr
3. OIL TOOLS Unit 12 Barratt Trading Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual Modular BOP System 6 3 8 ID 10K This is a certified safety critical product and modifications or changes not authorised by Phuel Oil Tools may compromise the Safety Functionality and Certification of the assembly OPS 4120 Rev F User Manual Phuel Modular BOP System OIL TOOLS Table of Contents Revision 4 IV vci ence V MEME iecore Jj e UP ME Product 5 2 1 3 Modular Traceability 2 2 Technical 4 2 ech OCO RI e Le LE 6 e 6 4 7 41 Operating the Rams 7 4 1 1 Hydraulic Operation 7 EE Hee 7 4 1 3 LOCKING the Rams 7 ANA Proper E 8 4 1 5 Bleed Down Rate in Gas Wells 8 4 2 Equalising across the rams 8 d E 13 4 3 1 Before the Job 13 4 3 2 During the Job 13 422 AIT Tm 13 5 Operational Characteristi
4. 1 7 642 T SEAL WITH BACK UPS N 5 196 3164 304 1 DOWEL 6MM X 32MM LONG 6 196 4559 STL 1 METAL SEAL Table 11 196 4403 Parts List 6 96 38 m ARN SS W ATTACH BAND HERE ES Note Item 6 is an optional metal to metal seal see section 6 7 Figure 30 7 1 16 BX Flange 10K Bottom Sub OPS 4120 Rev F 48 gt gt User Manual Phuel Modular BOP System OIL TOOLS Part Number Quantity _______ 1 196 4309 80 1 TOP SUB V3 9 00 4 99 910 3370 66 1 FEMALE PROTECTOR DW 9 4 ACME Table 12 196 4349 50 Parts List Note Fitting this part will reduce the bore of the BOP to 5 1 8 9 00 4 ACME 2 V gt H ZZ Figure 31 9 QU Top Sub Assy OPS 4120 Rev F 49 gt gt User Manual Phuel Modular BOP System OIL TOOLS 196 4310 480 Quanity BOTTOM SUB V3 9 00 4 110 2053 480 1 COLLAR 9 4 SPLIT TYPE 110 2054 480 1 SPLIT RING 9 4 110 2329 3A4 4 STOP PIN 190 2791 316 LOCK BLOCK 190 2804 304 SPIROL ROLL PIN 1 4 DIA X 1 196 3164 304 1 DOWEL PIN 6MM X 32MM LONG 802 2921 V80 1 7 642 T SEAL WITH BACK U
5. 45 Figure 28 Shear Ram Assy 190 3862 HH0 46 Figure 29 7 1 16 BX Flange 10K Sub 47 Figure 30 7 1 16 BX Flange 10K Bottom Sub 48 Figure 31 9 QU Top Sub Aeey a 49 Figure 32 9 QU Bottom Sub Assy secet tttm ten ten 50 Figure 33 9 QU Top Sub Assy 51 Figure 34 9 12 QU Bottom Sub 52 Figure 35 11 QU Top SUD 53 Figure 36 11 QU Bottom Sub ASSY 54 Figure 36 BOTTOM ASSY 5 1 8 API FLANGE 10K WP 55 Figure 37 Equalisation Assy 190 4187 HV0 26 Figure 38 Connecting Collar Assembly 196 4188 50 57 Figure 39 Equalizing Check Valve Assy 193 4192 HVO 59 Figure 40 Right Angled Swivel Assy 190 4262 HV0 60 OPS 4120 Rev F li User Manual uel Modular BOP System OIL TOOLS User Manual Phuel Modular BOP System OIL TOOLS Revision History Issue Release Date Hev A 10 Nov 11 Initial Issue Addition of 7 1 16 Flange Top and Bottom Subs Addition of Torque Value for AFO P
6. 2A allows access between upper Rams ALL VALVES CLOSED UNLESS STATED OTHERWISE Figure 8 Equalisation Operation 2 OPS 4120 Rev F 11 User Manual uel Modular BOP System OIL TOOLS Stop Chemical Injection 1B 1B OPEN OPEN 1C s CLOSED 1C 8 1A OPEN 2B OPEN Stop Dump If Plug 3B Removed OPEN Injection Stopped Pressure can be dumped between the rams or externally WARNING Pressure remains ALL VALVES CLOSED UNLESS STATED OTHERWISE Equalizing With Chemical Injection 2B 2B OPEN CLOSED 3A OPEN 3C OPEN 3D OPEN Pressure below shear ram Injection Started Open 2B 3D then to prevent freezing ALL VALVES CLOSED UNLESS STATED OTHERWISE Figure 9 Equalisation Operation 3 OPS 4120 Rev F 12 User Manual Phuel Modular BOP System 011 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 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 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 ope
7. 4 Soc Hd Cap Size 1 2 Length 0 5 in WNL 0580 316 5 WASHER NORDLOCK M12 SDU 0503 HTS 1 Set Screw Dog Point Size 1 4 Length 0 5in 47 100 2179 STL 1 GREASE NIPPLE 1 8 NPT 48 190 3870 H85 2 ROD SEAL 49 WNL 0500 304 2 Nordlock Washer size 1 4 Table 7 Modular Actuator Assembly 190 4186 HVO cc OPS 4120 Rev 43 User Manual Modular BOP System 25 842 14 OG Se 9 1 11 2 STAMP PER QP 14 E T 1 Z ke u Jr Met H E 24777 WY oe lian ZZ TD T 11 875 4777777777777777777777 7777 SIS NSSNNSNN Ni HERS UD sii 40 4 LOCTITE 9 99 x KIKA 87 212 DETAIL A 82 DETAIL C Figure 26 Modular Actuator 190 4186 HVO DETAIL B OPPOSITE PORT MUST NEVER BE BLANKED OFF OPS 4120 Rev F CHA User Manual gPhuel Modular BOP System OIL TOOLS 1 190 3705 480 1 GUIDE RAM 6 3 8 2 190 3706 480 1 SINGLE GUIDE RAM 6 3 8 3 190 1715 H70 2 Outer Seal 4 190 5307 H80 2 RAM INNER SEAL SIZE 7 00 Table 8 Wireline Ram Assy 190 3863 HHO WIRELINE RAM S 190 3863 HVO XXX YY Z TAG DETAILS Figure 27 Wireline Ram Assy 190 3863 HHO OPS 4120 Rev F 45 User Manual Phuel Modular BOP System OIL TOOLS 1 190 3811 480 1 SINGLE GU
8. 802 2921 V80 1 7 642 T SEAL WITH BACK UPS 11 801 0444 v9 0 1 5 Size 444 11 1 2 4 Quick Union 12 196 3164 300 1 DOWEL PIN 6MM X 32MM LONG 13 190 2791 316 1 LOCK BLOCK 14 SHC 0507 HTS 2 Soc Hd Cap Size 1 4 Length 1 in 15 190 2804 304 1 SPIROL ROLL PIN 1 4 DIA X 1 100 910 3620 66 1 DW MALE PROTECTOR 11 1 2 Table 17 196 4190 HVO Parts List N 17 86 99 e SC n 06 375 0 020 Figure 36 11 1 2 QU Bottom Sub Assy OPS 4120 Rev 54 User Manual Phuel Modular BOP System OIL TOOLS 1 196 51 15 480 1 5 1 8 BX 169 FLANGED BOTTOM SUB V2 2 802 2921 V80 IT SEAL WITH BACK UPS 7 642 3 196 3164 304 DOWEL PIN 6MM X 32MM LONG 4 190 2791 316 LOCK BLOCK 5 196 5819 80 MUSHROOM PLUG 0 393 LONG 6 ISHC 0507 HTS Soc Hd Cap Size 1 4 Length 1 in 7 1 96 4559 STL METAL SEAL Table 18 196 4651 HVO Parts List N 56 38 SN Is e lt ATTACH BAND HERE 51 250 THRU 12 EQUISPACED 10 25 0 26 m MAKE UP LENGTH NN Figure 37 BOTTOM ASSY 5 1 8 API FLANGE 10K WP OPS 4120 Rev F 55 User Manual Modular BOP System OIL TOOLS 1 190 4268 480 1 EQUALISATION BLOCK V3 2 110 2979 316 VALVE 4 190 2823 PE
9. 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 equalize 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 4120 Rev F 8 User Manual uel Modular BOP System OIL TOOLS Understanding The Layout Chemical Inject with check valve Grease Injection Figure 6 Equalisation Layout OPS 4120 Rev F 9 User Manual uel Modular BOP System OIL TOOLS Pressure Below Upper Rams Pressure Across Rams Equalised ALL VALVES CLOSED UNLESS STATED OTHERWISE 2B CLOSED Pressure reaches Isolation Valve Pressure reaches chemical line amp ALL VALVES CLOSED UNLESS STATED OTHERWISE Figure 7 Equalisation Operation 1 OPS 4120 Rev F 10 User Manual uel Modular BOP System OIL TOOLS 1C CLOSED 3C CLOSED Isolation valve C gives access to Ram Branch Each Ram Branch can be accessed individually ALL VALVES CLOSED UNLESS STATED OTHERWISE 1B OPEN 1C CLOSED CLOSED 2A CLOSED 2B OPEN 2C OPEN 3C CLOSED 3C CLOSED Starting with Isolation Valve 2C open Opening
10. enough stored energy to separate parts with considerable force 7 1 Prepare 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 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 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 The BOP is now prepared for testing 7 2 Body Test Ensure that all the rams are in the open position Close equalizing valve 1B 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 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 4120 Rev F 35 User Manua
11. 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 4120 Rev F 21 User Manual Phuel Modular BOP System OIL TOOLS Figure 12 Accessing the rams 6 5 2 Ram Removal not required to redress ram seals e Remove Ram from Actuator by sliding the Ram off the Ram Tee 6 5 3 Ram Seal Redress e The Inner Ram Seals can be removed by simply sliding the seal out to either side e Outer Seal can be removed by levering out one end with a suitable instrument and simply pulling off e he 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 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 groo
12. 00 psi 0 125 6 Slick line 250 Kg 800 psi 10 000 psi 0 160 Slick line 250 Kg 400 psi 10 000 psi Table 3 Shearing performance and limitations Note The shear blades are designed to cut only once The blades must always be replaced once they are used to cut wire OPS 4120 Rev F 17 User Manual Phuel Modular BOP System 011 TOOLS 5 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 5 6 Temperature and Pressure Limitations Testing has been conducted to verify the performance of the BOP at extreme operating temperatures 5 6 1 General Sealing The BOP seals typically 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 5 6 2 Blind Ram Shear Seals Bind inner seals part number 190 3921 H80 have been superseded with part number 190 5306 H80 which offer improved sealing at higher temperature The shear rams have been qualified for operation between 10C and 121C with
13. 190 3862 HHO 1 6 3 8 SHEAR RAM ASSEMBLY V2 7 193 4191 550 1 6 3 8 MODULAR CRASH FRAME 8 193 4192 Hvo 1 TRIPLE INJECTION MODULE V3 9 193 3591 HSO 1 MODULAR BOP HYDRAULIC FITTING LIST Table 5 193 4120 HVO Parts List OPS 4120 Rev F 38 User Manual OIL TOOLS Phuel Modular BOP System SUI TOP LEVEL FE 25 MIDDLE LEVEL 11 500 4 ACME 66 224 64 101 OPS 4120 Rev F i lli 11 500 4 ACME 77 640 5 F ED HF e L lie 0 lH ew eg b EL I L gt O o Figure 23 Modular Part 1 39 User Manual Phuel Modular BOP System DETAIL A Figure 24 Modular BOP Part 2 OPS 4120 Rev F 40 User Manual uel Modular BOP System OIL TOOLS MODULAR BOP BODY V3 ACTUATOR ASSEMBLY V3 EQUALISATION BLOCK ASSEMBLY 10k SLIDER ROD 40mm X 22 END STOP V3 7 642 T SEAL WITH BACK UPS BOP HOSE CLOSE BOP HOSE OPEN CONNECTOR 3 8 BSPP X 3 8 NPT 1252 06 06 CONNECTOR 1 4 BSPP X 1 4 NPT 1252 04 045 CSink Soc Hd Size 1 2 Length 1 in DOWEL PIN X 32MM LONG LOCK BLOCK SPIROL ROLL PIN 1 4 DIA X 1 Table 6 Modular Body Parts List 196 4185 HVO OPS 4120 Rev F 41 User Manual Modular BOP System OPS 4120 Rev F
14. 42 User Manual Phuel Modular BOP System OIL TOOLS En E 190 4231 480 a ROTATE CYLINDER CAP V3 190 4232 480 1 DRIVE ROD 190 4233 480 1 DRIVE SLEEVE V3 190 4234 316 1 INDICATOR ROD V3 190 1649 480 1 CAP COLLAR 190 1773 STL 1 DRIVE KEY PLATE CAST 190 4235 480 1 HOUSING V3 190 4236 480 1 PISTON V3 190 4241 STL 1 ACTUATOR BRACKET V3 B 190 1612 480 1 Piston Seal Sub 11 190 2863 480 1 ACTUATOR COLLAR 12 190 4240 STL 1 RAM KEY PLATE 13 190 1774 STL 1 14 190 4291 PLA 2 BEARING SPACER 190 1696 STL 1 Thrust Bearing FAG 812 06 T 190 4246 304 1 HAND WHEEL 250mm 22 190 1704 STL 1 Acorn Nut 1 2 13 23 190 4244 STL 2 BALL SLIDE 40mm SHAFT 30 802 1699 H85 1 Rod T Seal Assy 004 31 802 2505 H85 1 ROD T SEAL 0 825 DIA 32 801 0345 V90 1 O Ring B S Size 345 33 802 4242 H85 1 PISTON T SEAL 4 250 34 801 0344 V90 1 O Ring B S Size 344 36 801 0342 V90 1 O Ring B S Size 342 5 3 4 4 Ouick Union 37 801 0439 V90 1 O Ring B S Size 439 40 190 2491 STL 1 EXTERNAL CIRCLIP SH 75 0 750 DIA 41 190 4245 STL 4 SPIRAL SHAFT RING DCR 62 62mm SHAFT SHC 0503 B7M 4 Soc Hd Cap Size 1 4 Length 0 5 in SDU 0582 HTS 3 Set Screw Dog Point 1 2 UNC X 0 625 in SHC 0581 HTS
15. 50 T 190 1703 STL Hollow Lock Screw 3 4 16 MAC 765 11 801 0110 90 O Ring 5 Size 110 12 801 0119 90 O Ring 5 Size 119 13 SHC 0583 3A4 Soc Hd Cap 1 2 UNC Length 3 4 in 14 WNL 0580 316 WASHER NORDLOCK M12 Table 21 Triple Injection Module Parts List 193 4192 HVO gt gt En 1 900 3331 316 eem Bulkhead Connector 6MBC6N 2 9503337316 Male Connector 6MSC8N 3 900 3332 316 Elbow MSEL6N 4 900 333 316 3 8 5 950 3348 PLA Dual Clamp Assy 1 109 5 6 190 2746 STL Release Coupling QR74QC5 06 Table 22 Modular Hydraulic Fittings 193 3591 50 OPS 4120 Rev F 58 Ee User Manual Phuel Modular BOP System 193 TRIPLE SET UP i 5 D pea Figure 40 Equalizing Check Valve Assy 193 4192 HVO OPS 4120 Rev F 59 User Manual Phuel Modular BOP System OIL TOOLS PartNumber Quantity Description 2 190472440 1 SWIVELOUTLET 1 2NPT 3 31904268 PF 2 PIANBEANNG 4 801 0114V0 2 OHing BSSzelld 5 801011080 1 OHing BSSze110 6 __ 0542 316 910 2186 N66 Table 23 RIGHT ANGLED SWIVEL ASSY 1 2 NPT 190 4262 HVO Figure 41 Right Angled Swivel Assy 190 4262 0 OPS 4120 Rev F 60 User Manual Phu
16. 82 480 SPLIT RING 9 5 4 110 3147 3A4 STOP PIN FOR 9 5 SPLIT COLLAR 190 2791 316 LOCK BLOCK 190 2804 304 SPIROL ROLL PIN 1 4 DIA X 1 196 3164 304 1 DOWEL PIN 6MM X 32MM LONG 802 2921 V80 1 7 642 T SEAL WITH BACK UPS 801 0443 V90 1 O Ring B S Size 443 m SHC 0507 HTS 2 Soc Hd Cap Size 1 4 Length 1 in 11 WNL 0580 316 4 WASHER NORDLOCK M12 Table 15 196 4350 HVO Parts List Note The fitting of this part will reduce the maximum working pressure of the assembly to 6 500 psi 06 375 0 020 o bg sr d ee Figure 34 9 1 2 QU Bottom Sub Assy OPS 4120 Rev F ANTS Iu d 52 Modular BOP System OIL TOOLS Part Number Quantity 1 196 4258 480 1 TOP SUB V3 11 1 2 4 2 910 2154 66 1 11 1 2 4 ACME FEMALE PROTECTOR Table 16 196 4189 HVO Parts List 911 50 X EF AE AE 8 38 Figure 35 11 1 2 QU Top Sub Assy OPS 4120 Rev F 53 User Manual Phuel Modular BOP System 196 4259 480 1 BOTTOM SUB V3 11 1 2 4 10K 110 2546 480 1 SPLIT COLLAR 11 5 4 110 2547 480 1 SPLIT RING 11 5 4 110 2548 3A4 4 STOP PIN 1 25 LONG 5 WNL 0580 316 4 WASHER NORDLOCK M12 10
17. ATING PIN HOLE DETAIL B DETAIL D Figure 19 Assembling the Modules Part 1 OPS 4120 Rev F 30 User Manual Modular BOP System AU DETAIL E DETAIL F Figure 20 Assembling the Modules Part 2 OPS 4120 Rev F 31 User Manual Phuel Modular BOP System KA Y LI ee D Figure 21 Assembly of the Equalising Blocks OPS 4120 Rev F 32 User Manual Phuel Modular BOP System OIL TOOLS pene e See lt Se de EE n il Ms x 1 Kep 1 Ce Ul vi MS T m 19 Ej S MSS E M ER AS SS lA pe ies SC AU d EAM prom p V E IT i i OX E Ger ES H 27 H Pw P at gt Figure 22 Assembly of the Frame OPS 4120 Rev F 33 User Manual Phuel Modular BOP System 6 8 Maintenance Record Sheet Type of Performed Verified Comments Performed Maintenance By By Table 4 Maintenance Record OPS 4120 Rev F 34 User Manual Phuel Modular BOP System OIL TOOLS 7 Testing All testing is to be carried out in the designated test area and by suitably qualified 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
18. H85 2 SHC 0503 BzM 2 SocHdCapSze ix05in Older kits only Table 27 Actuator Redress Kit RDK 4186 HVO Part Number ae 190 1715 H70 Outer Seal 6 3 8 190 5307 H80 Inner Seal 6 3 8 M Table 28 Wireline Ram Redress Kit RDK 3863 HHO OPS 4120 Rev F 61 User Manual Phuel Modular BOP System OIL TOOLS Part Number Quantity ws 190 1715 H70 Outer Seal 6 3 8 190 5306 H80 Blind Inner Seal 6 3 8 Table 29 Shear Ram Redress Kit RDK 3862 HHO 801 10 70 24 ORingBS108 801 11 90 2 9081 190 2823 _ 22 Cave Seat Table 30 Equalisation Isolation Redress Kit RDK 4187 HVO 7 800110500 9 ORfig BSSzei _ sou ORng BSSzelld __ ORimg BSSzeii Table 31 Triple Injection Redress Kit RDK 4192 HVO Part Number Quantity 802 2921 V80 7 642 T SEALWITHBACK UPS 801 0438 V90 O Ring B S Size 436 71 Table 32 9 Bottom Sub Redress Kit RDK 4348 HVO Part Number Quantity 802 2921 V80 7 642 T SEALWITHBACK UPS 801 0443 V90 O Ring B S Size 443 MEE Table 33 9 1 2 Bottom Sub Redress Kit RDK 4350 HVO Part Number Quantity 802 2921 V80 7 642 T SEALWITHBACK UPS sis 801 0444 V90 O Ring B S Size 444 35 Table 34 11 1 2 Bottom Sub Redress Kit RDK 4190 HVO Part Number Quantity 196 4559 STL METAL SEAL Table 35 Optional Metal to Metal Seal Indiv
19. IDE SHEAR RAM 6 3 8 2 190 3812 480 1 SHEAR GUIDE RAM 6 3 8 3 190 5100 411 1 SHEAR BLADE 4 190 5102 411 1 SHEAR BLADE SINGLE GUIDE 5 190 3741 821 2 SHEAR BLADE PIN 6 SCU 0581 304 2 1 2 13 x 0 500 LONG SET SCREW CUP POINT UNC 7 190 1715 70 2 Outer Seal 8 190 5306 80 2 BLIND RAM INNER SEAL SIZE 7 00 SHEAR BLADE Was 190 3740 411 Now 190 5100 411 and BLADE SINGLE GUIDE Was 190 3815 411 Now 190 5102 411 Blades altered to improve the shearing capability for heavy duty cables such as 7 16 Dyform The older shear blade are still fit for purpose but will be phased out Table 9 Shear Ram Assy 190 3862 HHO SHEAR 5 190 3862 HVO XXX Y Y Z TAG DETAILS Care must be taken when fitting item 6 Pt No SCU 0581 304 DO NOT OVERTIGHTEN TORQUE TO 5 12 Ib ft 7 15 Nm Figure 28 Shear Ram Assy 190 3862 OPS 4120 Rev F 46 User Manual Modular BOP System Description 1 196 4399 480 1 7 1 16 FLANGED TOP SUB V2 2 195 1745 7 12 THREADED STUD 1 1 20 X 7 5 3 128 2280 A2H 12 HEAVY DUTY NUT 1 500 8 UN Table 10 196 4402 50 Parts List OPS 4120 Rev F 47 User Manual Modular BOP System 196 4398 480 1 7 1 16 FLANGED BOTTOM SUB V2 128 2280 A2H 12 HEAVY DUTY NUT 1 500 8 UN 195 1745 AL7 12 THREADED STUD 1 1 2UN X 7 5 802 2921 V80
20. K VALVE SEAT 10 190 1758 416 AFO Plug PLAA3124010A 11 801 0108 V90 O Ring B S Size 108 13 801 0113 90 O Ring B S Size 113 20 SHC 0555 AL7 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 316 10 Nord Lock Washer Size 3 8 Table 19 Equalisation Assy 190 4187 HVO T NI T LOCTITE Torque to 90in Ibs 10 2 Figure 38 Equalisation Assy 190 4187 0 OPS 4120 Rev F 96 User Manual Phuel Modular BOP System OIL TOOLS 1 196 4620 411 1 MODULAR CONNECTOR V3 2 196 4193 411 2 COLLAR KEY 3 WNL 0500 316 2 1 4 Nordlock Washer 4 SHC 0509 316 2 SOC HD CAP 1 4 UNC X 1 500 LONG Table 20 Connecting Collar Parts List 196 4188 50 Wem Torque to 7 15 Nm WEIGHT 76 16 ATTACH TAG PER QP 14 Figure 39 Connecting Collar Assembly 196 4188 50 OPS 4120 Rev F 57 bk User Manual Phuel Modular BOP System OIL TOOLS 900 3019 480 eem CHECK HOUSING 205 2105 480 BLANK TEST PORT 190 4262 HVO RIGHT ANGLED SWIVEL ASSY 1 2 NPT 190 4267 316 EXTENSION BAR 13 263 P C D 190 2821 316 PORT BLANK END 100 2114 PEK CHECK VALVE SEAL 190 2786 PEK CHECK CONE SEAL 145 2185 STL COMP SPRING D22120 190 1749 STL COMP SPRING C55156
21. OLS 1 Introduction 1 1 General The Modular Blow Out Preventer BOP provides essential safety barriers against well pressure during wireline operations It is usually located directly above the christmas tree flange The BOP Depending on configuration can have one or more sets of wireline rams for sealing against well pressure on slick line and or braided line Shear and seal rams are also available these are capable of cutting through the wire and then sealing against the well pressure The modular concept allows the operator to configure the BOP as required to suit even special operations main advantage comes when maintaining the equipment as ram bodies can be easily changed out with spares more cost effectively allowing the asset use to be maximised The ram consists of 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 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 eq
22. OP System OIL TOOLS 77 78 1976 mm 22 80 578 E c IB E E s E e Hi 9 D r EJ s T Le Wi e 82 05 1576 mm Figure 4 Dimensional Data 193 4120 OPS 4120 Rev F 5 User Manual Phuel Modular BOP System OIL TOOLS 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 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 Outer Seal Indicator Rod son Inner Seal Pressure Figure 5 Section through BOP rams closed position The rams are driven by a hydraulic actuator which consists of a piston with an Indicator ro
23. PS 801 0438 V90 1 O Ring B S Size 438 m SHC 0507 HTS 2 Soc Hd Cap Size 1 4 Length 1 in 11 WNL 0580 316 4 WASHER NORDLOCK M12 99 910 3369 N66 1 MALE PROTECTOR DW 9 4 ACME Table 13 196 4348 HV0 Parts List Note Fitting this part will reduce the bore of the to 5 1 8 15 089 5 a SSS gt Taam oam rame aee KC U e SEM Mem SS OH SS 5 125 0 020 rit 9 00 4 ACME Figure 32 9 QU Bottom Sub Assy OPS 4120 Rev F 90 CH User Manual gPhuel Modular BOP System Part Number ee NA uant pon 196 4311 480 TOP SUB V3 9 50 4 910 3540 66 DW FEMALE PROTECTOR 9 1 2 Table 14 196 4347 50 Parts List Note The fitting of this part will reduce the maximum working pressure of the assembly to 6 500 psi 9 500 LZ 9 1 2 4 ACME DULLES ARR lt 8 875 DERI lt a amar ATTACH BAND HERE 41 26 38 c 011 000 Figure 33 9 1 2 QU Top Sub Assy 99 910 3539N66 1 DW MALE PROTECTOR 9 1 2 User Manual Phuel Modular BOP System OIL TOOLS 196 4312 480 Quanity BOTTOM SUB V3 9 50 4 117 2381 480 1 SPLIT COLLAR 9 1 2 4 SPLIT TYPE 117 23
24. ar Ram Assy 190 3862 HH0 46 Table 10 196 4402 HSO Parts Det 47 Table 11 196 4403 Parts List 48 Table 12 196 4349 HSO Paris LS texte ton aoro 49 Table 13 196 4348 HVO Parts List 50 Table 14 196 4347 HS0 Parts List 51 Table 15 196 4350 HVO Parts Det 52 Table 16 196 4189 HVO Parts Uer 53 Table 17 196 4190 HVO Parts 5 54 Table 17 196 4651 HVO Parts Det 55 Table 18 Equalisation Assy 190 4187 HV0 56 Table 19 Connecting Collar Parts List 196 4188 50 57 Table 20 Triple Injection Module Parts List 193 4192 HVO 58 Table 21 Modular BOP Hydraulic Fittings 193 3591 50 58 Table 22 RIGHT ANGLED SWIVEL ASSY 1 2 NPT 190 4262 HVO 60 Table 23 BOP Redress Kit RDK 4120 HVO 61 Table 24 Modular Body Redress Kit RDK 4185 HVO 61 Table 25 Redress Kit RDK 4243 HV0 61 Table 26 Actuator Redress Kit RDK 4186 HVO
25. cs 16 51 Sealing Characteristics 16 5 1 1 Minimum Hydraulic 16 5 1 2 Opening the BOP with differential pressure 16 2 MTM T 16 Sr ANN Le tm 17 5 4 Shearing Performance and limitations 17 5 5 Performance of Ram Guides 18 5 6 Temperature and Pressure 18 5 6 1 General 18 5 6 2 Blind Ram Shear Seal 18 5 6 3 Wireline Multi Seals 18 SEE u ua aqapana ana 20 SN MEM IntroduCtion E 20 02 GOO G 20 6 2 1 e e DEE 20 6 2 2 20 623 Five Yearly EE 20 SC E 20 TTT OO a EET eee eee ee eee 21 552 gt 21 6 5 1 ACCESS HOS 21 6 5 2 Ram Removal not required to redress ram seals 22 OPS 4120 Rev F User Manual Phuel Modular BOP System OIL TOOLS 6 5 3 Ham Seal 22 6 5 4 Re attach to BOP Body
26. d 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 4120 Rev F 6 User Manual Phuel Modular BOP System OIL TOOLS 4 Basic Operation 4 1 Operating the Rams Note Always ensure that the pressure across the rams has been equalised before opening 4 1 1 Hydraulic Operation The BOP has been provided with flexible armoured piping to offer the required fire protection level wo 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 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 4 1 2 Manual Operation The rams can be closed manually out not opened again by turning the hand wheel in a clockwise dir
27. e seals should be changed every year as a minimum OPS 4120 Rev F 16 User Manual Phuel Modular BOP System 011 TOOLS 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 5 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 5 4 Shearing Performance and limitations Testing has been conducted to verify the shearing and sealing capabilities of the shear rams The table below shows the results of these tests 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 0 125 Slick line 250 Kg 400psi 10 0
28. ect lubrication for storage 15 Figure 11 Qualified Operating Envelope 19 Figure 12 Accessing the rams 22 Figure 13 BOP Wireline Hames 22 Figure 14 BOP Shear Rams 23 Figure 15 Connecting collar and lock block 25 FOUG TO 2 6 aO indie Sene 27 Figure 17 Actuator 2 28 Figure 18 Modular Body Assembly 29 Figure 19 Assembling the Modules Part 1 30 Figure 20 Assembling the Modules Part 2 31 Figure 21 Assembly of the Equalising Blocks 32 Figure 22 Assembly of the Frame 33 Modur BOP P TT u uu 39 Figure 24 Modular BOP Pait 2 40 Figure 25 Modular 196 4185 HV0 42 Figure 26 Modular Actuator 190 4186 44 Figure 27 Wireline Ram Assy 190 3863
29. ection 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 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 piston to move fully back 4 1 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 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 OPS 4120 Rev F 7 User Manual Phuel Modular BOP System It is important to remember that the manual lock must be fully withdrawn before the rams can be opened The mechanism is rated for operation at full working pressure
30. el Modular BOP System 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 Elastomeric spares are supplied in Viton material as standard Other materials are available please specify when ordering Part Number Quantity RDK 4186 HVO 6 Actuator Redress Kit RDK 4192 HVO Triple Injection Redress Kit FPF 802 2921 V80 7 642 T SEAL WITH BACK UPS RDK 4187 HVO Equalisation Isolation Redress Kit RDK 3152 HVO 11 1 2 QU Bottom Sub Redress Kit Table 24 BOP Redress Kit RDK 4120 HVO S VD 2 U Adualor Recess KL 1 Hedress i 802 2921 V80 1 7 642 T SEALWITHBACK UPS 1902804300 1 SPIROLROLLPIN14 Table 25 Modular Body Redress Kit RDK 4185 HVO 8022921 80 1 7 642 T SEALWITHBACK UPS 190 2804300 1 SPIROLROLLPIN1TA DIAX4 196 3164300 1 bDOWELPIN6MMX32MMLONG 0 Table 26 Redress Kit RDK 4243 HVO 801 0345 V90 me 80r0344V90 Ofing BSSzeG d 80r0439V90 Ofing BSSze439 802250585 1 RODTSEALOBPDIA 802424585 1 PISTONT SEALA280 802609485 RHodTsedAsy 1903870
31. eplaced OPS 4120 Rev F 23 User Manual Phuel Modular BOP System OIL TOOLS 6 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 6 6 1 Splitting the Connection e Locate and remove lock block equalisation blocks may need to be removed to allow access Remove each of the screws that holds in the key and then remove the keys e Split the Connector Collar using a cold chisel if required The two halves of the collar must be kept together and never mixed with those from another assembly e The two assemblies can now be pulled apart e Inspect the T Seal and replace if necessary e Inspect the Pins to make sure they are not damaged Replace if necessary 6 6 2 Re Making the Connection Note Take note of new body serial number to allow update of traceability Ensure that the Pin and T Seals are in good condition Lower the upper module down to locate the pin in the groove 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 The butress threads of the connecting collar must be degreased before assembly and must never be coated with grease or lubricant This would i
32. he pin in the fine emery both should be smooth to the groove then push down to engage the seal Drive finger touch down with a weight or blows with a soft face Fit the metal seal into the groove hammer if required The end faces should be almost flush within 1mm The buttress threads of the connecting Lock together using Collar Key socket head cap collar should only be lightly coated with screws and washers Tighten the collar by hand grease Fit the two halves of the collars ensuring that the gap between the two halves is completely closed Ensure the collar is free moving 196 5819 H80 puro m Jr Tighten the locking collar fully Top of collar Lock block were fitted to be fitted with to underside of BOP body should be no Mushroom Plug Push the lock block up to the more than 0 135 Additional load may collar and fit the two socket head screws need to be applied to achieve this gap OPS 4120 Rev F 26 User Manual Modular BOP System HYDRAULIC SIDE LES Al WELL SIDE Figure 16 Actuator Part 1 OPS 4120 Rev F 27 User Manual Modular BOP System OPS 4120 Rev F 28 User Manual Modular BOP System OPS 4120 Rev F 29 User Manual Phuel Modular BOP System lt gt SN X wen SS DETAIL A DETAIL ONCE FULLY TIGHTENED BACK OFF COLLAR TO THE NEAREST RE ONCE FULLY TIGHTENED BACK OFF COLLAR TO THE NEAREST LOC
33. idual seals and parts may be ordered as required See the parts list in the previous section for part numbers OPS 4120 Rev F 62
34. inimum closing pressure that can be applied for various well pressure levels Initial Well Bore Pressure Min Hydraulic Pressure zero to 4 000 psi 1 500 psi 4 000 6 000 psi 2 000 psi 6 000 to 10 000 psi 3 000 psi Table 2 Minimum hydraulic pressure to seal 5 1 2 Opening the 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 With differential pressures lower than 2 000 psi across the rams it is possible for the well pressure to force the BOP open if the hydraulic closing pressure is removed This is not the case when the differential pressure across the rams is greater than 2 000 psi The manual locking feature should therefore be used when the BOP is closed to prevent accidental opening 5 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 replaced before this limit is exceeded If records do not exist then th
35. l Phuel Modular BOP System 011 TOOLS 7 3 Ram test Shear seal With BOP Rams in the open position and fill up the with the test medium by using the test pump Ensure valve on test cap remains open for the duration of this test Close Shear Ram this is done by activating the BCU Shear seal valve to close position then pressurize up to a maximum of 3 000 psi on the ram Test fluid will be observed coming out of the Test Cap valve Close equalizing valves Note equalizing valve setup to be added to the test chart with number and position Connect pressure test pump to the Test Stump so that pressure testing is done from the underside of rams and up Observe Test Cap during testing for fluid leaking out under pressure Put up safety barrier in the work area Pressurize up to 300 psi low pressure test observe if there are leaks Hold Time 5 min Bleed the pressure to zero Press up to the MWP for the in accordance documentation maintain the pressure for 15 min without leakage Bleed the pressure to zero Open rams on by enabling BCU Shear seal valve to open position 7 4 Wireline Ram Seal Test Between the ram Ensure Test Cap 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 1B on equalizing block gauge port Close the Middle Ram Open S
36. lug and connecting collar screws RDK 2777 HHO Qty Change Updated with improved seals per FB 029 Added improved shear blades Added bottom sub 196 4651 0 Added details of metal to metal seal J J Rev F 17 Jan 13 OPS 4120 Rev F IV c User Manual gPhuel Modular BOP System 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 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 The Actuator piston has two seal with a vent hole to prevent communication of well pressure to the hydraulic chambers on opposite side of grease nipple This vent hole must never be blanked off Figure 1 BOP OPS 4120 Rev F V User Manual Phuel Modular BOP System OIL TO
37. lure of any part may cause injury Welding corrosion rough handling or other abuse may affect the Integrity of this product OPS 4120 Rev F 20 User Manual Phuel Modular BOP System 011 TOOLS e Many of the components are heavy and should not be lifted without lifting aids Wear appropriate personal protective equipment 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 4 Tools The following tools are recommended e Non marking Memac Chain Wrench Other pipe wrenches may be used but will mark equipment Piston Seal Sub Assembly Tool Part No 900 1577 400 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 6 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 6 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
38. naptite connector on the test stump for verification of leakage on the lower ram Fill the BOP with test fluid to above the Upper Ram Close the Upper Ram by setting Ram to 3 000 psi by activating the valves on the BCU to close position Pump test medium thru the equalizing Block 1A to see fluid is rising above the upper ram Close equalizing valve 1A 2B 2D 3B 3C Open equalizing valve 1B 1C 1D Put up safety barrier in the work area Pressure up to 300 psi in 5 minutes and observe for leaks OPS 4120 Rev F 36 User Manual Phuel Modular BOP System OIL TOOLS Bleed off to zero Pressurize to MWP according to documentation maintain the pressure for 15 min without leakage Bleed pressure to zero Open the rams open lower first and then the upper ram 75 Post Test Procedure e Disconnect All Hoses e Remove Test Drain out test fluid and circulate with water displacing fluid or lubricating oil Remove BOP from Test Stump Grease end connections and fit oiled thread protectors OPS 4120 Rev F 37 gt User Manual Phuel Modular BOP System OIL TOOLS 8 Parts List and Drawings 1 196 4185 HVO 3 6 3 8 MULTILINE BODY ASSY 2 196 4188 HS0 4 CONNECTING COLLAR ASSY V3 3 196 4189 HS0 1 11 1 2 QU TOP SUB ASSY 10k 4 196 4190 HVO 1 11 1 2 QU BOTTOM ASSY 10K 5 190 3863 HHO 2 6 3 8 WIRELINE RAM ASSEMBLY V2 6
39. ncrease the radial loading on the retaining keys and could lead to failure during operation e Fit the two halves of the collars ensuring that the gap between the two halves is completely closed Lock together using Collar Key Socket head cap screws and washers 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 Carry out pressure testing to maximum working pressure see Test Procedure below Update paperwork with new numbers for traceability OPS 4120 Rev F 24 Phuel User Manual Modular BOP System Figure 15 Connecting collar and lock block 6 7 Optional metal to metal seal Note This requires contact Phuel Oil Tools for further details OPS 4120 Rev F This seal fits between any of the main body and bottom top sub modules and is backed up by the elastomeric seal The seal comes as standard on flanged bottom subs only The seal crushes during installation and is therefore a single fit seal so once fitted the connection should not be disturbed If the connection is broken the metal to metal seal should be replaced an alternative collar locking mechanism where fitted 25 User Manual Phuel Modular BOP System OIL TOOLS 6 7 1 Procedure for fitting metal to metal seal in 6 3 8 Modular BOP 7 I mm Polish seal groove and mating surface with Lower the BOP down 4 locate t
40. no restrictions to the working pressure 5 6 3 Wireline Multi Seals The wireline multi seal part number 190 3689 H90 has been superseded with part number 190 5307 H80 which incorporates Phuel s anti extrusion pad which improves the sealing capability at higher temperature as show in the operating envelope 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 It should be noted that the point 82C 690 bar has been qualified on the basis of extrapolated test results and not directly confirmed by testing 16A does not require qualification below 82C Care should be taken when operating close to this point and further qualification testing may be required to confirm suitability Consult Phuel Oil Tools for advice and part numbers OPS 4120 Rev F 18 User Manual Modular BOP System A Phuel OIL TOOLS 12000 10000 5000 6000 Shear Seal Pressure psi es Wireline Seal 190 5307 80 4000 Wireline Seal 190 3689 90 2000 Ch ed O ed LD e LD ed IDN LD ed O LD cj O ei WwW d ci c q c m m sg mur m oo Oo c M Temperature Degrees C Figure 11 Qualified Operating Envelope OPS 4120 Rev F 19 User Manual Phuel Modular BOP System OIL TOOLS 6 Maintenance All maintenance to be carried
41. or at full hydraulic pressure but not both at the same time otrict measures must be taken to ensure that the BOP is not accidentally opened against the back up mechanism when the well pressures are in excess of 4 500 psi Damage to the mechanism may result and it may not be possible to fully withdraw the rams There would however be no expected loss of pressure containment as a result if this failure 4 1 4 Proper Use 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 closed during a live well operation they should be replaced when the operation is complete 4 1 5 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 pressure from 1000 Psi to zero at a rate of 20 psi per minute 4 2 Equalising across the rams Each ram has a dedicated equalising valve block
42. out by suitably qualified and competent personnel 6 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 6 2 Schedule The maintenance schedule may be governed by international or company standards and the following is considered to be the minimum requirements 6 2 1 Pre amp Post Job Hefer to Section 4 3 1 and Section 4 3 3 for details 6 2 2 Yearly e Disassemble BOP e Clean and degrease all components e Discard screws from ram plate and replace with new ones e Remove rust using a non toxic rust remover gel or liquid Inspect the condition of sealing surfaces and surface coatings repair replace as necessary Re coat threads and sealing surfaces if necessary Contact Phuel if in doubt Apply protective coating like Boeshield T 9 to non painted surfaces Replace all elastomeric seals Re assemble Pressure Test to 300 psi and to maximum working pressure Inspect paintwork and repair where necessary 6 2 3 Five Yearly 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 working pressure per API 6A PSL3 Witnessed by certifying authority 6 3 Safety e This product contains high pressures when in operation Fai
43. ration Functioning of the Rams 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 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 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 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 4 3 3 After
44. s list section of this manual should be used to determine how assemblies and components are grouped together It is recommended that the manufacturing documentation supplied with the BOP is reviewed before splitting the BOP to ensure that the assemblies can be put back together correctly with the traceability intact OPS 4120 Rev F 2 User Manual Phuel Modular BOP System OIL TOOLS Hecord the numbers for each of the modules and ensure that it matches on the corresponding product certificate Top Level Tag L we Level Stamped Figure 3 Modular Map OPS 4120 Rev F 3 User Manual Phuel Modular BOP System OIL TOOLS 2 Technical Specification Part Number 193 4120 HVO 77 79 1 98 m H2S 3 000 psi 200 Bar Max Standard Actuators Stroke Volume 67 cu in to close 58 cu in to open Total cycle volume 125 cu in 2 05 litres per Actuator 4233 Ibs 1920 Hydraulic Connections Wireline Rams 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Shear Rams 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Actuators 4 NPT 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 1 2 10 000 psi max WP Table 1 Technical Data OPS 4120 Rev F 4 User Manual Phuel Modular B
45. the Job After each job the BOP should be thoroughly cleaned repaired as may be required and redressed OPS 4120 Rev F 13 CHA User Manual Phuel Modular BOP System OIL TOOLS 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 4120 Rev F 14 User Manual Modular BOP System Phuel D OIL TOOLS Grease seal bore and threads Cover the assembly when before fitting thread protectors in long term storage Pump grease to all grease nipples until it flows through the other port Never block omear grease on all bars the opposite port Touch up paint when it is damaged or coat damaged area with thick grease ess Grease before fitting protectors For long term storage fit test stump and fill with oil Figure 10 Correct lubrication for storage OPS 4120 Rev F 15 User Manual Phuel Modular BOP System 011 TOOLS 5 Operational Characteristics 5 1 Sealing Characteristics 5 1 1 Minimum Hydraulic Pressure Testing has confirmed that the BOP requires 1500 psi minimum hydraulic closing pressure to close and seal when there is no initial well bore pressure The required closing pressure increases as the well bore pressure increases due to the effects of the well pressure acting against the piston rod The table below should be used a guideline of the m
46. ualisation across the rams Tightening the screw closes the seal and prevents pressure from passing through the valve assembly here 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 Between upper and middle ram it is possible to inject grease through the injection port located at the rear of the BOP 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 limited to the maximum working pressure of the BOP 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 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 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 4120 Rev F 1 User Manual Phuel Modular BOP System OIL TOOLS 1 2 Product Identification Phuel products are identified by a unique serial number that facilitates f
47. ull product traceability Each product is supplied with a documentation pack that 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 Ltc Description amp Size Customer ID No 2huel ID No MW amp Service Figure 2 Typical identification tag 1 3 Modular Traceability Map The modular BOP consists of individually certified assembles that are used to form an overall BOP The standard configuration is a triple BOP this manual but the modular design allows the BOP to be reconfigured to a single or dual BOP by removal of one or more of the individual assemblies or for individual modules to be replaced due to wear or damage It is essential that the documentation is maintained for each module in the assembly so that the traceability records reflect the modules that have been assembled The modular traceability map is intended to assist the user in recording the important trace information and also ensuring that certified components remain with the relevant assemblies The part
48. ve 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 Figure 13 BOP Wireline Rams OPS 4120 Rev F 22 CHA User Manual Phuel Modular BOP System OIL TOOLS Figure 14 BOP Shear Rams 6 5 4 Re attach to Body e fthe rams were removed from the actuator Section 6 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 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 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 r
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