FKDQ800-7

Control System for Surface Hydraulic BOP Stacks

Operation Instructions
(Read it before using the unit)

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E-mail:[email protected] [email protected]
Sales Tel:+86-20-84738727 84737193
Technology Consultation Tel:+86-20-84731961-206
After-Sale Service Tel:+86-20-34876392
Fax:+86-20-34735730

Main Product Series

Guangzhou Dongsu Machinery Manufacture Co. Ltd

Guangzhou Petroleum Machinery Factory
Address: 117 Daxiangchong Road, Shawan, Panyu District, Guangzhou
Http://www.gzdongsu .cn Emeil: sales @gzdongsu.cn
Tel: 020-84731961 84737193 34735730
Fax: 020-84731766 Post code: 511483
FOREWORD
The OPERATION INSTRUCTIONS issued by GGPMF is rather than
quality warranty. We will have the right to explain the misprint and
improvement of the products timely and add it to the new version of
operation instructions.

SAFETY INSTRUCTION
OF CONTROL SYSTEM FOR SURFACE MOUNTED BOP STACK
1

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Operation Instructions
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Preface 1 3 Operational Prinicple and Main Components 15

1 Types and Functions and Options for Control System for Surface Mounted 2 3.1 Operational Prinicple 15
BOP Stacks 3.1.1 Design features of the Surface BOP Control System 15
1.1 Types 2 3.1.2 The pump group inflates the accumulators and store energy in them 15
1.2 Components and Functions of Surface Mounted BOP Control System 2 3.1.2.1 Hydropneumatic Principle of Surface BOP Control System (Fig.2) 15
1.2.1 Remote Control Panel (see attached Fig.1) 2 3.1.2.2 Distribution of Hydraulic Oil Output from the Accumulators 18
1.2.2 Driller's Panel ( Fig.1a) 2 3.1.2.3 Hydraulic Pressure Transduction 18
1.2.3 Control cable for Remote contror 2 3.1.2.4 Output Pressure Adjustment of Pneumatic Regulator 18
1.2.4 High pressure hose 6 3.1.2.5 Pneumatic and Manual Control of 3-Position 4-Way Valve 18
1.3 Configurations and Main Specifications (Table 1) 6 3.1.2.6 Position Indicator 18
1.4 Options for Surface BOP Control System 6 3.2 Main Components 19
1.5 Technical Interfacing of Surface BOP Control System 6 3.2.1 Accumulator 19
2. Installation, Connection, Trial Running. Trouble Shooting. Daily Checking 6 3.2.2 Triplex Pump 21
and Maintenance 3.2.3 Pneumatic Pump 23
2.1 Field Installation and Connection 6 3.2.4 3-Position 4-Way Valve 24
2.1.1 Position of the Control System 6 3.2.5 Regulator 26
2.1.2 Hydraulic Pipes Connection (Fig.1) 9 3.2.6 2-Position 4-Way Valve 29
2.1.3 Connection of Back-Up Hydraulic Pressure Source 9 3.2.7 Relief Valve 33
2.1.4 Hose Bundle Connection for Remote Control 9 3.2.8 Hydro pneumatic Switch 34
2.1.5 Electric Power Connection and Compressed Air Connection 9 3.2.9 Motor Start-Stop Control 35
2.2 Trial Running (Fig.1) 9
2.2.1 Preparation for Trial Running (May Be Performed in Logistic Site) 9
2.2.1.1 Fill Hydraulic Oil in the Oil Tank 9
2.2.1.2 Fill lubricating oil in the triplex Pump and the Chain Box 9
2.2.1.3 Fill Oil in the Oil Atomizers on the Remote Control Panel and the Driller's Panel 10
2.2.1.4 Check Nitrogen Pressure in Accumulators 10
2.2.1.5 Check Direction of Motor Rotation 10
2.2.1.6 Air Venting From the Pipe of Remote Control Panel 10
2.2.2 Items of Trial Running 10
2.2.2.1 Charging Time of Accumulator Group 10
2.2.2.2 Automatic Pump Control Test 10
2.2.2.3 Automatic Control Test of Pneumatic Pump 11
2.2.2.4 Adjustment of Manifold Pressure (See attached Fig.2) 11
2.2.2.5 Adjustment of Annular Pressure Manifold 11
2.2.2.6 Oil Drips Adjustment of The Oil Atomizers 11
2.3 Test of BOP Control 11
2.3.1 To Control from The Driller's Panel 12
2.3.2 Seal Test under Nominal Pressure 12
2.4 Confirmation of Normal Working of the Remote Control Panel 12
2.5 Normal Lowering of Accumulator Pressure on Remote Control Panel 12
2.6 Indication Error Between Pressure Gauge and Secondary Digital Meter 12
2.7 Usual Failures and Recovery During Trial Running and Test of BOP Control System 13
2.8 Daily Checking and Maintenance 14
2.9 To Use Back-Up Pressure Source 14
 Operation Instructions Operation Instructions
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1. Types and Functions and Options for Control System for Surface
Mounted BOP Stacks
1.1 T ypes
FK

P re f a c e Design serial number of product, e.g. A, B,...

Amount of controlled items, e.g. 2, 3...
Nominal total volume of accumulators (L), e.g. 40~1440
Way of remote control: Q Pneumatic control;
DQElectropneumatic control; DY Electro-hydraulic control;
No remote control blank.
The control system for surface mounted BOP
Control system for surface mounted BOP stacks
(blowout preventer) stacks is special Example: FKDQ800-7 ---- the control system for surface mounted BOP stacks, with pneumatic remote control,

equipment, which is used to control BOP, 800 L in nominal total volume of accumulators, 7 objects able to be controlled.

hydraulic chock and kill system, and 1.2 C omponents and Functions of Surface Mounted BOP Control System
A BOP control system for well drilling is generally composed of:
indispensable equipment for blowout
(a)Remote control panel
prevention during drilling or well servicing (b)Driller's panel
(c)Control cable for remote control
in petroleum and natural gas industry. Refer
(d)High pressure hose
to the relevant provisions in the Operation
1.2.1 R emote Control Panel (see Fig.1)
Instruction in order to select a suitable type of
The hydraulic control system of a remote control panel is composed of the following items: heavy skid, oil reservior,
control system correctly, and install, connect, accumulator group, electric pump (electric triplex pump), pneumatic pump, pressure controller, pressure transmitter, relief valve,
and pressure regulator, solenoid (electromagnetic) valve, proximity switch, charger, battery, multiple adapter as well as change
maintain it properly. valve, etc. The electric triplex pump group charges the accumulators with hydraulic oil so that required hydraulic pressure is stored.
When the preset value is reached, the pump group stops automatically. When the blowout preventer is to be opened or closed, the
operator may remotely control the change valve to have the hydraulic oil fed into the hydraulic chamber of thus to open or close BOP.
When the hydraulic pressure in the remote control panel lowers to a preset value, the pump group will automatically activate and
maintain the required hydraulic pressure in the accumulators so that the blowout preventer may be closed in case of an emergency.
The remote control panel is equipped with a container made of sheet steel for protection. The user may choose from different houses
available basing on the environment where BOP is used to ensure the effective function of the remote control panel.

1.2.2 D riller's panel (see Fig.1a)

It is composed of explosion proof box, intelligent digital meter, button, lamp and multiple (54 pins) adapter, buzzer etc. The
driller's panel is installed on the driller panel for convenient operation.

1.2.3 Control cable for Remote Control

The control cable for remote control is composed of a 54 cores multiple armored cable with 54 pins multiple explosion proof
adapters at both ends , which are used to connected he driller's panel to the remote control panel. The functions of control cable are:
to transmit electrical signals of hydraulic pressure of the remote control panel to the driller's panel so that hydraulic pressure can be
read on the driller's panel; to transmit the control signal to adjust ( increase or decrease) the annular pressure; to transmit the control
panel to control the solenoid valves and actuate the air cylinders, and finally control the BOP and hydraulic valves; to transmit the
proximity switch signals so that the BOP conditions (open or close) are indicated on the driller's panel; to display the alarm signals
on the driller's panel.

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1.2.4 High pressure hose

The main function of the high pressure hose is to deliver hydraulic oil from the remote control panel to the hydraulic chambers
of BOP to open or close the blowout preventer and choke or kill valves, and to deliver oil from the pressure relief chambers of BOP
Buzzer or choke and kill valves hydraulic chambers back to the oil reservior on the remote control panel. It has the performance of easy
installation and convenient transportation.

1.3 Configurations and Main Specifications

Type of Type of Effective Useful Electric Total Total air Motor Type of Size Way of

oil liquid v displacement capacity accumulator

complete remote pump consumption driller's (mm)
reservoir of pneumatic (Kw) arrangement
Pilot lamp control control volume
olume of
displacement pump of pneumatic
accumulator panel
(GAL) (L/min)
system panel (L/min) pump
(GAL)

(m 3/min)
Figure shower
FKDQ YCDQ 423 105 3 2 3 1 SZD1-1-7
5900 2150 At both
2300
800-7 800-7 sides

Note: Usable liquid volume of a accumulator bank is the volume of liquid discharged from the accumulator bank when pressure of
nitrogen charge is 7MPa(1000 PSI) and accumulator pressure reduces from 21MPa(3000 PSI) to 8.4MPa(1200 PSI).

1.4 O ptions for Surface BOP Control System

Button
To control BOP reliably and safely as well as prevent uncontrollable blowout, petroleum & natural gas industry standards
SY/T5053.2-2001 and API SPEC.16D should be followed when you choose and purchase a suitable product. Factors to be
considered should at least be:
a.Relationship between liquid volume required for closing BOP stacks (including hydraulic valve) and liquid volume available
from the control system;
b.Relationship between liquid volume used to close an annular BOP and capacity of pump group;
c.Environmental adaptation;
d.Special requirements by offshore drilling platform.

1.5 Technical Interfacing of Surface BOP Control System

Hydraulic pressure Outlet of ID of air inlet pipe of

Type outlet of remote connecting
control panel pipe remote control panel

FKDQ800-7 FNPT 1" FNPT 1"

2. Installation, Connection, Trial Running. Trouble Shooting.

Daily Checking and Maintenance
Explosion plug bourd
High skill is required for installation, connection and trial running of the control system, which shall be undertaken by
professional technicians.

2.1 Field Installation and Connection

2.1.1 Position of the Control System

Position of the control system shall conform to relevant specifications on well drilling operation control. The driller's control
panel should be installed near the driller's post so that he can operate BOP conveniently. The remote control panel should be placed
on the ground and with a suitable safety distance from the wellhead so that BOP can be closed from the remote control panel when
the workers retreat from the wellhead in case of an emergency. The remote control panel should be placed on solid ground and soled
horizontal so that the sheet steel house can be opened and closed freely.

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2.2.1.3 Fill Oil in the Oil Atomizers on the Remote Control Panel

Hydraulic hoses connection should be started from BOP stacks. Screw out the oil-filling plug of the atomizer. Pour in lubricator of the same type as the electric pump. Then reinstall and

On the back of the remote control panel, conspicuous marks O (open) and C (close) is made at each hydraulic liquid outlet. tighten the oil-filling plug.

When hydraulic hoses are connected, marks Annular , Pipe Ram , etc. on the nameplate of the valves as well as the marks
2.2.1.4 Check Nitrogen Pressure in Accumulators
O and C for pipe outlets should be followed to avoid accidents.
Remove the upper guard cap of the accumulator. Mount the inflator a tool supplied with the control system (the hand wheel of the
charger valve must be turned anti-clockwise to the stop)-- in the position of the upper guard cap. After tightening the inflator, turn the
2.1.3 Connection of Back-Up Hydraulic Pressure Source
hand wheel of charger valve clockwise to open the inflation check valve on the top of the accumulator bladder so that nitrogen pressure
As specified in industrial standard related, the remote control panel shall be equipped with an inlet for back-up hydraulic in the bladder is sensed and displayed by the pressure gauge of the inflator. Nitrogen pressure in the bladder should normally be 6.3~7.7
pressure source. When required conditions are present and the user requires, this inlet should be connected for use in case that the Mpa (900~1100 PSI)(the higher nitrogen pressure, the larger liquid volume available from the accumulator).
remote control panel fails to supply sufficient hydraulic pressure while BOP stacks has to be closed urgently. The inlet for back-up Detailed information about the accumulator, please read the special OPERATION INSTRUCTION FOR THE ACCUMULATOR.
pressure source is located on the back of oil reservoir , with a conspicuous mark of BACKUP PRESSURE SOURCE INLET .
2.2.1.5 Check Direction of Motor Rotation
2.1.4 Control cable Connection for Remote Control The motor shall rotate in the direction indicated by the arrow mark on the chain guard, otherwise effect of splash lubrication in

The control cable with explosion proof adapters at both ends is used to transmit control and pressure signals. The control cable the crankcase is compromised, and thus the bearing bush of connecting rod will be burnt.
should be laid straight and smooth and enters the remote control panel through the dedicated hole so as not to hamper the action of
the house door. Twisting of control cable should be avoided. The multiple adapters at both ends have the same pins so it can be 2.2.1.6 Air Venting From the Pipe of Remote Control Panel
connected freely.
Air in the pipe affects normal operation of pump group. Before the accumulators are pressurized, air in oil suction pipe and the
pump must be completely vented. Air venting should be carried out as follows:
2.1.5 Electric Power Connection and Compressed air Connection 1.Open the ball valve in the oil suction pipe of the electric pump (No. 37). Open the ball valve (No.2) in the oil suction pipe of

The remote control panel requires power of 690VAC /60Hz three phase and 220VAC single phase for its operation. For the pneumatic pump;
690V/60Hz power, three-core cable of 10mm 2 or larger should be used. The cable should be connected to the explosion-proof circuit 2.Turn the 2-position 4-way valve (No.20) to "Open" position;
breaker on the inner wall face of the house. After checking of rotation direction of the motor, the cover of terminal box and the cable 3.Open the stop valve (No.22);
sleeve should be tightened so as to ensure explosion proof. For 220V power, 2-core cable of 2.5mm 2 or larger should be used and 4.Check that the stop valve (No.40) between the accumulators and the pipe are open;
connected in the same way. Earthed conductors shall not be smaller than 6mm 2. 5.Open the stop valve (No.3) of air source so as to start the pneumatic pump first;
The remote control panel needs compressed dry air for its operation. Compressed air hose should be lead in through the dedicated 6.Start the electric pump by turning main switch of magnetic starter (No.30) to "Automatic" position and run the pump in no-
hose of the house. ID 25mm air source pipe for remote control panel is required. After the hose is slid over the nipple, it should be
load condition for 3 minutes.
tightened with pipe band.
The normal operation pressure shall not be less than 0.53MPa(75 PSI).
2.2.2 Items of Trial Running

2.2 Trial Running (Fig.2) Trial running shall be carried out only after the relevant hydraulic hose and pneumatic control pipe are correctly connected and
the preparation work is finished.
2.2.1 Preparation for Trial Running (May Be Performed in Logistic Site)

2.2.1.1 Fill Hydraulic Oil in the Oil Tank 2.2.2.1 Charging Time of Accumulator Group

Hydraulic oil in the oil tank shall be clean. Depending on the ambient temperature, the following types of hydraulic oil should After the pipe venting as mentioned in 2.2.1.6, close air source stop valve (3) and stop the pneumatic pump (No.28), and close
be used: the release stop valve (No.22) so that the electric pump charges pressure to the accumulators. For charging the accumulators to
21MPa, an inflation time with an error of 7% from the value recorded in ex-work test report is still normal (because of the
tolerance in nitrogen pressure charged).
Hydraulic oil of different brands or different types of the same brand shall not be mixed.
2.2.2.2 Automatic Pump Control Test

2.2.1.2 Fill lubricatin in the Electric Pump and the Chain Box With master switch of the magnetic starter (No.30) turned to "Automatic" position, the electric pump should start
automatically when the accumulator pressure lowers to 18.9MPa, and should stop automatically when the accumulator pressure
Adequate lubricant is filled into the crankcase of the electric pump and the chain box for safe operation. However, it is
reaches 20.3~21MPa. Slowly open the stop valve (No.22), to lower the accumulator pressure to 18.9MPa. The electric pump should
necessary to change the lubricant according to the ambient environment. For ambient temperatures above 0 , 32HL hydraulic
automatically start.
oil may be recommended. For ambient temperatures below 0 , 32HV low temperature anti-wear hydraulic oil may be used.
However, higher quality hydraulic oil can be used.
The oil filling port is located in the end of the pump's crankcase. To fill oil in, just pull out the filling port cover (serving also as
vent cover) and fill in oil until the oil level reaches the mark on the dipstick (attached to the filling port cover). The chain box filling
port is on the top of the chain box. The inner hexagon plug can be screwed out with the attached tool delivered with the complete unit.

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2.2.2.3 Automatic Control Test of Pneumatic Pump 2.3.1 To Control from The Driller's Control Panel

When the accumulator pressure rises to 20.3~21MPa, hydropneumatic switch (No.8) should close automatically, the From the Fig. 2, you can see that to operate the buttons on the driller's panel can energize or de-energize the solenoid air
pneumatic pump should stop. When the accumulator pressure lowers to 18 Mpa (2556 PSI), the hydropneumatic switch should open valves, and then proceed to actuate the air cylinder; finally, the rotary valves are operated. This operation must be done with both
automatically and the pneumatic pump should stop automatically. It has been so adjusted in the factory. If readjustment is required,
hands (this is to avoid unintended activation). Push and hold the red button marked “PUSH & AND HOLD TO OPERATE” with
use the adjusting rod ( attached tool ) to adjust the round nut on the hydropneumatic switch. When the nut is turned in the direction for
your left hand, and then push function buttons to control the BOP or hydraulic valves with your right hand.
further compressing the spring, the closing pressure rises, and vice versa. After pressure adjusting, the hold-down nut should be
Note that to adjust the annular pressure is not needed two hand operation.
tightened. The pressure to open the hydropneumatic switch depends on the characteristics of the spring in the hydropneumatic
To test BOP for its behavior, all items to be controlled shall be tested one by one to see if they are the real items
switch and is un-adjustable.
corresponding to the aims of control, their motions are as required and the hydraulic piping is not leakage. In case of
inconformity, remove the hydraulic pressure in the system, find out the cause of trouble then retest.
2.2.2.4 Adjustment of Manifold Pressure (See attached Fig.3) To protect the stripper of the annular BOP, hydraulic pressure in the control oil loop for the annular BOP may be lowered a
little or run in a drill pipe of larger diameter may be used.
The manifold pressure (the hydraulic piping for controlling ram BOP and hydraulic valve) is adjusted through a 2-position 4-
After all items to be controlled are identified as aimed, two tests of opening and closing motions should be made so as to
way valve (No.20). When this valve is open, pressure is charged from the accumulators to the manifold. When this valve is closed,
vent all air in the hydraulic control cylinder and hydraulic piping.
the outlet of the regulator (No.15) is connected with the manifold. In normal operation, the 2-position 4-way rotary valve is in closed
During tests, " delay time of control " should be taken (with 3 people working cooperatively). To do this, operate the change valve
position and the manifold pressure is set by the relief valve . When turn the handwheel of the regulator clockwise and watch the
manifold pressure gauge, you can see the manifold pressure rising and the output pressure increase from the regulator is stepwise. on the driller's control panel. When the 3-position 4-way valve is in position, record the time for the 3-position 4-way valve on

So when the manifold pressure rises to about 10.5MPa(1500 PSI), it is necessary to open the relief valve (No.22) a little then close it the remote control panel to finish direction. This time should not be longer than 0.5 second.

immediately so that the outlet pressure of the relief valve slightly lowers then increases again. The re-increased pressure is the real
outlet pressure of the relief valve. Should the pressure be too high, the hand wheel has to be turned anti-clockwise. Usually after one
or two adjusting operations, the suitable output pressure of the valve can be made. After adjustment, engage the locking handle. 2.3.2 Seal Test under Nominal Pressure

Turn the 2-position 4-way valve (No.20) on the remote control panel to "Open" position so that manifold pressure rises to
2.2.2.5 Adjustment of Annular Pressure Manifold nominal value. Make seal test on each item controlled. In case that accumulator pressure is not high enough but does not lower to the
value at which the electric pump starts charging, open the bypass valve (No.3a) of compressed air source for the pneumatic pump for
The manifold pressure of the annular BOP is set by the manual-pneumatic regulator (No.21). In the normal situation,
pressurizing. If any seal test is not successful on any item controlled, the cause should be identified and removed or the item should
pneumatic control function should be used. As the back-up, manual pressure adjustment may be used when pneumatic control
be replaced in time. After test, turn the 2-position 4-way valve to "Close" position, close the bypass valve so that the remote control
completely fails. Adjusting of output pressure of the manual regulator is performed separately on the remote control panel and the
panel is again in normal working condition.
driller's control panel:
a.To carry out adjustment on remote control panel: Set the 3-way air tap (No.19) in position of "Remote Control Panel" by
2.4 Confirmation of Normal Working of the Remote Control Panel
referencing to the arrow marked on it. Turn he hand wheel of the air pressure regulator (No.18, Fig.1) to adjust the outlet pressure of
the relief valve to 10.5MPa(1500 PSI). Lock the hand wheel by tightening the locknut on it. After tests of BOP behavior and seal under nominal pressure, lower the accumulator pressure to 21MPa(3000 PSI). When the
b. To carry out adjustment on driller's control panel: Set the 3-way air tap (No.19) in position of " Driller's control panel' by pump group stops working, unscrew the screw plugs on either sides of the oil tank. Under illumination, check all visible oil return
referencing to the arrow mark on it. Push the red " INC. Button " on the driller's control panel to increase the annular pressure, and ports in the oil tank. There should be no dripping leakage from the oil return ports (except the remaining oil drips in the oil returning
push the green " "DEC. Button " to decrease the annular pressure. Watch the intelligent meter of " Annular Pressure " and adjust the chamber of the hydraulic valves).
outlet pressure of the regulator to the same reading of 10.5MPa (1500PSI). Please note that push (click) the button and remove hand
immediately to prevent the pressure from too fast increase or decrease. 2.5 Normal Lowering of Accumulator Pressure on Remote Control Panel

After accumulator pressure reaches 21MPa (3000 PSI), gradually lowering of this pressure is a normal phenomenon if no
leakage occurs. The rate of pressure lowering is related to the charging rate of the pump group. The higher charging rate, the more
heat is generated in the nitrogen inflated in the accumulators due to compression. When the accumulators are pressurized to 21MPa,
2.2.2.6 Oil Drips Adjustment of The Oil Atomizers
(3000 PSI) the pump group stops, and the temperature of nitrogen in the accumulators will gradually lower, volume of the nitrogen
When the pneumatic pump is in operation, oil drips supplied by the oil atomizer (No.5) as visible from its upper part should be will gradually become smaller. So the accumulator pressure will lower gradually.
checked. Number of drips per minute should be 5~8. In case of the contrary, this per-minute number of drips should be adjusted by
the small needle valve on the upper part of the oil atomizer so that sufficient oil mist is supplied to the pneumatic cylinder of the 2.6 Indication Error Between Pressure Gauge and Intelligent Digital Meter
pneumatic pump and the directional mechanism for lubrication.
The deviation between ccumulator Pressure Manifold Pressure , Annular Pressure and Air Source Pressure
on the remote control panel and hydraulic contact gauges of direct liquid contact type is generally not greater than 1.5%. What the
corresponding pressure gauges on the driller's control panel indicate are pressure signals output from the pressure transmitter.
2.3 Test of BOP Control Hence an indication error of 1 is possible. In total, an accumulated error not greater than 3% resulted from the two should be
acceptable.
Before testing the closing behavior of BOP, to avoid trouble, check that no foreign matters that can hamper the closing of BOP
are present.

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2.7 Usual Failures and Recovery During Trial Running and Test of BOP Control System 2.8 Daily Checking and Maintenance

Possible Causes Failure recovery Interval Items

2.7.1 The motor vibrates under load 1.Air in the electric pump and pipe is not 1.Vent all air as required in 2.2.1.6. Once for a 1.Check if "Accumulator Pressure", "Manifold Pressure" , "Annular Pressure" and " Air Source
totally vent. 2.Clean the filter. If it is blocked again soon work shift Pressure " on the remote control panel and driller's control panel are suitable.
2.Suction filter is partly blocked. after cleaning, replace the hydraulic oil. 2.Check if electric power supply and compressed air supply are OK.
3.Oil level is below the suction port. 3.Complement hydraulic oil. 3.Check if all control valves are in correct position.
4.Check if the seals on connections in hydraulic control pipe are good.
5.Check if there is sufficient oil in the oil tank.

2.7.2 During test of opening and closing 1.Dirt sticks on the exposed part of the piston 1.Check and remove the dirt.
the 3-position 4-way valve by operating rod. 2.Stop operation, turn the valve handle by hand Once a week 1.Lower the accumulator pressure on remote control panel to zero. Check if the electric pump and the
the solenoid valves on the driller's 2.The driving cylinder of the 3-position 4-way and move the piston to and fro for two times. pneumatic pump work normally.
valve has been in stillness for a long time, so 2.Check if the charging process of the accumulator group is OK.
the sealing elements give a high resistance. 3.Reduce the pressure of the manual pressure regulator and the pneumatic pressure regulator to zero, and
then readjust them to give suitable pressure.

2.7.3 a.Charging time of accumulators a.A suction valve of an accumulator group does a.Check for un-opened valve and open it.
is too short. not open. b.Discharge the hydraulic oil then inflates
b.Charging time of accumulator is too b.Nitrogen pressure is too low. accumulators with nitrogen.
long.
Once a month 1.Close the compressed air source; clean the air filter and the oil atomizer. Add lubricat in the oil
atomizer and adjust for proper dripping rate.
2.Lower the accumulator pressure to zero, check for nitrogen pressure of the accumulators. Add nitrogen
or replace rubber bladder (if damaged) as necessary.
3.Clean the screen of the high pressure filter (No.11).
2.7.4 During being released, high Some rubber bladders in accumulators Close the stop valve of the accumulator and
connect the release stop valve to the oil 4.Clean the screens of the inlet low pressure filters of the electric pump and pneumatic pump.
pressure drops quickly and low pressure are broken so nitrogen is mixed with
reservoir with the attached hose and then open 5.Check the lubricating oil level in the crankcase of the electric pump, replenish with lubricating if
falls slowly with large volume of gas the hydraulic oil.
the release stop valve to release the pressure of necessary. Replenish the chain box with lubricating .
entering oil tank and oil becoming milky the accumulator. Discharge the oil in the.
6.Pressurize the system after the procedure described in 2.2.1.6 "Air venting from the pipe of remote
white.
Check and replace the broken bladder(s) . control panel"and reset the remote control panel to normal working condition.

2.7.5 In the field, when the control 1.Leakage on the hydraulic hose connected to 1.Check along the hydraulic pipe and find out Once a year 1.Drain out all hydraulic oil from the tank. Clean the tank, the filter and replace hydraulic oil.
s y s t e m i s c o n n e c t e d t o a B O P, BOP. the leakage. Depressurize the pipe and 2.Drain out all lubricats from the crankcase of the electric pump. Clean the crankcase. Replace lubricator.
accumulator pressure lowers 2.A stop valve of the accumulator is not closed remove the leakage. 3.Follow the procedure of air venting from the piping of remote control panel (2.2.1.6) to vent the air in
continuously. completely. 2.Close the stop valve one by one the piing. Then inflate the accumulators. Turn the electric main switch to "Manual" position and test the
3.Outward or inward leakage of hydraulic (No.22a~22b). relief valve for its behavior of opening and closing. If the condition of overflowing is OK, turn the
chamber of BOP (hydraulic oil flows to the 3.Adjust the accumulator pressure and the electric main switch to "Automatic" position and reset the remote control panel to normal working
relieving chamber through the cylinder outlet pressure of the regulator to the condition.
p i s t o n a t t h e p i s t o n ) . highest normal pressure.Set the 3-position
4-way Valve in open or close
position.Remove the screw plugs on both sides of the oil tank and check the oil return ports of the valves. If so, check the corresponding valve
(see chapter 3 of these operation Instruction). If oil flows out from the return port for the 3-position 4-way valve, it is necessary to find out 2.9 To Use Back-Up Pressure Source
whether the leakage is from the inside of the hydraulic chamber of BOP. The method is to isolate the oil return pipe of the leakage rotary valve
from the remote control panel. After isolation, if the oil flow from the return port for the valve in the tank becomes smaller, leakage from BOP When power failure, failure of compressed air supply or zero accumulator pressure occurs and BOPs have to be closed
is meant. If the valve is considered leakage, it should be disassembled for check. Replace seals if damaged. If a component is damaged but can
not be repaired in the field, replace the whole valve.
emergently, back-up power source shall be used.
Such back-up power air source may be a pressurized accumulator group or a group of cylinders filled with high pressure
nitrogen. Before the stop valve (No.40Y) for the back pressure source is opened, the stop valve (No.40) for the accumulator group
on the remote control panel must be closed first lest the accumulators absorb the backup pressure energy.

13 14
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3. Operational Principle of Main Components

3.1 Operational Principle

3.1.1 Design features of the Surface BOP Control System

Charging with double pump groups: Electric, pneumatic
Automatic stopping of pump group at upper limit of pressurizing: controlled by electronic pressure controller
Automatic starting of pump group at lower limit of pressurizing: controlled by electronic pressure controller
Starting of pneumatic pump at hydraulic pressure exceeding upper limit: Compressed air by-pass valve
Safety protection of pump group: Relief valve
Independent trouble shooting of accumulators: High Pressure Ball valve
Visible Trouble on valve: Open and independent loop
Two independently adjustable hydraulic output pressures: Annular control pressure, manifold control pressure
Choosing between two manifold pressures: 2-position 4-way valve
Annular pressure controlled in two positions: realization by air pressure regulator and air cock
Back-up pressure for pneumatic pressure regulator: Small air bottle
Independent control of individual BOP: realization by 3-position 4-way valves
Control of BOP from different locations: Control by driller's , panel, and remote control
Compatibility among the control made from different locations: control from driller's control panel and auxiliary panel is
pneumatic pilot remote control driven by pneumatic cylinder; control from the remote control panel is direct manual control.
Multi-location indication of pressures in remote control panel: Electronic Pressure transmitter, intelligent digital meter.
Connection of back-up pressure: stop valve of OD25mm
Prevention from shear rams: Position limiting cover, position-limiting housing
Prevention of mistaken operation from driller's control panel: Double controls by the master control button and function button.

3.1.2 The pump group inflates the accumulators and store energy in them

Turn the main switch of the magnetic starter to " Automatic " position, when the accumulator pressure is below 18.9MPa(2684
PSI), one of electric pumps starts. Oil is sucked in through low pressure ball valve and low pressure filter, and is fed to the
accumulators via check valve and the high pressure ball valves. The oil with the pressures higher than the nitrogen compresses the
nitrogen-inflated bladders and so the oil can be stored in the accumulators. When oil pressure rises to 21MPa(3000 PSI), the
electronic pressure controller makes the magnetic starter de-energize and the motor stop working. When accumulator pressure
lowers to 18.9MPa(2684 PSI), the pressure controller makes the magnetic starter energize and the motor starts, and charges pressure
to the accumulators. A relief valve (No.26) is installed in the output pipe of the electric pump. When the pressure controller fails, the
relief valve will open and release excessive pressure to protect the electric pump.
With the remote control panel in normal working condition, the pump group is in oil pressure charging condition or stand-by
condition to maintain required hydraulic pressure on the remote control panel.

3.1.2.1 Hydropneumatic Principle of Surface BOP Control System (Fig.3)

15 16
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F i g . 4 3.1.2.2 Distribution of Hydraulic Oil Output from the Accumulators

After flowing through stop valves (No.40a~No.40d), stop valve (No.40) and high-pressure filter (No.11), pressurized
hydraulic oil from the accumulators is distributed in 3 passages:
Oil in the first passage: after pressure reducing (normal value is 10.5 MPa)(15000 PSI) by manual regulator (No.15), enters the
manifold via the 2-position 4-way valve (No.20), then is distributed to the 3-position 4-way valves (No.10b~10g) for controlling
ram BOP and hydraulic valves.
Oil in the second passage: flows to the 2-position 4-way valve (No.20), and if necessary, is fed to the manifold after diverted by
the valve.
Oil in the third passage: flows to manual-pneumatic regulator (No.21), then to 3-position 4-way valve (No.40a) for controlling
the annular BOP after reducing pressure by the same valve.

3.1.2.3 Hydraulic Pressure Transduction

The hydraulic pressure of accumulator, manifold, annular, and air source are transmitted into 4 to 20mA electric signal, which
can display on the driller's panel by intelligent digital meter.

3.1.2.4 Output Pressure Adjustment of Pneumatic Regulator

Output pressure of the manual-pneumatic regulator is adjusted from two locations:

Adjust from the remote control panel. So doing is for emergent backup. Compressed air supply comes from the compressed air
supply pipe (No.4) on the remote control panel, and is fed to small air bottle (No.43) and air pressure regulator (No.18) via stop
valve (No.3), air filter (No.6) and check valve (No.44). Then, air from the regulator (No.18) enters the air cock (No.19). When the
air cock is opened to the remote control panel, adjust the outlet pressure of the air regulator to the normal value (10.5MPa)(1500 PSI).
Then lock the hand wheel of the air pressure regulator.
Adjusting from driller's panel is the conventional operation. First set the air cock to the driller's panel position. When the INC.
button is pushed, the 2 position 3 way valve No.68 (NC) is energized, and the air goes into the air cylinder of the manual-
pneumatic regulator to increase the annular pressure. When the annular pressure is needed to be decreased, push the DEC. button,
and the vent 2 position 3 way valve No.68 (NC) is energized, and the air in the air cylinder of manual-pneumatic regulator is
vented to decrease the annular pressure.

3.1.2.5 Pneumatic and Manual Control of 3-Position 4-Way Valve

Simultaneously operate the PUSH & HOLD TO OPERATE button and red close button or green open button on the driller's
control panel. Compressed air will be fed into the 3 pneumatic cylinder (No.9) via air supply connecting pipe (No.4), air filter
(No.5), 2 position 5 way solenoid valve (No.66) (NC), 3-position 5-way solenoid valve (No.67).
When it is necessary to directly control BOP from the remote control panel, just directly operate the handle of 3-position 4-way
valve (No.10) by hand. Because in the normal condition, ports A and B of the 3-position 5-way solenoid valve (No.75) are open to
the atmosphere, the pneumatic cylinder will not hold pressure, which will block the manual control.

3.1.2.6 Position Indication

Real-time display of BOP condition is a big advantage compared to traditional pneumatic control BOP control system. When
the 3 position 4 way valve reaches OPEN or CLOSE position, the proximity switch is energized and the correspondent lamp on the
driller's panel is illuminated.

17 18
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3.2 Main Components Fig.5 Accumulator

3.2.1 Accumulator

3.2.1.1 20pcs 11gal accumulator is used for FKDQ800-7 BOP control system. Its type and 26.Valve cap
technical specifications is as follows: 24.Gasket

Maker: Tianren Pressure Vessel Factory, Chengdu 25.Retaining ring

Type: NVQB-11GAL/3000-L 23.Infating valve 20."0"ring
Ove rall dimensions: ö2 29 1705
22.Nut 12.Supporting ring
Weight: 120kg
Design pressure: 3000PSI 21.Clamping ring nut 19.Supporting ring

Nominal volume: 11GAL 9.Retaining ring 13.Rubber ring

Working fluid: Nitrogen, petroleum base hydraulic oil
10."0"ring
Precharged nitrogen pressure; 7 0.7 Mpa (100 100 PSI)
11.Retaining ring
Connection: NPT2
Seal test: 4500PSI
17.Shell
Mode of installation: Vertical
Construction: B (Large opening in the upper part) 18.Rubber bladder
Working temperature: -10~70 C
Threads on charge valve: M14 1.5

3.2.1.2 Construction:As shown in Fig.5

3.2.1.3 Principle of Operation

As may be seen from the construction drawing, the accumulator is composed of rubber bladder, body, charge valve, suction
valve, etc. The rubber bladder is charged with nitrogen through the upper charge valve. Thus the rubber bladder is expanded, presses
against the body. Finally the bladder is elongated and the suction valve is pressed down thus the bladder is protected and prevented
from expanding out of the body. Hydraulic oil of higher pressure than that of the nitrogen enters the accumulator from the bottom of
the accumulator and pushes the suction valve open. Oil pressure inside the body increases with the quantity of oil charged in the
accumulator. So the bladder is compressed and becomes smaller. The more oil is charged in the accumulator, the higher pressure in
the accumulator and smaller nitrogen volume will be, until the upper pressure limit is reached. In this way, energy is stored in the
accumulator. When the hydraulic oil is discharged via the oil discharging port in the bottom, pressure in the accumulator lowers
accordingly, and the nitrogen expands and forces out more oil from the accumulator. When the pressure lowers to the pre-charged
nitrogen pressure, all hydraulic oil charged in will be discharged.
Details on accumulator please read the special Operation Manual for Bladder Accumulator.

16.Valve
15.Spring 12.Supporting ring

14.Shell 9.Retaining ring

10."0"ring
11.Retaining ring
7.Nut
8.Clamping ring
6.Piston
4.Bulkhead
3.Split pin
5.Gasket
1.Nut

2.Gasket

19 20
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3.2.1.4 Features Fig.6 Triplex Pump QB21-62

B type accumulator has a large opening in its upper. To replace rubber bladder, it is necessary just to unscrew the upper cover.

3.2.1.5 Role Played in the Control System 10

1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
The accumulator stack stores energy for opening and closing BOPs. If the accumulator bank is charged to a pressure of
21MPa(3000 PSI), BOP stacks can be quickly and reliably closed with the hydraulic energy stored in the accumulator group even in
case of failures of power, compressed air source and pump starting. Under the condition of normal working of the control system,
pressure energy stored in the accumulator group also plays a role of pressure stabilizing and compensation for leakage from the
system. Besides, because energy can be stored, pump group of smaller capacity may be installed, so economics is better while
reliability of the system is enhanced.

3.2.2 Triplex Pump

3.2.2.1 Technical Specifications

Displace Working Connecting threads Motor

Speed weight
Type ment pressure
(rpm) (Kg) Suction Discharge
(L/min) (MPa) Type Capacity
port port

YB-160L-4

3.2.2.2 Construction As shown in Fig 6.

3.2.2.3 Working Principle

The motor drives the crankshaft of the pump via chain wheel and chain. Rotary action of the crankshaft is converted to
horizontal reciprocal movement of the plunger by the connecting rod and the crosshead. The top of the cylinder liner is connected to
a suction valve and a discharge valve. When the plunger moves backwards, a sucking effect is created so the discharge valve is
closed and the suction valve is opened. Thus, hydraulic oil is sucked in the cylinder. The above is the process of oil suction. When
the plunger moves forwards, a pressing effect is created so the suction valve is closed and the discharge valve is opened. Oil is
28
discharged via the discharge valve. This is the process of oil discharging. The three cylinders repeat the above two processes
29
alternatively way and the pump is working in this way.
30

3.2.2.4 Features
Because elastic material like rubber and graphite PTFE packing is used on the pump for sealing, filtering fineness
requirements of the pump is low. Wear of plunger and packing can be compensated by adjusting the compression ring, so discharge
pressure and oil volume discharged will not be affected by small wear. Replacing of rubber packing is also very easy and may be
done on-site.

3.2.2.5 Role Played in the Control System

As the main pump, it charges hydraulic pressure to the accumulators and directly pressurize to the hydraulic chambers of BOPs.

01

21 22
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3.2.3 Pneumatic Pump Fig.7 Pneumatic Pump QYB40-60L

3.2.3.1 Technical Specifications

Type: QYB35-175L

1:50 (pressure enhancement ratio) 1 2 2

Ratio of pneumatic pressure to hydraulic pressure:
2
Pressure of compressed air source: 0.8MPa
3
Maximum air consumption: 2.2m 3/min (if installed on the remote control panel, 1.5m 3/min) 4
Maximum working pressure: 40MPa 5 8
6
Connecting threads: Air inleNPT3/4 , oil inlet NPT1 ,oil outlet NPT1/2
7 V
Maximum diameter x height: 352 863 mm 8
Weight: 37kg 9
10
3.2.3.2 Construction As shown in Fig.7. 11

3.2.3.3 Working Principle 12

13
Compressed air comes in from the top of the pump, then enters the upper chamber of the pneumatic cylinder via inner chamber
14
of the shuttle valve (21) and the passage in the cylinder head (shown in Fig.5) and pushes the piston downwards. Air in the lower
15 0 1 50x5.7
chamber of the cylinder is forced out of the pump via a guide pipe, the middle passage of the shuttle valve and the gap between the
16
two seal rings of the shuttle valve. When the piston goes downwards and is about to compress direction reversing spring (10), the
tension bar of the shuttle valve does not move downwards because of the side spring and steel ball (16). With the piston continues to
17

move down and compresses the directional spring, the spring seat touches the shoulder of the tension bar and the piston forces 18
shuttle valve (21) down. Steel ball (16) is forced back. When the shuttle valve moves down to the middle between the two arc 19
grooves, compressed air is vented to the atmosphere, the shuttle valve stops moving and the shuttle valve is pushed down in-position 20
by the compressed directional spring. The steel ball is then forced by the side spring to enter the arc shape groove in the upper part of 21
1 6
the shuttle valve and the shuttle valve changes from downward movement to upwards movement. Compressed air flows through the
inner bore of shuttle valve and air pipe (19) to enter the lower chamber of the cylinder. The piston is forced upwards and passes
through the position where piston sheath (9) compresses directional spring (10). When the piston continues to go up and reaches the
limiting point, it forces the shuttle valve to go up. The steel ball retreats and fixes the shuttle valve in the upper position. To this
point, a stroke is completed. Then another stroke begins, compressed air flow reverses and the same process repeats. Such cycle
repeats continuously and the piston makes reciprocal movement continuously.
The oil pump's connecting rod attached to the lower end of the piston rod makes vertical reciprocal movement. A suction port is
equipped in the lower end of cylinder (3). Steel ball (1) is the core of the suction valve. The lower end of connecting rod serves as the
3.2.4 3-Position 4-Way Valve
body of the check valve, steel ball (4) in the inner chamber serves as the core of the check valve. When the connecting rod moves up,
the check valve is closed by steel ball (4), the suction valve opens and oil is sucked in, while the oil in the annular space between 3.2.4.1 Technical Specifications
connecting rod (7) and liquid cylinder (3 is forced out of the pump. When the connecting rod moves down, the suction valve is closed
and the check valve is opened. Oil in the liquid cylinder is forced out of the pump via the check valve and the annular space in the Type: 34ZS21- 25

upper part of the liquid cylinder. Quantity of oil discharged is equal to 50% of the oil sucked in, and the rest of the oil stored in the W orking pressure: 21M Pa
annular space will be discharged during the next upward movement. That is, the oil sucked in is discharged in two halves.
Flow rat e: 280L/m in

Nom inal diam et er: NPT 1 "

3.2.3.4 Features Funct ional st ruct ure: O t ype

Because the area ratio of the pneumatic cylinder to liquid cylinder is 50:1and direct link mode is used, the pump is very good at Connect ing t hreads: NPT1 "
under-load starting. Especially, it can be started under extra-high hydraulic load (higher than 32MPa)(4550 PSI).
Operat ing m ode: M anual and pneum at ic
3.2.3.5 Role Played in the Control System
Rot at ing t orque: 25N m
This is an independent pump group on the remote control panel. It is powered by compressed air and is indispensable for the
Lengt h x w idt h x height : 300 x 136 x 230m m
control system. This pump is particularly important when it is necessary to use a pressure higher than 21MPa (3000 PSI) to control
BOPs (for example shearing ram).
3.2.4.2 Construction as Shown in Fig.6

23 24
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Fig.8 3-Position 4-Way Valve 34ZS21-25 3.2.4.3 Working Principle

(1)When the valve handle is in the middle position, as shown in Fig.6-1 (b), the 4 oil ports of the valve core are offset by 45 to
the 4 oil ports of the body. So the 4 ports i.e. P, O, A and B in the body are blocked and not through to each other. Pressure oil cannot
flow through port P. No returning oil flows out from port O. Oil can neither be sucked in nor be returned from ports A and B that are
Function Symbol linked to the both ends of the oil cylinder so the oil cylinder is blocked in the previous open or closed position. The piston inside the
oil cylinder cannot be moved by external force like vibration (except that the pipe is leakage). Therefore, such functional structure
of the valve is called "O" type.
(2)When the valve handle is in left position, as shown in Fig.6-1 (a), the two passages in the valve core link port P with B, and A
as well as port O. Pressure oil flows from port P to B via the passage in the valve core, and enters BOP-opening chamber, forcing the
piston to move down and open BOP. At the same time, pressureless oil in BOP-closing chamber is forced out by the piston and
returns to the oil reservior via a pipe, port A, the other passage of the valve core and port O.
(3) When the valve handle is in right position, as shown in Fig.6-1 (c), the passages in the valve core link port P with port A, B
and O. Pressure oil flows from port P to port A via the passage in the valve core, enters BOP-closing chamber via a pipe and forces
4 5 6 7 8 9 10 11 12 13 14
the piston to go upwards to close BOP. At the same time, the pressureless oil in BOP-opening chamber is forced out by the piston and
returns to the oil reservior via pipe, port B, the other passage of the valve core and port O.
4-Z1"

2 Fig.8-1 Working Principle 3-Position 4-Way Rotary Valve

1

118 P P P

16 15
A B A B A B
182

Component O O O
No. Code Note

1 3.4HXF-00-01 Spindle
a b c
2 3.4HXF-00-02 Spindle sleeve

3 3.4HXF-01-00 Handle 3.2.4.4 Features

4 3.4HXF-00-03 Bush
O-ring,28X3.5 The valve is a shearing type rotary valve. Its seal would never be soled up by dirt, thus no leakage is caused.
5 GB1235-76
The wave spring gives a preload to the slide bush thus sealing is ensured when pressure is low.
3.4HXF-00-04 Bonnet
6
Pressure oil acts on the slide bush, giving an auxiliary effect of sealing (this effect is created by the difference of pressure
3.4HXF-00-05 Nameplate
7 bearing area between the both ends of the slide bush) thus sealing under high pressure is ensured.
3.4HXF-02-00 Valve core
8
GB1235-76 O-ring,110X3.1
9 3.2.4.5 Role Played in the Control System
GB1235-76 O-ring,25X2.4
10
3.4HXF-00-06 Detaining ring This valve changes oil flow direction for opening and closing BOPs.
11
3.4HXF-00-07 Valve seat
12
3.4HXF-00-08 Corrugated gasket
3.2.5 Regulator
13 Valve body
3.4HXF-00-09 There are two types of regulator used for the control system , manual and manual type is equipped with a spring and a hand
14 3.4HXF-00-10 Spring wheel. On pneumatic type, a pneumatic cylinder diaphragm replaces the spring and the hand wheel used on manual type to realize
15 3.4HXF-00-11 Positioning plate the pressure adjusting from distant location.
16

25 26
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3.2.5a.1 Technical Specifications of Manual regulator Fig.9 Manual Regulator JYS21-25

Type: JYS21-25

Range of pressure adjustment: 0~14MPa(0~2000 PSI) Function Symbol

1
Flow rate: 280L/min

Operation mode: Manual 18

Connecting threads: Inlet, NPT1"; Outlet NPT1/2" 2 19

Overall dimensions; 175 x 162 x 602

Weight: 20kg
20
3.2.5a.2 Construction As shown in Fig.7. 21
4

3.2.5a.3 Working Principle 5

6
The valve works on the principle of pressure balance. Hydraulic pressure in the inner chamber of the valve is proportional to
the load of the spring (see Fig.7). When the hand wheel is rotated, lengths of inner and outer rectangular springs are varied and the 7
spring load is also varied within some range. In this way, hydraulic pressure is also changed accordingly. According to the working 22
8
principle and construction, the valve may have 4 modes of working as follows. 23
a) "0" (zero) mode
24
When the hand wheel is turned loose to free the springs, the outlet is closed. The oil pressure of 21MPa(3000 PSI) enters the
inner chamber of the valve via the oil take-in plunger and forces the valve plate to slide up to a new position, which forces the oil 9 25
26

602.5(Hghest point)
take-in slide bush up to close the oil inlet of the plunger, so pressure in the inner chamber does not rise. Now the space in the oil take-
in slide bush is open to the oil inlet and is separate with the valve inner chamber. Under the pressure difference, the oil take-in slide 10 Z1/2"
bush is pressed tightly against the sealing face of the oil take-in plunger and an improvement in sealing is created. In this condition, 3
11 27
when the discharge port is open, there will be no oil flowing out. Therefore such mode is called "0" (zero) mode. Z1"
b)Pressure adjusting-stabilizing mode 28
12
In "0" mode, if the hand wheel is turned so that the rectangular springs are compressed, and the valve stem is forced downward. Z1"
When the spring load is greater than the friction between the oil take-in slide bush and oil take-in plunger as well as between the oil
relieving slide bush and the plunger, the valve plate slides down and opens the oil inlet. With oil entering, pressure in the valve inner
chamber rises, and the valve plate goes up accordingly. When the pressure in the inner chamber rises to the extent that is balanced 13
with the spring load, the valve plate moves the oil take-in slide bush up to the position where the oil inlet will be closed, and the 14
valve inner chamber pressure is also stabilized at a certain value. When the oil discharge port opens, pressure in the valve inner 15
chamber drops, the rectangular springs forces the valve plate to slide down and open the oil inlet port. Oil then flows in to replenish
16
until the hydraulic chamber of BOP is full, pressure rises again to the preset value and the oil inlet is closed by the oil take-in slide
102 17 102
bush again. Therefore this mode of working is called "pressure adjusting and stabilizing mode". The working mode of the valve
determines that pressure adjusting is by valves, with stepwise pressure rising. The step of rising depends on valve design and 132 178
manufacture.
c)Pressure reducing-relieving mode
In pressure adjusting mode, if the hand wheel is turned so that the rectangular springs are loosened to an extent that the valve No. Code Component No. Code Component
inner chamber pressure becomes greater than the spring load, the valve plate slides up until the oil discharge port is open to the valve Hand wheel
1 SDTYF-00-01 15 SDTYF-00-17 Valve plate
inner chamber. With the releasing of some oil from the valve inner chamber, the valve plate slides down until the oil relieving slide
2 SDTYF-00-02 Locking Handle 16 SDTYF-00-18 Valve body
bush just closes the oil discharge port. With the oil take-in slide bush sealing the oil inlet port, pressure in the valve inner chamber
will reduce to a value, which is equal to the spring load. When the load of the rectangular springs is adjusted to zero, the pressure in 3 SDTYF-00-10 Oil outlet flange 17 SDTYF-00-19 Lower plug
the valve inner chamber also drops to zero. This mode is called pressure reducing-relieving mode. 4 SDTYF-01-00 Spring sleeve 18 SDTYF-00-20 Screw rod
d)Mode of pressure relieving-stabilizing in the overflow Inner spring Spring cover
5 SDTYF-00-03 19 SDTYF-00-21
In pressure adjusting mode, when oil pressure at oil discharge port is higher than the preset level, if it is necessary to trip out
6 SDTYF-00-05 Outer spring GB301-64 Thrust ball bearing 8202
the drill pipe after the annular BOP is closed, the sealing pressure becomes higher when the joint of the drill pipe passes through 20
7 SDTYF-00-06 Guide ring SDTYF-00-23 Pressing seat for spring
BOP because the sealing parameter of the stripper is expanded. This high pressure reaches the valve inner chamber through the pipe 21
so the pneumatic pressure in the valve inner chamber over-balances the load of the rectangular springs; the valve plate slides up until 8 SDTYF-00-07 Upper plug 22 GB1235-76 O-ring,50 x 3.1
the oil discharge port is open. When some oil pressure is relieved, the valve plate slides down again until the oil relieving slide bush SDTYF-00-09 Blind flange for oil relieving port Corrugated spring (corrugated washer)
9 23 SDTYF-00-24
just closes the oil discharge port and the valve inner chamber pressure is stabilized at the preset level. Thus, pressure in the system is
10 SDTYF-00-11 Seat for oil relieving slide bush 24 GB1235-76 O-ring,54 x 3.5
stabilized at the preset level and not influenced by external or internal factor. This mode of working is called mode of pressure
relieving-stabilizing in the overflow. 11 GB1235-76 O-ring,32x3.1 25 SDTYF-00-25 Oil relieving plunger

12 SDTYF-00-13 Oil in-take plunger 26 SDTYF-00-26 Flange of oil relieving port

13 SDTYF-00-15 Oil inlet port spring SDTYF-00-27 Flange of oil in-take port
27
14 SDTYF-00-16 Oil in-take slide bush

27 28
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3.2.5a.4 Features
Fig.9a Manual-pneumatic Regulator JYSQ21-25
(1)The valve is of the shearing type. It would not be blocked by dirty oil, so its performance would not be compromised. Function Symbol
(2)The plunger and the slide bushes are ground and nitride, high in surface smoothness and hardness, wear resistant and long in 25
service life.
36
(3)Rational construction, with pre-sealing realized by wave spring and auxiliary sealing realized by oil pressure.
35
26

3.2.5a.5 Role Played in the Remote Control Panel

34
27
This valve is used to lower the hydraulic pressure of the accumulator group in accordance to the hydraulic pressure required by 33
28
different BOP stacks and to supply suitable hydraulic pressure to BOP stacks so that the life of the stripper in BOP is prolonged and
29
BOP is used in a more economic and rational way.
30
31
3.2.5 .1 Technical Specification of Manual-Pneumatic regulator 2 32
3
4

733
5

6
18
7 19
8 20
9 21
22
NPT NPT 10 Z1/2"
1 11 23
Z1"
24
12
Z1"

3.2.5b.2 Construction As shown in Fig.8a.

13
14
3.2.5 .3 Working Principle 15
The principle of operation and performance is roughly the same as that of the manual type except that diaphragm type pneumatic 16
102 17 102
cylinder is used for adjusting the screw rod instead of the hand wheel; compressed air instead of spring is used; hydraulic pressure is
132 178
adjusted by adjusting the pneumatic pressure in the cylinder. The higher pneumatic pressure is, the higher hydraulic pressure will be,
and vice versa. No. Code Component No. Code Component

3.2.5 .4 Features 1 SDTYF-00-10 Oil outlet flange 19 GB1235-76 O-ring,54x3.5

2 QDTYAF-02 Air cylinder upper cover 20 SDTYF-00-25 Corrugated spring (Corrugated washer)
In normal condition, pneumatic control is used. When conditions for pneumatic control are completely lost, manual mode is
3 QDTYF-00-02 Diaphragm 21 SDTYF-00-12 Oil relieving plunger
used as the backup for emergency control.
4 QDTYF-00-05 Spring 22 SDTYF-00-26 Oil relieving port flange
3.2.5 .5 Role Played in the Remote Control Panel 5 QDTYF-00-03 Supporting disc 23 SDTYF-00-27 Oil inlet flange
6 QDTYF-00-08 Air cylinder lower cover 24 SDTYF-00-01 Hand wheel
This valve is mainly used for adjusting of pressure of annular BOP.
7 SDTYF-00-06 Guide ring 25 SDTYF-00-02 Locking handle
3.2.6 2-Position 4-Way Valve
8 SDTYF-00-07 Upper plug 26 SDTYF-01-00 Spring sleeve
3.2.6.1 Technical Specifications 9 SDTYF-00-09 Blind flange for oil relieving port 27 SDTYF-00-03 Inner spring
10 SDTYF-00-11 Oil relieving slide bush seat 28 SDTYF-00-05 Outer spring
Type: 24ZS21-25 GB1235-76 O-ring,32x3.1 SDTYF-00-04
11 29 Spring seat
Working pressure: 21MPa (3000 PSI) 12 SDTYF-00-13 Oil in-take plunger 30 QDTYAF -0 3 Tappet
13 SDTYF-00-15 Oil inlet spring 31 QDTYAF -0 1 Guide ring
Displacement: 280L/min
14 SDTYF-00-16 Oil in-take slide bush 32 SDTYF-00-23 Pressing seat for spring
Operation mode: Manual, pneumatic
15 SDTYF-00-17 Valve plate 33 GB301-64 Thrust ball bearing 8202
Interface specification: 4 - NPT1" 16 SDTYF-00-18 Valve body 34 SDTYF-00-21 Spring cover
Overall dimensions: 300 x136 x 230mm 17 SDTYF-00-19 Lower plug 35 SDTYF-00-20 Screw rod
18 GB1235-76 O-ring,50x3.1
Weight: 11kg

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3.2.6.2 Construction As shown in Fig.9.

Fig.10 2-Position 4-Way Rotary Valve 24ZS21-25

3.2.6.3 Function, Working Principle

Function Symbol
A T

P1 P2

4 5 6 7 8 9 10 11 12 13 14

4-Z1"

3
3.2.6.4 Role Played In The Remote Control System

Port 2 of the valve is connected to the outlet of the manual regulator of the manifold. When the valve handle is turned right, the 2
port is open to the manifold. Port P1 is connected to the accumulators directly. When the valve handle is turned left, accumulator
1
pressure is supplied to the manifold. (This valve replaces the traditional 2-position 2-way valve. To follow the traditional custom of

118
manipulation, the same traditional pattern is used for the indication plate.)

16 15

182

No. Code Component Note

1 3.4HXF-00-01 Spindle

2 3.4HXF-00-02 Spindle sleeve

3 3.4HXF-01-00 Handle
4 3.4HXF-00-03 Bush

5 GB1235-76 O-ring,28x3.5

6 3.4HXF-00-04 Bonnet

7 3.4HXF-00-05 Nameplate

8 2.4HXF-01-00 Valve core

9 GB1235-76 O-ring,110x3.1

10 GB1235-76 O-ring,25x2.4

11 3.4HXF-00-06 Detaining ring

12 3.4HXF-00-07 Valve seat

13 3.4HXF-00-08 Corrugated washer

14 3.4HXF-00-09 Valve body

15 3.4HXF-00-10 Spring

16 2.4HXF-00-02 Positioning plate

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3.2.7 Relief Valve

3.2.7.3 Working Principle
3.2.7.1 Technical Specifications
Set the spring load acted on the ball seat (08) (valve core), which is higher than the hydraulic pressure, and the valve is closed.
Overall When an overpressure happens and the hydraulic pressure is higher than the spring load, the ball is pushed up, and the valve is
Set pressure Interface specification Weight
dimensions opened for pressure relieving. Pressure oil is discharged from the outlet. When the normal level is got, the ball seat is retreated to
Type
MPa Inlet Outlet mm kg close the valve under the action of the spring.

3.2.7.4 Features
56x50x193
Simple in construction and small in size. No leakage in normal condition, adjustable opening pressure and overflow oscillation.

3.2.7.2 Construction As shown in Fig.10.

3.2.7.5 Role Played in The Remote Control Panel
The relief valve is purposed to protect the equipment form damage due to overpressure.
Fig.11 Relief Valve Y30-25
Y40-15 3.2.8 Hydro pneumatic Switch

01 3.2.8.1 Technical Specifications

02 W orking pressure: Air, 0.8M Pa

03 Liquid, 21 M Pa(3000 PSI )

Pressure set t ing: Upper lim it : 21M Pa (3000 PSI ) (t he sw it ch closes)

Function Symbol
04 Low er lim it : Usually 18M Pa(2550 PSI ), depending on t he upper lim it . Once t he upper lim it is set ,

no adjust m ent needs t o be m ade.

05
Connect ing t hreads: Liquid side: NPT 1/4"
06
Air side: NPT 1/2" xNPT 1"
07
Overall dim ensions: 88 x 392m m

08 W eight : 7kg
19 3

3.2.8.2 Construction As shown in Fig.11.

11
Outlet
3.2.8.3 Working Principle

The thrust exerted on the plunger area by the hydraulic pressure is balanced by the adjustable spring load. When the hydraulic
Z 1 " ( or Z 1 / 2 " )
thrust is greater than the preset spring load, the spring is compressed. So the sealing gasket on the other end of the plunger rod is
pressed against the sealing face of the outlet, compressed air source is cut off. When the thrust is smaller than the preset spring load,
the spring moves the plunger rod up, the sealing gasket gets away from the sealing face, and compressed air supply is reconnected.
09

No. Code Component Note

1 YLF-01 Sealing nut 3.2.8.4 Features

10
2 YLF-02 Pressure adjusting scrrew Simple construction, reliable working, long service life and adjustable upper limit.
3 YLF-03 Locknut
Z1" Spring seat 3.2.8.5 Role Played In the Remote Control Panel
4 YLF-04
5 YLF-05 Spring This switch is for automatic control to start and stop the pneumatic pump.
56 6 YLF-06 Valve stem
7 YLF-07 Valve body

8 YLF-08 Ball seat

Inlet 9 YLF-09 Guide ring

10 YLF-10 Adaptor

11 YLF-11 Nameplate

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Fig.12 Hydropneumatic Switch QKY21-25

Fig.13

No. Code Component Note No. Code Component Note

1 YQKG-01 Connecting flange 9 YQKG-09 Supporting core sleeve

2 YQKG-02 Sealing gasket 10 YQKG-10 Connecting bush

3 YQKG-03 Pressing bush 11 YQKG-11 Core stem

4 YQKG-04 Sealing seat 12 YQKG-12 Spring

5 YQKG-05 Gasket 13 YQKG-13 Supporting bush

6 YQKG-06 Bonnet 14 YQKG-14 Detaining ring

7 YQKG-07 Locknut 15 YQKG-15 Valve seat

8 YQKG-08 Supporting nut 16 YQKG-16 Key

3.2.9 Motor Start-Stop Control

3.2.9.1 Electric control principle Pressure setting procedure

1. Install the pressure control to control system as figure1 as above, and make sure that a visual
Control import supply voltage pressure gauge is installed on the control system.
Control low pressure import voltage 2. Put the selector switch to terminal set1 with electricity on.
Control supply loss current 3. adjust the system pressure to upper limit value, and then push the setting button “uup”, the
Export control voltage indicating light blinks for three times, upper limit setting is finished.
Export control electric current 4. adjust the system pressure to lower limit value, and then push the setting button “low”, the
Pressure transmitter power source indicating light blinks for three times, low limit setting is finished.
Pressure transmitter import 5. Put the selector switch to the terminal set0. Now all the work is finished.
Input voltage resolution

3.2.9.3 Conection diagram of pressure controuer

Pressure controller wiring as figure 1 IN OUT connectors are used to connect AC contactor 0 110V

220V 380V 460V connectors are control supply input JP4 connects to pressure transmitter (4 20mA)

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3.2.9.5 Electric control principle

Motor start/stop is realized via a control circuit formed by a magnetic starter and a pressure
controller, as shown in Fig.12. Main switch, AC contactor and thermal relay are equipped in the magnetic
starter. In the pressure controller, pressure transducer button and circuit board are installed.
a.Automatic start/stop control
When the main switch is set at " Automatic " position and pressure in the accumulator group is lower than 18.9A,
controlling power is supplied to the magneto electric coil of the AC contactor via the pressure controller. The AC contactor
attacks. When the motor starts up and runs, the 3-cylinder pump (crankshaft-driven plunger pump) charges pressure to the
accumulators. When the hydraulic pressure rises to 21MPa, pressure controller cuts of the power of the magneto electric
coil of the AC contactor, the AC contactor opens and the motor stops running. When the accumulator pressure drops to
18.9MPa, pressure controller puts through the power of the magneto electric coil of the AC contactor again, the motor
starts again and the 3-cylinder pump charges pressure to the accumulator.
b. Manual start/stop control
Manual start/stop control is only used for relief valve performance adjusting from the remote control panel or as an
emergency means in case of automatic control failure. In manual control mode, the motor is not controlled by the
accumulator pressure. So long as the main switch is at " Manual " position, the motor will never stop. Therefore, the
operator must stay in the site to monitor and avoid long time over-load operation of the 3-cylinder pump.
Before setting the main switch at " Manual " position, be careful that hydraulic pressure of the accumulators must be lower
than 18.9MPa so as to avoid motor starting under heavy load.

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Alarm Function Operation Instruction

1. Alarm and display function
for surface mounted BOP control system 1.1 Usage

FOREWORD It is used for indicating or alarming low accumulator pressure, low air pressure, low oil level and
pump running at two positions.
This OPERATION INSTRUCTION on alarm function, is specially compiled in
accordance with technical agreement. 1.2 Structure and working principle
1.2.1 Structure
TABLE OF CONTENTS It consists of as following:
Pressure relays (hydraulic or pneumatic), middle relay, liquid level switch, alarm box, audible and
1. Alarm and display function 1 visual alarm, indicating lights and multipolar plugs and connection cable for remote control panel.
1.1 Usage 1 1.2.2 Working principle (see electrical diagram)
Structure and working principle Put the power supply switch of driller's panel at ON position.
1.2 1
a. When accumulator pressure reaches the minimum rate, pressure relay (KP1) is energized, the
1.2.1 Alarm data 1 middle relay (1K) in alarm box joints and it makes the indicator lights (H17, H18) work and the
1.2.2 Mounting and connecting 2 audible and visual alarm device (BZ1, BZ2) work, When accumulator pressure rises to 15MPa, the
1.2.3 Notices 2 pressure relay (KP1) cuts off and middle relay (1K) de-energized, alarm stops, indicator lights
(XH17, H18) are off, alarm stops.
1.2.4 Fault control 2
b. The pressure relay (KP2) joints when air resource pressure reaches the minimum rate, the middle
1.3 Maintenance 2 relay (2K) in alarm box joints then, it makes the indicator lights (H19, H20) work timely and it
1.4 Alarm Pressure Controller 3 makes the alarm device (BZ1, BZ2) work, When air source pressure reaches 0.65MPa, pressure relay
(KP2) disconnects and middle relay (2K) is de-energized, alarm stops.
c. The middle relay (3K) is energized and level switch (XK) joints when oil level reaches the limited
level; it makes the indictor (H21, H22) the audible and visual alarm device (BZ1, BZ2). The middle
relay (3K) is de-energized, when the oil level reaches over limited line and level switch (XK) is cut
off, alarm stops.
d. When electric motor starting running, the relays in the magnetic starter (1KM, 2KM) joints, the
low accumulator pressure alarm stops (if alarm exists), the indicator light (H16) shines.
e. Press the button (SB20 or SB21) to stop audible alarm if needed. At this time, middle relay (4K) in
the alarm is energized, the power of audible and visual alarm (BZ1, BZ2) is de-energized and stop
working, and the audible alarm stops and its indicating lights (H23,H24) start working until the
alarm situation is removed.

1.3 Alarm data

a. Alarming when accumulator pressure rated =13 0.4MPa.
b. Alarming when air resource pressure rated =0.6 0.04MPa.
c. Alarming when the oil level rated less one time of filling accumulator groups.

1.4 Mounting and connecting

Mounting and connecting be carried after the power is cut off.

Alarm and display devices have been assembled on both the remote control panel and the driller's
panel. It is only required to connect the remote control panel with driller's panel with electric control
cable.

1.5 Notices
a. Immediately after alarming, the alarming light and the alarm device must be released to
avoid them to work long time.
b. The electric motor running indicator light will work less than twelve minutes. If it is on for a long
time, and the accumulator pressure does not rise, it means that the charging pressure is invalid, it is
needed to check the remote panel and shoot the trouble.

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1.6 Fault control

Description Cause Trouble shooting Noted

No power in alarm device 1 fuse is welded out in the box. 1 replace the fuse. 5A welding
control box 2 power ling is in trouble. 2 c h e e k t h e p o w e r cores
supply and repair.

The other indicating light The resistance on the abnormal Change the damaged 55W30K
t h a t s h o u l d n o t w o r k circuit loop is invalid resistance for a new one
works when one light after power off
works.

No alarming on the Transferring cable is damaged Check cable plugs,

driller's panel when fault or power failure repair or replacement
happens.

No alarming on both the 1 Rated volume of pressure 1 rest pressure relay or

remote console and relay is changed or magnetic replace the float of level
driller's panel when fault spring tube of level switch is switch.
happens not effective Replace the middle
relay.

1.7 Maintenance
a. When the cable plugs are removed from multipolar plugs, they must be protected by caps in which
it is clear.
b. The explosion proof multipolar plugs with their lips, sealing gasket must be complete and
effective.
c. When the transfer cable is not in use, or in the process of transportation, they must be collected
carefully, their insulating cover muse not be damaged by sharp things.

1.8 Alarm Pressure Controller

The above mentioned action must be taken by the qualified operators.

YKX-00a alarm pressure controller (see instruction Fig 1 Item 68) on its right side is low
accumulator pressure alarm pressure relay. Screw out the nut on the up right of the box before
calibration, Calibrating the pressure by putting the hexagon wrench into the hexagon hole on the
pressure relay and relating it , clockwise rotation, pressure will be high , anticlockwise rotation ,
pressure will be low , low pressure alarming device is on the left side of the pressure control box ,
screw out the nut on the top of the pressure relay, Calibrating the pressure by putting the hexagon
wrench into the hexagon hole and rotating it , clockwise rotation , pressure will be high ,
anticlockwise rotation , pressure will be low.

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