CAMERON France S.A.S
FRONT SHEET
Project name
1
REVISE AND RESUBMIT
2
TO BE ISSUED AS FINAL PROVIDED COMMENTS ARE INCORPORATED
3 SIGN.
NO COMMENT, FINAL ISSUE DATE :
Seadrill Deep Driller MOBILE OFFSHORE DRILLING UNIT 246 ft x 218 ft x 258 ft PO No : JU 312046
Rig : B312
BOP Equipment 18-3/4” 15K BOP Stack /W Manual Locking Screw Operating & Maintenance Manual Doc. Number
Rev
B011
01
File Name : SD-B312-BOP-B011-01-01
Operation and Maintenance Manual Cameron TL Blowout Preventer 18-3/4" 15000 psi WP (BF temp Class) Operation and
SD-010274-10-01
All the information contained in this manual is the exclusive property of Cameron. Any reproduction or use of the calculations, drawings, photographs, procedures or instructions, either expressed or implied, is forbidden without the written permission of Cameron or its authorized agent.
Initial Release 01 December 2005
Copyright © 2005 all right reserved Cooper Cameron Corporation, Cameron France
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PREFACE The procedures included in this book are to be performed in conjunction with the requirements and recommendations outlined in API Specifications. Any repairs to the equipment covered by this book should be done by an authorized Cameron service representative. Cameron will not be responsible for loss or expense resulting from any failure of equipment or any damage to any property or injury or death to any person resulting in whole or in part from repairs performed by other that authorized Cameron personnel. Such unauthorized repairs shall also serve to terminate any contractual or other warranty, if any, on the equipment and may also result in the equipment no longer meeting applicable requirements. File copies of these manuals are being maintained. Revisions and/or additions will be made when deemed necessary by Cameron. Refer to component part numbers in all communication concerning this equipment. This book covers Cameron products, which are products of Cooper Cameron Corporation.
Cooper Cameron Corporation Cameron France, SAS Plaine St Pierre – CS 620 34535 Béziers Cedex Fax : 04-67-11-16-00 http://www.coopercameron .com
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TABLE OF CONTENTS Reference Document: Detailed drawing W/ BOM - SD-010274-04-01
Double TL BOP 18-3/4” 15.000 PSI WP Operation and maintenance I.
PHYSICAL DATA............................................................................................................... 5
II.
APPLICABLE OPERATING CHARACTERISTICS ........................................................... 6
III.
DISASSEMBLY PROCEDURE .......................................................................................... 7
IV.
ASSEMBLY PROCEDURE .............................................................................................. 10
V. OPERATION AND INSTALLATION...................................................................................... 13 VI. MAINTENANCE.................................................................................................................... 13 VII.TESTING............................................................................................................................... 14 VIII.STORAGE ........................................................................................................................... 16
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I.
Physical Data
A) Lubricants 1)
Ram lubricant, Cameron P/N 713878 or a water resistant non petroleum base grease.
2)
Thread lubricant, API-5A-Lub, Fel-Pro Paste #670, or SLECT-A-TORQ Paste #503 (4 lb can P/N 705444).
3)
Multi-purpose lubricant or grease.
4)
Multi-purpose lubricant or grease for cold weather operation.
5)
Hydraulic operating system: (a) Storage –TOTAL Equivis ZS32 or equivalent (b) Standard operation – Use TOTAL Equivis ZS32 or Citgo Aquamarine#32 or equivalent
6)
Seals and sealing surfaces: SAE-30 Wt. Oil
B) Dimensional Drawing with bill of material Refer to doc SD-010274-04-01, 18-3/4” 15,000 psi WP Double TL BOP
C) Weights 1)
18-3/4” 15,000 psi WP TL double BOP, Flange bottom x Studded top with housing locking screws - 28300 kg.
2)
Bonnet assembly 18-3/4” 15,000 psi WP 2700 kg.
3)
Average rams assembly 285 kg each.
D) Lifting and Handling 1)
Lift BOP assemblies only with slings appropriately rated for the maximum weight of the BOP.
2)
Lift ram assemblies by installing a lifting eye in the threaded preparation in the ram.
3)
Handle all other subassemblies using appropriately and certificated rated slings. 5
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E) External Thread Connections Description Size Location Open Port 1” SAE BOP Body, Front Close Port 1” SAE BOP Body, Back F) hydraulic Operating System Requirements 1)
Use TOTAL Equivis ZS32 or Citgo Aquamarine#32 or equivalent
2)
Fluid Requirement: Rams (One Set) Open
Gallons 23.4
Rams Closing Ratio Opening Ratio
Close Litres 88.6
Gallons 24.6
Litres 93.1
6.7:1
3.1:1
G) API 16A Drift Diameter API drift for 18-3/4” is 18.720” (475 mm)
H) Temperature Rating: 1) 2)
Continuous Service 40°F to 250 °F Extreme Service 0°F to 350 °F
Note: There is no industry accepted method of establishing BOP temperature ratings at this time. These are estimates based on lab testing and field performance. Temperature ratings for rubber components must take into account the environmental exposure history, the chemical environment while at temperature, and other factors. Therefore, a single number rating can be misleading if all conditions are not understood. II.
Applicable Operating Characteristics
A) Subassemblies 1)
Pipe rams a - Seals around 5-7/8” drill pipe
2)
Flexpackers Rams a - Seals around 3-1/2” to 5” drill pipe and b - Seals around 5” to 5-7/8” drill pipe c- Seals around 5” to 6-5/8” drill pipe
3)
Shear Rams- type DVS 6
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III.
Disassembly Procedure
Note: The work area should be clean and well lighted. A) Ram Removal 1)
Connect the OPEN and CLOSE ports of the BOP to the hydraulic power supply.
2)
Apply 1500 psi (104 Bars) opening pressure to the BOP and remove the bonnet cap nuts (9).
3)
Apply 200-300 psi (14-20 Bars) closing pressure to the BOP to open the bonnets.
4)
Install the ram trays (P/N 2163881-01) on the bonnet studs.
5)
Apply 500 psi (34.4 Bars) opening pressure to clamp the tray between the body and bonnet and to move the rams to the open position.
6)
Install a lifting eye in the side of the rams and use a pry bar in the ram tray slots to move the ram to the side of the preventer.
7)
Remove the grating elements if necessary to reach the single ram BOP.
8)
Install a lifting eye in the top of the rams and remove from the ram tray.
9)
Apply 500 psi (34.4 Bars) closing pressure to the preventer long enough to unclamp the ram trays from their position between the body and the bonnet.
10) Remove the ram tray. 11) Apply 200-300 psi (14-20 Bars) opening pressure to move the bonnet assembly to the closed position. Take care of O-Rings during closing on seal carrier. 12) Vent opening pressure and disconnect the hydraulic supply lines from the preventer.
B) BOP Disassembly Refer to SD-010274-04-01 1)
Install lifting eyes in the bonnet and cylinder head of one bonnet assembly. 7
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2)
Use a chain sling to pick up on these two points enough to take the bonnet weight off the ram change pistons
3)
Remove the ram change access caps (7) and remove the O-rings (38) from the access caps
4)
Back out the ram change pistons (4 and 5) it might be necessary to adjust the tension in the chain sling to achieve the proper lift to take the load off the ram change pistons and allow them to turn freely
Caution: It is essential to alternate between pistons when backing out to ensure even load distribution. 5)
Remove the ram change pistons from the bonnet.
6)
Remove the bonnet from the body.
7)
Remove the bonnet seal (21).
8)
Remove the bonnet seal carrier (20), bonnet seal, and retainer ring (22) using the seal carrier removal tool P/N 2010064-05.
9)
Take the bonnet assembly down and place it in the bonnet assembly stand.
Caution: Take care not to damage the connecting rod (3). 10) Remove the six screws (46) and housing (43). 11) Remove the cylinder head screws (26) from the bonnet assembly and use a sling to lift the cylinder head assembly from the bonnet. 12) Install a C clamp on the tail rod of the operating piston (3) and remove the operating piston from the bonnet. The operating cylinder (23) may come out with the operating piston. If so, use a rubber hammer to drive the operating cylinder off the operating piston. 13) Remove the wear ring (32) and seal (30) from the operating piston. 14) Use two .250”-20 eye bolts to remove the operating cylinder (23) from the bonnet. 15) Remove the O-rings (31), (51) and back-up ring (52) from the operating cylinder. 16) Remove the ram change cylinders (6) from the bonnet. 17) Remove the O-rings (35) from the ram change cylinders. 18) Remove the following items from the bonnet: a. Studs (25) 8 SD-010274-10-01 Rev01
b. Spirolox Ring (19) c. Retainer Ring (18) d. Seal Ring (16) e. Back-Up Ring (17) 19) Turn the bonnet over (body side up) and remove the following items: a. Spirolox Ring (11) b. Retainer Ring (12) c. Seal Ring (14) d. Back-Up Ring (13) e. Spacer Ring (15) and wear ring (20) f. Seal Ring (16) g. Back-Up Ring (17) h. Seal (36) and Bearing (63) 20) While the cylinder head is lying on its side, remove the following items: a. Spirolox Ring (29) b. Back-Up Ring (28) c. Seal ring (27) d. Back up ring (42) e. Seal ring (45)
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IV.
Assembly Procedure
Reference document SD-010274-04-01 A) Part Preparation Prior to Assembly The work area should be clean and well lighted. 1)
Remove all dirt, grit, oil, and contaminants from the ram bore, ram change piston holes, bonnet stud holes, all fluid passageways in the body and bonnet. Clean detergent and fresh water should be used for cleaning. High pressure air may also be used if it is dry air.
2)
Clean all internal surfaces of the bonnets using clean detergent and fresh water. Lubricate internal sealing surfaces.
3)
Clean pistons and cylinders, using clean detergent and fresh water. Lubricate areas that will come in contact with other parts.
4)
Sealed elastomer containers should not be opened until they are required for assembly. This is to prevent contamination and damage to the seal.
Caution: Never lay the operating piston down so that the seal surface on the connecting rod, tail rod or OD of the piston can be damaged. B) Bonnet Assembly 1)
Place each bonnet (2) on stands or pallets with the body side up.
Caution: Take care to ensure that the bonnet does not roll over. 2)
Install the following parts in the connecting rod bore: a. Back-Up Ring (17) b. Seal Ring (16) c. Spacer Ring (15) d. Wear ring (20) e. Back-Up Ring (13) f. Seal Ring (14) g. Retainer Ring (12) h. Spirolox Ring (11)
3)
Install seals (36) and bearings (63) in the ram change piston bores.
4)
Turn the bonnet over. Set the bonnet on a raised surface which will allow the operating piston connecting rod to be installed through the bonnet past the bonnet face. Install the following items: a. Back-Up Ring (17) b. Seal Ring (16) c. Retainer Ring (18) d. Spirolox Ring (19) 10
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5)
Remove any excess lubricant to prevent it from holding debris.
6)
Lubricate the ram change piston bores, connecting piston bore, ram change cylinder, and operating piston cylinder preparations.
7)
Install the O-rings (31), (51) and back-up ring (52) onto the operating cylinder (23) and install the operating cylinder on the bonnet. The end with the backup ring goes into the bonnet.
8)
Install the O-rings (35) on the ram change cylinders (6) and install the ram change cylinders on the bonnet.
9)
Install the seal rings (30) and wear ring (32) on the operating piston (3) and install on the bonnet.
Caution: Take care to protect the connecting rod and tail portions of the operating piston during assembly. These two surfaces are coated with an abrasion resistant coating that is brittle. The operating piston may be lifted by a C clamp around the tail rod. 10) Prepare the ram change pistons (4 and 5) for installation by installing the seal and bearing (33 and 37). Caution: Take care to protect the piston rod portions of the ram change pistons. 11) Review the appropriate documentation to determine if a left or right hand bonnet is required and refer to the assembly drawing for the proper location of the open and close ram change pistons. Caution: Take care to ensure that the ends of the ram change pistons are not damaged during this operation. 12) Lower the ram change pistons (4 and 5) into the appropriate ram change piston preparations. 13) Coat the shorter threaded end of the studs (25) with thread lubricant. Install the coated ends in the bonnet. Torque until the last of the thread is flush with the surface of the bonnet 14) Install the O-ring (45), back-up ring (42), seal ring (27), back up ring (28) and spirolox ring (29) in the cylinder head (24). Note: If C.O.G ADJUSTING PLATE ASSEMBLY (65) is part of the assembly, mount it before installing screws (26). 15) 15. Install the cylinder head (24) 16) Coat the threaded end of the screws (25) with thread lubricant and tighten the 8 nuts (26) uniformly. (See torque chart). 11 SD-010274-10-01 Rev01
17) Install O-rings (38) on the ram change access caps (7) and install them. Note: There is no torque for these caps. They bottom out in the head. 18) Install the locking housing (43) with six housing screws (46), lubricated with thread lube. (See torque chart) 19) Install O-rings (21) on the seal carrier (20) and lubricate well. 20) Install O-ring (22) on the bonnet and lubricate well. 21) Install seal carrier (20) onto the bonnet by pressing one end in first. Then (using the connecting rod button for leverage) pry the opposite end in while maintaining uniform pressure on the installed end. C) BOP Assembly 1) Install the extension rods (2163165-01) on each of the two top bonnet studs on each side of the BOP. 2) Install lifting eyes in the bonnet and cylinder head of one bonnet assembly. Use these lifting points to bring the bonnet to the BOP straight and level and guide it over the extension rods. 3) Align the ram change pistons (4 and 5) to their respective preparations and thread them in the body. Note: The ram change pistons have different thread sizes. The ‘OPEN’ piston has a thread size of 3 1/8”. The ‘CLOSE’ piston has a thread size of 3”. They should make up and tighten freely, without difficulty. Make sure the proper piston is installed to line up with the proper preparation on the body. The bonnet level may have to be adjusted to allow easy tightening of these pistons. 4) Rest the bonnet on the extensions and remove the lifting slings. 5) Repeat steps 1 thru 4 for the bonnet on the other side of the BOP. 6) Connect the OPEN and CLOSE ports of the BOP to the hydraulic power supply. Note: The operation of Cameron ram type BOPs is as follows: When pressure is applied to the ‘OPEN’ port, the rams will open or retract within the bonnet AND the bonnets will close if they are in the open position. Conversely, when pressure is applied to the ‘CLOSE’ port, the rams will close in on the well-bore AND the bonnets will open if the cap nuts are not installed. All personnel should be clear of the bonnets when operational pressure is applied during the following steps. 7) Apply 1500 psi closing pressure to the BOP (which opens the bonnets 12 SD-010274-10-01 Rev01
completely) and install the ram trays. 8) Apply 500 psi opening pressure to the BOP to clamp the trays between the body and bonnet. This application will also retract the con-rods into the bonnets. 9) Install the rams by sliding them onto the buttons. 10) Apply 500 psi closing pressure to unclamp the trays. This application will also close the rams. Remove the ram trays. 11) Apply 1500 psi opening pressure to the BOP (which closes the bonnets). 12) Remove the extension rods 13) Install bonnet cap nuts (9) and tighten them uniformly. (See torque chart)
Torque Chart Item
Name
Size
46 26 9
Cap Srew Screw Bonnet Cap Nut
2-1/2’’-8UN 2-3/4’’-8UN 5’’-4 ACME
Moly 503 Ft-lb 4325 3500 2000
API 5A Nm 5862 4745 2711
Ft-lb 6295 5096 2912
Nm 8535 6909 3948
V. Operation and Installation A) Preparation Prior to the installation of the preventer, ensure that the following requirements are met: 1)
The capacity and the pressure rating of the accumulators and the pressure pumps must comply with the API RP 53 recommendations or appropriate regulatory agency requirements.
2)
Ensure that the ring gaskets are correct for the preventer flange, the hub size, and the pressure rating.
VI. Maintenance
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A) Routine Maintenance 1)
If more than 500 psi (34.4 Bars) hydraulic pressure is required to operate the ram subassemblies when there is no pressure in the well bore, determine the cause and correct any irregularities.
Caution: To avoid damage to the packers, close pipe and flexpacker rams only when pipe is in the preventer. 2)
Pressure test and operate the preventer once a week per API RP 53
3)
Once a month inspect the tail rod of the operating piston. The surfaces in contact between tail rod and manual locking screw must always be lubricated. Lubricate if necessary.
4)
“Periodic Field Testing” or appropriate regulatory agency requirement.
B) Periodic Maintenance 1)
Once a year, or every six months in cold weather conditions, completely disassemble the preventer.
Note: For a detailed description of disassembly, see Part III, DISASSEMBLY PROCEDURE. a - Clean all parts. Do not use a wire brush on sealing areas. b - Replace all rubber seals, gaskets, and O-rings. c - Replace ram packing according to condition. d - Repair or replace damaged metal parts. 2)
Reassemble the preventer.
Note: For a detailed description of assembly, see Part IV, ASSEMBLY PROCEDURE. a - After reassembling the preventer, test the rams and operating system. Refer to Part VII, TESTING for the correct procedure. VII.Testing A) Hydraulic Operating System
Test the hydraulic operating system after installation. 1)
Flush the hydraulic operating system with clean operating fluid. 14
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Test for proper stroking of the rams and operating system. 1)
Apply a maximum of 300 psi (20 Bars) hydraulic pressure to the OPEN port.
2)
Ensure that the rams open.
3)
Reduce hydraulic pressure to zero psi.
4)
Apply a maximum of 300 psi (20 Bars) hydraulic pressure to the CLOSE port.
5)
Ensure that the rams close.
6)
Reduce hydraulic pressure to zero psi.
Test for leaks in the operating system. 1)
Remove the hydraulic line from the OPEN port.
Note: If testing pipe, casing, or flexpacker rams, be sure that an appropriate size test mandrel is installed into the preventer. DO NOT close the rams on anopen hole unless closing pressure is less that 300 psi. Flexpackers should betested with the largest pipe size for that packer. 2)
Apply 300 psi (20 Bars) hydraulic pressure to the CLOSE port, and observe the OPEN port for leaks.
3)
Increase the pressure to 3000 psi (200 Bars), and observe the OPEN port for leaks.
4)
Inspect for leaks between the bonnet and the BOP body. Bleed all pressure from the BOP closing line.
5)
Replace the hydraulic line to the OPEN port.
6)
Remove the hydraulic line from the CLOSE port.
7)
Apply 300 psi (20 Bars) hydraulic pressure to the OPEN port, and observe the CLOSE port for leaks.
8)
Increase the pressure to 3000 psi (200 Bars), and observe the CLOSE port for leaks.
9)
Inspect for leaks between the body and the bonnet. Bleed all pressure from the BOP opening line.
10) Replace the hydraulic line to the CLOSE port. 15 SD-010274-10-01 Rev01
11) Replace the seals if leaks were observed and repeat the test with new seals. 12) Repeat the procedure for each preventer.
B) Ram Test (After installation and as required by API RP53 or appropriate regulatory agency.)
Hydraulically test ram packers with water using the following procedure: 1)
Install the BOP stack on a prepared test stump or install a test plug below the BOP if on the wellhead.
2)
Inspect for ram packer leaks at low pressure by closing rams on an appropriate size test mandrel (none if blinds or shears are used) with 1500 psi (103 Bars) operating pressure, and apply 200 psi (14 Bars) pressure under the rams. Hold pressure for 3 minutes. Maximum pressure drop is 10 psi (.69 Bars) in 3 minutes.
3)
Increase pressure slowly to the rated working pressure of the preventer. Hold pressure for 3 minutes. Maximum pressure drop is 100 psi (7 Bars) in 3 minutes.
4)
If rams leak at low pressure or at working presure, inspect for worn ram packers and replace if necessary.
5)
Repeat the above procedure for each set of casing, pipe, shear, and flexpacker rams.
VIII.Storage A) Preventer 1)
Open the bonnets and remove the ram subassemblies.
2)
Remove the top seals and packers, then wash the ram subassemblies.
3)
Lubricate the ram bodies, covering them with a heavy grease.
Caution: DO NOT lubricate the top seals or packers. 4)
Do not store the ram subassemblies inside the preventer.
Note: Rubber products that have been put into service and that are subsequently stored, will have an unpredictable shelf-life. This is attributable to their varied physical condition when returned to storage, due to the inability to completely 16 SD-010274-10-01 Rev01
remove elastomeric solvents (hydrocarbon contaminates, etc.) and storage in a container filled with air (chemically active gases). 5)
Clean the inside and outside machined surfaces of the preventer.
6)
Dry with an air blaster until no moisture is left inside or outside the preventer.
7)
Inspect the ram bores and the vertical bores for burrs.
8)
9)
Remove burrs by touching the surface lightly with a grinder using 36 to 60 grit paper. Lubricate the ram bore with a heavy grease.
10) Lubricate the end and outlet connection faces with a heavy grease and cover them with flange protectors. 11) Flush the operating system using clean operating fluid. 12) Fill the operating system with preservation fluid. 13) Install pipe plugs into the OPEN and CLOSE connections. Caution: DO NOT use the bonnet lifting eyes to lift a preventer. 14) 14. To lift the preventer, use ropes or slings around the ends of the body.
B) Elastomers 1)
Store rubber products inside a cool dark, dry storage area. a - The preferred storage temperature range for rubber goods is from 40°F (5°C) to 80°F (25°C). b - Rubber goods should be wrapped or otherwise protected from direct exposure to sunlight or artificial light with a high ultraviolet content (such as fluorescent lighting). Do not store in direct sunlight even if wrapped, as overheating will result. c - Store rubber parts in a relaxed position. Do not stretch or hang O-rings and seals. Labels should not be attached to seals with string, wire, or tape, as these items may deform the sealing surface.
2) 3)
Use airtight containers when possible to protect against circulating air. Ozone is extremely harmful to rubber. Ensure that there is no equipment in the storage area which may generate ozone, such as mercury vapor lams, high-voltage electrical equipment, electric motors, or any electric apparatus which produces arcing. 17
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4)
Keep the rubber products clean and free of solvents, oil, greases, or any other semisolid or liquid materials during storage. Rubber goods should specifically be protected against direct contact with: manganese, copper, copper alloys (including brass), polyvinyl chloride (PVC), creosoteimpregnated timber, other rubber goods of different rubber compounds, sulfur, and copper napthenate.
5)
When cleaning is necessary, rubber goods may be cleaned with either soap and water or methyl alcohol. After cleaning, the rubber goods should be dried at room temperature.
6)
Examine the part before installation.
Important: Rubber goods taken from storage must ALWAYS be inspected before installation. Rubber goods should not be flexed at temperatures below 40°F (5°C). Rubber goods in storage should be inspected every 12 months to ensure that they are still serviceable. a - Ensure that the part does not have a tacky surface or noticeable softening or hardening of the surface. b - Flex the part and inspect with a magnifying glass to ensure that there are no cracks. c - Replace items which show any of the aging signs mentioned above.
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