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User Manual Quin BOP Assembly All Sizes
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1. 11 4 4 Fitting the Magnet Detector 12 4 5 Job PI NE D E 13 5 OSEE 14 5 1 nA aa 14 5 2 Schedule 14 5 3 ecl a 14 5 4 TOS a ZZ Ll ce 15 5 5 Ram Seal Redress irii xi dr tiM entra 15 5 6 Actuator Redress 17 5 7 Shear Actuator Redress 19 5 8 Equalisation Block Redress ee eaten etti n tonta e eres 21 5 9 Grease Injection Assembly 23 5 10 Sensor Housing 55 24 5 11 Maintenance Record Sheet 26 CWS tO 27 6 1 BOR AA HOD DD URDU 27 6 2 AU ii 28 6 3 Equalisation Block fe 28 6 4 Grease Injection Assembly 29 7 Parts List and Drawings 31 8 c c a 49 8 1 Available Spare io ott treten tra xxt qe sona n neu e iia 49 8 2 Fest PINES u 51 8 3 Part Number Deviations 2i tni DAT GER GRE nOn Lau pM www 51 Appendix A Increasing the Shearing Capacity of the A 1 Table 1 Technical Specification 3 Table 2 Maintenance Record
2. 26 Table 3 BOP Parts List Part No 195 2220 31 Table 4 BOP Parts List Part No 195 1878 33 Table 5 Wireline Ram Assembly Parts List Part No 190 1764 35 Table 6 WireLine Ram Assembly Parts List Part No 190 1879 35 Table 7 Pipe Ram Assembly Parts List Part No 190 1765 35 Table 8 Pipe ram Assembly Parts List Part No 190 1880 35 OPS 2220 Rev K ii User Manual Phuel Quin BOP Assembly E OIL TOOLS All Sizes Table 9 Shear Ram Assembly Parts List Part No 190 1766 HH0 36 Table 10 Shear Ram Assembly Parts List Part No 190 1881 HH0 36 Table 11 Actuator Parts List Part No 190 2247 38 Table 12 Actuator 190 1932 HVO Parts 40 Table 13 Shear Actuator Parts List Part No 190 2190 42 Table 14 Equalising Block Assembly Parts List Part No 190 1863 44 Table 15 Grease Injection Assembly Parts List Part No 190 2787 HVO 45 Table 16 Hydraulics Parts List 48 Table 17 Redress Kit Part No RDK 2220 HV0 49 Table 18 Redress Kit Part No RDK 1878 HV0 49
3. 17 195 1745 7 24 THREADED STUD 18 195 1964 A2H 24 HEXNUT 1 125 8 UN 19 ISHC 0752 HTS 8 Soc Hd Cap Size 1 Length 3 5 in Table 3 BOP Parts List Part No 195 2220 HH0 OPS 2220 Rev K 31 User Manual Phuel Quin BOP Assembly 3 OIL TOOLS All Sizes Figure 15 BOP Assembly Drawing 195 2220 HH0 OPS 2220 Rev K 32 User Manual Phuel Quin BOP Assembly OIL TOOLS All Sizes Item Number Part Number Quantity Description 1 195 1832 880 1 QUIN BOP BODY 2 190 1932 HH0 8 ACTUATOR ASSEMBLY 3 190 3190 HH0 2 SHEAR ACTUATOR ASSY 4 190 1863 5 Equalisation Block Assembly 5 190 2787 0 4 Grease Injection Assembly 6 190 1879 HH0 2 Wire Line Ram Assembly 7 190 1880 2 PIPE RAM ASSEMBLY 8 190 1881 1 Shear Ram Assembly 190 1671 174 SLIDE ROD T 190 1672 174 END STOP 11 206 1860 NI5 SENSOR HOUSING 12 195 1862 STL Welded Frame 13 SHC 0586 HTS 2 Soc Hd Cap Size 1 2 Length 1 25 in 14 801 0119 V90 O Ring B S Size 119 15 ICSU 0585 HTS x C Sink Soc Hd Size 1 2 Length 1 in 16 WNL 0580 STL 12 Nord Lock Washer M12 17 195 1963 7 24 STUD 1 125 8 UN X 6 500 LONG 18 195 1964 A2H 24 HEXNUT 1 125 8 UN 19 ISHC 0752 HTS 8 Soc Hd Cap Size 1 Length 3 5 in Table 4 BOP Parts List Part No 195 1878 HH0 OPS 2220 Rev K 33 User Manual
4. Table A 1 Bill of Materials Manufacturer is only suggested Technical Explanation The minibooster consists of an oscillating pump together with several free flow through check valves integrated into one small package When fluid enters the inlet IN it freely passes through the booster until the outlet pressure builds up to the match that of the inlet When that happens the internal valves close and the oscillating pump then increases the pressure at the outlet up to the magnification factor selected 1 5 The pump discharges fluid through the return port R while its operating The pump automatically operates when there is drop in the outlet pressure The remaining circuit manages the supply and return of the minibooster so that the rams can still be closed and opened as normal When closing the delivered fluid enters the actuators through the minibooster only the low pressure fluid is then returned through the open port When opening the open pressure will force open the pilot check valve so that the low pressure fluid can be returned through the close port A separate check valve prevents the open fluid entering the minibooster in the reverse direction Implementation The modification of the hydraulic circuit may be implemented locally using appropriately skilled mechanics The minibooster should be supported on the frame of the BOP using a suitable clamp and bracket These components used should be sourced locally T
5. All eo d 1 QD Ql 9 9 7 O 8 m ol c 25 T 7 7 X UN 25 iz lt cum 3 Je SS img WINES 1777 ZZ Z ym 7177 Wh dell u T 21 _ AQ 2 25 WA 2440 o 24 OG 18 22 9 2 Figure 19 Actuator Assembly 190 1932 HV0 OPS 2220 Rev K Sa Phuel User Manual Quin BOP Assembly All Sizes Item Number Part No Quantity Description 1 190 2072 480 1 SHEAR PISTON HOUSING 2 190 2071 480 1 SHEAR SEAL SUB 3 190 2069 480 1 LOCKING SLEEVE 4 190 2073 480 1 SHEAR PISTON 5 190 1967 480 1 CYLINDER CAP 6 190 1649 480 1 CAP COLLAR 7 190 1971 480 6 LOCKING DOG 8 190 1928 480 1 INDICATOR ROD 9 190 1969 480 1 SUPPORT SLEEVE 10 190 1968 480 1 OCK SLEEVE 11 190 1774 STL 1 RAM TEE 12 190 1611 480 1 Ram Key Plate 13 190 1607 480 1 Bearing Bracket 14 802 2163 H85 1 PISTON T SEAL 5 500 15 802 1931 H85 1 ROD T SEAL FOR 1 250 ROD DIA 16 802 2162 H85 2 ROD T SEAL 1 625 17 801 0439 V90 1 O Ring B S Size 439 18 801 0354 V90 1 o Ring B S Size 354 19 801 0345 V90 1 O Ring B S Size 345 20 801 0227 V90 1 O Ring B S Size 227 21 SHC 0503 B7M 2 Soc Hd Cap Size 1 4 Length 0 5 in 22 SHC 0585 HTS 6 Soc Hd Cap Size 1 2 Length 1 in 23 SDU 0582 HTS 3 Set Screw Dog Point Size 1 2 Length 0 625 in 24 SHC 0502
6. Remove O rings 22 and 23 and 2 x T Seals 19 Un screw bearing support bracket 5 and remove from Housing 1 Un screw locking sleeve 3 and remove The Actuator is completely stripped down clean and inspect all parts for evidence of damage or excessive wear Discard all rubber seals and back ups and replace them with new ones from the specified redress kit Repair or replace any damaged or worn parts 5 6 4 Actuator Re assembly Before actual Assembly begins all parts should be carefully cleaned inspected and greased using good quality lightweight grease Use new seals from the appropriate redress kit and check that the dates are within a useable period Ensure that seals are not damaged or excessively stretched during assembly When fitting T Seals ensure that the back ups are oriented with the splits at 180 apart and that they are sitting down correctly Trim the scarf cut with a sharp blade if required to get them to sit down correctly e Fit Screws 27 to Locking Sleeve 3 e Fit Locking Sleeve 3 to Housing 1 then fit Bearing Support Bracket 5 and hold in place using Set Screws 23 OPS 2220 Rev K 18 User Manual Phuel Quin BOP Assembly DUE All Sizes e Insert Ball Slide 15 into Bearing Support Bracket 5 and fit External Circlips 16 e Fit 2 x T Seals and backups 19 and O Rings 22 and 23 to Seal Sub 14 e Fit Seal Sub 14 into Housing 1 e Fit T seal and backup 18 to Piston 6
7. Slide Piston carefully into Seal Sub and Housing taking care not to damage the seals e Fit T seal and backups 20 and O Ring 21 to Cylinder Cap 7 and carefully insert into Housing 1 pushing down until sitting on top of Piston Fit Support Sleeve 2 and Screw 29 Ensure Screw is flush to Support Sleeve when fitted Cylinder cap may need to be pushed further into Housing to allow proper fit e Fit Cap Collar 8 Carefully insert Indicator Rod 10 into Cylinder Cap and screw into top of Piston Fit Dog Housing and Locking Dogs 9 See Section 5 6 1 Fit Handles 17 to Lock Sleeve 11 Fit Ram Key Plate 13 and Ram Tee 12 Fit Ram Key Plate Screws 26 5 6 5 Final Assembly e Lift the Actuator at the bracket and make up onto Slide Rods It is best to engage one bearing at the start of the slide rod and then lower and rotate the assembly on the crane until the second slide rod can be engaged e Slide the redressed Ram onto Ram Tee 12 Follow the instructions in Section 5 5 4 to re attach the actuator to the BOP 5 7 Shear Actuator Redress This procedure results in the complete redress procedure of an Actuator assembly 5 7 1 Removal of the Locking Dogs This might be required to solve manual locking problems or as part of the pre and post job routines e Remove the pin 26 from the Support Sleeve 9 e Unscrew the Lock Sleeve 10 from the Support Sleeve 9 to gain access to the Dogs e Remove the o ring 20 whi
8. Before actual Assembly begins all parts should be carefully cleaned inspected and greased using good quality lightweight grease Ensure that the seal is not damaged or excessively stretched during assembly Use new seals from the specified redress kit and check that the dates are within a useable period e Assemble O Ring 17 e Gently push the Sensor Housing 7 into the BOP Body make up the Cap Screws 16 and tighten 1 4 CAP SCREW MAGNET DETECTOR Figure 12 Sensor Housing components OPS 2220 Rev K 25 Phuel User Manual Quin BOP Assembly All Sizes 5 11 Maintenance Record Sheet Date Type of Performed Verified Comments Performed Maintenance By By Table 2 Maintenance Record OPS 2220 Rev K 26 User Manual Phuel Quin BOP Assembly UE All Sizes 6 Testing All testing is to be carried out in the designated test area and by suitably qualified and competent personnel WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous It has enough stored energy to separate parts with considerable force 6 1 BOP e Using Appropriate test caps blank off either end of the e Fill with test fluid and bleed off any air in the system e Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes e Increase pressure to 10 000 psi Maximum Working Pressure a
9. Comments RDK 1932 HHO 8 Redress Kit for 190 1932 HVO Actuator All seals required for a full redress RDK 2190 HHO 2 Redress Kit for Shear Actuator All seals required for a full redress RDK 1863 HHO 5 Redress Kit for Equalisation All seals required for a full Assembly redress RDK 1759 HHO 4 Redress Kit for Grease All seals required for a full Injection Assembly redress 801 0119 V90 6 O Ring For Sensor Housing Table 18 BOP Redress Kit Part No RDK 1878 HV0 OPS 2220 Rev K Item Number PartNo Qty Item Description 18 802 2162 H85 2 RODT SEAL 1 625 19 802 2161 85 1 PISTON T SEAL 4 000 20 802 1931 H85 1 ROD T SEAL FOR 1 250 ROD DIA 21 801 0345 V90 1 O Ring B S Size 345 22 801 0342 V90 1 O Ring B S Size 342 23 801 0344 V90 1 O Ring B S Size 344 24 801 0439 V90 1 O Ring B S Size 439 25 801 0227 V90 1 O Ring B S Size 227 Table 19 Actuator Redress Kit Part No RDK 2247 HV0 Ph uel OIL TOOLS User Manual Quin BOP Assembly All Sizes Item Number Part No Item Description 18 802 2162 H85 ROD T SEAL 1 625 19 802 2161 H85 PISTON T SEAL 4 000 20 802 1931 H85 ROD T SEAL FOR 1 250 ROD DIA 21 801 0345 V90 O Ring B S Size 345 22 23 24 25 801 0342 V90 801 0344 V90 801 0439 V90 801 0227 V90 O Ring B S Size 342
10. FEMALE MALE I Phoenix ASSY QR74AC5 06S QR74AC5 08SS Ben EINE CAP PLUG CAP DUST CAP PLU QR7z4 PP oe pvc OR74PC 06 QR74 PP 08 QR74 PP 08 PVC PVC PVC 3 8 TUBE 5 Hydrasun UNION TEE SETG 3 8 TUBE 6 Hydrasun KELF SEAT BALL VALVE 6A B6LJ2 SSP 7 Hydrasun TUBE 316 STAINLESS STEEL 3 8 OD 20 SWG 0 036 WALL THICKNESS OPS 2220 Rev K Table 16 Hydraulics Parts List 48 Ph 8 Spares uel OIL TOOLS User Manual Quin BOP Assembly All Sizes 8 1 Available Spare Kits 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 No Qty Item Description Comments RDK 2247 HHO 8 Redress Kit for 190 2247 HVO Actuator All seals required for a full redress RDK 2190 HHO 2 Redress Kit for Shear Actuator All seals required for a full redress RDK 1863 HHO 5 Redress Kit for Equalisation All seals required for a full Assembly redress RDK 1759 HHO 4 Redress Kit for Grease All seals required for a full Injection Assembly redress 801 0119 V90 6 O Ring For Sensor Housing Table 17 BOP Redress Kit Part No RDK 2220 HV0 Part No Qty Item Description
11. HTS 3 Soc Hd Cap 1 4 UNC x 0 38 Long 25 190 1954 STL 2 HANDLE 26 190 1970 304 1 QUICK RELEASE PIN FPSC5 35R 27 190 2188 STL 1 LANYARD 8 x 10 35mm RING ID 28 190 1608 STL 2 Ball Slide TK 25 UU 29 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 Table 13 Shear Actuator Parts List Part No 190 2190 HH0 OPS 2220 Rev K 42 User Manual Phuel Quin BOP Assembly E 7 OIL TOOLS Sizes 26 511 Figure 20 Shear Actuator Assembly OPS 2220 Rev K 43 User Manual Phuel Quin BOP Assembly UE All Sizes Item Number Part Number Quantity Description 1 190 1861 480 1 Equalization Block 2 190 1781 316 1 Equalization Valve 3 190 1758 316 1 JAFO Plug 4 801 0011 VOO 2 OHing B S Size 011 5 SBC 0542 HTS 1 Button Hd Screw Size 3 8 Length 0 5 in 6 SHC 0551 HTS 6 Soc Hd Cap Size 3 8 Length 2 in 7 801 0113 V90 2 Q Ring B S Size 113 8 190 2823 PEK 1 Valve Seat 9 WLK 0540 304 6 Spring Lock Washer 3 8 10 WNL 0540 316 1 Nordlok Washer Size 3 8 Table 14 Equalising Block Assembly Parts List Part No 190 1863 HH0 O o d I nen Ws SN SX 8 o lt x SECTION Figure 21 Equalisation Block Assembly OPS 2220 Rev K 44 User Manual Phuel Quin BOP Assembly OIL TOOLS All Sizes Item Number Part Number Quantity Description 190 1716 480 190 1703 STL 190 1749 STL GREASE INJ
12. O Ring B S Size 344 O Ring B S Size 439 O Ring B S Size 227 Table 20 RDK 1932 HV0 Part No Qty Item Description Comments 802 2163 H85 PISTON T SEAL 5 500 802 1931 85 ROD T SEAL FOR 1 250 ROD DIA 802 2162 H85 ROD T SEAL 1 625 801 0439 V90 O Ring B S Size 439 801 0354 V90 O Ring B S Size 354 801 0345 V90 O Ring B S Size 345 801 0227 V90 DND O Ring B S Size 227 Table 21 Shear Actuator Redress Kit No RDK 2190 HH0 Part No Qty Item Description Comments 801 0108 V90 1 O Ring For Equalisation Valve 801 0112 V90 2 O Ring For Equalisation Block Table 22 Equalisation Block Assembly Redress Kit Part No RDK 1863 HH0 Part No Qty Item Description Comments 801 0117 V90 1 O Ring For Grease Injection Body Table 23 Grease Injection Assembly Redress Kit Part No RDK 2787 Part No Qty Item Description Comments 190 1715 H70 Outer Ram Seal For All Phuel 6 3 8 BOP Rams 190 1961 H90 Pipe Inner seal Size 5 1 8 For use in 5 1 8 BOP Ram 190 2020 H90 Inner Wire line Seal 6 0 For Use in 5 1 8 BOP Ram 190 1748 H90 Inner Pipe Seal 6 3 8 To suit 1 38 Dia Bar 190 3689 H90 Or 190 2998 H90 Inner Wire line Seal 6 3 8 Multi line blind to
13. Quin BOP Assembly All Sizes 75 799 OPS 2220 Rev K Figure 16 BOP Assembly Drawing 195 1878 HH0 34 IL TOOLS User Manual Quin BOP Assembly All Sizes Item Number Part No Quantity Description 1 190 1706 480 2 WIRE LINE RAM 2 190 1709 B21 4 WIRE LINE GUIDE 3 190 1715 H70 2 OUTER SEAL 4 190 3689 H90 2 RAM INNER SEAL 5 190 1739 B7M 4 RAM SHOULDER SCREW 6 SHC 0582 B7M 4 Soc Hd Cap Size 1 2 Length 0 625in Table 5 Wireline Ram Assembly Parts List Part No 190 1764 HHO Item Number Part Number Quantity Description 1 190 1854 480 2 PIPE RAM 2 190 1857 21 4 Wire Line Ram Guide 3 190 2035 H70 2 RAM OUTER SEAL 4 190 2020 H90 2 RAM INNER SEAL SIZE 6 00 5 190 1934 B7M 4 RAM SHOULDER SCREW 6 SHC 0582 B7M 4 Soc Hd Cap Size 1 2 Length 0 625in Table 6 WireLine Ram Assembly Parts List Part No 190 1879 HH0 Item Number Part No Quantity Description 1 190 1707 480 2 PIPE RAM 2 190 1710 STL 4 PIPE RAM GUIDE 3 190 1715 H70 2 Outer Seal 4 190 1748 H90 2 PIPE INNER SEAL 190 1739 B7M 4 RAM SHOULDER SCREW SHC 0582 B7M Soc Hd Cap Size 1 2 Length 0 625in Table 7 Pipe Ram Assembly Parts List Part No 190 1765 HHO Item Number Part Number Quantity Description 1 190 1854 480 2 PIPE RA
14. Table 19 Actuator Redress Kit Part No 2247 49 Table 20 RDK 1932 HV0 50 Table 21 Shear Actuator Redress Kit No 2190 50 Table 22 Equalisation Block Assembly Redress Kit Part No RDK 1863 HH0 o IAA WE 50 Table 23 Grease Injection Assembly Redress Kit Part No RDK 2787 50 Table 24 Ram Seals order individual parts as required 50 Table 25 Shear Blades order by pair as required 51 Table 26 51 Figure 1 uwiii iv Figure 2 BOP General 4 Figure 3 Section through rams closed position 5 Figure 4 Ram 5 Figure 5 Using 5 16 A F Key to equalise pressure across rams 10 Figure 6 Injection 5 11 Figure 7 Fitting the Detector iacu tom bra p te Sainte maine 12 Figure Accessing the EEA EE es Rd 15 Figure 9 BOP Rarmn8s a 16 Figure 10 Exploded View of Equalisation Assembly 22 Figure 11 Grease Injection Assembly 24 Figur
15. acceptable to use the seals supplied providing that the difference in the part number is only in the last three digits For example a requirement for O Ring 801 0108 V90 may be substituted for a part 801 0108 H70 if that was previously supplied in a kit marked for the assembly in question This allows the use of previously supplied redress kits and provides for stock management over the period of standardisation OPS 2220 Rev K 51 User Manual Phuel Quin BOP Assembly Ue Sizes Appendix A Increasing the Shearing Capacity of the BOP Introduction In some operations it may be necessary to increase the shearing capacity of the shear rams so that stronger deployment bars can be cut To achieve this without increasing the piston area of the actuators a minibooster system must be added to the shear ram hydraulic circuit This method avoids the need to change the operating pressures of the BCU which are normally limited to 3 000 psi Method The hydraulic circuit shown below replaces the standard circuit for the shear rams only Shear Ram Actuators Open Close OPS 2220 Rev K A 1 User Manual Phuel Quin BOP Assembly OIL TOOLS All Sizes Item Part Number Qty Description Manufacturer 1 HC2W 1 5 A 1S 1 Minibooster x1 5 Minibooster Hudraulics AS 2 CKCB XCN 1 Pilot Check Valve 3 8 Sun Hydraulics 3 1 Ratio 3 VH36B D 6T 5 S 1 Check Valve 3 8 DK LOK Crack 5psi 6000psi
16. cannot be opened again until the mechanism is deliberately withdrawn Each of the actuators assemblies are identical on the Phuel deployment BOP and so can be positioned in any ram bore This provides excellent flexibility for maintenance and redress of the equipment OPS 2220 Rev K 6 User Manual Phuel Quin BOP Assembly UE All Sizes 4 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 hard piping to offer the required fire protection level Two connections are required for each ram set for open and close It is important that both connections are connected as the fluid displaced by the movement of the piston must be allowed to pass through the valve system back to the reservoir A Well Control Unit WCU 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 When closing the two sets of pipe rams to seal on the deployment bar the manual hydraulic valves on the right hand side must be closed to allow the left hand rams to stroke out fully first This ensures that the two rams are vertically aligned which is essential to avoid bending the bar or twisting it with
17. 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 Body taking care that the edges of the guide pass into the seal bore and make up the thread using a 3 8 hex key in the cap head screws to provide the torque Making up the thread will drive the actuator assembly fully home Note When making up Actuator thread into the BOP Body ensure the Hydraulic line fittings line up with the Actuator Lines as the Actuator is being made up e Make up the hydraulic fittings hand tight Do not over tighten as this causes problems when disassembling again later e The Ram Assembly is now fully made up Repeat this procedure for each ram seal that need to be replaced 5 6 Actuator Redress This procedure results in the complete redress procedure of an Actuator assembly 5 6 1 Removal of the Locking Dogs This might be required to solve manual locking problems o
18. is achieved Remove the pin from the actuator that has just been closed and pull the Locking Sleeve back to the lock position If the Sleeve does not pull back then increase the ram pressure slightly to 2 500 psi approx and then pull the sleeve back refit the pin The BOP is now closed around the deployment bar and deployment operations can continue as normal until the BOP is ready to be opened With the pressures equalised across the rams Ensure the both manual hydraulic valves are open Bleed off the ram closing pressures on both rams Remove the pin from the top two actuators and push the Locking Sleeve to the unlock position refit the pin Remove the pin from the second two actuators and push the Locking Sleeve to the unlock position refit the pin Pump the second rams fully open Ensure that the tool string weight is being taken by the wire to avoid the tool string suddenly dropping Pump the upper rams fully open The BOP is now open and deployment operations can continue as normal It is important to remember that the fast lock must be fully withdrawn before the rams can be opened No damage to the mechanism will occur if pressure is reversed with the lock in place providing that the maximum operating pressure is not exceeded 4 1 3 Common problems when using the Fast Lock mechanism It is important to remember that the locking mechanism cannot be withdrawn until it is safe to do so It is not possible to release the l
19. lt a Phuel Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don AB23 8UW User Manual Quin BOP Assembly All Sizes This Manual Covers the Following Part Numbers 195 2220 195 1878 OPS 2220 Rev K i Phuel User Manual Quin BOP Assembly All Sizes Revision History Issue Date Remarks Rev A 08 10 08 Initial Issue Rev B 16 02 09 Addition of Fast Lock Operation Rev C 08 05 09 Inclusion of 5 1 8 BOP Rev D 21 6 10 Correction of spares list numbers Rev E 16 08 10 Correction of parts list Rev F 15 09 10 Figures 18 amp 19 Updated Rev 18 10 10 Parts List Updated Rev H 22 10 10 Grease Injection Assembly Part No Changed Rev 02 02 11 Added replaceable valve seats on Equalising Blocks Rev J 05 Jul 11 Pt No Correction for Eq Valve from 190 1871 to 190 1781 Rev K 03 Oct 11 New Tag Info Addition of Appendix A OPS 2220 Rev K User Manual Phuel Quin BOP Assembly OIL TOOLS All Sizes Revisi n E c i Safely coron MI EN ME IM acted iv MEME lem 1 1 1 Generale Rc 1 1 2 Product Identification RERO 2 2 Technical Specificato u o o 3 3 Technical Description mL 5 RS Lo 4 1 Operating the Rams 7 4 2 Equalising across the enne 9 4 3 Injecting pressure between rams
20. respect to the lubricator axis When the left hand rams are fully stroked as seen by the position of the indicator rod open the manual hydraulic valves and continue to pump closed thus introducing the right hand rams to the bar If the manual locks are required then follow the procedure below to ensure that they can be operated 4 1 2 Using the Locking Mechanism in Deployment Operations This procedure is what would be required to operate the BOP for offshore use With the deployment bar in the correct position see the detection system manual Close the manual hydraulic valves on the top two rams Pump the upper ram until fully closed Remove the pin from the actuator that has just been closed and pull the Locking Sleeve back to the lock position refit the pin Open the top ram manual hydraulic valve Pump the upper ram closed until 2 000 psi is achieved Remove the pin from the actuator that has just been closed and pull the Locking Sleeve back to the lock position If the Sleeve does not pull back then OPS 2220 Rev K 7 User Manual Phuel Quin BOP Assembly DUE All Sizes increase the ram pressure slightly to 2 500 psi approx and then pull the sleeve back refit the pin Pump the second ram until fully closed Remove the pin from the actuator that has just been closed and pull the Locking Sleeve back to the lock position refit the pin Open the second ram manual hydraulic valve Pump the second ram closed until 2 000 psi
21. sub 2 e Un screw locking sleeve 3 and remove e The Actuator is completely stripped down clean and inspect all parts for evidence of damage or excessive wear Discard all rubber seals and back ups and replace them with new ones from the specified redress kit Repair or replace any damaged or worn parts 5 7 4 Actuator Re assembly Before actual Assembly begins all parts should be carefully cleaned inspected and greased using good quality lightweight grease Use new seals from the appropriate redress kit and check that the dates are within a useable period Ensure that seals are not damaged or excessively stretched during assembly When fitting T Seals ensure that the back ups are oriented with the splits at 180 apart and that they are sitting down correctly Trim the scarf cut with a sharp blade if required to get them to sit down correctly e Fit Screws 22 to Locking Sleeve 3 OPS 2220 Rev K 20 User Manual Phuel Quin BOP Assembly UE All Sizes Fit Locking Sleeve 3 to Seal Sub 2 then fit Bearing Support Bracket 13 and hold in place using Set Screws 23 Insert Ball Slide 28 into Bearing Support Bracket 13 and fit External Circlips 29 Fit 2 x T Seals and backups 16 and O Rings 18 and 17 to Seal Sub 2 Place the Housing 1 in a suitable pipe vice and grip on the diameter where the hydraulic fittings are taking care not to damage the fittings Make up the Piston Seal Sub 2 using Piston Seal
22. 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 with solvent and the hydraulic fluid replaced 4 5 3 After the Job After each job the BOP should be stripped down thoroughly cleaned repaired as may be required and redressed redress procedures are in section 5 OPS 2220 Rev K 13 User Manual Phuel Quin BOP Assembly UE All Sizes 5 Maintenance 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 4 5 1 and Section 4 5 3 for details 5 2 2 Yearly e Disassemble para 5 5 to 5 10 clean and degrease all components e Inspect the condition of sealing surfaces and surface coatings repair replace as necessary e Re coat threads and sealing surfaces if necessary Contact Phuel if in doubt e Replace all elastomeric seals e Re assemble BOP para 5 5 to 5 10 e Pressure Test to maximum working pressure and 300 psig per API 6A PSL3 Witnessed by certifying authority where
23. 7 16 dia wire OPS 2220 Rev K Table 24 Ram Seals order individual parts as required 50 User Manual Phuel Quin BOP Assembly OIL TOOLS All Sizes Part No Qty Item Description Comments 190 1705 STL 1 Shear Blade Set pair 6 3 8 Blades for 1 38 dia Bar 190 2647 STL 1 Shear Blade Set pair 5 1 8 Blades for 1 38 dia Bar Table 25 Shear Blades order by pair as required Individual seals and parts may be ordered as required See the parts list in the next section for part numbers 8 2 Test Fixtures The following test fixtures are available for order directly from Phuel Oil Tools Ltd Part No Item Description Comments 900 1577 400 Seal Sub Assy Tool For Removal of Piston Seal Sub 900 1806 400 Pressure Test Fixture For Testing or Equalisation Injection Block 900 1807 480 Flange End Cap For blanking end connections 7 1 16 BX 900 1808 STL 3 8 Hex Key Handle For removal of rams from body Table 26 Test Fixtures 8 3 Part Number Deviations In recent times Phuel has standardised the supply of elastomers in viton material and during that process of change it is possible that some part numbers in the kits previously supplied may differ from that on the specifications above In general the last three digits of the part number identify the material and the hardness of the seal If a redress kit has been supplied before the standardisation it is still
24. ECTION SUB 190 1760 316 Hollow Lock Screw 3 4 16 MAC 765 COMP SPRING C5515650 AutoClave Plug CPX40 Autoclave Gland CGLX40 CHECK CONE SEAL 801 0117 V90 O Ring B S Size 117 SHC 0551 HTS 3 Soc Hd Cap Size 3 8 Length 2 in Table 15 Grease Injection Assembly Parts List Part No 190 2787 HV0 190 1761 316 190 2786 PEK 22 d CO N Figure 22 Grease Injection Assembly Drawing OPS 2220 Rev K 45 User Manual Phuel Quin BOP Assembly E 7 TOOLS All Sizes 79 6 Ea 73 9 LOCK Figure 23 General Layout with crash frame OPS 2220 Rev K 46 User Manual Phuel Quin BOP Assembly Sizes j CYLINDER CONNECTION 2 3 NM QUICK CONNECTIONS TEE JUNCTIONS 6 7 BALL VALVES Figure 24 General Layout of hydraulics OPS 2220 Rev K 47 Sa Phuel User Manual Quin BOP Assembly All Sizes Item Supplier Description 1 4 OPEN 1 4 CLOSE 5 OPEN 5 CLOSE 3 8 TUBE X 1 Hydrasun MALE CONNECTOR HT NIA 3 8 TUBE X 3 8 3 8 TUBE X 3 8 3 8 TUBE X 3 8 TUBE X 2 siydtastin CONNECTOR NPT NPT NPT NPT 6MBC6N 6MBC6N 8MBC8N 8MBC8N 3 8 NPT X 3 8 Ve X 1 1 2 X 3 Hydrasun NPT STREET ELBOW 45 v E NPT NPT NPT 6 6SVE 8 8SVE 8 8SVE QUICK RELEASE COUPLING 3 8 FEMALE 3 8 MALE
25. M 2 190 1858 M20 4 PIPE GUIDE 3 190 1715 H70 2 Outer Seal 4 190 1961 H90 2 PIPE INNER SEAL SIZE 5 13 5 190 1934 B7M 4 RAM SHOULDER SCREW 6 SHC 0582 B7M Soc Hd Cap Size 1 2 Length 0 625in Table 8 Pipe ram Assembly Parts List Part No 190 1880 HH0 OPS 2220 Rev K 35 Prue User Manual Quin BOP Assembly All Sizes Item Number Part No Quantity Description 1 190 1708 480 2 SHEAR RAM 2 190 1705 STL 1 SHEAR BLADE SET 3 190 1715 H70 2 OUTER SEAL 4 190 3689 H90 2 RAM INNER SEAL 5 190 1739 B7M 4 RAM SHOULDER SCREW 6 ISHC 0587 HTS 2 Soc Hd Cap Size 1 2 Length 1 5 in Table 9 Shear Ram Assembly Parts List Part No 190 1766 HHO Item Number Part Number Quantity Description 1 190 2643 480 2 2 190 2647 STL 1 SHEAR BLADE SET 3 190 1715 H70 2 Outer Seal 4 190 2020 H90 2 IRAM INNER SEAL SIZE 6 00 5 190 1934 7 4 RAM SHOULDER SCREW 6 SBC 2691 304 2 HEAD SOC SCREW M12X30 Table 10 Shear Ram Assembly Parts List Part No 190 1881 HH0 OPS 2220 Rev K 36 User Manual 3 Phuel Quin BOP Assembly OIL TOOLS All Sizes Wire line Ram Pipe Ram Shear Ram Figure 17 Ram Assembly Drawings OPS 2220 Rev K 37 User Manual Quin BOP Assembly All Sizes Item Number Part
26. No Quantity Description 1 190 2070 480 HOUSING 2 190 1969 480 SUPPORT SLEEVE 3 190 2069 480 LOCKING SLEEVE 4 NOT USED 5 190 1607 480 1 Bearing Bracket 6 190 1929 480 1 7 190 1967 480 1 8 190 1649 480 1 9 190 1971 480 6 LOCKING DOG 10 190 1928 480 1 INDICATOR ROD 11 190 1968 480 1 LOCK SLEEVE 12 190 1774 STL 1 RAM TEE 13 190 1611 480 1 Ram Key Plate 14 190 1612 480 1 Piston Seal Sub 15 190 1608 STL 2 Slide TK 25 UU 16 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 17 190 1954 STL 2 HANDLE 18 802 2161 H85 1 PISTON T SEAL 4 000 19 802 2162 85 2 ROD T SEAL 1 625 20 802 1931 85 1 ROD T SEAL FOR 1 250 ROD DIA 21 801 0345 V90 1 O Ring B S Size 345 22 801 0342 V90 1 O Ring B S Size 342 23 801 0344 V90 1 o Ring B S Size 344 24 801 0439 V90 1 O Ring B S Size 439 25 801 0227 V90 1 O Ring B S Size 227 26 SHC 0503 B7M 2 Soc Hd Cap Size 1 4 Length 0 5 in 27 SHC 0585 HTS 6 Soc Hd Cap Size 1 2 Length 1 in 28 SDU 0582 HTS 3 Set Screw Dog Point Size 1 2 Length 0 625 in 29 SHC 0502 HTS soc Hd Cap 1 4 UNC x 0 38 Long 30 190 1970 304 1 QUICK RELEASE PIN FPSC5 35R 31 190 2188 STL 1 LANYARD 8 x 10 35mm RING ID Table 11 Actuator Parts List Part No 190 2247 HH0 OPS 2220 Rev K 38 User Manual Phuel Quin BOP Assembly E OIL TOOLS Sizes Figure 18 Actuator Assembly Drawing 190 2247 HH0 OPS 2220 Rev K 39 Sa Phuel User Manual Quin BOP Asse
27. Sub Assembly Tool Fit T seal and backup 14 to Piston 4 Slide Piston carefully into Seal Sub and Housing taking care not to damage the seals Fit T seal and backups 15 and O Ring 19 to Cylinder Cap 5 and carefully insert into Housing 1 pushing down until sitting on top of Piston Fit Support Sleeve 9 and Screw 24 Ensure Screw is flush to Support Sleeve when fitted Cylinder cap may need to be pushed further into Housing to allow proper fit Fit Cap Collar 6 Carefully insert Indicator Rod 8 into Cylinder Cap and screw into top of Piston Fit Dog Housing and Locking Dogs 7 See Section 5 6 1 Fit Handles 17 to Lock Sleeve 10 Fit Ram Key Plate 12 and Ram Tee 11 Fit Ram Key Plate Screws 21 5 7 5 Final Assembly Lift the Actuator at the bracket and make up onto Slide Rods It is best to engage one bearing at the start of the slide rod and then lower and rotate the assembly on the crane until the second slide rod can be engaged Slide the redressed Ram onto Ram Tee 11 Follow the instructions in Section 5 5 4 to re attach the actuator to the BOP 5 8 Equalisation Block Redress This procedure results in the complete dis assembly and re assembly of an Equalisation Block Assembly for redress purposes 5 8 1 Disassembly Back off the six Cap Screws 6 holding the Equalisation Sub 1 on the BOP Bogy Pull the Block from the BOP If its difficult to remove try screwing the longer screw in to the t
28. 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 Inner Seal Outer Seal Indicator Rod Piston Pressure Figure 3 Section through BOP rams closed position For standard deployment operations the top two rams are used as pipe rams to seal against the deployment bar The next two sets are used when running wire line operations PIPE RAM and the last is a shear and seal set for cutting either the deployment bar or the wire and then 2 PIPE RAM sealing in the event of a dangerous situation arising The standard configuration of the rams 3 WIRE LINE outer seals are shown in Figure 4 and allows grease to be injected between the two pipe rams 4 WIRE LINE to maintain a positive barrier against well pressure if required and the same for when sealing on SHEAR braided line if required Figure 4 Ram Configuration The rams are driven by a hydraulic actuator which consists of a piston with an indicator rod to provide visual confirmation of the position of the rams A manual locking mechanism is also provided to ensure that when the BOP is OPS 2220 Rev K 5 User Manual Phuel Quin BOP Assembly OIL TOOLS All Sizes closed hydraulically during operations it
29. aning kits 5K Hydraulic pump and Gauge to operate Actuators Lifting equipment Aids as required 5 5 Ram Seal Redress Note If rams are required to be removed ensure they have been pumped forward until only 2 of the indicator rod is visible 5 5 1 Access Rams This procedure results in the removal of the actuator assembly from the BOP body in order to gain access to the rams Ensure Rams are fully opened Break hydraulic lines to the Actuator Oil is likely to bleed out of lines once broken Back off the Actuator from the BOP using the extended 3 8 Allen Key in the Cap Screw heads on the Locking Sleeve Do not loosen the cap screws during this process Once the thread is fully disengaged pull the Actuator fully back to the End Stops Figure 8 Accessing the rams OPS 2220 Rev K 15 User Manual Z Phuel Quin BOP Assembly UE Sizes 5 5 2 Ram Removal not required to redress ram seals e Remove Ram from Actuator by sliding the Ram off the Ram Tee 5 5 3 Ram Seal Redress e Remove the Cap Screw 6 on the Guide 2 or Shear Blade 2 whichever Ram is being re dressed e Un screw the two Cap screws 5 on the Ram to remove Inner Seal 4 e Remove Outer Seals 3 by using a flat ended screwdriver to lever the seal from the groove Take care not to damage the metal seal face of the Ram e The Ram is now completely stripped down Clean and inspect all parts for evidence of damage or excessive wear Check
30. apped hole where the button screw 5 is fitted to gain more leverage Remove the O rings 7 Remove Button Head Screw 8 and Nordlock washer 10 Back off remove Equalisation Valve 2 and remove O Rings 4 OPS 2220 Rev K 21 User Manual Phuel Quin BOP Assembly nue Sizes e Remove the valve seat 8 using a hex key e The Equalisation Block is completely stripped down Clean and inspect all parts for evidence of damage or excessive wear Discard the O Ring seals and replace them with new ones Repair or replace any damaged or worn parts 6 0 ul U d Sp ae A 8 4 Figure 10 Exploded View of Equalisation Assembly OPS 2220 Rev K 22 User Manual Phuel Quin BOP Assembly UE All Sizes 5 8 2 Re Assembly Before actual Assembly begins all parts should be carefully cleaned and greased using good quality lightweight grease Ensure that seals are not damaged or excessively stretched during assembly Use new seals from the specified redress kit and check that the dates are within a useable period Insert the valve seat into the block and screw fully in but do not over tighten as the hex can be easily damaged and become difficult to remove again Invert the Equalisation Valve 2 and screw into the Equalisation Sub 1 Using two pieces of string assemble the O Rings 4 Be very careful not to cut or damage the O Ring while assembling Remove the Equalisation Valve 2 from the Eq
31. applicable e Inspect paintwork and repair where necessary 5 2 3 Five Yearly e Yearly maintenance plus the following e Carry out surface NDE on all component threads and damaged surfaces e Pressure Test to maximum test pressure and 300 psig per API 6A PSL3 Witnessed by certifying authority where applicable 5 3 Safety e This product contains high pressures when in operation Failure of any part may cause injury Welding corrosion rough handling or other abuse may affect the Integrity of this product e Many of the components are heavy and should not be lifted without lifting aids e Wear appropriate personal protective equipment e Do not over exert yourself while using torque wrenches Use appropriate mechanical advantages when available OPS 2220 Rev K 14 User Manual 7 Phuel Guin BOP Assembly E viit All Sizes Ensure that all tools and equipment are in good condition and are suitable for intended use 5 4 Tools The following tools are required Non marking Memac Chain Wrench Other pipe wrenches may be used but will mark equipment 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 Adjustable Spanner s External Circlip Pliers 20 UNC Socket Head Cap Screw x 1 Long Pair of Long Nose Pliers Large Flat ended Screwdriver Hide or Rubber Mallet Silicon Grease Seal Grease Oil spillage cle
32. are placed back with the same orientation as each other the orientation grooves should all be at the same end Can t unlock the rams If the hydraulic pressure is left on the rams when the rams are exposed to well pressure or grease injection pressure then the resulting movement of the rams squeezing together more causes the piston to want to move forward As itis locked from doing so by the dogs the resulting load is passed through the dogs into the locking sleeve preventing it from moving To release the load you need to bleed off the hydraulic pressure in the rams this will return the piston back to its original position and relieve the load from the dogs allowing the lock to be removed 4 2 Equalising across the rams The Equalisation Valve is situated at each set of rams and allows the pressure to by pass the closed ram seals and thus allows the pressure to be equalised It is important to realise that the piston forces on the ram seals are significant so it is not possible for the hydraulic actuator to open the rams even with small differential pressure It is therefore essential that the pressure be equalised before the rams are opened To open the equalisation valve insert a 5 16 or 8mm hex key into the valve Turn anti clockwise slowly by one half to one turn The movement of fluid should be noticeable either by sound or by the vibration felt through the key It is recommended that the valve be left opened until the rams have
33. been withdrawn To close the valve use the same key and tighten in a clockwise direction There is no need to use excessive force when closing as doing so may result OPS 2220 Rev K 9 User Manual 7 Phuel Quin BOP Assembly nue Sizes in damage to the seal face Always ensure that the valve is closed when attempting to seal pressure across the rams Hex Key 5 16 AF Figure 5 Using a 5 16 A F Key to equalise pressure across rams OPS 2220 Rev K 10 User Manual Phuel Quin BOP Assembly Sizes 4 3 Injecting pressure between rams To provide a positive pressure barrier fluid grease is injected between two sets of opposing rams Simply connect the outlet of the fluid pump to the connection on the injection port An optional gauge port is provided to allow a pressure gauge to be connected so that the pressure can be monitored This is necessary due to the presence of the check valve that prevents well pressure escaping into the fluid pumping system The check valve therefore prevents the injected pressure from being bled back and so may prevent the pump system gauge from displaying the actual pressure between the rams The gauge connection is an autoclave SF250CX port so fittings to attach to the gauge will be readily available from hydraulic fitting suppliers The check valve can be disabled by referring to section 5 9 and re building without the ball and spring Ensure that the final system st
34. ch the test fixture and make up all three bolts see Figure 14 Attach a pump and gauge to port 3 Pressure test to 10 000 psi for 5 minutes Bleed off Pressure test to 300 500 psi for 10 minutes then increase pressure to 10 000 psi for 10 minutes Bleed off This test checks that all of the seals are functioning correctly OPS 2220 Rev K 29 User Manual Z Phuel Quin BOP Assembly Sizes Port 43 Injection Port Figure 14 Testing Set Up On completion of all maintenance ensure the maintenance record sheet Para 5 11 is completed OPS 2220 Rev K 30 User Manual Phuel Quin BOP Assembly E viit All Sizes 7 Parts List and Drawings Item Number Part No Quantity Description 1 195 2049 480 1 QUIN BOP BODY 6 3 8 2 190 2247 ACTUATOR ASSEMBLY 3 190 2190 2 SHEAR ACTUATOR ASSY 4 190 1863 HH0 5 Equalization Block Assembly 5 190 2787 HVO 4 Grease Injection Assembly 6 190 1765 2 PIPE ASSY PAIR 7 D 2 8 1 190 1764 WIRE LINE RAM ASSY PAIR 190 1766 SHEAR ASSY PAIR 9 190 1671 174 20 SLIDE ROD 10 190 1672 174 20 STOP 11 206 1860 NI5 6 Sensor Housing 12 95 2203 STL 1 CRASH FRAME 13 SHC 0586 HTS 12 Soc Hd Cap Size 1 2 Length 1 25 in 14 801 0119 V90 6 O Ring B S Size 119 15 CSU 0585 HTS 20 C Sink Soc Hd Size 1 2 Length 1 in 16 WNL 0580 STL 12 Nord Lock Washer M12
35. e 12 Sensor Housing 25 Figure 13 Test Fixture Layout 29 Figure 14 Testing Set 30 Figure 15 BOP Assembly Drawing 195 2220 32 Figure 16 BOP Assembly Drawing 195 1878 34 Figure 17 Ram Assembly 37 Figure 18 Actuator Assembly Drawing 190 2247 39 Figure 19 Actuator Assembly 190 1932 HV0 41 Figure 20 Shear Actuator Assembly 43 Figure 21 Equalisation Block Assembly 44 Figure 22 Grease Injection Assembly Drawing 45 Figure 23 General Layout with crash frame 46 Figure 24 General Layout of hydraulics 47 Figure 25 Clamping of the Minibooster to the BOP frame A 3 Figure 26 Clamping of the Minibooster to the frame A 3 OPS 2220 Rev K iii User Manual Z Phuel Quin BOP Assembly DUE Sizes Safety WARNING Trapped air requires considerable time to compress and when it is compressed is high
36. ed during the deployment operation Across each pair of 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 OPS 2220 Rev K 1 User Manual Phuel Quin BOP Assembly DUE All Sizes As part of the detection system the BOP has six possible locations to mount the magnet sensor The normal Wireline operation uses the upper and lower most locations but other configurations may be used when shorter bar assemblies are being used for perforating guns The deployment bars used must match the locations used in the BOP as the spacing of the magnets is critical to successful operation The sensor housing is a separate part from the BOP body and is manufactured from non magnetic steel in order to maximise the sensitivity of the detection system The BOP is mounted to a crash frame assembly that provides forklift pockets protection during transport The crash frame has foldable platforms for the operators to stand on when operating the BOP and stabbing in the lubricator not shown in diagrams below This user manual serves as an introduction to the equipment and contains the relevant specifications operati
37. from the grease injection port between the 2 pipe rams 3 from the top Close both pipe rams Apply a pressure through the grease injection port of 500 psi and ensure pressure holds for a minimum of 10 minutes Increase pressure to 10 000 psi Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks Release pressure open rams and re assemble the upper grease injection port Close Shear Ram Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes Increase pressure to 10 000 psi Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks Bleed off pressure drain test fluid and dry Remove test caps and plug Apply coating of de watering solution to protect the bore and threads 6 2 Actuator Connect both ports to a suitable pump system preferably with two way valve and reservoir Use a good quality hydraulic fluid Tellus 22 Pump into the open port to fill the system and drive the piston fully back Do exceed the maximum operating pressure of the cylinder 3 000 psi Reverse the direction of the valve and pump the piston to the fully open position to displace any remaining air for the system Increase pressure to 3 000 psi and maintain for 10 minutes to ensure that all seals are holding Reverse the valve and pump the piston to the closed position Increase the pressure to 3 000 p
38. he implementation work must be tested before being released and the implementation should be documented with a list of parts used test report and declaration of conformity Testing must ensure that the outlet of the minibooster is reaching the desired magnification factor This should be verified by attaching a gauge on the outlet while cycling the actuators to the closed position Sufficient open and close cycles should be completed to confirm that the BOP is operating correctly OPS 2220 Rev K A 2 User Manual Phuel Quin BOP Assembly All Sizes Typical Installation Example Figure 25 Clamping of the Minibooster to the BOP frame Figure 26 Clamping of the Minibooster to the BOP frame OPS 2220 Rev K A 3
39. hecked 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 Check the fast lock system is operational by closing the Rams and pulling the handles to operate the locks Remember to push the handles back to release the locking system first before opening with hydraulic pressure 4 5 2 During the Job Special care should be taken that the Rams are fully open when passing any equipment through them The impact of a collar hitting a Ram may damage the Ram to such an extent that the Ram may no longer Seal or prevents it from fully opening Only lift the BOP using suitable lift caps Do not sling or attach lifting equipment to the crash frame to lift the BOP assembly Care should be taken to completely remove any residual pressure or accumulated pressure existing on Lubricator equipment above the before disconnecting the Lubricator or opening the window Hydraulic Hose ends should never be allowed to drop in to dirt or grit or otherwise become contaminated with foreign matter Any dirt or grit introduced into the BOP is very injurious to the equipment If hoses become dirty they should be cleaned thoroughly with solvent and dried Only clean Hydraulic fluid should be used Shell Tellus 22 is recommended
40. ill meets any obligatory safety requirements before using in a well pressure environment Gauge Connection SF250CX WAZI EC Gauge Check Valve Circuit Layout Injection Port 1 2 d Figure 6 Injection Assembly OPS 2220 Rev K 11 User Manual Z Phuel Quin BOP Assembly UE Sizes 4 4 Fitting the Magnet Detector The magnet detector simply slides into the bore provided by the non magnetic Sensor Housing It most cases the weight of the cable is not sufficient to pull the sensor out but just in case the sensor can be retained by the means of two 14 20 UNC x 1 5 long screws Always ensure that the sensor has been pushed fully home as even a small distance can have a large effect on the sensor detection ability Refer to the specific bar operating manual to determine which sensor positions are to be used for the deployment operation as different bar configurations may require different detection positions be used Sensor Housing Figure 7 Fitting the Detector OPS 2220 Rev K 12 User Manual Phuel Quin BOP Assembly UE All Sizes 4 5 Job Planning 4 5 1 Before the Job Check that the certification is within date and that the scheduled maintenance is up to date 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 Functioning of the Rams may be c
41. le preventing the lowermost dogs from dropping and remove the dogs 7 Assembly is the reverse to this but ensure that the orientation grooves line up around the circumference OPS 2220 Rev K 19 User Manual Phuel Quin BOP Assembly DUE All Sizes 5 7 2 Access 8 Remove Rams e Remove the rams as described in the section 5 5 2 and remove the ram from the actuator Replace ram seals if required 5 7 8 Remove the Actuator amp Strip Down e Remove End Stops and Cap Screws from Slide Rod s Support the weight of the actuator and expect the centre of gravity to be at the bracket that contains the slide bushes Slide the Actuator off the Slide Rods and place in a pipe vice gripping on the Housing Take care not to damage the hydraulic lines that are still attached Remove Ram Key Plate Cap Screws 21 Remove the Ram Tee 11 by lifting up and sliding out Remove the Ram Key Plate 12 Remove O ring 17 from Seal Sub 2 Remove the locking dogs 7 See Section 5 6 1 Remove indicator rod 8 Back off Cap Collar 6 and remove Remove support sleeve 9 Withdraw Cylinder Cap 5 and remove O ring 19 and T seal 15 Drive Piston 4 back out of Housing 1 using a wooden or plastic block and remove T Seal 14 e Un screw the Piston Seal Sub 2 from the Housing 1 using the Piston Seal Sub Assembly Tool 900 1577 400 Remove O ring 18 T Seals 16 e Un screw bearing support bracket 13 and remove from seal
42. llow to stabilise and maintain this pressure until it is evident there are no apparent leaks Testing to be carried out to Test pressure when decreed by maintenance schedule e Remove pressure and remove the top test blank e Close the upper wireline rams e Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes e Increase pressure to 10 000 psi Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks e Release pressure e Remove hollow lock screw spring and ball bearing from upper grease injection port e Ensure test fluid is above the top wireline ram e Close both wireline rams e Apply a pressure through the grease injection port of 500 psi and ensure pressure holds for a minimum of 10 minutes e Increase pressure to 10 000 psi Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks e Release pressure open rams and re assemble the upper grease injection port e Close upper Pipe ram e Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes e Increase pressure to 10 000 psi Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks e Release pressure OPS 2220 Rev K 27 User Manual Phuel Quin BOP Assembly DUE All Sizes Remove the hollow lock screw spring and ball bearing
43. ly 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 Figure 1 BOP Safety OPS 2220 Rev K iv User Manual Phuel Quin BOP Assembly UE All Sizes 1 Introduction 1 1 General The Deployment Blow out Preventer BOP provides essential safety barriers against well pressure during the deployment operation It is located directly above the wellhead flange and immediately below the Deployment Window The BOP has five sets of rams two pipe rams that seal against the deployment bar two wire line rams for sealing against braided line and one shear and seal ram that is capable of cutting through the deployment bar and then sealing against the well pressure Each ram consists of a standard and interchangeable actuator assembly A hydraulic pisto
44. mbly OPS 2220 R All Sizes Item Number Part No Quantity Description 1 190 1643 480 1 Housing 2 190 1969 480 1 SUPPORT SLEEVE 3 190 1777 480 1 LOCKING SLEEVE 4 190 1574 480 1 SPLIT RING 5 190 1607 480 1 Bearing Bracket 6 190 1929 480 1 PISTON 7 190 1967 480 1 CYLINDER CAP 8 190 1649 480 1 CAP COLLAR 9 190 1971 480 6 LOCKING DOG 10 190 1928 480 1 INDICATOR ROD 11 190 1968 480 1 LOCK SLEEVE 12 190 1774 STL 1 13 190 1611 480 1 Ram Key Plate 14 190 1612 480 1 Piston Seal Sub 15 190 1608 STL 2 Slide TK 25 UU 16 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 17 190 2342 304 2 HANDLE PART No GN310 12 100 E NI 18 802 2162 H85 2 RODT SEAL 1 625 19 802 2161 H85 1 PISTON T SEAL 4 000 20 802 1931 H85 1 ROD T SEAL FOR 1 250 ROD DIA 21 801 0345 V90 1 O Ring B S Size 345 22 801 0342 V90 1 O Rirg B S Size 342 23 801 0344 V90 1 O Ring B S Size 344 24 801 0439 V90 1 O Ring B S Size 439 25 801 0227 V90 1 O Ring B S Size 227 26 SHC 0503 B7M 2 Soc Hd Cap Size 1 4 Length 0 5 in 27 SHC 0585 HTS 6 Soc Hd Cap Size 1 2 Length 1 in 28 SDU 0582 HTS 3 Set Screw Dog Point Size 1 2 Length 0 625 in 29 SHC 0502 HTS 3 Soc Hd Cap 1 4 UNC x 0 38 Long 30 190 1970 304 1 QUICK RELEASE PIN FPSC5 35R 31 190 2188 STL 1 LANYARD 8 x 10 35mm RING ID Table 12 Actuator 190 1932 HV0 Parts List ev K 40 User Manual Quin
45. n can be extended or retracted to energise or retract the rams Each ram has a set of inner and horse shoe 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 rams consequently can be arranged so that they hold pressure from below the BOP or from above The actuators are connected with hard hydraulic piping to provide sealing integrity during a fire The hydraulic circuit includes a ram valve on each of the four upper ram pairs to allow one half of the rams to be extended without the other half This is used during the deployment operation when setting the pipe rams against the deployment bar and ensures that the bar is not damaged by the slight misalignment of the two sets of pipe rams The shear rams do not have a ram valve for safety reasons Between each of the ram pairs it is possible to inject pressure or grease through the injection port For the deployment operation this can be used to create an area of pressure that is greater than wellhead pressure and thus provide a safety barrier For braided line operations or in cases where an effective seal cannot be achieved with fluid the injection port can be used to inject grease at pressures greater than the well head pressure The injection port has a check valve to prevent well pressure entering the injection lines and also has a gauge port that allows the pressure between the rams to be monitor
46. ocking mechanism if there are any loads being transferred back through the locking dogs The following events can cause this to occur Can t lock the rams As the piston moves to close the rams the grooves in the piston indicator move across the grooves in the dogs In order to fully engage the groove profiles must match exactly to allow the dogs to settle down enough for the OPS 2220 Rev K 8 User Manual Phuel Quin BOP Assembly DUE All Sizes locking sleeve to pass over them The mechanism is designed such that small deviations in pitch alignment are automatically adjusted when the sleeve is pulled back In cases where the difference is high it can be difficult to apply enough force to cause the dogs to jump almost a full pitch and this prevents the rams from being locked Usually all that is required is a small further movement of the piston to get the necessary alignment Increasing the ram closing pressure even by 250 psi or so is enough to allow the locking mechanism to be activated If the grooves in the piston indicator or the dogs are filled with debris then the dogs may not engage enough to allow the locking sleeve to pass over them To avoid this occurring keep the grooves clean and debris free and ensure that these areas are cleaned before and after the operations It is possible to unscrew the locking sleeve to expose the dogs and clean them during operations but this is not considered normal practice Ensure that the dogs
47. on planning and maintenance instructions parts list and drawings 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 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 Man Phuel Oil Tools Ltd Desc Quin 6 3 8 Dep BOP ID HSAS 1000 Man ID 06 065 1 MWP 5000 Psi Serv 25 Temp Class XX iaw API 16A Temp Range 4 82 OPS 2220 Rev 2 User Manual Phuel Quin BOP Assembly E wi Sizes 2 Technical Specification Part No 195 2220 HHO 195 1878 7 1 16 10K Flange 5 1 8 BX 10K Flange Bottom Connection 7 1 16 BX 10K Flange 5 1 8 BX 10K Flange Height 75 8 1 93 m Make up Height 65 1 65 m Width 23 78 0 6 m Working Pressure 10 000 PSI 690 Bar Test Pressure 15 000 PSI 1035 Bar Service 25 Hydraulic Pressure 3 000 psi 210 Ba
48. r Max Standard Actuators 5 000 psi 345 Bar Max Shear Actuators Stroke Volume Standard Act 52 cu in to close 48 cu in to open Total 107 cu in 1 64 litres Stroke Volume Shear Act 105 to close 100 cu in to open Total 205 cu in 3 36 litres Weight 7930 Ibs 3 600 Kg Hydraulic Connections Pipe Rams 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Wireline Rams 3 8 Phoenix Beattie HP Quick Release Coupling QR74 Range Shear Rams 1 2 Phoenix Beattie HP Quick Release Coupling QR74 Range Actuators 74 NPT x 3 8 Tube Grease Injection NPT 10 000 psi max WP Gauge Port Autoclave SF250CX Table 1 Technical Specification OPS 2220 Rev K User Manual Phuel Quin BOP Assembly E Figure 2 BOP General Layout OPS 2220 Rev K User Manual 7 Phuel Quin BOP Assembly Sizes 3 Technical Description The Phuel Deployment BOP provides a positive barrier against well pressure while performing intervention operations The equipment consists of five sets of hydraulically operated rams Figure 3 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
49. r as part of the pre and post job routines e Remove the pin 30 from the Support Sleeve 2 e Unscrew the Lock Sleeve 11 from the Support Sleeve 2 to gain access to the Dogs e Remove the o ring 25 while preventing the lowermost dogs from dropping and remove the dogs 9 Assembly is the reverse to this but ensure that the orientation grooves line up around the circumference OPS 2220 Rev K 17 User Manual Phuel Quin BOP Assembly DUE All Sizes 5 6 2 Access 8 Remove Rams e Remove the rams as described in the section 5 5 2 and remove the ram from the actuator Replace ram seals if required 5 6 3 Remove the Actuator amp Strip Down e Remove End Stops and Cap Screws from Slide Rod s Support the weight of the actuator and expect the centre of gravity to be at the bracket that contains the slide bushes Slide the Actuator off the Slide Rods and place in a pipe vice gripping on the Housing Take care not to damage the hydraulic lines that are still attached Remove Ram Key Plate Cap Screws 26 Remove the Ram Tee 12 by lifting up and sliding out Remove the Ram Key Plate 13 Remove O ring 24 from Housing 1 Remove the locking dogs 9 See section 5 6 1 Remove indicator rod 10 Back off Cap Collar 8 and remove Remove support sleeve 2 Withdraw Cylinder Cap 7 and remove O ring 21 and T seal 20 Drive Piston 6 back out of Housing 1 using a wooden or plastic block and remove T Seal 18
50. s should be carefully cleaned inspected and greased using good quality lightweight grease Ensure that seals are not damaged or excessively stretched during assembly Use new seals from the specified redress kit and check that the dates are within a useable period e Insert Check Valve 6 followed by the Compression Spring 3 into Grease Injection Sub 1 e Make up the Hollow Lock Screw 2 ensure the Screw is flush to sub flush to the Spigot face e Make up Autoclave Plug 4 and the Autoclave Gland 5 into the Grease Injection Sub 1 and tighten by hand e Assemble the O Ring 7 5 9 3 Final Assembly e Push the Grease Injection Sub 1 into the BOP Body ensuring correct orientation Apply thread lock substance such as Loctite to Cap Screws 8 make up and tighten 5 10 Sensor Housing Redress This procedure results in the complete Dis Assembly of a Sensor Housing Assembly for redress 5 10 1 Disassembly e Back off and remove the Cap Screws 16 OPS 2220 Rev K 24 User Manual Phuel Quin BOP Assembly ult Sizes e Screw in a 4 Socket Head Cap Screw into of the Sensor holes the Sensor Housing 7 face Using a pair of Pliers grip the 77 Screw head and ease the Sensor Housing 7 out of the Body Remove the Cap Screw e Remove O Ring 17 e The Sensor Housing is completely stripped down clean and inspect for evidence of damage or excessive wear 5 10 2 Re assembly
51. si and maintain for 10 minutes to ensure that all seals are holding Strip down and replace any seals that are leaking until this test can be achieved successfully Remove the pump 6 3 Equalisation Block The Equalisation Block Assembly can either be tested along with the final BOP assembly or can be individually tested using test Fixtures which must be purchased from Phuel separately This procedure assumes the use of the test fixtures Attach the test fixture and make up all six bolts Blank off Port 2 and attach a hand pump and gauge pump to port 1 With the valve open fill the fixture and pressure test to 10 000 psi for 5 minutes Bleed off Pressure test to 300 500 psi for 10 minutes then OPS 2220 Rev K 28 ai User Manual Phuel Quin BOP Assembly re All Sizes increase pressure to 10 000 psi for 10 minutes Bleed off This test checks that all of the seals are functioning correctly Close the valve without exerting excessive force and repeat the pressure test This test verifies that the metal seal is working Remove the test fixture and use the same o unde 6 6 when to the Port 2 Valve Port 1 Figure 13 Test Fixture Layout 6 4 Grease Injection Assembly e The Grease Injection Assembly can either be tested along with the final BOP assembly or can be individually tested using test Fixtures which must be purchased from Phuel separately This procedure assumes the use of the test fixtures Atta
52. 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 3 by pushing the tab into the slot in the ram and working it around the radius of the ram Tap home using a rubber or hide mallet and if required use a screwdriver to lever the second tab over the edge of the slot Take care not to significantly damage Seal during assembly but expect that some slithers of rubber will be produced as the corners of the rubber seals are removed by the assembly operation Tap all around the circumference of the seal to ensure that it is bedded into the groove and that the seal is not protruding above the ram diameter e Slide the Inner Seals 4 into Ram make up Cap Screws 5 and gently tighten Check that there is still some float in the seals as this is essential for the correct operation of the rams Back off the cap screws slightly if required to get the seals to float e Assemble the Guide 2 or Shear Blade 2 whichever is being assembled apply thread lock such as Loctite to the Cap Screw 6 make up and tighten Wire line Ram Pipe Ram Shear Ram Figure 9 BOP Rams OPS 2220 Rev K 16 User Manual Phuel Quin BOP Assembly UE All Sizes 5 5 4 Re attach to BOP Body e fthe rams were removed from the actuator Section 5 5 2 then slide the ram back onto the Tee taking careful note of the orientation of the rams
53. ualisation Sub 1 and assemble in the correct position as shown Gently tighten Assemble the Button Head Screw 5 with Nordlock Washer 10 and tighten Assemble the O Rings 7 and lightly grease 5 8 3 Final Assembly Mount Equalisation Sub 1 on BOP Body and apply thread locking substance such as Loctite to Cap Screws 6 together with the lock washers 9 When making up Cap Screws make up one then do the opposite continue doing this until all six are made up Tighten Screws 5 9 Grease Injection Assembly Redress This procedure results in the complete dis assembly and re assembly of a Grease Injection Assembly for redress purposes 5 9 4 Disassembly Back off the three Cap Screws 8 holding the Grease Injection Sub 1 on the BOP Gently pull the Grease Injection Sub 1 out of the Remove the O ring 7 Back off Hollow Lock Screw 2 remove Compression Spring 3 and Check Valve 6 Remove the Autoclave Gland 5 from the Grease Injection Sub 1 and remove the Autoclave Plug 4 The Grease Injection Assembly is completely stripped down clean and inspect all parts for evidence of damage or excessive wear Discard the O Ring seals and replace with new one Repair or replace any damaged or worn parts OPS 2220 Rev K 23 User Manual Quin Assembly TOOLS All Sizes Figure 11 Grease Injection Assembly 5 9 2 Re assembly Before actual Assembly begins all part
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