User Manual 3`` Modular BOP System OPS-4611
Contents
1. 11 5 2 Fatigue Testing E 11 FESTEN 12 5 4 Shearing Performance and limitations 12 5 5 Performance of Ram Guides cccceeccceececeeeeceeeeceeeeseeeeseueenaees 12 5 6 Temperature and Pressure Limitatlons 13 Maintenance E 15 SIGN GA NN UU 15 SEET 15 JE EEE 16 E un cad le AA aa 16 65 Modular CGonnechon eee n2 1S HH ng khu 19 6 6 Maintenance Record heel 26 o n 27 FA 27 165 ad UA AA 28 8 Parts List and Drawings ssssssssekee eres t SH HH nh nh nha 29 E 51 OPS 4611 Rev D EU User Manual uel 3 Modular BOP System OIL TOOLS Table of Tables Table T TEN 4 Table 2 Shearing performance and limitations 12 Table 3 Maintenance Record nennen nnn 26 Table 4 Available Top amp Bottom Sub Assemblies 30 Table 5 Available Hydraulic Connection Kits lt 30 Table 6 Single BOP 4 3 4 4 Manual Parts List 191 4331 HVO 31 Table 7 Dual BOP 4 3 4 4 Hydraulic Parts List 192 4490 HVO 31 Table 8 Triple BOP 5 3 4 4 Hydraulic Parts List 193 4498 HVO 31 Table 9 3 Modular Body2. 52 Table 28 Shear Ram Redress Kit RDK 4359 HHO 52 Table 29 Single Injection Module Redress Kit RDK 4450 HV 1 52 Table 30 Dual Injection Module Redress Kit RDK 4450 HV2 52 Table 31 Triple Injection Module Redress Kit RDK 4450 HV3 52 Table 32 4 34 4 Top and Bottom Sub Redress Kit RDK 4325 HVO 52 Table 33 5 34 4 Top and Bottom Sub Redress Kit RDK 4327 HVO 52 OPS 4611 Rev D I D User Manual uel 3 Modular BOP System OIL TOOLS Table of Figures Figure 1 3 Modular BOP Triple Build gt gt gt gt gt gt EE ede ERR a reri V Figure 2 Typical identification Lag 2 Figure 3 Generic 3 Modular Map 3 Figure 4 Section through BOP rams closed position 5 Figure 5 Equalisation Valve Layout 8 Figure 6 Correct lubrication for s orage c cc n o 10 Figure 7 Qualified Operating Envelope rarrrrrranrnvrrnnnronrnnnnrnrnnnnennnnnnennnnnnee 14 Figure 8 Accessing the rams arrnnnnrnnnennnrnnnnnnnnrnnnrnnnnnnnnennnrnnnnnnnnennnennnnennn 16 FOUG O BOP NNN 17 Figure 10 BOP Shear Rams cccccccccsececeececeeeceueeceueeceueecsueeseeessneesseees 18 Figure 11 Connecting Multiple MOdUules ccccccecseseeeeseeeeeeeeseeeeeseeeeeeas 20 Figure 12 Hydraul
3. Phuel Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual 3 Modular BOP System OPS 4611 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 4611 Rev D i User Manual Fuel 3 Modular BOP System OIL TOOLS Table of Contents Table of Contents eesseeessssssssseesseseen nennen nennen nnne nnn nnns nans FETT Em I FET AT ga lil REVISION ISIONY E IV CC 6 6 6 _ WATIA V 1 lIntfOdUGIiOn Q0 HH TH TT TK nnn ng cha 1 _ 1 L2 ProSgucb gel 2 1 3 Modular Traceability Map 2 2 ege 2 2 KE el eiie o DRE EOS 4 9 PECHMICAWISSCHDUOM AAA 5 o Basic Desc ON ersen rE EEEE 021960 5 22 Bance PIS ON eae see eee 5 4 Basic ODeratiOn Q00 SH SH ng TT KT nh nh 6 4 1 Operating heams Q QC n nennen nnn nnns 6 42 Eguallsing across iNe sai souder icut dn aen cR dU matr RE 4 3 JOD UMM E 9 o 063008 hel cle 2 to eegen 11 5 1 Sealing C I8 CL6 I5LC5 gt
4. Table 33 5 347 4 Top and Bottom Sub Redress Kit RDK 4327 HVO Individual seals and parts may be ordered as required See the parts list in the previous section for part numbers 9 1 Supporting Equipment 950 4656 316 Piston Assembly Tool OPS 4611 Rev D 52
5. 19 VE GREASE INJECTION PORT CLOSE ACTUATOR AND INJECT UNTIL GREASE l5 VISABLE IN VENT PORT Figure 22 Modular Manual Actuator OPS 4611 Rev D 37 User Manual Phuel 3 Modular BOP System OIL TOOLS _ EU 190 4277 480 Quantty SE iesen 3 MOD PISTON HOUSING 190 4282 480 3 MOD HYDRAULIC CYLINDER HOUSING 190 4281 480 3 MOD CYLINDER CAP 190 4198 480 3 MOD ACTUATOR COLLAR 190 4278 480 3 MOD BALANCED PISTON 190 4201 480 3 MOD SEAL RING 190 4279 480 3 MOD HYDRAULIC PISTON 190 4286 480 3 MOD DRIVE ROD 190 4287 480 3 MOD DRIVE SLEEVE To 190 4283 460 1 3 MOD KEY PLATE 11 190 4284 316 3 MOD INDICATOR ROD 12 190 4290 480 3 RAM GUIDE BAR 13 190 4202 ALU 3 MOD BEARING BRACKET 14 190 4319 PEK 3 MOD KEY BUSH 15 190 4335 316 COLLAR BOLT 3 MOD 16 801 0340 V90 1 O Ring B S Size 340 17 190 3870 H85 1 ROD SEAL 18 190 4343 PEK 1 GREASE SCRAPPER RING 19 802 4340 H85 1 PISTON T SEAL 2 385 20 802 4339 H85 2 ROD T SEAL 1 750 21 801 0231 V90 1 O Ring B S Size 231 22 802 4341 H85 1 PISTON T SEAL 2 750 23 801 0235 V90 1 O Ring B S Size 235 24 802 2505 H85 1 ROD T SEAL 0 825 DIA 25 802 4342 H85 1 ROD T SEAL 0 245 26 WNL 0540 316 8 Nord Lock Washer Size 3 8 27 SDU 0585 316 4 Set Screw Dog
6. 196 4328 HVO Body amp Actuators 192 4450 KIT Injection 192 4330 SS0 Tie Bars 190 4360 HHO Wireline Rams Hydraulic Fittings see table SINGLE Additional Modules Required 191 4330 SS0 Tie Bars 190 3161 HVO Bank Port End Conversion Kit 4x KIT 4298 HVO Hydraulic Fittings 2x 190 4433 HS Redress Kits 2x RDK 4328 HVO Body amp Actuators 1x RDK 4450 HV2 Injection 2x RDK 4360 HHO Wireline Rams 1x Top amp Bottom Subs see Table 4 Redress Kits 2x RDK 4329 HVO Body amp Actuators 1x RDK 4450 HV2 Injection RDK 4360 HHO Wireline Rams x Top amp Bottom Subs see Table 4 DUAL Additional Modules Required Additional Modules Required 196 4329 HVO Body amp Actuators 196 4328 HVO Body amp Actuators 193 4450 KIT Injection 193 4450 KIT Injection 193 4330 SS0 Tie Bars 193 4330 SS0 Tie Bars 190 4359 HHO Shear I 190 4359 HH0 Shear Rams Additional Modules Required Hydraulic Fittings see table 192 4330 SS0 Tie Bars Additional Modules Required 190 3161 HVO Bank Port End 192 4330 SS0 Tie Bars 190 3161 HVO Bank Port End _ Conversion Kit 6x KIT 4298 HVO Hydraulic Fittings 3x 190 4433 HS TRIPLE Redress Kits Redress Kits ER 3x RDK 4328 HVO Body amp Actuators 1x RDK 4450 HV3 Injection ds IC 1x RDK 4450 HV3 Injection 2x RDK 4360 HHO Wireline Rams sr 2x RDK 4360 HHO Wireline Rams 1x RDK 4359 HHO Shear Rams 1x
7. 1904349PEK 1 GREASESCRAPPERRNG _ _ 802 4340 H85 1 PISTONTSEAL2385 AA 802 4339 H85 1 RODT SEAL1750 8010281 V O0 1 OHing BSSze281 _ _ Table 26 Manual Actuator Redress Kit RDK 4299 HVO Part Number Quantity 190 4171 H80 3 GUIDING INNER MULTI SEAL een 190 4170 H80 3 POINTED INNER MULTI SEAL 190 3107 H70 BOP OUTER SEAL 3 50 gt OPS 4611 Rev D 51 User Manual Phuel 3 Modular BOP System OIL TOOLS Table 27 Wireline Ram Redress Kit RDK 4360 HHO Part Number Quantity Comment 190 4142 H80 3 BLIND GUIDING INNER SEAL 190 4141 H80 3 BLIND POINTED INNER SEAL 190 3107 H70 BOP OUTER SEAL 3 50 Table 28 Shear Ram Redress Kit RDK 4359 HHO Comment 190 2823 PEK 801 0119 V90 801 0108 V90 Table 29 Single Injection Module Redress Kit RDK 4450 HV1 Comment 190 2823 PEK 801 0119 V90 8 O Ring B SSizet19 801 0108 V90 Table 30 Dual Injection Module Redress Kit RDK 4450 HV2 Comment 190 2823 PEK 801 0119 V90 801 0108 V90 Table 31 Triple Injection Module Redress Kit RDK 4450 HV3 Part Number Quantity 802 4390 H85 PISTON T SEAL 4 300 801 0340 V90 O Ring B S Size 340 D Table 32 4 347 4 Top and Bottom Sub Redress Kit RDK 4325 HVO Part Number Quantity 802 4390 H85 PISTON T SEAL 4 300 801 0342 V90 O Ring B S Size 342 9
8. Parts List Manual 33 Table 10 3 Modular Body Parts List Hydraulic 33 Table 11 Modular Manual Actuator Assembly 190 4299 HVO 36 Table 12 Modular Hydraulic Actuator Assembly 190 4289 HVO 38 Table 13 Wireline Ram Assy 190 4360 HHO esses 40 Table 14 Shear Ram Assy OU A23b0 HH 40 Table 15 4 3 4 Top Sub Parts List 196 4324 HVO 41 Table 16 4 3 4 Bottom Sub Parts List 196 4325 HV0 42 Table 17 5 3 4 Top Sub Parts List 196 4326 HVO 43 Table 18 5 3 4 Bottom Sub Parts List 196 4327 HV0 44 Table 19 190 4450 HVO Parts Uer 45 Table 20 Connecting Collar Parts List 196 4188 S850 49 Table 21 Modular BOP Hydraulic Fittings 190 4433 HS0 50 Table 22 Modular BOP Hydraulic Fittings 190 4433 HS1 50 Table 23 BOP Body with Hydraulic Actuator Redress Kit RDK 4328 HVO 51 Table 24 BOP Body with Manual Actuator Redress Kit RDK 4329 HVO 51 Table 25 Hydraulic Actuator Redress Kit RDK 4289 HVO 51 Table 26 Manual Actuator Redress Kit RDK 4299 HVO 51 Table 27 Wireline Ram Redress Kit RDK 4360 HHO
9. RDK 4359 HHO Sh R 1x Top amp Bottom Subs see Table 4 p Shear Rams 1x Top amp Bottom Subs see Table 4 OPS 4611 Rev D 29 kb o User Manual Phuel 3 Modular BOP System OIL TOOLS 196 4324 HVO IMODULAR TOP SUB ASSY 4 3 4 196 4325 HVO MODULAR BOTTOM SUB 4 3 4 HDK 4325 HVO 4 3 4 BOTTOM SUB REDRESS KIT 196 4326 HVO IMODULAR TOP SUB ASSY 5 3 4 196 4327 HVO IMODULAR BOTTOM SUB ASSY 5 3 4 HDK 4327 HVO 5 3 4 BOTTOM SUB REDRESS KIT Table 4 Available Top amp Bottom Sub Assemblies Part Number Description 190 4433 HS0 HYDRAULIC KIT BEATTIE QR 74 190 4433 HS1 HYDRAULIG KIT SNAP TITE HC 44 Table 5 Available Hydraulic Connection Kits New items can be made available upon request Contact Phuel Oil Tools with your requirements OPS 4611 Rev D 30 User Manual Phuel 3 Modular BOP System OIL TOOLS 1 196 4329 HVO 1 3 MOD BOP WITH MANUAL ACTUATORS 2 196 4324 HVO 1 3 MODULAR TOP SUB ASSY 4 3 4 3 196 4325 HVO 1 13 MODULAR BOTTOM SUB 4 3 4 4 191 4330 SS0 1 13 MOD SINGLE TIE BARS 6 190 4360 HHO 1 MODULAR 3 GUIDE RAM ASSEMBLY 7 191 4450 HVO 1 18 MOD SINGLE INJECTION MODULE Table 6 Single BOP 4 3 4 4 Manual Parts List 191 4331 HVO 1 196 4328 HVO 2 13 MOD BOP WITH HYDRAULIC ACTUATORS 2 196 4324 HVO 1 3 MODULAR TOP SUB ASSY 4 3 4 3 196 4325 HVO 1 13 MODULAR BOTTOM SUB 4 3 4 4 192 4330 SS
10. lt lt s 46 Figure 29 Equalisation Assy 1071 4420 HVU 47 Figure 30 End Saversub Assy 191 4450 HVO gt gt c 48 Figure 31 Connecting Collar Assembly 196 4188 LI50 49 OPS 4611 Rev D II User Manual Phuel 3 Modular BOP System OIL TOOLS Revision History Issue Release Date Description Rev A 02 Feb 12 Initial Issue Addition of Height of Modular Body to aid Calculation of VU May IE Make Up Length Height Rev C 07 Jan 13 Correction to Shear Ram Part numbers 5 Yr Maintenance i text change to ref E101 Simplified yearly inspection 6 2 2 and improved test procedure 7 1 Rev D 16 Sep 13 OPS 4611 Rev D IV zm User Manual Phuel 3 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 appropri
11. 0 1 3 MOD DUAL TIE BARS 6 190 4360 HHO 2 MODULAR 3 GUIDE RAM ASSEMBLY 7 192 4450 HV0 1 3 MOD DUAL INJECTION MODULE 8 190 4433 HS1 2 13 Mod Hydraulic Kit Snap Tite Table 7 Dual BOP 4 3 4 4 Hydraulic Parts List 192 4490 HVO 1 196 4328 HVO 3 3 MOD BOP WITH HYDRAULIC ACTUATORS 2 196 4326 HVO 1 3 MODULAR TOP SUB ASSY 5 3 4 3 1196 4327 HVO 1 13 MODULAR BOTTOM SUB ASSY 5 3 4 4 193 4330 550 1 13 MOD TRIPLE TIE BARS 5 190 4359 HHO 1 MODULAR 3 SHEAR RAM ASSEMBLY 6 190 4360 HHO 2 MODULAR 3 GUIDE RAM ASSEMBLY 7 193 4450 HV0 1 3 MOD TRIPLE INJECTION MODULE 8 190 4433 HS1 3 13 Mod Hydraulic Kit Snap Tite Table 8 Triple BOP 5 3 4 4 Hydraulic Parts List 193 4498 HVO OPS 4611 Rev D 31 _ User Manual IQ Phuel 3 Modular BOP System OIL TOOLS TYPICAL TRIPLE HYDRAULIG ACTUATOR TYPICAL DUAL MANUAL CONFIGURATION WITH CRASH FRAME ACTUATOR CONFIGURATION N gt er 2 NSS ATTACH BAND WITH ASSEMBLY TAG ATTACH BAND WITH ASSEMBLY TAG c SANG ya SK gt E e 19 PO 7 Y n 5 4 1 WIRELINE RAMS 9 16 A Figure 19 Typical Configuration of Modular BOP All versions OPS 4611 Rev D 32 User Manual Phuel 3 Modular BOP System OIL TOOLS 6 CSU 0585 3A4 4 GSink Soc Hd Size 1 2 Length tin Table 9 3 Modular Body Part
12. 0 4293 480 1 3 MOD MANUAL CYLINDER CAP 190 4198 480 1 3 MOD ACTUATOR COLLAR 190 4278 480 1 3 MOD BALANCED PISTON 190 4201 480 1 3 MOD SEAL RING 190 4297 480 1 3 MOD MANUAL DRIVE SHAFT 190 4298 480 1 3 MOD MANUAL DRIVE SHAFT RETAINER 190 4290 480 1 3 RAM GUIDE BAR 9 190 4202 ALU 1 3 MOD BEARING BRACKET 10 190 4335 316 8 COLLAR BOLT 3 MOD 11 801 0340 V90 1 O Ring B S Size 340 12 190 3870 H85 1 ROD SEAL 13 190 4343 PEK 1 GREASE SCRAPPER RING 14 802 4340 H85 1 PISTON T SEAL 2 385 15 802 4339 H85 1 ROD T SEAL 1 750 16 801 0231 V90 1 O Ring B S Size 231 17 WNL 0540 316 8 Nord Lock Washer Size 3 8 18 WNL 3703 316 1 NORDLOCK WASHER M4 19 SDU 0585 316 4 Set Screw Dog Point 1 2 UNC X 1 000 in 20 WNL 4344 316 1 NORD LOCK WASHER M30 1 125 21 190 1608 STL 2 Ball Slide TK 25 UU 22 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 23 100 2209 316 2 NPT SOCKET HEAD PLUG 1 8 Table 11 Modular Manual Actuator Assembly 190 4299 HVO O NSI D UO RI O NR OPS 4611 Rev D 36 User Manual IQ Phuel 3 Modular BOP System 18 58 F _ 1i 1i ym S Oo ay 2 D j E Vd V a x SC Fm 1918 HEX au EJ ATTACH B ND HERE LNOTE ORIENTATION OF La VENT PORT TOBRAGKET
13. 587316 4 MALE NIPPLE 1 4in NPT 4 950 4434 316 4 NPT SOCKET HEAD PLUG 1 4 Table 22 Modular BOP Hydraulic Fittings 190 4433 HS1 OPS 4611 Rev D 90 User Manual Phuel 3 Modular BOP System MIL 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 ES 802 4390 H85 PISTON T SEAL 4 300 RDK 4289 HVO Hydraulic Actuator Redress Kit Table 23 BOP Body with Hydraulic Actuator Redress Kit RDK 4328 HVO Part Number SES 802 4390 H85 4390 802 4390 H85 PISTON T SEAL 4 300 RDK 4299 HVO Manual Actuator Redress Kit Table 24 BOP ged with Manual Actuator Redress Kit RDK 4329 HVO 190 4319 PEK _ BCEE 1903870485 1 ROD SEAL 190434 PEK 1 GREASESCRAPPERRNG 8024440H85 1 PISTONTSEAL2385 8024338H85 2 RODTSEAL 1750 801028 V60 1 ORin BSSzm aam 1 PISTONT SEAL 2750 801 0235V90 1 C0 8 59 gt 0235 802250586 1 RODTSEAL0825DA 802442H85 1 RODTSEALOPS Table 25 Hydraulic Actuator Redress Kit RDK 4289 HVO 801 0840 V90 1 ORing B SSze30 gt 190 3870 H85 1 RODSEAL li
14. HREAD PROTECTOR Table 16 4 3 4 Bottom Sub Parts List 196 4325 HVO C 01 RA O N 18 14 STAMP PER QPI la LENGTH 7 88 in 0 20 m amp X TAG DETAILS PHUEL OIL TOOLS DESCHIPTION PART NUMBERS SERIAL NUMBER CUSTOMER NUMBER API 18A API SA PSLI PU MWP 88905 H25 Figure 27 4 3 4 QU Bottom Sub Assy OPS 4611 Rev D 42 gt User Manual Phuel 3 Modular BOP System OIL TOOLS Item Part Number E 1 196 4316 480 5 3 4 4 MODULAR TOP SUB 2 j802 4390 H85 PISTON T SEAL 4 300 Table 17 5 3 4 Top Sub Parts List 196 4326 HVO 7 82 MAKE UP LENGTH 6 89 in 0 17 m STAMP PER OP14 _ N FIT TAG i d gt 22 TI N 844 ACME 8 00 53 00 PHUEL OIL TOOLS DESCRIPTION PART NUMBER HSERIAL NUMBER CUSTOMER NUMBER API 16A API 6A PSL3 P U MWP PSI H2S LATTATCH BAND Figure 28 5 34 4 QU Top Sub Assy OPS 4611 Rev D 43 gt User Manual Phue 3 Modular BOP System OIL TOOLS Part Number Quantity Description 4 198 4315 480 1 05 3 4 4 MODULAR BOTTOM SUB 2 1 69 1995 480 1 SPLIT COLLAR 5 3 4 4 ACME 3 1 69 1996 480 1 SPLIT RING 5 3 4 4 ACME 4 ISHC 0543 3A4 4 Soc Hd Cap Size 3 8 Length 0 625 in 5 IWNL 0540 31 6 4 Nord Lock Washer Size 3 8 6 801 0342 V90 1 O Ring B S Size 342 5 3 4 4 Quick Union Tab
15. OPS 4611 Rev D User Manual 33 Phuel 3 Modular BOP System OIL TOOLS 193 TRIPLE SET UP 192 DUAL SET UP 191 SINGLE SET UP C86 ee END SAVERSUB EQUALISING BLOCK EQUALISING BLOCK XXX 4450 A m BOP SET UP Qo gt 191 SINGLE Zut c EN m Eu CI DOCUMENT NUMBER 7 I T LL 1 DETAIL Zi PO NA d Oo a b HVO FULL MODULE C KIT UPGRADE KIT Figure 30 Equalising Block Configurations OPS 4611 Rev D 46 _ User Manual IQ Phuel 3 Modular BOP System el Figure 31 M Assy 191 4450 HVO OPS 4611 Rev D 47 User Manual 3 Phuel 3 Modular BOP System Figure 32 End Saversub Assy 191 4450 HVO OPS 4611 Rev D 48 User Manual Phue 3 Modular BOP System OIL TOOLS fem Number Part Number _ Guantiy 191 4288 AL7 4 3 MOD SINGLE BODY TIE BAR 195 1964 A2H HEX NUT 1 125 8 UN Table 20 Connecting Collar Parts List 196 4188 SS0 Figure 33 Connecting Collar Assembly 196 4188 HS0 OPS 4611 Rev D 49 kb User Manual Phuel 3 Modular BOP System OIL TOOLS 1 190 2746 STL 2 1 4 SNAPTITE COUPLER PT NO SVHC44FV 2 950 3717 316 4 3 8 NPT x 14 NPT Connector 3 9504434316 4 NPT SOCKET HEAD PLUG 1 4 Table 21 Modular BOP Hydraulic Fittings 190 4433 HS0 1 950 2558 316 2 1 4 SNAPTITE COUPLER PT NO SVHC44FV 2 9502559316 2 1 4 SNAPTITE NIPPLE PT NO SVHN44FV 3 9502
16. Point 1 2 UNC X 1 000 in 28 SDU 0505 HTS 3 Set Screw Dog Point Size 1 4 Length 0 75 in 29 SHC 0503 HTS 2 Soc Hd Cap Size 1 4 Length 0 5 in 30 WNL 0500 316 2 1 4 Nordlock Washer 32 WNL 3703 316 1 NORDLOCK WASHER M4 33 100 2209 316 2 NPT SOCKET HEAD PLUG 1 8 34 190 1608 STL 2 Ball Slide TK 25 UU 35 190 4338 STL 1 Thrust Bearing FAG 811 06 36 190 1756 STL 4 EXTERNAL CIRCLIP EXT 0400 37 190 2491 STL 1 EXTERNAL CIRCLIP SH 75 0 750 DIA Table 12 Modular Hydraulic Actuator Assembly 190 4289 HVO cc OPS 4611 Rev D 38 IQ Phuel 7 oi TOOLS 5 00 OPS 4611 Rev D User Manual 3 Modular BOP System 20 67 ne EE ga PISTON AREA TO OPEN 5 85 SOIN FULL STROKE VOLUME 15 7 CUIN 0 26 LITRE IM PISTON AREA TO CLOSE 3 56 SOIN FULL STROKE VOLUME 9 4 CUIN 0 15 LITR d EI PISTON STROKE 2 E3 IN Go AMP PER QP 14 2 NOTE ORIENTATION OF VENT PORT TO BRACKET CLOSE ACTUATOR AND INJECT UNTIL GREASE IS VISABLE IN VENT PORT Figure 23 3 Modular Actuator Hydraulic 39 m User Manual Phuel 3 Modular BOP System DIL TOOLS 1 190 4363 480 1 MODULAR NO GUIDE RAM 3 00 2 190 4364 480 1 MODULAR GUIDED RAM 3 00 3 190 4171 H80 1 3 GUIDING INNER MULTI SEAL 4 190 4170 H80 1 3 POINTED INNER MULTI SEAL 5 190 3107 H70 2 BOP OUTER SEAL 3 50 Tab
17. ate PPE Ensure the identification plate is fitted and is displaying the correct information This equipment and the equipment it is attached to is heavy never position yourself below a suspended load Figure 1 3 Modular BOP Triple Build OPS 4611 Rev D V User Manual IQ Phuel 3 Modular BOP System OIL TOOLS 1 Introduction 1 1 General The Modular Blow Out Preventer BOP provides essential safety barriers against well pressure during wireline operations It is usually located directly above the Xmas 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 utilising single or multiple modules in varying configurations The 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 manual or 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 direct
18. 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 4611 Rev D 2 User Manual IQ Phuel 3 Modular BOP System ML TOOLS Record the numbers for each of the modules and ensure that it matches on the corresponding product certificate The BOP will have been supplied with a map whan it was assembled in the factory and must be kept up to date whenever changes are made TOP LEVEL MUMBERS SR dE 19 8 sl ES EE E Penn Ee A G l a A E E eia WIRELINE RAMS TIE BOLT MODULE F MC LL III MODULE SHEAR RAMS d r Le Figure 3 Generic 3 Modular Map OPS 4611 Rev D 3 User Manual Phuel 3 Modular BOP System OIL TOOLS 2 Technical Specification DE S S Manual Actuator Hydraulic Actuator Working Pressure 10 000 Psi May be further restricted by end connections fitted 15 000 Psi May be further restricted by end connections fitted Service 25 cu in 0 41 Litre Total Cycle Stroke Volume N A 15 6 cu in 0 26 Litre to Close 9 4 cu in 0 15 Litre to Open 331 Ibs 155 kg 364 Ibs 170 kg Weight Test Pressure Dual 526 Ibs 238 6 kg 592 Ibs 268 5 kg D 721 lbs 327 kg 820 Ibs 372 kg Table 1 Technical Data OPS 4611 Rev D 4 gt User Manual IQ Phuel 3 Modular BOP Syst
19. der to gain access to the rams e Ensure Rams are fully opened e Back off the Actuator from the BOP using the extended 5 16 Allen Key in the Cap Screw heads on the Locking Sleeve Do not loosen the cap screws during this process e Once the thread is fully disengaged pull the Actuator fully back to the End Stops Figure 9 Accessing the rams 6 4 2 Ram Removal not required to redress ram seals e Pump or manually wind the actuator forward until the back of the ram is clear of the Collar e Undo guide bar ensuring the nordlok washer remains in the actuator piston housing and slide into ram e Remove Ram from Actuator by sliding the Ram off the Piston OPS 4611 Rev D 16 User Manual IQ Phuel 3 Modular BOP System OIL TOOLS 6 4 3 Ram Seal Redress e The Inner Ram Seals can be removed by simply sliding the seal out to either side e The Outer Seal can be removed by levering out one end with a suitable instrument and simply pulling off e The Ram is now completely stripped down Clean and inspect all parts for evidence of damage or excessive wear Check the seals and replace if required Repair or replace any damaged or worn parts If the seals are to be redressed use the parts from the specified redress kit e Assemble Outer Seals by pushing the tab into the slot in the ram and working it around the radius of the ram Tap home using a rubber or hide mallet and if required use a screwdriver to lever the seco
20. em 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 one or more sets of rams operated either manually or hydraulically that can be individually closed to form a seal against pressure The orientation of the ram outer seal determines whether the rams hold pressure from above or below By opposing adjacent ram sets it is possible to apply pressure between the rams through a grease injection port normally at a pressure greater than the well pressure and thus form a positive protection barrier This technique is particularly effective when sealing against braided wire line as a leak tight seal cannot be obtained due to the construction of the wire The high viscosity of the grease allows the pressure to be maintained even though a small leak of grease still exists Figure 4 Section through BOP rams closed position 3 2 Balanced Piston The actuator is designed with a balanced hydraulic piston that eliminates the end load that can be created due to well pressure This means that the torque or closing pressure of the actuator is independent of the well pressure inside the BOP This feature has two major advantages The BOP can be closed with the same amount of effort no matter what the well bore pressure exists in the bore This is particularly useful with a manual actuator and ensures qu
21. he 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 OPS 4611 Rev D 12 User Manual Phuel Modular BOP System OIL TOOLS 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 O Rings and T Seals of 90 hard Viton material with part numbers listed in this manual have been qualified for operating temperatures between 10C and 121C with no restrictions to the operating pressure 5 6 2 Blind Ram Shear Seals The shear rams using blind ram inner shear seals part number 190 4141 H80 amp 190 4142 H80 have been qualified for operation between 10C and 121C with no restrictions to the working pressure 5 6 3 Wireline Multi Seals The wireline multi seal part number 190 4170 H80 amp 190 4171 H80 are qualified to be used within the operating envelope shown below If operations dictate that the expected surface temperatures and pressures exceed the operating envelope then wire specific inner seals must be used instead of the standard multi seal Consult Phuel Oil Tools for advice and
22. i per minute 2 Reduce pressure from 2000 psi to 1000 psi at a rate of 100 psi every one minute 3 Reduce pressure from 1000 Psi to zero at a rate of 20 psi per minute 4 2 Equalising across the rams There is an external port that allows the connection of a pressure gauge or dump valve if required The number of valves actually available will depend on the BOP configuration Valves 1 and 2 are always available but valve HU is only available in Dual and Triple configuration and Valve L is only available in the Triple configuration Other configurations are available if the standard set up does not meet the operational needs Contact Phuel Oil Tools for advice if required OPS 4611 Rev D 7 gt User Manual IQ Phuel 3 Modular BOP System VALVE HU VALVE HU VALVE 1 VALVE 2 VALVE FL VALVE HL Figure 5 Equalisation Valve Layout OPS 4611 Rev D 8 User Manual Phuel 3 Modular BOP System OIL TOOLS 4 3 Job Planning 4 3 1 Before the Job Note Configuration will determine which processes are required e Check that the certification is within date and that the scheduled maintenance is up to date e All blind shear inner seals need to be inspected after 30 pressure cycles and replaced where necessary Wire line seals must be tested without the use of test rods and must always be replaced after being closed on wire during normal operations Always inspect the wireline seals for signs
23. ic Actuator Assembly Part 1 sssseusssueuus 21 Figure 13 Hydraulic Actuator Assembly Part 2 ssessssuuss 22 Figure 14 Manual Actuator Assembly S 23 Figure 15 Manual Hydraulic Conversion c lt c c 24 Figure 16 Instructions for greasing of the Piston Shaft 25 Figure 17 Typical Configuration of Modular BOP All versions 32 Figure 18 3 Modular Body Manual 34 Figure 19 3 Modular Body Hydraulic rrrrnrrrnnrrnnnrronnvrernvrennrrnnnerennrrennerennne 35 Figure 20 Modular Manual CIV L0L gt sen 37 Figure 21 3 Modular Actuator Hydraulic lt lt s o 39 Figure 22 Wireline Ram Assy 190 4360 HHO euvnnnrnnnnrnnnnrnnnvrennvrnnnrrennerennnn 40 Figure 23 Shear Rams 190 4359 HHO cccccccesceceeeeceeeeceeeeceesecseeeseases 40 Figure 24 4 34 4 QU Top Sub ASSY cccccccccceeeeceeeseeeeeeeeeeeeeeeeeseaeeeeeeeaes 41 Figure 25 4 34 4 QU Bottom Sub Assy rrrrrrnnnnrrvrrnnnnrvnvrnnnnrrnrrnnnnrrnnnnnsnnennnn 42 Figure 26 5 34 4 QU Top Sub Assy ENEE 43 Figure 27 5 34 4 QU Bottom Sub ASSY rrrrrrnnnnrvrrrnnnrrrvrrnnnrrvnnrnnnnrennrnnsrnennn 44 Figure 28 Equalising Block Configurations lt lt lt lt
24. ick and safe closure The hydraulic volume requirements of the actuator are much less than a conventional BOP this reduces the requirements for accumulator storage and charging OPS 4611 Rev D 5 User Manual Phuel 3 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 Manual Ram Operation The manual rams are operated by turning the drive shaft using a suitable tool 9 16 Socket recommended in a clockwise direction some 20 25 turns 4 1 2 Hydraulic Operation The BOP has two pairs of connections for each ram set for open and close It is important that both connections are connected as the fluid displaced by the movement of the piston must be allowed to pass through the valve system back to the reservoir A Well Control Unit WCU is normally used to operate the BOP in an offshore environment Refer to the relevant manual for that equipment for details of operation and connection An alternative pump pack may be used for onshore maintenance work but the operation of this equipment is out with the scope of this manual 4 1 3 Locking the Hydraulic Rams After closing with hydraulic pressure the piston can be mechanically locked by winding in the manual mechanism Turning the drive shaft in a clockwise direction will advance the locking mechanism by 3mm per turn It is therefore necessary to turn
25. ing pressure see Test Procedure below e Update paperwork with new numbers for traceability 6 6 Special Tools General workshop tools will be required to maintain and assemble and disassemble the BOP To undo and tighten the balanced piston from the hydraulic piston two hex keys are required 3 8 and 1 1 8 Phuel can supply a Hex bar to fit this piston and allowa 1 1 8 socket to be connected Figure 12 950 4656 316 Piston Assembly Tool OPS 4611 Rev D 19 User Manual uel 3 Modular BOP System OIL TOOLS TORQUE NUTS TO 686ft Ibf 925 Nm Figure 13 Connecting Multiple Modules OPS 4611 Rev D 20 User Manual 3 Modular BOP System OPS 4611 Rev D 21 User Manual 3 Modular BOP System As an alternative to hex key an Assembly Tool Part number 950 4656 316 is available to allow use of 1 1 8 socket COMPLETE Figure 15 Hydraulic Actuator Assembly Part 2 OPS 4611 Rev D OPS 4611 Rev D User Manual 3 Modular BOP System es Denia JIJ Figure 16 Manual Actuator Assembly User Manual Phuel 3 Modular BOP System OIL TOOLS EXISTING COMPONENTS FROM MANUAL ACTUATOR NEW COMPONENTS FROM HYDRAULIC UPGRADE KIT Figure 17 Manual Hydraulic Conversion OPS 4611 Rev D 24 OPS 4611 Rev D User Manual 3 Modular BOP System User Manual Phuel 3 Modular BOP System 6 7 Maintenance Record Sheet Date Type of Pe
26. ion 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 screw Unwinding the screw opens the valve and allows equalisation across the rams Tightening the screw closes the seal and prevents pressure from passing through the valve assembly There is also a circuit to allow the injection of chemicals into the well or across the equalisation valves and can be used to prevent the valves freezing while bleeding down gas by injecting glycol for example The injection port has a check valve to prevent well pressure entering the injection system The BOP can be mounted to a crash frame assembly that provides forklift pockets protection during transport This user manual serves as an introduction to the equipment and contains the relevant specifications operation planning and maintenance instructions parts list and drawings OPS 4611 Rev D 1 i User Manual 353 Phuel 3 Modular BOP System OIL TOOLS 1 2 Product Identification Phuel products are identified by a unique serial number that facilitates full product traceability Each product is supplied with a documentation pack that contains product certification and material inspection reports The serial number is a
27. le 13 Wireline Ram Assy 190 4360 HHO Figure 24 Wireline Ram Assy 190 4360 HHO 1 190 4362 480 1 MODULAR 3 GUIDING SHEAR RAM BODY 2 190 4361 480 1 MODULAR 3 SHEAR RAM BODY NO FINS 3 190 4141 H80 1 2 POINTED INNER BLINDSEAL 4 190 4142 H80 1 3 GUIDING INNER BLIND SEAL 5 190 3107 H70 2 BOP OUTER SEAL 3 50 Table 14 Shear Ram Assy 190 4359 HHO OPS 4611 Rev D 40 User Manual 733 Phuel 3 Modular BOP System OIL TOOLS Part Number Quantity Description 1 196 4211 480 1 4 3 4 4 MODULAR TOP SUB 2 802 4390 H85 1 PISTON T SEAL 4 300 Table 15 4 3 4 Top Sub Parts List 196 4324 HVO r 6 82 gt MAKE UP LENGTH 5 69 in 0 14 m 8 00 TAG DETAILS 8 PHUEL OIL TOOLS DESCRIPTION PAHT NUMBER SERIAL NUMBER CUSTOMER NUMBER z C API 16A API 6A PSL3 P U MWP PSI H25 Ca 3 4 4 ACME LATTATCH BAND STAMP PER CEA Figure 26 4 34 4 QU Top Sub Assy OPS 4611 Rev D 41 gt User Manual Phue 3 Modular BOP System OIL TOOLS fem Part Number Quantity Description 196 4212 480 1 4 3 4 4 MODULAR BOTTOM SUB 169 4216 480 1 4 75 4 SPLIT COLLAR 10K 169 4217 480 1 4 750 4 SPLIT RING 10K SHC 0543 3A4 4 Soc Hd Cap Size 3 8 Length 0 625 in WNL 0540 316 4 Nord Lock Washer Size 3 8 801 0340 V90 1 O Ring B S Size 340 99 910 4088 N66 1 4 750 4 ACME MALE T
28. le 18 5 3 4 Bottom Sub Parts List 196 4327 HVO 1297 STAMPE PER OP t MAR E F LENGTH 9 13 im 1 23 m SAT TAG PHUEL OIL TOOLS 8DESCHRIPTIONS SPART NUMBERS SERIAL NUMBERS CUSTOMER NUMBER API 16A AFI 5A PSL3 P U MWP H PSI H25 Figure 29 5 4 QU Bottom Sub Assy OPS 4611 Rev D 44 User Manual Phuel 3 Modular BOP System OIL TOOLS 1 190 4255 480 MOD EQUALISATION BLOCK 2 190 4285 480 MOD EQUALISING END VALVE SAVERSUB 3 190 4275 480 3 MOD CONNECTING BAR 4 145 2176 480 SAVER SUB PORT 5 1205 2105 480 BLANK TEST PORT 6 900 3019 480 CHECK HOUSING 7 110 2979 316 VALVE 8 190 2823 PEK VALVE SEAT 9 100 2114 PEK CHECK VALVE SEAL 10 190 2786 PEK CHECK CONE SEAL 11 145 2185 STL GOMP SPRING 12 190 1749 STL COMP SPRING 13 190 1703 STL Hollow Lock Screw 3 4 16 14 1801 0119 V90 O Ring B S Size 119 15 B01 0108 V90 O Ring B S Size 108 16 1801 0110 V90 O Ring B S Size 110 17 SHC 0583 3A4 Soc Hd Cap 1 2 UNG Length 3 4 in 18 SHC 0585 3A4 Soc Hd Cap Size 1 2 Length 1 in 19 WNL 0580 316 WASHER NORDLOCK M12 20 SBC 0543 304 Button Hd Screw Size 3 8 Length 0 625 in 21 WNL 0540 316 Nord Lock Washer Size 3 8 22 SHC 0586 3A4 Soc Hd Cap Size 1 2 UNC Length 1 25 in 23 190 2821 316 PORT BLANK END Quantities depend on the configuration Table 19 190 4450 HVO Parts List
29. luid Once all air is expelled close test cap valve e The valve is now prepared for testing 7 1 2 Body Test e Ensure that all the rams are in the open position Open all the equalizing valves e Pump slowly up to 300 psi and observe for leaks Hold Time 5 min with no leaks e Bleed the pressure to zero e Pressurize to MWP in accordance with documentation and observe for leaks Hold Time 15 min with no leaks e Bleed of pressure to zero OPS 4611 Rev D 27 User Manual Phuel 3 Modular BOP System OIL TOOLS 7 1 3 Lower Ram Test e Close Lower Ram this is done by activating the BCU Lower ram valve to close position then pressurize up to a maximum of 3 000 psi on the ram e Close valves 1 and U and open valve 2 so that pressure testing is done from the underside of rams and up e Pressurize up to 300 psi low pressure test observe if there are leaks Hold Time 10 min with no leaks e Bleed the pressure to zero e Pressurize up to the MWP in accordance with documentation maintain the pressure for 10 min without leaks e Bleed the pressure to zero e Open the lower rams by enabling BCU Lower ram valve to open position 7 1 4 Upper Ram Test e Close Upper Ram this is done by activating the BCU Upper ram seal valve to close position then pressurize up to a maximum of 3 000 psi on the ram e Close valves 1 and U and open valve 2 so that pressure testing is done from the underside of rams and u
30. lways etched on the surface of the product but can sometimes be difficult to find or read after painting A customer identification number is also included to allow the customer to track the asset in their system The nameplate tag that is stamped with the information shown below is secured either by a stainless steel band or fixed directly onto the assembly This tag should be located in the first instance to ensure that this manual and any other paperwork refers to the correct equipment PHUEL OIL TOOLS DESCRIPTION PART NUMBER ZSERIAL NUMBER CUSTOMER NUMBER API 16A API 6A PSL3 P U MWP PSI H2S 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 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 parts list section of this manual should be used to determine how assemblies and
31. ly cleaned repaired as required and redressed The BOP should be protected against the effects of corrosion to ensure that the expected functionality is achieved The diagram overleaf highlights the key areas to consider OPS 4611 Rev D 9 User Manual IQ Phuel A Modular BOP System OIL TOOLS Grease seal bore and threads Cover the assembly when before fitting thread protectors in long term storage With the actuators closed pump grease to all grease ports until it flows through the Smear grease on all bars S other port Touch up paint when it is damaged or coat damaged area with thick grease Grease before fitting protectors For long term storage fit test stump and fill with oil Figure 6 Correct lubrication for storage OPS 4611 Rev D 10 User Manual Phuel Modular BOP System OIL TOOLS 5 Operational Characteristics 5 1 Sealing Characteristics 5 1 1 Minimum Hydraulic Pressure The actuator is pressure balanced and so it is possible to close the rams against any well pressure with more than 500 psi In order to ensure that the BOP seals correctly it is recommended to apply the full closing pressure of 2900 psi 200 bar In most cases the BOP will seal with pressures greater than 1 000 psi 70 bar applied For a manual BOP the torque required to generate 1 000 psi is approximately 100 Nm 73 Ibs ft As a general rule of thumb 100ft lbs torque applied to the manual actuator is equivalent
32. more effort may be required to allow the thread to make up e Apply a generous coating of grease to the inner and outer seals e Push the Actuator back into BOP Body taking care that the edges of the guide pass into the seal bore and make up the thread using a 5 16 hex key in the cap head screws to provide the torque Making up the thread will drive the actuator assembly fully home e The Ram Assembly is now fully made up Repeat this procedure for each ram seal that need to be replaced OPS 4611 Rev D 18 User Manual Phuel 3 Modular BOP System OIL TOOLS 6 5 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 5 1 Splitting the Connection e Locate and remove the 4 Tie Bar Nuts e The two assemblies can now be pulled apart e Inspect the T Seal and replace if necessary 6 5 2 Re Making the Connection Note Take note of new body serial number to allow update of traceability e Ensure that the T Seals are in good condition e Ensure correct length of Tie Bars are fitted for the amount of modules to be fitted e Lower the upper module down over the Tie Bars e Fit 4 Tie Bar nuts and tighten to a Torque of 686 Ibft 925 Nm e Carry out pressure testing to maximum work
33. nd tab over the edge of the slot Take care not to damage the Seal during assembly but expect that some slithers of rubber will be produced as the corners of the rubber seals are removed by the assembly operation Tap all around the circumference of the seal to ensure that it is bedded into the groove and that the seal is not protruding above the ram diameter e Slide the Inner Seals into Ram taking care not to dislodge the outer seal the process Ensure the Guided Inner Seal is fitted to the correct ram as shown below Figure 10 BOP Wireline Rams OPS 4611 Rev D in 17 o User Manual IQ Phuel 3 Modular BOP System OIL TOOLS Figure 11 BOP Shear Rams 6 4 4 Re attach to BOP Body e fthe rams were removed from the actuator Section 6 4 2 then slide the ram back onto the actuator and guide bar out of the ram and attach the bar back to the piston housing taking careful note of the orientation of the rams depending on its intended use for the BOP assembly i e if 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 if required to the open port of the actuator and pump or manually wind 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
34. o the balanced piston ref Figure 18 Verify that the equalising valves are moving freely and smoothly Verify that the tie bolt nuts and all other screws are tight Remove external rust or treat using a non toxic rust remover gel or liquid Inspect the condition of quick union sealing surfaces and surface coatings repair replace as necessary e If any of the above are showing signs of wear or damage then strip down to investigate and replace parts or seals as necessary e Re assemble and then pressure test according to Section 7 e Inspect paintwork and repair where necessary 6 2 3 Five Yearly e Recertification by Phuel Oil Tools in accordance with DNV RP E101 OPS 4611 Rev D 15 gt User Manual IQ Phuel 3 Modular BOP System OIL TOOLS 6 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 Wear appropriate personal protective equipment e Do not over exert yourself while using torque wrenches Use appropriate mechanical advantages when available e Ensure that all tools and equipment are in good condition and are suitable for intended use 6 4 Ram Seal Redress Note If rams are required to be removed ensure they can be moved fully forward when the time comes 6 4 1 Access Rams This procedure results in the disconnection of the actuator assembly from the BOP body in or
35. of wear or damage and replace if necessary e Examine the BOP Assembly to make sure that it is good operating order and assembled with the Rams in the correct orientation for the desired operation e Functioning of the Rams may be checked by running both Rams to the closed position 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 or bars to lift the BOP assembly e Care should be taken to completely remove any residual pressure or accumulated pressure existing on Lubricator equipment above the BOP 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 the Job After each job the BOP should be thorough
36. p e Pressurize up to 300 psi low pressure test observe if there are leaks Hold Time 10 min with no leaks e Bleed the pressure to zero e Pressurize up to the MWP in accordance with documentation maintain the pressure for 10 min without leaks e Bleed the pressure to zero e Open upper rams by enabling BCU Upper ram valve to open position 7 2 Post Test Procedure e Disconnect All Hoses Remove Test Cap Drain out test fluid and circulate with water displacing fluid or lubricating oil Re fit the gauge to the Equalising Block if required or re fit the check valve if removed earlier e Remove BOP from Test Stump Grease end connections and fit oiled thread protectors OPS 4611 Rev D 28 bk User Manual IQ Phuel 3 Modular BOP System OIL TOOLS 8 Parts List and Drawings MANUAL ACTUATORS HYDRAULIC ACTUATORS por Kit 2x KIT 4298 HVO 2 p Hydraulic Fittings 1x 1x ee 8 Actuators Redress Kits 1x RDK 4450 HV1 Injection 1x RDK 4328 HVO Body amp Actuators 1X RDK 4450 HV1 Injection 1X RDK 4360 HHO 1x Top amp Bottom Subs see Table 4 1x Top amp Bottom Subs see Table 4 Additional Modules Required 196 4329 HVO Body amp Actuators 192 4450 KIT Injection 192 4330 SS0 Tie Bars 190 4360 HHO Wireline Rams Additional Modules Required 191 4330 SS0 Tie Bars 190 3161 HVO Bank Port End Additional Modules Required
37. part numbers OPS 4611 Rev D 13 Pressure bar 8 8 8 8 8 8 OPS 4611 Rev D User Manual 3 Modular BOP System 3 BOP Operating Envelope Wireline seal S blind slickline TIN JR I TSG MULTI LINE REGION IRRRRRRRR IT TT Shear seattimits _ Temperature C Figure 7 Qualified Operating Envelope User Manual Phuel 3 Modular BOP System OIL TOOLS 6 Maintenance All maintenance to be carried 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 Refer to Section 4 3 1 and Section 4 3 3 for details 6 2 2 Yearly e Visually inspect the BOP for signs of wear or damage e Close the rams with 3 000 psi and hold for 10 minutes with no leaks allowed Open the rams with 3 000 psi and hold for 10 minutes with no leaks allowed If there are leaks then the actuators will need to be dis assembled and the seals replaced e Disconnect the actuators and inspect the rams guides and seals Replace the seals if they are worn or damaged Re assemble Re apply grease t
38. rformed Verified Comments Performed Maintenance By By e Li Ale au Table 3 Maintenance Record OPS 4611 Rev D 26 User Manual Phuel 3 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 7 1 Hydraulic BOP Check the build configuration then adapt the procedure to test using the procedures laid out below for a Dual BOP 7 1 1 Prepare for pressure testing e Check the pressure rating for all test equipment is sufficient to allow testing to be carried out Check replace o ring on the pin part of the quick union connection Ensure valve is placed in an area suitable for pressure testing Fit the valve to the test stump Makeup valve collar on test stump by turning the collar all the way down and then back off 1 4 turn Fit the test hose to the Gauge port on the Equalizing Block Do not fit anything to the Inject port so as to test the check valve Fill valve with test fluid Connect the hydraulic hoses from the BCU to valve to operate the rams e Check all connections hoses that they are secured with safety wire before use e Vent behind the rams by opening and closing all the rams a few times each e On completion of venting the rams fit test cap ensuring the test cap valve is in the open position to allow air to vent and top up the valve with test f
39. s List Manual 6 CSU 0585 3A4 4 CSink Soc Hd Size 1 2 Length tin Table 10 3 Modular Body Parts List Hydraulic Note to aid calculation of make up length the Modular Body is 6 875 High OPS 4611 Rev D 33 User Manual Tapa i 17 Phuel 3 Modular BOP System OIL TOOLS TAG DETAILS STAMP ACTUATOR PHUEL OIL TOOLS SERIAL NUMBER DESCRIPTION PER GP 14 HPART NUMBER SERIAL NUMBER CUSTOMER NUMBER API 16A API 6A PSL3 P U NEANS PA MWP PSI H25 GUIDE BAR TO BE POSITIONED DEPENDING UPON RAM ORIENTATION STAMP ASSEMBLY SEAL DETAIL SERIAL NUMBER d PER QP 14 FIT TAG SEE SEAL DETAIL SERIAL NUMBER PER GP 14 Ben Figure 20 3 Modular Body Manual OPS 4611 Rev D 34 User Manual Phuel 3 Modular BOP System TAG DETAILS STAMP ACTUATOR PHUEL OIL TOOLS SERIAL NUMBER DESCRIPTION PER QP 14 PART NUMBER SERIAL NUMBER CUSTOMER NUMBER NEAN API 16A API 6A PSL3 6 SF lt lt MWP PSI H2S pen p 8 A e e e Be I N we e gt lt NYD o Y UIDE BAR TO BE POSITIONED DEPENDING UPON RAM ORIENTATION STAMP ACTUATOR SERIAL NUMBER PER QP 14 STAMP ASSEMBLY BEAL RETAIL SERIAL NUMBER ir SEE SEAL DETAIL Figure 21 3 Modular Body Hydraulic OPS 4611 Rev D 35 User Manual Phuel 3 Modular BOP System OIL TOOLS 190 4277 480 1 3 MOD PISTON HOUSING 19
40. the hand wheel 20 25 turns to lock in the piston Continue to turn until the hand wheel stops indicating that the piston is now against the back up lock For safety reasons and to reduce the mechanical effort required Phuel recommends that the hydraulic pressure be removed or reduced while closing the mechanical back up This reduces the risk of injury caused by the failure of a seal under hydraulic pressure and decreases the time required to implement the back up feature It is important to remember that the manual lock must be fully withdrawn before the rams can be opened OPS 4611 Rev D 6 User Manual Phuel 3 Modular BOP System OIL TOOLS 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 ps
41. 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 minimum tool string weight must be achieved either by direct weight or the combination of that and additional tension to ensure that the cutting performance is achieved Wire Size No of Wire Minimum Hydraulic Maximum dia wires Type Tool String Pressure needed Wellbore Weight to shear at zero Pressure bore pressure psi 0125 1 Slick line 250 Kg 1060 psi 10 000 psi 0 125 6 Slick line 250 Kg 2120 psi 10 000 psi 0 160 Slick line 250 Kg 1670 psi 10 000 psi Table 2 Shearing performance and limitations Note The shear rams are designed to cut only once The rams must be replaced once they are used to cut wire 5 5 Performance of Ram Guides Testing has been conducted to verify that the wireline rams can centralise t
42. to 100 bar when applied with a hydraulic actuator 5 1 2 Opening the BOP with differential pressure It is not recommended that the BOP should be opened with differential pressure across the rams The pressure should always be equalised first using the equalising valves Even with differential pressure applied across the rams it is possible for the BOP to be opened if the opening pressure is greater than 1400 psi The manual locking feature should therefore be used when the BOP is closed to prevent accidental opening 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 the seals should be changed every year as a minimum Fatigue life has not been defined on the wireline seals due to their less critical function and the fact that these are to be replaced whenever they are closed OPS 4611 Rev D 11 User Manual Phuel Modular BOP System OIL TOOLS on the wire Pre job inspection to verify
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