User’s Manual

BOP Control System

Ideal Rig
WITH PLC OPERATED REMOTE
PANELS AND ALARMS

Customer Name Reference Reference Description

National Oilwell Varco BOP Control System
Rig Name
This document contains proprietary and confidential NOV SARA
Ideal Rig information which belongs to NOV SARA ; it is loaned for
limited purposes only and remains the property of NOV 7/1, Pritam Road
Sales Order Number Dehradun - 248001, India
SARA. Reproduction, in whole or in part; or use of this
design or distribution of this information to others is not Tel +91 135 2672395
permitted without the express written consent of NOV Fax +91 135 2673109
SARA . This document is to be returned to NOV SARA www.NOV.com
upon request and in any event upon completion of the use
for which it was loaned.
© NOV SARA

Document Number Rev.

29101501 A

Sara
Revision History

A 19.11.2008 Isued for implementation Naveen Naveen KKD

Rev Date (dd.mm.yyyy) Reason for Issue Prepared Checked Approved

Change Description
Revision Change Description

A First Issue
 BOP Control System
Revision A
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Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Chapter 2: System Description

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
BOP Control Sysrem Accumulator Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operating Fluid and Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Remote Control Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Control Panels – Theory of Operation2-8
Emergency Battery Backup2-8
BOP Control System Components2-9
General Safety Precautions2-14
Electric Circuit Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Hydraulic Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Cable and Hoses Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Work Area Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Use Correct Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Chapter 3: Installation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Accumulator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Drill Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Illustration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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Table of Contents
Chapter 4: Operation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accumulator Unit Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Air pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electric Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hydraulic Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Air Remote Control Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Chapter 5: Maintenance
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Accumulator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Air Operated Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Electric Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
1 " TR Pressure Reducing and Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . 5-7
1" AMKR Pressure Reducing and Regulating Valve. . . . . . . . . . . . . . . . . . . . . . 5-11
Gallon 3000 PSI Accumulator Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Hydraullic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Model TD60 Triplex Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Chapter 6: Trouble Shooting Instructions

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Accumulator Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Air Supply Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Pump Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electric Motor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Four Way Valve Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Gauge Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Regulator Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Engineering Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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General Information
This manual is intended for use by field engineering, installation, operation, and
repair personnel. Every effort has been made to ensure the accuracy of the
information contained herein. NOV SARA will not be held liable for errors in this material,
or for consequences arising from misuse of this material.

Conventions

Notes, Cautions, and Warnings

Notes, cautions, and warnings provide readers with additional information, and to advise
the reader to take specific action to protect personnel from potential injury or lethal
conditions. They may also inform the reader of actions necessary to prevent equipment
damage. Please pay close attention to these advisories.

Note:

i
The note symbol indicates that additional
information is provided about the current topics.

Caution:

The caution symbol indicates that potential damage to

equipment or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken
when performing operations or procedures preceded
by this caution symbol.

Warning:

ning
War

The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
observe and follow proper procedures could result in
serious or fatal injury to personnel, significant

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Illustrations
Illustrations (figures) provide a graphical representation of equipment components or
screen snapshots for use in identifying parts or establishing nomenclature, and may or
may not be drawn to scale.

For component information specific to your rig configuration, see the technical drawings
included with your NOV SARA documentation.

Safety Requirements
NOV SARA equipment is installed and operated in a controlled drilling rig environment involving hazardous
situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in NOV
SARA manuals are the recommended methods of performing operations and maintenance.

To avoid injury to personnel or equipment damage,

carefully observe requirements outlined in this

Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.

Personnel should wear protective gear during

installation, maintenance, and certain operations.

Contact the NOV SARA Equipment training department for more information
about equipment operation and maintenance training.

Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
described. NOV SARA recommends that only those tools specified be used when stated. Ensure
that personnel and equipment safety are not jeopardized when following service
procedures or using tools not specifically recommended by NOV SARA.

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General Information 1

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such
as electrical, hydraulic, pneumatic, or cooling water.

Read and follow the guidelines below before installing

equipment or performing maintenance to avoid
endangering exposed persons or damaging
equipment.
..

qIsolate energy sources before beginning work.

qAvoid performing maintenance or repairs while the equipment is in operation.

qWear proper protective equipment during equipment installation, maintenance, or

repair.

Replacing Components
qVerify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
qReplace failed or damaged components with NOV SARA certified parts. Failure to do
so could result in equipment damage or injury to personnel.

Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for
maintenance recommendations.

Failure to conduct routine maintenance could result in

equipment damage or injury to personnel. section.

Proper Use of Equipment

NOV SARA equipment is designed for specific functions and applications, and
should be used only for its intended purpose.

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System Description

This NOV SARA manual provides installation, operation, and maintenance information for
the NOV SARA BOP Control System. This chapter provides an overview of the system
components and their functions.

Introduction
The BOP Control System is a skid mounted pumping assembly consisting of fluid
storage tank, hydraulic pumps, control valves, regulators and various control components.
See Figure 2-1. The BOP Control System provides pressurized fluid for the BOP system
using the same electric driven hydraulic triplex pumps & Air Pumps. Hydraulic pressure from
both the pumps is stored in the accumulator bottles mounted on the skid. The accumulator
bottles have a working pressure of 3,000 psi (207 bar) dedicated to the BOP system.

In addition to the above, there is a remote control panel that remotely operate the rams,
annular and choke & kill valves on the master hydraulic control manifold on the The BOP
Control System. It should be noted the remote panel does not interfere with the manual
operation of the control valves at the The BOP Control System. The valves may be remotely
operated at the remote control panel or manually at the The BOP Control System.

The following describes the components of the BOP control system.

Figure 2-1. BOP Control System

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System Components
The following describes the components of the BOP control system.

Accumulator Bottles

The accumulator bottles within this control system

are nitrogen gas precharged to high pressure and
are not protected by an over-pressure relieving
device. Steps should be taken to prevent over-
pressuring and possible failure of these bottles due
to the excessive heat associated with fire.
Consideration should be given to the hazards
associated with these bottles and the provision for
adequate fire protection measures.

Twenty Four 11-gallon (41.6-liter) accumulator bottles are mounted on the BOP Control System. All
have a working pressure of 3,000 psi (207 bar).

Each float accumulator bottle contains nitrogen. The nitrogen pressure in the accumulator
bottles is charged to 1,500 psi (103 bar) through the cap at the top of the bottle. The
hydraulic fluid is then pumped into the bottle cavity through the lower end and the nitrogen
is compressed until the maximum working pressure is reached.

Each header/bank is provided with a shutoff valve, a pressure gauge, and a bleeder valve.

The shutoff valves control the flow of hydraulic fluid to and from each header. In normal
operation, the shutoff valve is open and allows fluid to enter the accumulator banks and
pressurize the system. For repair operations of any equipment on the hydraulic control
manifold, the accumulator bottle rack shutoff valves are closed, thus maintaining system
pressure in the four accumulator header banks. Pressure in the manifold piping is then
bled off, and the maintenance operation is performed. After repairs to the control manifold
are completed, the shutoff valves to the pressurized accumulator banks are reopened and
the system is back on line, fully pressurized.

The bleeder valve on each header enables the pressurized fluid in the bank to be vented
into the reservoir. In normal operation, the bleeder valve is closed. Prior to maintenance
operations on an accumulator bank, the bleeder valve is opened and the fluid in the
accumulator banks is vented into the reservoir.

The pressure gauge reads the manifold supply pressure, which is normally 3,000 psi
(207 bar). Prior to starting maintenance operations, the header should be vented and the
gauge pressure should read 0 psi (0 bar).

The relief valves, set at a pressure of 3,300 psi (228 bar), relieve any over-pressure
condition.

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Introduction 2

Pumps
The BOP control system is provided with two independent pumping systems that are
mounted on the BOP Control System skid. Each system consists of a 60 HP electric
motor/Triplex pump assembly. Either pump system is capable of supplying fluid to the
accumulators at full operating pressure.

Electrically Operated Hydraulic Pump

The electrically operated hydraulic pumps pressurize the system accumulator bottle racks.
The triplex pumps are complete with 480/380 VAC, 3-phase, 60HZ/ 50 Hz explosion-proof
motors.The triplex pumps generate hydraulic pressure for the BOP control system (see
Figure 2-2).

Each pump is fitted with an ON/OFF pressure switch assembly. One pump is set to turn on
when the system pressure falls below 2,800 psi (193 bar), and turn off when the system
pressure reaches 3,000 psi (207 bar). The other pump is set to turn on when the system
pressure falls below 2,750 psi (190 bar), and turn off when the system pressure is greater
than 2,900 psi (200 bar). This lead/lag design minimizes pump duty cycles for maximum
pump life.

60 Hp Motor

RESERVOIR

Triplex Pump
Assemby

Figure 2-2 Triplex Pump Assembly

Control Manifold
The master hydraulic control manifold is integral with the BOP Control System. See Figure 2-3
on page 2-4. The hydraulic control manifold should be located 100 to 150 feet from the well
bore and controlled by a panel near the driller. If a blowout occurs, controls on the drill floor
might be destroyed or become inaccessible. The hydraulic control manifold should be located
within the recommended distance so that the well can be closed in quickly. The control system
has separate hydraulic supply manifolds for the BOP Ram and Annular circuits. The first
manifold supplies hydraulic pressure to the 4-way control valves that operate the ram-type
preventers and stack mounted gate valves. The other manifold supplies hydraulic pressure to
the 4-way valve that operates the annular preventer. A MKR pressure regulator is installed
upstream of the BOP Ram control manifold. This regulator is factory preset at 1,500 psi (103
bar), the hydraulic operator’s normal working
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pressure for the BOP Ram preventers. A quick-opening regulator bypass valve, capable of being
remotely operated, is fitted to allow the full 3,000 psi (207 bar) accumulator pressure to the ram
preventers for fast, positive closure in emergency situations. A high-pressure strainer is installed
upstream of the regulator and 4-way valves to reduce the possibility of foreign matter affecting the
sealing capacity of the valves.

A remotely controlled, hydraulic pressure HMKR regulator is also provided upstream of the 4-way
valve controlling the annular preventer. It is capable of regulating and maintaining pressures from
500 psi (73 bar) to 1,500 psi (130 bar). It is also capable of relieving pressures in excess of its set
operating pressure to minimize buildup in the annular preventer during stripping. A high-pressure
strainer is also located upstream of the annular preventer regulator and 4-way valve.Clearly marked
nameplates on the control manifold indicate which Ram preventer or hydraulic valve each 4-way
control valve operates and indicates the position. During drilling operations, valves should be left in
either “open” or “close” position – never in the center (block) position.

Regulator Bypass

Kill Choke Shear Pipe Blind

Annular
Valve valve Ram Ram Ram

Figure 2-3 The Master Hydraulic Control Manifold

Operating Fluid and Reservoir

Hydraulic Fluid

A clean, lightweight high-quality hydraulic control fluid, or fluid concentrate, which is

capable of being mixed with potable water, should be used as the operating fluid. Do not
use motor oil, kerosene, diesel fuel, chain oil, or petroleum products containing aromatics
that can damage rubber components and seals.

Reservoir capacity equals approximately twice the usable fluid capacity of the accumulator
system. Access ports of 4"ID (102 mm) are at each end of the reservoir to allow detection
of any leaking components on the manifold. Internal baffles in the reservoir restrict fluid
movement should the unit be transported.

Hydraulic fluid should have the following properties:

No freezing in cold climates

q

Lubricity to reduce wear

q

Chemical compatibility with the elastomer seals

q

Corrosion inhibitors for metal surfaces

q

Where pollution due to accidental spillage of hydraulic fluid is a problem, use environment
safe water-based fluid or pre-mixed fluids.

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Introduction 2

i
To prevent freezing at temperatures below 35°F (2°C),
ethylene glycol without any additives is recommended.

Do not use commercial antifreeze mixes.

Reservoir
The reservoir capacity of 350 gallons (1325 liters) equals approximately twice the usable
fluid capacity of the accumulator system. Access ports of 4? ID are placed at each end of
the reservoir for visual inspection of the inside of the reservoir, and to allow detection of
any leaking components on the manifold. Internal baffles in the reservoir restrict fluid
movement when the unit transported.

Junction Box
The BOP Control System is provided with a junction box mounted on the BOP Control System
skid (see Figure 2-6 on page 2-12). Behind the junction box are the solenoid valves for remote
operation of the Annular AMKR valve and 4-way control valves. The AMKR valve has two
solenoids, one for the increase function and one for the decrease function. Each 4-way control
valve has two solenoids, one for each operating position (e.g. close, open).
The junction box houses the pressure switches which operate the indicator lights on the remote
control panel. The junction box also contains pressure transmitters which convert the fluid
pressure at the HPU gauges to electrical signals to register the pressures on the electric meters
on the Driller and Toolpusher’s control panel.
The HPU Junction Box has the following alarm indicators and buttons installed on the front
cover of the junction box:

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Gauges
The BOP Control System is fitted with a number of gauges for monitoring of critical parameters. The
BOP Control System gauge panel has the following indicators:

BOP Manifold Pressure

q

BOP Accumulator Pressure

q

Annular Pressure
q

Bypass Valve
The BOP Control System hydraulic control manifold Bypass Valve (see Figure 2-11) is intended for
emergency use only. The bypass valve can be operated at the BOP control system control panel or
remotely from the Driller or Toolpusher’s control panel. During the drilling operation, it remains in the
normal position. In an emergency, this valve can be moved to the bypass position, which allows the
full 3,000 psi (207 bar) accumulator pressure to flow to all functions in the hydraulic control manifold.

Low High

Figure 2-4. Bypass Valve Assembly

In addition to the above, the accumulator bottles may be isolated and the electric pumps used to
pump the rams closed.

Remote Control Panel

The BOP control system is operated from the remote control panel (see Figure 2-5 on page 2-7). The
remote control panel has a sufficient number of buttons to remotely operate all 4-way valves on the
BOP control system hydraulic control manifold to either the 'Open' or the 'Close' position and to
remotely control the operation of the BOP annular pressure. In addition, the annular and accumulator
pressures can be monitored from this panel.

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Introduction 2

Figure 2-5 Remote Control of Panel(Driller's Panel Shown)

The remote control panel is a steel junction box with buttons mounted on the front doors of the panel
arranged as a mimic of the BOP and Diverter systems.

The Driller's remote panel are acceptable for installation in a Zone 1 hazardous area.

Function Button/Indicator Lights

The remote control panels contain combination button/indicator lights for control and indication of the
BOP stack functions and status.

Push And Hold Button

Located near the panel stack overlay is the Push And Hold button. This button must be held down
continuously with one hand while the appropriate function push button is operated with the other hand.
The two-handed operation prevents accidental operation of any control function.

Another safety feature of the remote panels are the acrylic covers mounted over certain critical BOP
stack functions. These covers must be lifted before the function buttons can be operated. The covers
prevent accidental activation of any of the critical BOP functions.

Lamp Test Button

When the Lamp Test button is pushed, all lights on the remote control panel will illuminate. The Lamp
Test button enables rig personnel to locate quickly any burned-out lamps on the panel. The Lamp Test
button should be pushed at the beginning of each work shift to confirm that all lights are operational.
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i
The Lamp Test button does not require the Push And
Hold button to be activated.

Pressure Indicators
There are two pressure indicators on the remote control panel:
q Accumulator Pressure
q Annular Pressure

Control Panels – Theory of Operation

At the remote control panel, while holding the “Push & Hold” to Operate button, the driller initiates a
function such as upper annular close by pushing the “Upper" Annular Close” button. This sends an
electric signal to energize the solenoid in the junction box, which is dedicated for the specific function, in
this case “upper annular close.” When the solenoid energizes, it sends air pressure to the actuator on the
4-way control valve. This moves the valve lever to the right. This allows regulated hydraulic pressure to
flow through the valve and close the upper annular.

The indicating lamp at the control panel is activated by the use of (normally open) pressure switches
connected to the regulated hydraulic fluid sent to close the upper annular. In this instance the green lamp
was illuminated for the upper annular open function. However, when the upper annular “close” function
was activated, this vented the pilot signal for the upper annular “open” function, which allowed the
pressure switch to return to its normally open position breaking the electric circuit to turn off the green
lamp. Conversely, the pilot signal for the upper annular “close” also closes the pressure switch for that
function. This completes the electric circuit, which turns the red lamp on for the upper annular close
function.

Emergency Battery Backup

In the event the rig electric power supply is unavailable, the emergency battery backup system supplies
24VDC power to the hydraulic power unit PLC junction box, and the remote control panels. In this
manner the BOP control system will remain operational until the electric power stored in the battery
backup system is depleted, before this occurs the rig electric power supply must be restored or the
blowout preventers closed.

i
The emergency battery backup system does not supply
power to run the triplex pumps.

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Introduction 2

For more information on the emergency battery backup system see the Vendor Documentation in this
manual.

BOP Control System Components

Figure 2-6 on page 2-12 and Figure 2-7 on page 2-13 show a typical pumping unit and the location of the
components on the unit. This figures are used as an example ONLY; customers equipment may vary in
components and quantities used. Item numbers refer to the figures.

1. Customer Air Supply (1) – Normal air supply is at 100 psi (7 bar). Higher air pressure may
require an air regulator.

2. Air Filter – Filters supply air with 40 micron element.

3. Check Valve – 1” free flow.

4. Lubricator – Lubricates supply air for air pumps.

5. Poppet Valve – Air pilot operated valve controlling supply air pressure to the air pumps. Valve
controlled by a pressure switch set at 2,900 psi.

6. Suction Strainer – Located in each suction line of the air pumps. Clean every 30 days.

7. Air Pumps – 43:1. Secondary pressure source.

8. Electric Motor Driven Triplex Pump Assembly – Primary pressure source. Horse power rating
can vary.
9. Check Valve – High pressure fluid.

10. Automatic Pressure Switch – Pressure switch is set at 3,000 psi (207 bar) cutout and 300-400
psi (21-28 bar) cut-in differential. Adjustable.

11. Electric Motor Starter (Automatic) – Automatically starts or stops the electric motor driving the
triplex pump. Works in conjunction with the automatic pressure switch and has a manual
on/off/auto switch.

12. 4-Way Valves – With air or hydraulic cylinder actuators for remote operation from the control
panels. Keep in standard operating mode (‘Open’ or ‘Close’)—never in the center position.

13. Bypass Valve – With air or hydraulic cylinder actuators for remote operation from the control
panels. In ‘Low’ position, 1,500 psi (103 bar), it allows regulated pressure on control valve
manifold, and in ‘High’ position, 3,000 psi (207 bar), it allows full accumulator pressure on the
control valve manifold. Keep in ‘Low’ position, 1,500 psi (103 bar), unless 3,000 psi (207 bar) or
more is required on ram-type BOPs.

14. Alternate Hydraulic Supply – Connection point for supply of fluid from other source.

15. Accumulators – Check nitrogen precharge in accumulator system every 30 days. Precharge
should be 1,500 psi (83 bar) ±10%. Size and configuration may change per order specification.

i
Use nitrogen when adding to precharge. Other gases
and air may cause fire and/or explosion.

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16. Pressure Reducing and Regulating Valve – Manually operated. Adjust to the required
continuous operating pressure of ram type BOPs. Typically 1,500 psi (130 bar).

17. Pressure Reducing and Regulating Valve, Air Operated – Reduces the accumulator pressure
to the required annular BOP operating pressure. Pressure can be varied for stripping operations.
Maximum recommended operating pressure of the annular preventer should not be exceeded.

18. Pressure Gauges – Panel of 6” gauges providing typical readings of: a. Annular Pressure
b. Accumulator Pressure
c. Manifold Pressure

19. Annular Increase and Decrease – Remote air control valve for increasing ordecreasing the
annular regulator (Item 17).

20. Control Valve Manifold – 3,000-psi (207 bar) W.P., 2" (5 mm).

21. Junction Box (J-Box) – Component housing for electric remote panels. Houses the system
pressure switches, pressure transmitters and solenoids.

22. Air Receiver – 30 gallon air supply for operating the air solenoids in the J-box. Systems with air
remote operated control panels have a 7 gallon air receiver.

23. Hydraulic Bleeder Valve – Manually operated, normally left closed.

i
This valve should be kept open when precharging the
accumulator bottles.

24. Air Shut Off Valve – Ball valve controls supply air to the air pumps.

25. Air Pressure Transmitters – Transmitters used in conjunction with air remote operated control
panels. Replaces J-Box (Item 21). Provides typical readings of:
a. Annular Pressure
b. Accumulator Pressure
c. Manifold Pressure

26. Transmitter Regulator – regulates the operating pressure to the transmitters.

27. Suction Strainer – Located in the suction line of the electric pump. Clean every 30 days.

28. Relief Valve – Accumulator supply pressure set at 3,300 psi.

29. Pressure Gauge – Accumulator supply pressure.

30. Bleed Valve – Bleed or drain accumulator header (Item 32) pressure.

31. Reservoir Drain Plug

32. Accumulator Header with Shut off Valve – Mounting point for accumulator bottles.

33. Inspection Plug Port

34. Hydraulic Fluid Fill Port

35. Suction Shut-off Valve – Located in the delivery line of the triplex pump.
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Introduction 2

36. Junction Plate (Primary) – Connection point for air hose bundle between the HPU and the
remote air operated control panel.

37. Junction Plate (Secondary) – Connection point for air hose bundle between the HPU and a
secondary remote air operated control panel.

38. Fluid Shut Off Valve - Ball valve controls fluid from reservoir to air pumps.

39. Accumulator Shut Off Valves - Valve controls high pressure fluid to accumulators.

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Figure 2-6 Typical Accumulator Unit

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Introduction 2

Figure 2-7 Typical Accumulator Unit (Top View)

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General Safety Precautions

Operation of the control systems may present certain hazards that require the attention
and caution of operators and technicians. Normally, many hazards are avoided by
observing and exercising standard safety precautions.

Electric Circuit Safety Precautions

Certain safety precautions must be exercised regarding the electric circuits of the control
system. The precautions will prevent damage to equipment and injury to personnel that
might result from electric power. Personnel engaged in electrical work should receive
proper instruction in accident prevention and first aid procedures.
qAn electric power source must be supplied at correct voltage, current, and phase
to enable safe and correct operation of equipment.

qExercise caution when working around exposed electrical conductors, terminals,

and remotely activated equipment.

qEnsure flashproof integrity of explosion-proof electrical junction boxes,

connections, and circuit breakers. This will prevent fires or explosion that might
result from a spark during electrical switching.

qDo not override or tamper with electrical or mechanical interlocks and safety
devices.

qBefore attempting any corrective action on the electrical circuit, verify that all
electric power sources have been removed from the circuit. Ensure that all
electrical switches are set to “Off” and the appropriate breakers are set to “Open”.

qDo not service or adjust the electrical circuits alone. Always verify that a qualified
person is present who can render aid in case of accident and who is familiar
with emergency shutdown procedures.

qAppropriate warning tags labeled “Requiring Open Circuit Condition” shall be

placed on all necessary switches and circuit breakers to prevent accidental
application of power to units of the system during maintenance procedures.

qWear suitable protective clothing while working within 4 ft. of exposed electrical
equipment. Do not wear rings, wrist watches or clothing with exposed metal
buttons, zippers or fasteners.

qMetal handles of hand-held tools should be insulated by an approved taping,

coating or sleeve method.

qWhenever it is necessary to work on electrical circuits or equipment in wet or

damp locations, dry, wooden (or similar non-conducting material) platforms should
be provided to prevent the possibility of contact between the wet floor and the
worker’s Shoes

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Introduction 2

Pneumatic Circuit Safety Precautions

Pneumatic power source supplied to the control unit is of sufficiently high pressure and volume to present
a hazard if required safety practices are not followed. Exercise the following precautions to aid in
preventing damage to equipment and injury to personnel that might result from pneumatic power.

Ensure that the pneumatic power source is supplied at adequate pressure and volume to enable
q
safe and proper operation of equipment. Maximum system air pressure is 125 psi (9 bar).

Ensure that the air is filtered to prevent any dirt or debris from entering the Pneumatic circuit.
q

Ensure that air is dried and lubricated before it pilots or operates any motor (hydraulic pump);
q
moisture can damage components and result in unit failure.

Should there be a rupture or break in the pneumatic circuit (when pressurized), do not place
q
hands, face, or any part of the body over the escaping air. Severe bodily injury may result.

Before attempting any corrective action on the pneumatic circuit, verify that the pneumatic power
q
source is cut off and that all pneumatic pressure is completely vented. Verify that all pneumatic
pressure gauges read 0 psi (0 bar).

Hydraulic Safety Precautions

Hydraulic power source produced by the accumulator control/pump unit is at sufficiently high pressures
and volumes to present a hazard if required safety practices are not followed. Exercise the following
precautions to aid in preventing damage to equipment and injury to personnel that might result from
hydraulic power related accidents:

Mop
q up spilled hydraulic fluid immediately. Immediately investigate and correct the because of any
leakage of hydraulic fluid.
If clothing
q becomes drenched with hydraulic fluid, change immediately to dry clothing. The fluid is
severely irritating to eyes and skin. Prolonged contact with hydraulic fluid may cause dermatitis,
which may progress to allergic sensitization.
Ensure that only correct hydraulic fluid is supplied and used for safe and correct operation of the
q
control systems unit.

Hydraulic fluid must be filtered to prevent any dirt or debris from entering the hydraulic circuit.
q

Ensure that the pressure relief valves are in working condition, and that the valves are set to
q
relieve at their designated pressure levels.

Should there be a rupture or break in the hydraulic circuit (when pressurized), do not place hands,
q
face, or any part of the body over the escaping jet stream of fluid. Severe bodily injury will result.

Never
q torque leaking connections or fittings while lines are pressurized. Application of torque to
fitting or connections while lines are pressurized may cause lines to rupture and result in
injury to personnel.

Before attempting any corrective action on the hydraulic circuit, verify that:
q

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The electric power source is turned off.

q

The pneumatic power source is turned off.

q

All hydraulic pressure is completely vented. Verify that all hydraulic gauges read
q
0 psi (0 bar).

When precharging accumulators, use only dry nitrogen gas. The use of another gas
q
may cause unit failure or explosion.

Cable and Hoses Safety Precautions

Protect all hydraulic hoses from cutting, scraping, pinching, abrasion or any physical damage. Route
q
all cables and hoses outside of the crew’s traffic patterns and away from mechanical equipment.

Welding or acetylene cutting must not be done near unprotected cables or hoses, as this may result
q
in damage to cables or hoses.

Consideration must always be given to the prescribed minimum bend radius for cables and hoses.
q
Twisting or bending cables or hoses beyond the minimum bend radius can damage the insulation,
conductors, or reinforcing wire shield

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Introduction 2

Work Area Safety Precautions

The following safety precautions should be observed in the work area:

Work in an area free of any dangerous obstructions, chemicals or hazards.

q

If any dangerous obstruction is located overhead, to the side, or on the surrounding

q
floor of the work area, the hazard must be removed as safely and quickly as
possible by appropriate personnel.

If any flammable materials are located or are spilled within or in proximity to the
q
work area, the hazardous material must be removed and cleaned from the work
area. Flammable materials include but are not limited to those listed below:

Oily rags, paper products or any combustible solid.

q

Kerosene, gasoline or any combustible liquid.

q

Oxygen tanks, acetylene tanks or any combustible gas.

q

Should any condition, situation, or circumstance occur that may pose serious hazard(s),
appropriate action must be taken to correct or remove the hazard(s) from the work area and to
return to a safe working environment.

Use Correct Replacement Parts

Many Koomey system components are specially manufactured to system design and
specifications, although apparently similar to commercial available hardware. To avoid
possible hazardous failures, use only NOV SARA replacement parts, components, and
assemblies.

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Installation

General
The following instructions explain how to hookup and checkout a standard Sara BOP
Control Unit. These guidelines will ensure that all the equipment is operational so that
drilling operations may begin safely.

Located in the Specifications and Spare Parts Section of this manual are drawings containing
information necessary to properly install the equipment. Also, in order to identify
specific component parts referenced in the Operation Manual, it may be necessary to
review the assembly drawings and material lists also located in the parts Section.

While reviewing the instructions, particular attention is called to all notes and cautions
as these are important to ensure safety during all phases of equipment use.

There are two major steps that must be performed during all phases of equipment use.
Wherever the following instructions are given, refer to these steps :-

Stop Pumps
a. Close air supply valves.

b. Turn triplex pump motor starter to OFF position.

Start Pumps

a. Open air supply valves.

b. Turn triplex pump motor starter to AUTO position.

Accumulator Unit

Set Up Location
1, The distance recommended to provide maximum protection of the accumulator
unit during a blowout or other emergencies is approximately 150 feet from the
well bore.

2. Location placement should consider maintenance and service with respect to :-

a. Accessibility

b. Illumination

c. Ventilation

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3. Accumulator unit SHOULD NOT be:

a. Placed near oxygen storage.

b. Where there would be high heating effects from surrounding

equipment.

Inspect Reservoir
1. Open the 4" inspection/fill ports on the sides of the fluid reservoir and make
sure the tank is free of any debris that could contaminate the system. A clean
reservoir reduces maintenance costs. For reservoir cleaning see Maintenance
Section .

2. Make sure all reservoir connections are tightly secured.

Fill Reservoir
1. Fill with a high quality SAE 10 hydraulic oil to 8" from the top of the reservoir.

Check Accumulator Precharge

(See Nitrogen Precharge Instructions in the Maintenance Section )

1. Open the manifold bleeder valve.

2. Open the accumulator bank isolation valves.

3. Remove the guard from the valve stern of the accumulator and attach a
Charging and Gauging Assembly (P/N 0902-0100).

4. Screw on gauge and screw down T-handle.

5. Gauge pressure reading should be 1500 psi + 100 psi.

a. Low precharge reading:

(1) Attach the precharge line from the nitrogen bottle to the charging and
gauging assembly. procedures

Do not use Oxygen

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Installation 3

(2) Slowly open the nitrogen bottle valve until the precharge pressure
reaches 1500 psi.

(3) Close the nitrogen bottle valve and verify that the gauge reading is still
1500 psi.

b. High precharge reading:

(1) Open the charging and gauging assembly bleeder valve until the
precharge drops to 1500 psi.

(2) Close the bleeder valve and verify that the gauge reading is still 1500 psi.

i
Keep A Charging And Gauging Assembly Accessible To
The Accumulator Unit..

Check Air Pumps

1. Check that the air lubricator is full of SAE 10W lubricating oil.

2. Close the air supply valve(s).

3. Close the air pressure switch bypass valve (if so equipped).

4. Purge a 1" airline from the main rig air supply line and connect it to the customer
air supply connection on the accumulator unit.

Check Electric Pumps

1. Turn off the electrical power at the rig main generator panel.

2. Turn the triplex pump motor starter switch to the OFF position.

3. Ensure that the accumulator unit is grounded.

4. Check the resistance, voltage, and current of the power lines to be connected.
For electrical power requirements see the Installation Data .

5. Connect the electrical power lines to the three-phase terminal connections In

the triplex pump motor starter (See Starter Wiring Diagram located in Parts
Section). Similar metal conductors (copper) should be used. Ensure that a
good ground connection is made.

6. Check that the triplex pump crankcase is full of oil (weight will vary with the
ambient temperature). For crankcase oil specifications see Maintenance
.

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2. Close the air supply valve to each pump.

3. With the rig main generator power ON, place the triplex pump motor starter
switch to the AUTO position. Check that the pump runs smoothly and without
leaks.

4. Close the manifold bleeder valve.

5. Open all air supply valves.

6. Set air lubricator to 6 drops per minute.

7. Pumps should continue running until accumulator pressure reaches 3000 psi. If
problems occur during initial start-up, consult the Troubleshooting Section.

Interconnect Piping
1. Lay interconnect piping of sufficient size and pressure rating from the
accumulator unit to the connections on the Blowout Preventer stack.

2. Connect Piping to the function outlets on the back of the accumulator unit. DO
NOT connect to BOP stack.

Check Valve Positions

1. Place all four-way control valves on the hydraulic manifold in the CENTER
position.

2. Place the manifold regulator bypass/internal override valve in the LOW

pressure (handle left) position.

3. Open the manifold bleeder valve.

4. Open the suction valves of all pumps.

5. Check that the air pressure switch bypass valve is closed (if so equipped).

6. Check that the accumulator bank isolation valves are open.

7. Check that the accumulator bank bleeder valves are closed

Verify Gauges
1. All gauges on the hydraulic manifold should read 0 psi.

2. Air supply gauge should read 125 psi.

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Installation 3

Start Pumps

1. With the manifold bleeder valve in the OPEN position, alternately open the air
supply valve to each pump to ensure that each pump operates smoothly and
without leaks.

Check Pressure Switches

1. After the system pressure has reached 3000 psi and the pumps have stopped,
open the manifold bleeder valve.

2. Pumps should automatically start when accumulator pressure is 2500-2700 psi. If

lower, the pressure switches need adjustment (See Maintenance Section ),

3. Close manifold bleeder valve and recharge the system to 3000 psi.

Check Gauge Readings

1. All accumulator pressure gauges should read 3000 psi.

2. Manifold pressure gauge should read 1500 psi i.e. the pressure setting of the
manifold regulator. To adjust the manifold regulator set ting see Operation Section

A. Alternately decrease and increase the setting of the manifold regulator and
verify the correct response on the manifold pressure gauge.

B. Move the manifold bypass/internal override valve into the HIGH pressure
(handle right) position and verify that the manifold pressure gauge increases to
3000 psi.

3. Annular pressure gauge should indicate the pressure setting recommendations of

the annular preventer manufacturer. To adjust the annular regulator see Operation
Section . Adjust annular regulator through various operating pressures and
check for correct response on the annular pressure gauge.

7. Check that the chain guard is filled with oil. For chain guard oil specifications see
Maintenance Section

8. Turn on the electrical power at the rig main generator panel.

9. Check the rotation of the motor by turning the triplex pump motor starter switch to
AUTO and then OFF. If the rotation is backwards from arrow indication on chain
guard, swap any two-phase terminal connections to reverse the motor rotation.

10. Use a sealing compound with a melting point of at least 200°F and pour the
electrical conduit seal. Seal should be at least 5/8" thick.

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Connect To Bop Stack

1. Move the manifold bypass / internal override valve into the LOW pressure (handle
left) position.

2. Stop pumps.

3. Open manifold bleeder valve and relieve system pressure.

4. Make sure swivel-joint and hammer union connections on function outlets are tight
and secure.

5. Start pumps.

6. Open each four-way control valve to flush the Open function line.

Do Not Flush With High Pressure.

7. Close each four-way control valve to flush the Close function line.

8. Return the control valves to the Center passion.

9. Open the 4" inspection/fill ports and check the control valves for leaks.

10. Connect but do not tighten each swivel-joint assembly to its correct inlet on
the BOP stack.

11. Operate each function to ensure correct function operation and to purge
BOP stack. Make sure a joint of drill pipe is in the hole to prevent damage
to rubber element of the annular preventer.

12. Return the control valves to the Centre position.

13. Securely tighten the swivel-joint assemblies and hammer union connections
at the BOP stack.

14. Stop pumps.

15. Open the manifold bleeder valve and relieve all system pressure.

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Installation 3

Refill Reservoir
1. Check the fluid level of the reservoir after line flushing.

2. Refill the reservoir to 8" from the top.

Remote Panel

Set Up Location
1. Install the remote panels securely on firm foundation, mounting taking into
consideration the following:

a. Operation and service accessibility,

b. Illuminated areas.

c. Unobstructed ventilation.

d. Minimal heating effects from surrounding equipment.

2. The driller's panel should be installed on the drill floor at or near the driller's
position.

Panel Preparation
1. Refer separate PLC panel manual.

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Drill Ahead
The following list identifies the normal operating position of the shut-off valves and
control valves of the BOP Control System.

1. Shutoff Valves

a. Air pump supply valves - OPEN.

b. Air and electric pump suction valves - OPEN.

c. Accumulator bank isolator valves - OPEN.

d. Accumulator bank bleeder valves - CLOSE.

e. Manifold bleeder valve - CLOSE.

f. Air pressure switch bypass valve (If so equipped) - CLOSE.

2. Control Valves

a. Annular - OPEN.

b. Pipe and Blind Rams - OPEN,

c. Choke and Kill Valves - CLOSE.

d. Manifold Regulator Bypass/Internal Override Valve - LOW PRESSURE

(Handle left).

e. Annular Regulator Lock Handle - TIGHTEN FOR REMOTE OPERATION.

Installation Data
Electric Pump Assembly
Each electric pump assembly includes an explosion-proof electric motor starter. The
customer must provide the power to this starter as indicated in Table 2-1. The data in this table
is for each electric pump assembly included with the BOP Control System.

1. Customer to furnish wiring to meet applicable codes and standards for

installation.

2. Maximum allowable voltage variation is + 10%.

3. Maximum allowable frequency variation is + 5%.

4. Combined voltage and frequency variation is + 10%. (With no more than 5%

frequency variation.)

5. Similar metal conductors (Copper) should be used.

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Installation 3

This Page is Intentionally Left Blank

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Operation

General

The Operation Section of this manual contains functional descriptions of the

subassemblies and components that comprise the Control System. Understanding
the proper operation of the BOP Control System is very important for proper operation
in emergency situations.

The BOP Control System provides the hydraulic power and controls necessary to
operate the Blowout Preventers during drilling operations. It consists of the
accumulator unit assembly, remote control panels and interconnect assemblies. The
accumulator unit assembly consists of the accumulator unit module, air and electric
pump assemblies, hydraulic control manifold and remote control interface assembly.
While reviewing the instructions, particular attention is called to all NOTES and
CAUTIONS, as these are important to ensure safety during all phases of equipment
use.
Accumulator Unit Module
The accumulator unit module provides the accumulators for storage of the high
pressure control fluid, a reservoir for storage of the atmospheric fluid, supply for the air
and electric pump assemblies, accumulator piping and a master skid for all
components of the accumulator unit assembly.

Accumulators (Item 1 Fig. 4-1)

Accumulators provide the means for storage of large volumes of high-pressure fluid
necessary to control the BOP stack. These ASME coded pressure vessels have a
working pressure of 3000 psi and can be field repaired without destroying their stamp
of approval. These bladder type accumulators are precharged to 1000 psi + 100 psi of
nitrogen.

Never Use Oxygen For Precharging Accumulators

When there is a demand for fluid to operate a preventer, the high-pressure fluid
contained in the accumulator is forced out by the nitrogen. The port assembly contains
a poppet valve, which prevents the bladder from extruding through the port as the fluid
is discharged. The precharge of each accumulator should be checked during
installation (see Installation Section) as a loss of precharge pressure means a loss of
available operational fluid. The precharge should also be checked periodically during
normal operation to ensure a proper precharge being maintained. Always keep a
charging and gauging assembly readily accessible. If adjustments are necessary, see
the Maintenance Section.

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Reservoir (Item 36 Fig. 4-1)

A reservoir provides the means for storage of the atmospheric fluid supply for the highpressure
pumps. It contains baffles, a sight glass (Item 38 Fig. 4-1) for fluid level indication and fill and
inspection ports (Item C Fig. 4-1). The reservoir should be filled with a high quality SAE 10 hydraulic
oil (for filling procedures see Installation Section).The BOP Control System is a closed-loop system
where all vented fluid is returned to the reservoir. Therefore, it is very important to inspect the
preventers. Debris can clog pump suction filters and make the control system inoperative. For
procedures to cleanthe reservoir or change the fluid , see the Maintenance Section.

Accumulator Piping
The accumulators are mounted in banks (Item 42 Fig. 4-1) to minimize leaks and line restrictions.
These banks contain isolator valves (Item 2 Fig. 4-1), which should be open during normal
operation, and bleeder valves (Item 3 Fig. 4-1), which should be closed during normal operation. If it
is known an accumulator is faulty, that bank may be isolated until it can be serviced.

Never Try To Service An Accumulator While The

Accumulator Unit Is Pressurized

Since the accumulators are 3000-psi working pressure, the accumulator piping includes a 3300-psi
relief valve (Item 4 Fig. 4-1) to protect them against higher pressures. A plug should never be
substituted for this valve. If the valve is faulty, it should be repaired and replaced or a new valve
should be installed:

Air Pump Assembly

The air pump assembly is one of the high-pressure power sources used to pressurize the
accumulator unit. This assembly normally produces a maximum pressure of 3000 psi but is capable
of much higher pressures. It is therefore important to know how to operate this assembly, along with
when and how to control the use of higher-pressure outputs. These pumps require a customer
furnished air supply of sufficient pressure

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and volume to operate them (see Installation Section). The air pump assembly
consists of air supply manifold, fluid suction manifold, air pumps, and air pressure
switch.

Air Supply Manifold

The customer furnished air supply (Item A Fig.4-1) should be connected to the air
supply manifold as indicated in the Installation Section. Included in the air supply
manifold is:

1. Air Filter (Item 5 Fig. 4-1) -

This filter removes contaminants in the air supply which may damage the air pumps.
This filter must be cleaned periodically to maintain maximum air flow (see Maintenance
Section).

2. Air Lubricator (Item 6 Fig. 4-1) -

This device impregnates the air with oil to lubricate the pumps during operation. This
lubricator should also be serviced periodically to replenish the oil (see Maintenance
Section).

3. Air Supply Gauge (Item 7 Fig. 4-1) -

A 0-300 psi gauge is mounted in the air supply manifold for monitoring of the air supply
pressure at the unit.

4. Air Supply Valve (Item 9 Fig. 4-1) -

One air supply valve is provided for each pump to enable independent operation. Under
normal operation, these valves should remain open at all times. To stop the air pumps
from operation, these valves should be closed.

Fluid Suction Manifold

The fluid suction manifold is used to connect the high-pressure pumps to the reservoir,
which contains the operating fluid. This manifold includes:

1. Suction Valve (Item 10 Fig. 4-1) -

This valve is used to isolate the pumps during servicing. During normal operation, it
should remain open at all times.

2. Suction Strainer (Item 11 Fig. 4-1) -

The suction strainer helps to remove impurities from the fluid. Impurities can enter the
system through the preventers and return to the reservoir with the vented fluid. This
strainer should be serviced periodically to prevent clogging which could damage the
pumps by running them dry (see Maintenance Section).

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Air Pumps (Item Fig,)

Air pumps are used to convert lower air pressure into higher hydraulic fluid pressures.
They consist of two (2) main components: the air motor and the fluid end. They are sized by the
fluid ratio of the piston area of the air motor to the area of the piston in the fluid end. The
standard double action pumps are 60:1 ratio. This means there is 60 times the piston area in the
air motor as in the fluid end. Therefore, 1 psi of air will produce 60 psi of hydraulic fluid pressure.
The pumps have self-adjusting packing glands and therefore should require no adjustment in
normal operation. The pumps are double acting so air is exhausted on each upstroke and down
stroke of the pump. As the pumps exhaust the lubricated air, it is normal to find oil on surrounding
equipment, and for the moisture in the exhausted air to cause an ice formation on the air pump.
Excessive freezing may cause operational problems (See Troubleshooting Section). Before
servicing the pump, bleed off the system pressure. The pump0 discharge line is fitted with a check
valve (Item13 Fig. 4-1) to allow the system to be replenished while the pump is being serviced.

Air pressure Switch (Item Fig )

Since the air pumps are capable of producing pressures in excess of 3000 psi, it is necessary to
automatically stop the pumps when the discharge pressure reaches 3000 psi. The air pressure
switch is adjustable in that it senses the discharge pressure and blocks the air supply to the
pumps when the set pressure is reached. Normally the pressure switch is set for 3000 psi for
accumulator units with air pumps only and 2900 psi on accumulator units with both air and electric
pumps. When the system pressure drops to 2700 psi, the pressure switch automatically allows
the air to flow to start the pumps. To adjust the pressure switch setting, see the Maintenance
Section, The line to the air pressure switch is fitted with a bypass valve to allow the pumps to
produce higher fluid pressures. In normal operation this valve should be closed. If pressures in
excess of 3000 psi are required, such as during testing:

1. Close the electric pump isolator valve (Item Fig. ).

2. Move the manifold regulator bypass/internal override valve (Item Fig. ) to the
high-pressure position.

3. Open the air pressure switch bypass valve.

This will produce pressures up to 3300 psi, which is the setting of the manifold relief
valve.

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Electric Pump Assembly

The electric pump assembly is a primary, or additional, high-pressure pump source used on the
accumulator unit. This assembly requires a customer furnished power supply (Item15 Fig. 4-1).
The amount of current required depends on the horsepower of the electric motor (see Installation
Section). The pump output remains constant up to the maximum pressure of 3000 psi,
independent of the system backpressure. This pump assembly is very important to the overall
performance of the accumulator unit. Therefore it is necessary to understand its function and
operation. The electric pump assembly consists of fluid suction manifold, triplex pump, electric
moto and drive assembly which includes chain, sprocket, chain guard and pressure switch.

Fluid Suction Manifold

The fluid suction manifold connects the high-pressure pump to the reservoir, which
contains the operational fluid. This manifold includes:

1. Suction Valve (Item19 Fig.4-1) - This valve should remain open at all times in normal
operation; but should be closed to isolate the pump during servicing.

2. Suction Strainer (Item20 Fig.4-1) - This strainer helps to remove impurities that have
entered the system with the vented fluid from the preventers. It should be serviced
periodically (see Maintenance Section) to prevent damaging the pump by running it dry.

Triplex Pump (Item 14 Fig.4-1)

In normal operation the pumps operate automatically, however the plunger, packing and
crankcase should be inspected periodically. For adjustments, see Maintenance Section. The
pump discharge line is fitted with a check valve (Item 21 Fig. 4-1) and an isolator valve
(Item 40 Fig. 4-1). The isolator valve remains open at all times in normal operation but is
closed to isolate pumps either for servicing or to bypass the accumulators so pressures
higher than 3000 psi can be reached.

Electric Motor (Item 16 Fig. 4-1 )

All electric motors used in the pump assemblies are of the explosion-proof design. These
motors are either 50 or 60 cycle turning at speeds of 1500 and 1800 RPM respectively.
Because most pumps cannot turn at these speeds, reducing drive assemblies are used.

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Drive Assembly (Item15 Fig. 4-1)

This assembly connects the pump to the drive motor. It consists of:

1. Sprockets - The pump and motor sprockets are sized to reduce the speed of the motor
to the operating limits of the pump.

2. Chain complete with oil-bath-type chain guard - This assembly is used in place of belts
to eliminate slippage and prolong service life. The oil level in the chain guard should be
periodically inspected. For procedures and oil specifications, see Maintenance Section.

3. Motor Starter (Item 18 Fig. 4-1) - The motor starter controls the power to the electric
motor and is housed in an explosion-proof enclosure. The starter control switch should
always be in the AUTO position during normal operation.

4. Electric Pressure Switch (Item 17 Fig. 4-1) - This switch stops the electric motor when
discharge pressure reaches 3000 psi and automatically restarts the motor when
discharge pressure reaches 2700 psi. This protects the pump from over pressuring
which can damage the packing or the power frame. Pressure switch settings have a
tendency to drift and require periodic calibration. This is especially true when the
equipment has been moved to a different location. To adjust the pressure switch
setting, see Maintenance Section.

Hydraulic Control Manifold

The control manifold directs the flow of the high-pressure fluid stored in the accumulators to
operate the preventers and gate valves. Most preventers operate at a maximum of 1500 psi,
however the accumulator pressure is 3000 psi. Therefore, regulators are required to reduce the
operating pressure from 3000 psi to 1500 psi.

Annular (Bag Type) preventers require different operating pressures from the other functions on
the BOP stack, so all control manifolds use the double manifold design. The control manifold
consists of: (1) control valves, (2) cylinders, (3) regulators, (4) gauges, and (5) manifold piping
which includes a supply header, high pressure strainer, relief valve and bleeder valve.

Control Valves(Item Fig. )

The control valves are 1" (1-1/2" are available for annular requiring large volumes of (fluid),
four-way, three-position shear seal selector type valves. They have 90° handily rotation with
45 detents. There is one for each preventer and gate valve, complete with an aluminum
nameplate stating function name with OPEN and CLOSE positions marked in relation to
handle position. The control valves should always be in either the OPEN or CLOSE position.

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Never Leave The Valves In The Center Position As

This Blocks Both The Function Ports Of The
Control Valve. To Operate The Valve From Open
To Close Or From Close To Open, Move The
Handle In One Swift Motion.

Pausing will cause the valve to interflow, thus venting some of the supply fluid and delaying
function operation. The CENTER position could be used to block further pressure drop of the system
if caused by regulator malfunction while operating a preventer. The control valves should be serviced
periodically to ensure proper operation (See Maintenance Section).

Regulators
The double manifold, designed to accommodate variable pressure requirements, consists of
a manifold regulator assembly, a bypass valve assembly, and an annular regulator assembly.

Manifold Regulator Assembly (Item 24 Fig. 4-2 )

The manifold regulator reduces the 3000-psi fluid pressure from the accumulators to a
maximum of 1500 psi. This regulated pressure becomes the supply to operate the ram
type preventers and gate valves; pressures greater than 1500 psi cannot be regulated.
The pressure setting of this regulator must be manually adjusted; to do this:

1. Loosen the locknut on the adjustment handle and hold with one hand.

2. Rotate the regulator adjustment handle with the other hand.

a. To increase pressure rotates clockwise.

b. To decrease pressure rotates counterclockwise.

3. Read manifold pressure gauge for the pressure setting of the regulator. Set at desired
pressure.

4. Tighten the locknut of the adjustment handle.

Bypass/Internal Override Valve Assembly (Item 25 Fig. 4-1)

To operate with pressures up to 3000 psi, the manifold regulator assembly is fitted with a
quick opening bypass/internal override valve that can shut off the supply through the
manifold regulator and supply direct accumulator fluid pressure to the ram preventers and
gate valves.

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The Regulator can be fitted with an internal override assembly that when operated will allow
the full accumulator pressure supply to flow through the manifold regulator. In normal
operation the bypass/ internal override valve should be in the regulated or LOW-pressure
position. For pressures up to 3000 psi, the valve must be in the HIGHpressure position. For
remote operation of the bypass valve an air cylinder can be fitted to the valve.

Annular Regulator Assembly (Item 30 Fig. 4-1)

The annular regulator controls the operating pressure settings for the annular preventer.
Since the annular preventer requires different operating pressures for stripping and well
control it is necessary to consult the annular preventer manufacturer's recommendation for
optimum pressure settings to prolong the life of the element. Regulators are available for
regulation up to 3000 psi and in 1" and 1-1/2"sizes.

The regulation of the annular operating pressure is adjusted at the accumulator unit by
operation of the manual adjustment handle on top of the regulator. It is adjusted in the same
manner as the manifold regulator (See Section ). Annular regulators fitted with air motor
operators include two (2) quick release valves to reduce air motor "run-on". For instructions
on remote regulation of the annular operating pressure, (See Section)

Gauges
The gauges on the hydraulic manifold are 6" face, glycerin-filled, panel mount type gauges which
connect to the pressure pick-up points with stainless steel tubing or mud pump type, glycerin-
filled gauges which mount in-line. Three (3) gauges are provided to monitor:

1. Accumulator Pressure, 0-6000 psi (Item 29 Fig. 4-1)

2. Manifold Pressure, 0-10,000 psi (Item 28 Fig. 4-1)

3. Annular Pressure, 0-3000 psi (Item 31 Fig. 4-1)

Manifold Piping
The manifold piping consists of a supply pressure header, a high-pressure strainer, a bleeder
valve, and a relief valve.

Supply Pressure Header (Item 43 Fig. 4-1) - A 2" header provides a common pressure to the ram
preventer and gate valve control valves to maximize flow and minimize leaks.

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High Pressure Strainer (Item 22 Fig. 4-1) - This strainer helps to remove debris from the control
fluid that could damage the regulators and control valves. It should be serviced Periodically to
ensure proper operation (See Maintenance Section).Manifold Bleeder Valve (Item 27 Fig 4-1) -
This valve is used to bleed off the system pressure for servicing. In normal operation it should be
in the closed position.

Manifold Relief Valve (Item 41 Fig. 4-1) - This valve is set to relieve excess system pressures to
prevent component or system failure. For systems with an air pressure switch bypass valve, it is
set at 5500 psi and for systems without an air pressure switch valve it is set at 3300 psi.

Air Remote Control Interface Assembly

Air remote control Interface assemblies include additional components necessary on the accumulator
unit to enable the BOP Control System to be remotely controlled and/or monitored from an air panel.

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TABLE 4-1
LEGEND - TYPICAL ACCUMULATOR UNIT ASSEMBLY
ITEM CUSTOMER LOCATIONS
A Customer Air Supply Connection
B Customer Motor Starter Power Connection
C 4" Fill/Inspection Port

ITEM DESCRIPTION ITEM DESCRIPTION

1. Accumulators 25. Manifold Regulator Bypass/
2. Accumulator Bank Isolator Valve Internal Override Valve
3. Accumulator Bank Bleeder Valve 26. Four-way Control Valve
4. Accumulator Relief Valve 27. Manifold Bleeder Valve
5. Air Filter 28. Manifold Pressure Gauge
6. Air Lubricator 29. Accumulator Pressure Gauge
7. Air Supply Gauge 30. Annular Air Motor Driven
8. Air Pressure Switch Regulator
9. Air Supply Valves 31. Annular Pressure Gauge
10. Air Pump Suction Valve 32. Transmitter - Annular
11. Air Pump Suction Strainer Pressure
12. Air Operated Hydraulic Pumps 33. Transmitter - Accumulator
13. Air Pump Discharge Check Valve Pressure
14. Reciprocating Hydraulic Pump 34. Transmitter - Manifold
(Duplex or Triplex) Pressure
15. Electric Pump Drive Assembly 35. Fixed Plate Half - Air
16. Electric Motor Junction Box
17. Electric Pressure Switch 36. Reservoir
18. Electric Motor Starter 37. Clean out man-way
19. Electric Pump Suction Valve (T-Series Units)
20. Electric Pump Suction Strainer 38. Sight Glass (T-Series Units)
21. Electric Pump Discharge 39. Air Pressure Switch Bypass
Check Valve 40. Electric Pump Isolator Valve
22. High Pressure Strainer 41. Manifold Relief Valve
23. Shutoff Valve - Normally 42. Accumulator Supply Header
Closed.Connection for separate 43. Manifold Supply Header
operating fluid pump or for
auxiliary hydraulic supply. 44. Air Cylinders
24. Manifold Regulator 45. Transmitter Air Regulator

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Figure 4-1 : Typical Accumulator Unit Assy.

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Maintenance

General

A regularly scheduled maintenance program must be developed to sufficiently maintain the BOP Control
System. The operator must develop an appropriate program based on the operating, testing and drilling
programs. The entire system should be tested a minimum of once a week. This may involve simply
operating all functions and noting gauge readings. When performing routine maintenance and/or major
service and repair around high pressure and electrical equipment, care should be taken to ensure the safety
of all personnel. Remove and verify line pressure is released before attempting to disconnect pressure
lines.

Accumulators
Precharging Instructions
1. Relieve system pressure.

2. Remove the valve guard and secondary valve cap from the accumulator and attach a charging and
gauging assembly part number 0902-0100 . Screw down T-handle (6) and observe reading on
gauge. It should read 1000 psi. If pressure is high, open bleeder valve (9) until pressure drops to
1000 psi. If pressure is low, attach the charging line (7) to a nitrogen bottle.

Use Nitrogen Only - Do Not Use Oxygen

Gradually open valve (8) to slowly increase precharge to 1000 psi. Then close valve. If pressure
does not increase, the bladder is faulty and should be replaced.

3. Remove charging and gauging assembly and Check valve core for leaks.

4. Replace valve guard and secondary valve cap on accumulator.

5. Pressurize system.

Service and Repair Instructions

1. Drawings, material lists, disassembly and assembly instructions are located in the
Parts Section.

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Accumulator Unit
Fluid Reservoir
1. The fluid reservoir should be checked regularly, drained and cleaned to eliminate sludge build-
up. The control fluid should be kept clean and free of debris. A high quality SAE 10W hydraulic
oil or suitable lightweight oil should be used in the system.

i
NEVER USE FUEL OIL, KEROSENE OR SALT WATER IN
THE RESERVOIR.

2. To clean the reservoir use the following procedure:

a. Stop pumps.
b. Open manifold bleeder valve and release system pressure.
c. Drain the fluid from the system. Remove any sludge/slime or other material from the
reservoir.
d. Flush the entire system with 140°F (60°) hot water.
e. Circulate a mixture of hot water and Trisodium Phosphate (2 pounds in 5 gallons water)
until the sludge and oil are removed from the metal parts. Optional - Circulate a warmto-
hot bacteriacidal solution through the system.
f. Rinse the system thoroughly with hot water.
g. Refill the system with hydraulic fluid mixture.
h. Start pumps and operate to ensure that pumps are primed.
i. Close manifold bleeder valve.

Relief Valves
Check the high-pressure relief valves for leaks. Open the 4" inspection ports on the side of the
reservoir and check the vent lines from the relief valves for leakage,

Piping
Visually check all fluid lines and connections for possible leaks.

Air Operated Pumps

Hydro-pneumatic Pressure Switch
1. Turn the spring adjustment nut from left to right to increase pressure setting and from right to
left to decrease pressue setting.

2. Check air pressure switch bypass valve for leaks.

Air Lubricator
1. Check the air lubricator to make sure it is full of SAE 10W lubricating oil.

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Maintenance 5

Open the petcock of lubricator to drain moisture that may have accumulated.

Check that drip setting flows 6 drops per minute. To adjust setting see Troubleshooting Section.

Filters
Drain and flush accumulated moisture. Open the manual drain on the filter housing, as pumps are
running.

Clean elements.

a. Stop pumps.
b. Unscrew housing and lift out o-ring and louver.
c. Remove filter elements and wash in warm water or kerosene.
d. Dry elements and check that bowl gasket is in good condition.
e. Replace parts and housing.

Strainers
1. Clean Y-type strainers. Ensure lines are free of pressure before attempting maintenance.

a. Stop pumps.
b. Close pump suction valves.
c. Remove Y-type strainer plugs.
d. Remove strainer elements.
e. Open pump section valves to flush piping, then close valves.
f. Clean strainer elements in warm water or kerosene.
g. Replace elements and Y-type strainer plugs.
h. Open pump suction valves.
i. Startpumps.

Pump Packing
The pump packing is spring loaded and spring adjusted. No maintenance is required.

Air Exhaust
Clean sludge build-up.

Check end caps for leaks.

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Electric Pumps
Hydro-electric Pressure Switch
1. To adjust the pressure setting for:

a. Pump Start-up

(1) Close air supply valves.

(2) Remove explosion-proof cover of electric pressure switch.
(3) Open manifold bleeder valve and bleed system pressure to
desired start-up pressure.
(4) Close manifold bleeder.
(5) Move the adjustment wheel upward until the pump comes on,
reaches shutoff pressure,
and stops.
(6) Open manifold bleeder and check that start-up is at-proper
pressure.
(7) Close manifold bleeder valve.
(8) Replace explosion-proof cover.
(9) Open air supply valves.

b. Pump Shut Off

Figure 5-1: Pressure Switch
(1) Remove access screw on right hand side of switch.
(2) Turn the adjusting screw counterclockwise to increase pressure
setting.
(3) Turn adjusting screw clockwise to decrease pressure setting.

To replace limit switch:

1. To adjust the pressure setting for:
a. Loosen the set screw(s) on housing stem.
b. Remove the pressure fitting from housing.
c. Remove the extension fitting of adjustment screw.
d. Remove the mounting screws from terminal bracket.
e. Loosen the screws of terminal wire connections.
f. Pull away the terminal assembly.
g. Loosen the retaining nut at base of bourdon tube assembly.
h. Remove the tube and switch assembly.
i. Replace with new tube and switch assembly from the repair
kit. If replacing the limit
switch only:

(1) Remove screws (Switch mounting bracket to bourdon tube).

(2) Pull off switch assembly.
(3) Replace new switch assembly to bourdon tube.
(4) Replace mounting bracket screws.

j. Replace the tube and switch assembly.

k. Tighten retaining socket nut.
l. Pull wires through terminal assembly.
m. Replace the mounting screws through terminal bracket.
n. Replace wires to terminate connection screws and tighten.
o. Replace the extension fitting of adjustment screw.

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Maintenance 5

Crankcase.
1. Check the pump crankcase to make sure it is full of good, clean engine oil.
Eight will vary depending on the ambient temperature (See Table ),

2. Clean the pump crankcase of accumulated sludge.

PART NUMBER CAPACITY (OTS) OIL TYPE

3000-2100
3000-3100 4

3001-3100
3001-4100
5-1/2
3001-5100 SAE 20 @40°F-115°F
SAE 10 @0°F-60°F

3002-2100 7

3003-1100 9

3001-3200
3001-5200 2 SAE 30

Chain Guard
1. Remove the lower drain plug and check for water or sludge build-up.

2. Check the oil level in the oil bath chain guard. It should be filled up to the spill plug.

a. Above 20 F use SAE 90 Compound Chain Oil.

b. Below 20 F use SAE 80 Compound Chain Oil.

3. Chain Tension Adjustment and Initial Setting

a. Adjust Drive Centers and Chain Tension.

(1) Horizontal drives should be installed with initial sag equal to two percent (2%) of
sprocket centers.

(2) Vertical center drives should be operated with both spans of chain close to being taut.
Periodic inspection of such drives should be made to avoid operation with excessive
slack and to maintain proper chain tension.

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b. Determine the Amount of Sag.

(1) Pull one side of the chain taut, allowing all the excess chain to accumulate in the opposite
span.
(2) Place a straight edge over the slack span and, pulling the chain down at the center, measure
the amount of sag. When necessary, adjust drive centers for proper sag that will result in
correct chain tension.

Motor Bearings
1. Disassemble motor and lubricate bearings.

Pump Packing
1. The packing glands should be tight enough to eliminate leaking and loose enough to
lubricate the plungers with a fine oily film. Over tightening the packing will damage the
motors.

Strainers
1. Clean Y-type strainers. Ensure lines are free of pressure before attempting maintenance.

a. Stop pumps.
b. Close pump suction valves.
c. Remove Y-type strainer plugs.
d. Remove strainer elements,
e. Open pump suction valves to flush piping, then close valves.
f. Clean strainer elements in warm water or kerosene.
g. Replace elements and Y-type strainer plugs.
h. Open pump suction valves.
i. Startpumps.

Hydraulic Manifold

Four-way Control Valves

1. Apply grease to the detents on the four-way control valves.
2. Open view ports and check that control valves are not leaking.

Cylinders
1. Clean piston rods of corrosion by wiping with an emery cloth.
2. Lubricate the piston rods on the cylinders with a good quality silicone based lubricant.

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Maintenance 5

3. Grease the mounting bolt on the cylinder.

Filters
1. Drain and flush accumulated moisture. Open the manual drain on the filter housing as
pumps are running.
2. Clean elements.

a. Stop pumps.
b. Unscrew housing, lift out o-ring and louvre.
c. Remove filter elements and wash in warm water or kerosene.
d. Dry elements and check that bowl gasket is in good condition.
e. Replace parts and housing.

Gauges
1. Check that system pressures are maintained at proper levels,
2. When there is no pressure in system ensure that gauges are properly zeroed. If gauges are
not properly zeroed see Troubleshooting Section.
3. When system is pressurized ensure that gauges on the control manifold match gauges on
the remote control panel(s),

1" TR Pressure Reducing and Regulating Valve (P/N 1500-1588)

This section outlines the disassembly and reassembly procedures for the 1? T-Regulator (TR)
valve. These procedures are provided for field repair operations and involve the total replacement
of all valve O-rings, backup rings, seals, and certain other components. The valve must be
removed from the system equipment for this total overhaul procedure. The numbers in
parentheses correspond to the item numbers shown in Figure 5-2 and the table following it.
Assembly and kit part numbers are also listed in the table. Do not attempt to disassemble this
regulator valve without the correct repair kit or seal kit. Use the proper tools and work in a clean,
dry atmosphere.
ning
War

Isolate the TR valve from all system pressure before

performing any disassembly procedures or removing
the TR from the panel.
Disassembly
1. Remove bottom flange valve body using 3/8? hex key.
2. Use 1/2?-13 body bolts as jack screws to remove bottom flange
3. Inspect bottom flange O-ring and Backup Ring. Check Orifice plug and O-ring on Seal container.
4. Remove side flange from body by using 3/8? hex key.
5. Use 1/2?-13 body bolts as jack screws to remove side flange.
6. Check O-ring and Backup Ring. Inspect condition of flow plate surface.
7. After removing flange and flow plate, check valve interior for contamination and/or obstructions.
8. Extract piston and seal container by pushing on ball end of piston while holding end of seal
container.
9. Remove port plate retaining screw using 3/16? hex key.
10. Use paper or cloth to protect flow plate, and push out port with non metallic object.
11. Inspect seal and Backup Ring in Port Plate and check surface of flow plate.
12. Examine flow plate surface for wear marks, nicks or scoring.
13. Protect piston guide with cloth or paper, and push out with nonmetallic object.
14. Remove flow plate from flange using 5/32? hex key.
15. Flow plate and flange surface should be clean and smooth. Inspection condition of three O-rings.
16. With 1/8? hex key, push seal plug out of flow plate. Inspect O-rings and Backup rings.
17. Inspect O-ring and Backup rings on seal container.

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18. Extract seats and springs from seal container. Note location of backup rings, inboard on vent
seats, outboard on primary seats.

Figure5-2 : 1" TR Valve

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Maintenance 5

Major Minor
Item # Description P/N Qty.
Kit Kit

AAssy Hyd.Pr.Red.and Reg.Valve 1110-3100

Kit Repair Kit 1110-3199
Kit Seal Kit 1110-3197
1 Body 0150-1141 1
2 Pin 8599-0216 1
3 Pin 8599-0012 1
4 Socket Head Cap Screw 8506-0012 1
5 Port Plate 0150-1140 1
6 O-Ring 8717-2019 4
7 O-Ring 8717-2014 2
8 O-Ring 8717-2218 1
9 O-Ring 8717-2222 1
10 Seal Plug 0150-1143 3
11 O-Ring 8717-2010 3
12 Back-up Ring 8841-2010 6
13 O-Ring 8717-2232 3
14 Back-Up Ring 8841-2232 3
15 Socket Head Cap Screw 805391 4
16 ü Flow Plate 0150-1139 2
17 Flange 0150-1149 1
18 ü Socket Head Cap Screw 8504-4024 12
19 ü Pipe Plug 805394 1
20 ü Hydraseat(Inlet) 0150-1142 4
21 ü O-Ring 8717-2117 5
22 ü Backup-Ring 8841-2117 6
23 ü Seat Spring(Inlet) 0150-1161 2
24 Hydraseat(Vent) 0150-1144 2
25 ü O -Ring 8717-2113 4
26 Backup Ring 8841-2113 2
27 ü Seal Spring (Vent) 0150-1162 1
28 ü Bottom Flage 0150-1148 1
29 ü Pipe Plug 805392 1
30 Piston guide 0150-1150 1
31 O-Ring 8717-2226 1
32 O-Ring 8717-2224 1
33 ü Backup-Ring 8841-2224 1
34 Piston and Seal container 0150-1538 1
35 O-ring 8717-2115 1
36 ü Orifice Plug 0150-1172 1

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Risassembly
Use replacement parts from seal kit (P/N 1110-3197), and/or repair kit (P/N 1110-3199). Item numbers
in the text refer to Figure 4-34.
1. Install new O-rings (31, 32) and Backup ring (33) into grooves of piston guide (30).
2. Push piston guide into top opening of body (1).
3. Install an O-ring (11) and two backup rings (12) on each seal plug (10), and insert one seal plug
into each flow plate (16).
4. Install an O-ring (11) and two backup rings (12) on seal plug (10), and insert seal plug into port
plate (5).
5. Install two O-rings (6) and O-ring (7) in port plate (5) and mount to flow plate (16).
6. Install two O-rings (6) and O-ring (7) in flange (17) and mount to flow plate (16).
7. Secure flow plates (16) to port plate (5) and flange (17) with two screws (15) each. Use 5/32? hex
key and torque to 40 in-lb.
8. Install O-rings (13) and backup rings (14) on port plate, flange (17) and flange (28). Note location
of backup rings.
9. Install O-rings (8, 9 and two item 25) on port plate. Check that three seal plugs are installed and
pipe plug (19) is installed in flange (17).
10. Inspect flow plate for nicks and burrs by gently sliding a seat over the sealing surface.
11. Install O-rings (21) and backup rings (22) onto seal container (34) and hydraseats (20). Install O-
rings (25) and backup rings (26) to hydraseats (24). Note position of backup rings on seats,
outboard on primary and inboard on vent.
12. Install seats into seal container from one side and springs (23, 27) and remaining
seats from the other side.
13. When installed, seats should extend equally from each side with O-rings and
backup rings confined.
14. To install flow and port plate assembly into body, line up retaining screw holes.
15. Push flow and port plate assembly into body by hand. Install retaining screw (4) with
3/16? hex key. Tighten to 90 in-lb torque.
16. Insert piston at top of seal container assembly into piston guide while holding lower
seats above flow plate to avoid nicking seats.
17. Align dowel pin with dowel hole and push side flange assembly into body by hand.
Note seal plugs and orifice plug.
18. Secure side flange to body using six screws (18) with 3/8? hex key, and tighten to
100 ft-lb.
19. To ensure proper assembly, stroke seal container assembly by hand. It should take
15–20 pounds force.
20. Align holes in bottom flange with tapped holes in body, and push flange into body by
hand. Secure with six screws (18) using 3/8? hex key and tighten to 100 ft-lb torque.

Do not use a metal object to push the seal rings into the seal
container. The seal rings are manufactured to very specific
tolerances. These tolerances would be damaged by contact
with metal tools. Use fingers, preferably protected with clean
gloves. Avoid contacting the beveled edges of the seal rings
directly with the fingers. The beveled edges are sealing
surfaces, which will corrode if contacted by the natural acids
on fingers. If it is necessary to push the seal rings in with the
fingers, apply a coating of oil to the seal rings. The oil acts as
a barrier between the acids and the metal

i
It may be necessary to lubricate the inside of the flanges with
a lightweight lubricant prior to reassembly.

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Maintenance 5

Fig 5-3 : Installing Seal Cartridge and Flanges

1" AMKR Pressure Reducing and Regulating Valve (P/N 20071102)

1" AMKR Pressure Reducing and Regulating Valve This This section outlines the disassembly and
assembly procedures for a 1" air motor Koomey® regulator (AMKR) valve. These procedures are
provided for field depot repair operations and involve the total replacement of all valve O-rings, backup
rings, seals, and certain other components. The valve must be removed from the system equipment
for this total overhaul procedure.

The numbers in parentheses correspond to the item numbers shown in Figure 4-6 and the associated
parts table. The table also provides the assembly and kit part numbers. Do not attempt to disassemble
this regulator valve without the correct repair kit or seal kit. Use the proper tools and work in a clean,
dry atmosphere.

1" AMKR Valve Disassembly

1. Replace the valve on a clean area, free of dust, sand, grease, grit, etc.
2. Relieve the pressure on the compression springs (8, 9) by releasing the lock nut (3) and rotating
the ball handle (2) counter-clockwise until it moves freely.
3. Loosen and remove the four socket head cap screws (12) using a 6 allen wrench. Remove the
adjustment head (11) from the body.
4. Slowly tighten down on the ball handle (2) until both compression springs force the plunger guide
(20) out the lower end of the adjustment head.
5. Loosen and remove the six socket head cap screws (26) on the outlet flange (25). Slowly remove
the flange so as not to damage the O-ring (24).
6. Loosen and remove the eight socket head cap screws (12) on the inlet flange (14). Remove the
inlet flange by rotating it slowly back and forth.
7. Loosen and remove the eight socket head cap screws (12) from the bottom flange (23). Remove
the flange by rotating it slowly back and forth.
8. Loosen and remove the eight socket head cap screws (12) from the bottom flange (37). Remove
the flange.
9. Cap lightly with a rubber mallet on the plunger (43). The seal container (38) and its components
will fall out the lower end of the body (18).

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Figure 5-4. 1"AMKR Pressure Reducing and Regulating Valve(P/N 10-00539), Exploded View

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Maintenance 5

Parts List 1" AMKR Valve

Major Minor
Item # Description P/N Qty.
Kit Kit

Assy. Air Pr. Red. & Reg. Valve 1000539 -

Kit Repair Kit 9910182 -
Kit ü Seal Kit 9910181 -
1 Actuator Assembly,Motor Driven 1000209 4
2 Ball Handle 1000114 4
3 Lock Nut 1000512 4
4 Air Motor 1000233 1
6 Steel Ball, 1/2” 8310016 2
7 Spring Guide 1000542 3
8 Compression Spring 1000119 3
9 Compression Spring 1000548 3
10 Spring Plate 1000553 3
11 Adjustment Head 1000158 1
12 Socket Head Cap Screw 8002559 1
13 üSocket Head Cap Screw 8002525 1
14 Flange 1000133 -
15 üO-Ring 5001025 1
16 Flow Port 1000135 1
17 üO-Ring 5001093 1
18 Body 1000204 1
20 Plunger Guide 1000554 1
21 üO-Ring 5001154 1
22 ü Plate 1000139 1
23 Flange 1000140 1
24 üO-Ring 5001146 1
25 Flange 1000141 1
26 Socket Head Cap Screw 8002558 6
27 üBackup Ring 5001027 1
28 üO-Ring 5020028 1
29 3/8” NPT Pipe Plug 2023966 2
30 üBackup Ring, 1”X7/8” 5020020 4

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Parts List 1" AMKR Valve Contd......

Major Minor
Item # Description P/N Qty.
Kit Kit

31 üO-Ring 5001019 4
32 ü Seal Ring 1000134 4
34 ü Seal Ring 1000143 2
35 üBackup Ring, 13/16” X 11/16” 5020017 2
36 üO-Ring 5001016 2
37 Flange 1000142 1
38 Seal Container 1000203 1
39 üO-Ring 5001154 1
40 ü Wave Spring 1000147 1
41 ü Compression Spring 1000138 2
42 Spring Pin 1000551 1
43 Plunger 1000555 1
44 üO-Ring 5001017 1

1" AMKR Valve Assembly

Prior to assembly, wash all metal parts with a cleaning solvent. Thoroughly wash inside the valve body
(18). Check all valve parts for scarring and washout. Replace parts, which are badly scarred or damaged
by washout.

1. Replace the items below in the seal container (38):

Four seal rings (32)

¦

Two compression springs (41)

¦

Two seal rings (34)

¦

One wave spring (40)

¦

These items, along with the following O-rings and backup rings (31, 30, 36, 35), are provided in the
repair kit. Apply a generous amount of Dow Corning #44 or other equivalent seal lubricant to the O-
rings prior to the replacement. Install the seal rings wth the beveled edges facing outward toward the
surface of the seal container.

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Maintenance 5

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It may be necessary to lubricate the inside of the flanges
with a SAE 10W lightweight lubricant prior to assembly.

2. Install the new O-ring (28) and backup rings (27) on the plunger (43).

3. Gently replace the seal container assembly back into the body (18) with the indentations in the
upper end of the seal cartridge facing toward the inlet flange (14). (See Figure 4-7.)

4. Install a new O-ring (39) onto the bottom flange (37). Mount the bottom flange onto the body
(18). Install and tighten the eight socket head cap screws (12).

5. Replace the O-ring (17), the plate (22), and the two socket head cap screws (13) on the flange
(23). Reassemble the new plate to the flange using the new socket head cap screws.

Figure 5-5 :Installing Seal Cartridge

7. Replace the O-rings (15, 17, 39, 44), the socket head cap screws (13), and the flow port (5) on the
inlet flange (14). Reassemble the new flow port to the inlet flange using the new socket head cap
screws.

i
Do not use any metal object to push the seal ring into the seal
container. The seal rings are manufactured to a very specific
tolerance. These tolerances would be damaged by contact
with metal tools. Use fingers, preferably protected with clean
gloves. Avoid contacting the beveled edges of the seal rings
directly with the fingers. The beveled edges of the seal rings
are sealing surfaces which will corrode if contacted by the
natural acids on fingers. If it is necessary to push the seal rings
in with the fingers, apply a sufficient coating of oil to the seal
rings. The oil acts as a barrier between the acids and the
metal.

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8. Mount the inlet flange onto the body. Align the ''on the flange with the ''on the body. (See Figure 4-
8.) Install and tighten the eight socket head cap screws (12).
9. Replace the O-ring (24) on the outlet flange (25). Mount the outlet flange onto the body (18). Install
and tighten the six socket head cap screws (26).
10. Replace the O-rings (21) on the plunger guide (20). Place the plunger guide (20) onto the plunger
(43), which protrudes from the top of the body (18).
11. Set the adjustment head assembly (11) down over the plunger guide and onto the top of the body.
Align the four holes for the socket head cap screws.
12. Remove the ball handle (1) down to its original position and set the lock nut (4). The valve is now
ready for operation.

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Maintenance 5

11 Gallon, 3,000 PSI Accumulator Bottles

Replacing the Accumulator Bladder

Required Tools

Core Tool 0902-0200

Bladder Pull Rod 0902-0300
Charging and Gauging Assy. 0902-0100
Valve Extension -

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Do not attempt to replace the accumulator bladder

until all hydraulic pressure is vented to atmosphere
and all gauges show 0 psi (0 bar).

Replacing the accumulator bladder requires all hydraulic pressure to be vented from the
accumulator in accordance with the following steps:

q
Isolate the accumulator bottles from the main hydraulic supply by closing the appropriate
ball valve.

q
Vent the residual nitrogen precharge pressure from the bottle to atmosphere using the
charging and gauging assembly.

q
Drain the fluid from the accumulator by opening the 1/2 inch ball valve.

Removal

1. Remove the gas protective cap and valve cap from accumulator.

2. Install the proper charging and gauging assembly on the gas valve stem. Attach the air
chuck to the accumulator bladder gas valve by hand tightening the swivel hex connection.

3. Open the valve by turning the air chuck T-handle clockwise until it stops. This opens the
valve core.

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HIGH PRESSURE GAS IS DANGEROUS! Wear proper

eye protection and take proper safety precautions.

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4. Bleed off all nitrogen gas pressure by opening the bleed valve completely. Open the gas
valve fully and then remove the gas valve.

5. Remove the gauging device from the gas valve stem.

6. Remove the accumulator bottle from the bottle rack.

7. Remove the hex jam nut and name plate.

8. Remove the lock nut from the bottom of unit using a spanner wrench.

9. Remove the spacer and the rings.

10. Push the plug assembly into the accumulator and through the anti-extrusion ring.

11. Remove the anti-extrusion ring by folding it and pulling it through the hole.

12. Remove the plug assembly and pull the old bladder out from the bottom of the
accumulator.

Installation
1. Remove the valve core from the new bladder and squeeze all air from the bladder.
Replace the valve core.

2. Unfold bladder completely.

3. Lubricate the bladder and the shell with system fluid.

4. Attach a bladder pull rod to the bladder by carefully threading over the Schrader
connection. Insert the rod through the accumulator (bottom to top). Pull the bladder into
the shell. Do not allow the bladder to bind or kink.

5. Attach the name plate and hex jam nut to the exposed gas valve stem and hand-tighten.
Remove the pull rod.

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Verify the bladder is not bent, twisted or folded in the

shell, as this will cause the bladder to burst.

6.. Push the plug assembly and then the anti-extrusion ring into the shell.

7. Pull the plug assembly through the anti-extrusion ring. Seat the ring in the hole, metal
side up.
8. Install a new metal back-up ring and a new O-ring, making sure not to pinch the O-ing.
Install a new rubber backup ring, spacer, and lock nut. Hand-tighten the lockut.

9. Precharge the accumulator (see the section titled “Precharging Accumulator Bottles”

10. Tighten the hex jam nut, making sure the gas valve stem does not rotate.

11. Tighten the lock nut on the fluid end.

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Maintenance 5

Figure-5-6 Bottom Loading Accumulator Bottle

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Parts List – 3,000 psi (207 bar) Bottom Loading

Accumulator Bottle(Continued)

Item # Description P/N Qty.

Assembly Accumulator Bottle (P/N 1000-9400)

1 Valve Gaurd 1000-3101 1

2 Valve Cap 1000-0105 1

3 Valve Core 1000-0106 1

4 Valve Nut 1000-3102 1

5 Name Plate 1000-9421 1

5 Shell 1000-9401 1

6 Bladder Assy. 817100 1

7 Ring, Anti-Extrusion 1000-4105 1

8 Poppet 1000-4103 1

9* Spring, Poppet 1000-4104 1

10** Plug Body 1000-3111 1

11** Piston, Poppet 1000-4108 1

12** Stop Nut, Poppet 1000-4111 1

13** Washer,Backup 1000-4106 1

14** O-Ring 8717-2338 1

15* Backup Ring 8842-8338 1

16* Spacer 1000-4107 1

17* Lock Nut, Plug 1000-4110 1

18 Plug 1/4” - 1

19 Valve Adopter Assy. 817098 1

* Parts may be ordered by referencing the item number, description, accumulator size,
accumulator pressure rating and accumulator bottle part number.

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Maintenance 5

Hydraulic Pump
The hydraulic pump assembly (3324000) is an integrated pump assembly consisting of a close-
coupled, 73/8" air-driven motor (3324057) and a 60:1 ratio hydraulic pump (3324056). This section
outlines the corrective maintenance procedures for the 60:1 ratio hydraulic pump. The hydraulic pump
operates when air pressure applied to the air motor forces hydraulic fluid through the pump.
The numbers in parentheses correspond to the item numbers shown in Figure 5-7 and the associated
table. For assembly and kit part numbers, see the table titled "Parts List, Hydraulic Pump".

Hydraulic Pump Disassembly

1. Remove fluid supply and discharge line assembly.

2. Hold piston rod of motor with wrench and unthread coupling nut (2).

3. Remove connecting rod (1), coupling nut (2), and jam nut (3) from plunger (11).
Then pull plunger through lower cavity of pump block (4).

4. Remove pump cylinder gasket (8), packing spring (7), and packing set (6).

5. Hold plunger rod (11) in vise by the flats at top of plunger and remove piston
seat (16) with wrench while holding plunger horizontal with wooden support if
necessary. Remove piston ball (15), packing set (14), lower packing spring (13), and
spring retainer (12).

6. Secure foot valve (20) in vise and unthread pump cylinder (9).

7. Remove ball stop cage (18), both pump cylinder gaskets (17) and foot valve
ball (19). Remove O-ring (10) from pump cylinder (9).

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Hydraulic Pump Reassembly

1. Install pump cylinder O-ring (10) into O-ring groove of pump cylinder (9).

2. Place foot valve ball (19) in foot valve (20) and install ball stop cage (18) between
the two pump cylinder gaskets (17).

3. Connect foot valve (20) to pump cylinder (9).

4. Place packing set (14) over piston seat (16). Place piston ball (15) on piston seat
(16), follow with lower packing spring (13) and spring retainer (12). Thread plunger
rod (11) onto piston seat (16) tightly using loctite.

Peak of V-packing must point down toward foot valve (20).

5. Insert packing set (6) into pump block (4). Place upper packing spring (7) and pump
cylinder gasket (8) into the lower cavity of pump block (4) behind upper packing set
(6).

Peak of V-packing must point up toward motor.

6. Insert plunger (11) through lower cavity of pump block (4).

7. Pump cylinder (9) over packings and connect to pump block (4).

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Maintenance 5

Pump cylinder gasket and packing spring must be

in place before connecting pump cylinder to pump
block.

8. Insert connecting rod (1) through coupling nut (2). Thread jam nut (3) into
connecting rod. Connecting rod should then be screwed into plunger (11).

9. Attach pump assembly to stanchion, inserting stanchion washers on both sides of

pump block (4). Attach and tighten stanchion nuts.

10. Connect coupling nut (2) to piston rod of motor.

Use teflon tape on all threaded pipe connections.

11. Attach fluid supply and discharge line assembly.

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1
2
2a

3
11

12

13
6

7 14

8
15

16

17

18

17

19

10 20

Figure 5-7 - Hydraulic Pump Exploded View

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Maintenance 5

Parts List, Hydraulic Pump

Major Minor Description Qty.

Item # P/N
Kit Kit

Assembly 3324056 Hydraulic Pump —

Kit 9933240 Minor Kit —

Kit 9933245 Minor Kit —

1 3324034 Connecting Rod 1

2 3324035 Coupling Nut 1

3 334036 Jam Nut 1

4 3324043 Pump Block 1

6 ü ü 3324040 Upper Packing Set 1

7 3324039 Upper Packing Spring 1

8 ü ü 3324046 Pump Cylinder Gasket 1

9 ü 3324047 Pump Cylinder 1

10 ü ü 3324048 O-Ring 1

11 ü 3324037 Plunger Rod 1

12 3324038 Spring Retainer 1

13 3324045 Lower Packing Spring 1

14 ü ü 3324044 Lower Packing Set, Leather 1

15 ü ü 3324041 Piston Ball 1

16 3324042 Piston Seat 1

17 ü ü 3324049 Pump Cylinder Gasket 2

18 3324050 Ball Stop Cage 1

19 ü ü 3324051 Foot Valve Ball 1

20 3324052 Foot Valvle 1

Hydraulic Pump
The hydraulic pump assembly (3324063) is an integrated pump assembly consisting of a close-coupled,
73/8" air-driven motor (3324057) and a 300:1 ratio hydraulic pump (3151000). This section outlines the
corrective maintenance procedures for the 300:1 ratio hydraulic pump. The hydraulic pump operates
when air pressure applied to the air motor forces hydraulic fluid through the pump.

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The numbers in parentheses correspond to the item numbers shown in Figure 5-8 and the
associated table. For assembly and kit part numbers, see the table titled "Parts List, Hydraulic
Pump" .

Hydraulic Pump Disassembly

1. Remove fluid and discharge line assembly.

2. Remove the pump from the air motor.

3. Loosen the packing gland nut (3). Then pull the rod (2) through upper cavity of the
pump block (1).

4. Remove packing spring (3).

5. Hold pump block (1) in vise and remove cover nut (8) with wrench.

6. Remove the packing set (5) and rod sleeve (6) from the pump block.

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Before beginning disassembly of the hydraulic pump,

ensure all hydraulic pressure is vented to zero psi.

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Maintenance 5

Figure 5-8 Hydraulic Pump, Cutaway Unit

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Parts List Hydraulic Pump

Item # Major Kit P/N Description Qty.

Assembly

3151000 Hydraulic Pump —

Kit 9931510 Repair Kit —

1 3151001 Pump Block 1

2 3151004 Pump Rod 1

3 3150003 Gland Nut 1

4 3150004 Spacer Nut 1

5 ü 5105002 Packing Set 1

6 ü 3150006 Rod Sleeve 1

7 ü 5001142 O-Ring 1

8 ü 3150007 Cover Nut 1

Hydraulic Pump Reassembly

1. Install a new O-ring (7) into the cover nut (8).

2. Install the packing set (5) and rod sleeve (6) into the pump block (1) (see Figure 4-3
on page 4-8 for correct installation) of packing set.

3. Install the cover nut (8) into the pump block (1) and tighten with wrench.

4. Install the gland nut (3), finger tight, onto the pump block.

5. Lubricate the packing (5) and Pump rod (2) with SAE 10W oil and install pump rod
through packing into rod sleeve (6).

6. Install the assembled pump onto the air motor.

7. Install fluid supply and discharge line assembly.

8. Start pump and adjust gland nut to allow slight leakage for rod to packing
lubrication.

Air-Driven Motor
The hydraulic pump assemblies (3324000 and 3324063) are integrated pump assemblies consisting of a
close-coupled, 73/8" air-driven motor (3324057) and either a 60:1 or 300:1 ratio hydraulic pump (3324056
or 3151000). This section outlines the corrective maintenance procedures for the 73/8" air-driven motor.
The hydraulic pump operates when air pressure applied to the air motor forces hydraulic fluid through the
pump.

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Maintenance 5

The numbers in parentheses correspond to the item numbers shown in Figure 4-4 on page 4-10
and the associated table. For assembly and kit part numbers, see the table titled "Parts List, 7-3/8"
Air-Driven Motor" on page 4-12.

i
Peak of V-packing must point up toward gland nut.
Use teflon tape on all threaded pipe connections.

Figure 5-9 Air-Driven Motor (P/N 3324057), Exploded View

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The air motor should be supplied with moisture-free
air. For use under very cold and humid air conditions,
coupled with high speed and high operating pressure,
a moisture separator and an automatic oiler may be
necessary to avoid icing.

Air-Driven Motor Disassembly

1. Disconnect air hose from elbow (1).

2. Remove locking bolts and nuts (24, 23), trip spring retainers (6), O-ring (5), trip
springs (4), and balls (3) from both sides of cylinder head (25).Disconnect air
line (26) from adaptors (28), top and bottom.

3. Disconnect air line (26) from adapters (28), top and bottom.

4. Remove six nuts (38) and six bolts (2).

5. With piston (33) in down position, place wrench on flats of piston rod (36) and
disconnect piston rod from pump connecting rod.

6. With piston (33) at top of stroke, raise cylinder head (25) and remove retainer (20).
Lift off the cylinder head (25). The valve sleeve (10) may pull out of cylinder head; lift
sleeve off separately.

7. Remove stop nut (12) and then unthread keeper (13).

8. Remove air valve (14), followed by lower valve keeper (16) and bushing (17).

9. If valve sleeve (10) is still in cylinder head, leave it there unless it is necessary to
change O-rings. To remove, insert head of bolt (2) into large hole in valve
sleeve (10) and pull it out very carefully.

10. Remove cylinder (30).

11. Remove piston rod (36) and piston (33) from motor base (39).

12. Secure piston (33) in vise and remove piston nut (21) and piston washer (22).

13. Remove valve rod assembly (32) and valve trip collar (35).

14. Unscrew piston rod (36) from piston (33).

15. Remove O-ring (34) from piston (33).

16. Remove O-rings (18, 19) from bushing (17) and O-ring (37) from motor base (39).

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Maintenance 5

Parts List, 7-3/8" Air-Driven Motor

Major Minor Description Qty.
Item # P/N
Kit Kit

Assembly

3324057 Air-Driven Motor Assembly

Kit 9933243 Minor Kit for Air Motor 3324000 -

Kit 9933244 Major Kit —

1 2041062 Elbow 1/2" x 1/2" 1

2 3324009 Bolt 6

3 ü ü 3324006 Valve Ball 2

4 ü ü 3324005 Trip Spring 2

5 ü ü 3324004 O-Ring 2

6 3324003 Trip Spring Retainer 2

7 3324012 Nut 2

8 3324011 Exhaust Plate 2

9 3324010 Adapter 2

10 ü 3324013 Valve Sleeve 1

11 ü ü 3324014 Valve Sleeve O-Ring 4

12 ü ü 3324015 Stop Nut 1

13 ü 3324016 Upper Valve Keeper 1

14 ü 3324017 Valve 1

15 ü ü 3324018 Air Valve O-Ring 2

16 ü 3324019 Lower Valve Keeper 1

17 3324021 Bushing 1

18 ü ü 3324014 O-Ring 1

19 ü ü 3324020 O-Ring 1

20 3324022 Retainer 1

21 3324026 Piston Nut 1

22 3324027 Piston Nut Washer 1

23 3324002 Nut 2
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Parts List, 7-3/8" Air-Driven Motor Cont...

Major Minor Description Qty.
Item # P/N
Kit Kit

24 3324008 Bolt 2

25 3324007 Cylinder Head 1

26 3304058 Air Line (includes Item #27) 2

27 — Nut and Ferrule —

28 3324001 Adapter 2

29 ü ü 3324023 Gasket 1

30 3324024 Cylinder 1

31 ü ü 3324022 Gasket 1

32 ü 3324025 Valve Rod Assembly 1

33 3324028 Piston 1

34 ü ü 3324030 Piston O-Ring 1

35 ü 3324029 Valve Trip Collar 1

36 3324031 Piston Rod 1

37 3324032 O-Ring 1

38 33254012 Nut 6

39 3324033 Motor Base 1

40 3324058 Air Line Adapter 1

Air-Driven Motor Reassembly

Wash all replaceable parts thoroughly with kerosene and lubricate with lubri-plate or similar non-water soluble
grease. For routine servicing, use the air motor seal kit. For major overhaul, replace all parts contained in the air
motor repair kit. Inspect all other parts for abnormal wear or damage and replace, if necessary.
1. Install new O-ring (37) into motor base (39) and new O-rings (18, 19) into bushing (17). Do not damage
O-rings and make sure they are properly seated in the O-ring grooves.

2. Place valve trip collar (35) into piston rod (36), followed by valve rod assembly (32).

3. Screw piston rod (36) into piston (33). Replace piston nut and washer (21, 22).

4. Install piston O-ring (34) into piston (33).

5. Place new gasket (31) into position in motor base (39).

6. Place piston assembly (33, 36) into motor base (39). Do not damage O-ring (37).

7. Place new O-rings (15) onto air valve (14).

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Maintenance 5

8. Mount air valve assembly onto valve rod (32) by placing bushing (17) over valve rod,
followed by keeper (16), which should be threaded down on air valve hand tight and
then loosened approximately 1/4 turn. Place wrench on flats of valve rod and hold to
prevent valve rod from turning. Thread stop nut (12) down on valve rod to lock upper
valve keeper (13) in position. Be sure upper valve keeper (13) does not change
position.

9. Grease inside of cylinder (30) and work cylinder down over piston gently in order to
avoid damaging piston O-ring (34).

10. Install new O-rings (11) on valve sleeve (10). Grease valve sleeve and install into
cylinder head (25) so large holes in sleeve line up with trip retainer holes in cylinder
head. Put one trip retainer (6) with O-ring (5) into cylinder head without ball (3) or
spring (4) and hold in position temporarily with locking bolt (24) and nut (23).

11. Place new gasket (29) into position in cylinder head (25) and hold with gasket
cement or grease.

12. Carefully position air valve assembly up into cylinder head (25).

13. Push bushing (17) up into bottom of cylinder head (25) sufficiently to permit
installation of retainer (20).

14. To install trip spring retainer, be sure one of the detents of valve (14) is properly
lined up with hole in cylinder head (25). Place trip spring retainer O-ring (5) onto
remaining trip spring retainer (6). Install ball (3), followed by trip spring (4) and trip
spring retainer, into hole in cylinder head. Lock into position with bolt (24) and
nut (23).

15. Remove opposite trip spring retainer (6) and repeat Step 14.

16. Connect air line (27) to adapters (26), top and bottom.

17. Replace bolts (2) and nuts (38). Always tighten nuts 180≡apart in order to obtain
proper and even compression. Do not over tighten.

18. Place wrench on flats of piston rod (36) and connect pump connecting rod.

19. Reconnect air hose to elbow (1).

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Model TD60 Triplex Plunger Pump

The model TD60 is an advanced design Triplex Power Pump with exceptional flexibility and versatility
to efficiently meet the requirements of a wide variety of pumping applications. The unit is ruggedly
designed for minimum maintenance and to meet the heavy-duty requirements of continuous duty
operation of general industry, as well as, API 674 applications.

Design Ratings:

Continuous Duty – 61.0 HP (45.49 kW) input at 400 RPM, pressures to 10,000 psig (703
q
kg/cm2g), capacities to 72.6 U.S. GPM (16.48 M3/Hour)

Intermittent Duty - Up to 77.7 HP (57.94 kW) at 510

q

Power End Features:

Stroke: 3.00 inch (76.2 mm).

q

Maximum Plunger (Frame) Loading for Continuous Service: 5,700 pounds (25,355 Newtons).
q

Construction - Power Frame - A48 Class 30 Cast Iron construction designed with rigidity and
q
ease of maintenance as objectives. Full cylindrical crosshead bores are cast with sufficient extra
thickness to allow for over-boring and installation of liners in case the bores become damaged.
This model pump has the following component features:

Power Pump Lubrication - Used on Union Pump power pumps for decades, the simple and
q
sure splash / gravity feed system serves the Power Frame to provide positive lubrication to the
crossheads and bearings. The crankcase is a generous oil reservoir with provisions for adding
an oil heater and thermostat when required. An option external electric driven positive
lubrication system is available for crankshaft speed below 50 RPM or for use during pump idle
periods to enable the pump to be started under discharge pressure loads without loss of
lubrication to crossheads and bearings.

Crankshaft - One-piece SAE 4140-4145 heat treated steel for toughness and high endurance
q
limit. Reversible in Power Frame for drive input from either side of pump.

5-34
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BOP Control System
Revision A
Page 5-35 of 39
Maintenance 5

Construction - Power Frame (continued)

mMain Crankshaft Bearings - The crankshaft has two anti-friction taper roller bearings
designed for a minimum L10 life of 30,000 hours (3.4 years); an average life of 150,000
hours.

Connecting Rods and Bearings - Carry loads in compression only. The connecting rods are
m
heavy duty with separate bolted caps at the crankshaft end to simplify assembly and bearing
insert replacement. Crankshaft end connecting rod bearings are split, replaceable, precision
type babbitt lined steel. Crosshead pin bearings are oil-impregnated bronze. These bearings
provide a smooth-running unit with excellent longevity and adjustment-free bearing life.

mCrossheads - Large diameter full piston type that are extra long for maximum support and
large bearing area. Each Crosshead operates in a full cylindrical bore in the power frame with
the entire cylindrical surface is lubricated; which in combination with the large bearing area
reduces wear to negligible proportions.

mCrosshead Wrist Pins - Crosshead wrist pins are alloy steel, carburized, hardened and
accurately ground. They slip into the crosshead and are positively locked with two (2)
setscrews.

m
Crosshead Extensions - Threaded into the crosshead providing excellent alignment with the
steel for corrosion resistance and increased wiper seal life.

m
Crosshead Extension Seals - Are spring loaded lip type that press fit into the Crosshead
Stub Seal Cap.

mCrosshead Extension Deflectors - Are made of neoprene rubber and are located in grooves
in the crosshead extensions.

m
Crossheads, Crosshead Wrist Pins Crosshead Extensions, Crosshead Extension Seals, and
Crosshead Extension Deflectors are interchangeable with those in the TD90 and QD100
models.

q
Drive Methods:

q
Pump-mounted (bolt-on) “Gear-Pac” speed reducer made by Union Pump with 3.82:1, 4.80:1,
5.00:1; 6.32:1 and 8.00:1available. See page 42070-1001 for “Gear-Pac” features.

m
Separate speed reducer.
m
Gear-head motor.
m
Top mounted “V” belt drive (standard). Provides most compact and economical drive
m
arrangement.
m
Rear mounted “V” belt drive (non-standard).
m
Variable speed drivers.

Driver Types: – Electric motor, air motor, turbine or engine may be used with any drive
q
method,except the Top mounted “V” belt drive arrangement that will not accept and engine.

Liquid End Features:

q
Liquid Cylinder - Four (4) standard vertical valves and one (1) straight line (“SL”) suction valve
designs with low internal clearance volumes maximizes volumetric efficiency. Liquid Cylinder
designsare available to accept plunger diameters from 0.750” (19.05 mm) to 2.500” (63.5 mm).

Both suction and discharge connections are standard NPT Pipe taps at both ends of the
m
liquid cylinder.
5-35
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 BOP Control System
5 Maintenance Revision A
Page 5-36 of 39

Figure5-10 : Triplex Pump Exploded View

5-36
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BOP Control System
Revision A
Page 5-37 of 39
Maintenance 5

Main Crankshaft Bearings - The crankshaft has two anti-friction taper roller bearings

Optional flanged suction and discharge connections in appropriate flange facings and ratings
m
are available for all liquid cylinders.

Standard Liquid Cylinders are available in steel, nickel-aluminum bronze, 18-8 stainless steel
m
and duplex stainless steel.

Liquid Cylinder Connections - Each liquid cylinder is standard with two (2) suction and two (2)
q
discharge NPT pipe tapped connections. Optional flanged suction and discharge connections in
appropriate flange facings and ratings are available for all liquid cylinders, consult factory.

Stuffing Boxes - Standard stuffing boxes are gland design for manually adjusting plunger
q
packing. Spring loaded self-adjusting plunger packing design stuffing boxes are optional.

Stuffing boxes are readily removable for ease of maintenance by bench replacement of
m
plungers, packing and other stuffing box internal parts.

Each stuffing box is designed for a range of plunger sizes, with several stuffing boxes
m
available to cover the entire range of plungers within each liquid cylinder size. This design
then enables changes in Plunger sizes as necessary to accommodate changes in pump
operating conditions with minimal parts required for the conversion.

A wide range of stuffing box configurations are available, including lantern ring lubrication
m
designs, Union Pump Uni-Lok® double packed leakage control designs.

Stuffing Boxes are interchangeable with those within the same size Liquid End as the TD90
m
and QD100 models.
Plungers - Plungers are threaded to the crosshead extensions outside the power frame housing
q
to simplify assembly and to keep plungers replacement cost low.

A 60 RC nickel-base alloy (#6 Colmonoy®) is fused to the plunger packing wear surface,
m
then ground to an 8 RMS micro inch mirror finish for long packing and plunger life. Other
plunger base materials and hard face coatings in the packing wear area are available to
meet application requirements.
Plunger sizes are available in standard 0.125” (3.18 mm) increments, starting at 0.750”
m
(19.05 mm). Non-standard Plungers are available in 0.063” (1.59 mm) increments – consult
factory for further details.
mPlungers are interchangeable with those within the same size Liquid End as the TD90 and
QD100 models.

Valve Assemblies – The liquid cylinder valves are a standard wing guided design, which are
q
quiet and quick acting.

Are of a wing guided design with beveled seating surface between the Valve and Valve Seat
m
for effective sealing and provides for maximum wear life.

Both the Valve and Valve Seat are made of hardened stainless steel for long wear life.
m
The Valve Seats are straight press fit into the Liquid Cylinder.
m

Suction and discharge valves assemblies within the same liquid cylinder are
m
interchangeable.

Valve Assemblies are interchangeable with those within the same size Liquid End as the
m
TD90 and QD100 models.

Optional “Abrasion Resistant” or “Ball” type Valve designs are available at extra cost as
m
operating conditions warrant their use.
5-37
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 BOP Control System
5 Maintenance Revision A
Page 5-38 of 39

Parts List, Triplex Pump

Item # P/N Description

1 177-5 Capscrew, Frame Cap, Crankshaft,

2 132 Cap, Crankshaft Frame, Outboard

3 134 Shim, Crankshaft Frame Cap

4 107 Bearing, Crankshaft Cup

5 107 Bearing, Crankshaft Cone

6 621 Gasket, Crosshead Inspection Cover

7 153 Cover, Crosshead Inspection

8 9122 Drive Screw, Lubrication Nameplate

9 179 Nameplate, Lubrication

10 649 Plug, Fill

11 100 Power Frame

12 620 Gasket, Crankcase Cover

13 154 Cover, Crankcase

14 175 Sightglass, Oil Level Gauge

15 649-1 Pipe Plug, Sq Head, Oil Drain

16 653 Pipe Tee, Oil Level Gauge

17 668 Nipple, Oil Level Gauge

18 177-11 Cap Screw, Cover, Crankcase

19 113 Cap Screw, Connecting Rod Assembly Crosshead Inspection

20 171-3 Lockwasher, Connecting Rod

21 112 Connecting Rod Assembly

22 116 Bearing, Connecting Rod

23 133 Frame Cap, Crankshaft, Inboard

24 630 Oil Seal, Crankshaft Frame Cap

5-38
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BOP Control System
Revision A
Page 5-39 of 39
Maintenance 5

Parts List, Triplex Pump Contd....

Item # P/N Description

25 666-2 Key, Crankshaft

26 103 Crankshaft

27 649-2 Pipe Plug, Socket Head, Oil Sump

28 120 Bearing, Crosshead Pin

29 178 Set Screw, Socket Head, Crosshead

30 117 Crosshead Assembly

31 119 Pin, Crosshead

32 123 Deflector, Crosshead Stub

33 177-10 Capscrew, Stub Seal Cap Clamp

34 632 Oil Seal, Crosshead Stub

35 141 Seal Cap, Crosshead Stub

36 623 Gasket, Crosshead Stub Seal Cap

37 643 Stud, Liquid Cylinder Tie

38 644 Nut, Liquid Cylinder Tie Stud

39 650-6 Dowel Pin, Cylinder

40 177-3 Capscrew, Cover, Crosshead Inspection

41 634 Oil Breather, Crankcase

5-39
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 BOP Control System
Revision A
Page 6-1 of 25

Troubleshooting Instructions

6.1 General

The purpose of the Troubleshooting Section is to enable the operator to quickly identify and correct each
malfunction. The action taken will result in minimum downtime and prevention of additional damage.
Although the information in this section is comprehensive, other problems may arise which are not
listed. As these are solved, either locally or with the aid of a Sara representative, all steps taken should
be documented and inserted into this manual. Some repairs may void the Sara. Warranty on certain
components. Before such repairs are contemplated, contact Sara or it's nearest service representative.

The Troubleshooting Charts contain information presented in three vertical columns. The first column
identifies the problem or symptom, the second column lists probable causes and the third column
describes corrective action. In preparing these Troubleshooting Charts, it is assumed that normal
preventative maintenance procedures have been followed.

It may be necessary to consult other sections of the manual to become familiar with the BOP Control
System. The Operation Section includes a more detailed description of the system operation. To make
repairs, first locate the faulty component. Use the drawings and material lists located in the Parts
Section to determine the part number of the component. Many components are field repairable. Refer to
the Parts Section for repair instructions and available repair parts. Always order replacement parts by
part number.

Pay particular attention to notes, cautions and bold type words as these are added to ensure safety
during all phases of equipment use. The following instructions are major steps that must be performed
during the maintenance and troubleshooting procedures.

Wherever these instructions are given, refer to these steps:-

1. Stop Pumps

a. Close air supply valves.

b. Turn triplex pump motor starter to OFF position.

2. Start Pumps

a. Open the air supply valves.

b. Turn triplex pump motor starter to AUTO position.

i
THE TROUBLESHOOTING PROCEDURES SHOULD BE
PERFORMED ONLY AT TIMES THAT WILL NOT AFFECT
THE SAFETY OF DRILLING OPERATIONS. REMEMBER
TO REPLENISH THE FLUID SUPPLY AFTER FLUSHING
LINES.

6-1
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-2 of 25

6.2 Accumulator Problems

Problem Possible Cause Remedy

6.2.1 Loss of Faulty precharge 1. Stop pumps.

Accumulator valve permits 2. Open manifold bleeder valve and
Precharge nitrogen toescape Pressure nitrogen to relieve all
Pressure system pressure.
3. Check precharge pressure on each
accumulator and record.
4. Tighten valve cores snugly with
valve core tool (#0902-0200).
5. Precharge each accumulator with
1000 psi of nitrogen, starting with
accumulator that had highest
recorded pressure. This will
conserve nitrogen.
NEVER USE OXYGEN.
6. Observe precharge pressure on
precharge gauge.
7. Check all precharge valves for gas
leaks by placing drops of Light oil
across tops of valves.
8. If valve:
1) Bubbles, nitrogen is escaping.
Replace valve core (See
Section 7.0).
2) Does not bubble, accumulators
are ready for normal use.
9. Close manifold bleeder valve.
10. Start pumps

Ruptured Bladder 1. Stop pumps.

2. Bleed fluid system pressure by
slowly opening bleeder valve.
3. Listen for poppet valves to close
while observing accumulator
pressure gauge.
4. If poppet valves do not close at
pressure, and pressure continues to
drop to zero, at least one
accumulator has lost its precharge.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-2
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BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-3 of 25

Problem Possible Cause Remedy

6.2.1 (Continued) Ruptured Bladder 5. Check and record precharge

(Continued) pressure of each accumulator.
6. Those with zero precharge may
have faulty bladders. To check
this:
a. Tighten valve cores snugly with
valve core tool.
b. Precharge with 200 psi of
nitrogen. If pressure does not
decrease;
c. Precharge with 1000 psi of
nitrogen,
7. If an accumulator does not sustain
200 psi precharge, the bladder is
ruptured and must be replaced
(.See Section 7.0).
8. Close manifold bleeder valve.
9. Start pump.

6.3 Air Supply problem

Problem Possible Cause Remedy

6.3.1 Lack Of No Lubricant 1. Cut of f main ai r supply to unit.

AirLubrication InBowl 2. Open pet cock at bottom of air
lubrication, bowl.
3. Drain off any moisture or emulsified
oil.
4. Unscrew fill cap and refill lubricator
with 10W motor oil.
CAUTION: Do not use synthetic or
aromatic type oil.
5. Open main air supply valve to unit.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-3
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-4 of 25

Problem Possible Cause Remedy

6.3.2 Excessive Air Lubricator Out 1. Close accumulator isolator valves.

Lubrication OfAdjustment 2. Turn motor starter to OFF
position.
3. Open manifold bleeder valve,
4. Operate air pumps at full capacity.
5. Open lubricator fill cap.
6. Use a thin screwdriver to adjust
lubricator to provide 6 (six) drops of
oil per minute.
Rotation of metering screw:
a. Clockwise-increases flow,
b. Counterclockwise-decreases
flow.
7. Close manifold bleeder valve.
8. Open accumulator isolator valves.
9. Turn motor starter to AUTO position.

6.3.3 Air Operated Moisture In Rig 1. Make sure unit is being sup-plied
Pumps IcingOver Air Supply with clean , dry air.
Orfreezing 2. Cut off main air supply to unit.
3. Close accumulator isolator valves.
4. Turn motor starter to OFF position.
5. Open petcock at bottom of air
lubrication bowl.
6. Remove plug from Y-type strainer.
7. Open main air supply valve to the
unit.
8. Open manifold bleeder valve.
9. Run air pumps at full capacity until
all moisture has been removed.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-4
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BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-5 of 25

Problem Possible Cause Remedy

6.3.3 (Continued) Moisture In RigAir 10. Close air supply valves to stop
Supply (Continued) pumps.
11. Cut off main air supply to unit.
12. Replace plug in Y-type strainer.
13. Open main air supply to unit.
14. Close manifold bleeder valve.
15. Open accumulator isolator valves.
16. Open air supply valves.
17. Turn motor starter to AUTO position.

6.4 Pump Problems

Problem Possible Cause Remedy

6.4.1 Pumps Run Air pump pressure 1. Close the bypass valve tightly
Excessively switch by pass 2. Reset automatic pressure
valve is open or switch(See Maintenance Section) to.
faulty shut off air pumps at:
a. 2900 psi for units with air
and electric pumps.
b. 3000 psi for units with air
pumps only.
3. If air pumps continue operating,
bypass valve may be defective.
a. Loosen tubing connector
downstream from air bypass
valve.
b. If air is escaping,replace the
bypass valve.
c. Close bypass valve tightly.
4. Check pump shutoff pressure.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-5
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-6 of 25

Problem Possible Cause Remedy

6.4.1 (Continued) Hydraulic seals 1, Stop pumps.

in automatic 2. Open manifold bleeder valve and
pressure switch
are leaking. relieve system pressure,
3. Remove automatic pressure
Switch for inspection.
4. Replace pressure switch and
adjust setting.
5. Close manifold bleeder valve.
6. Start pumps.
7. Check pressure switch settings.

Faulty Precharge 1. Stop pumps.

Valve (Bladder 2. Open manifold bleeder valve.
Type Separator) 3. Check precharge pressure on
Each accumulator and record.
4. Tighten each precharge valve
assembly by using valve core
tool.
5. Precharge each accumulator with
1000 psi of nitrogen starting with
accumulator that had highest
recorded pressure. This will
conserve nitrogen.
6. Check all precharge valves for
gas leaks by placing drops of
saliva across tops of valves
(Light oil may also be used) if:
a. Bubbles appear, replace
valve core (See Section
7.0)
b. No bubbles appear,
accumulators are ready
for normal use.
7. Close manifold bleeder valve.
8. Start pumps.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.
6-6
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BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-7 of 25

Problem Possible Cause Remedy

6.4.1 (Continued) Four-way Valve 1. Open inspection ports located

Leaking at each end of reservoir.
2. Observe which valve is leaking.
3. Operate valve several times.
4. If leaking persists, remove valve.
5. Use special repair kits containing
necessary parts for overhaul (See
Parts Section).
6. The maintenance instructions
supplied with the kit must be
consulted for proper assembly.
Improper or reverse assembly can
result in high pressure and cause
injury.

Relief Valve 1. Open inspection ports at each end

Leaking of reservoir.
2. Observe relief valve return lines
to see which one is leaking.
3. Note pressure reading on gauge
when flow begins to check if
setting is incorrect.
4. Remove and replace faulty valve.

Regulator 1. Open inspection ports at each

Leaking end of reservoir.
2. Observe regulator return lines to
check If leaking.
3. Remove and replace faulty
regulator.

Bleeder Valve 1. Close manifold bleeder valve

Leaking tightly.
2. Check for leakage by looking
through inspection ports located at
each end of reservoir.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-7
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-8 of 25

Problem Possible Cause Remedy

6.4.1 (Continued) Bleeder Valve 3. If valve is leaking, remove and

Leaking (Continued) replace it.

Leaks In Fluid Visually inspect:

System 1. All piping and connections on The

accumulator unit.
2. All connecting lines Co the BOP
stack.
3. Relieve all system pressure.
4. Repair all fluid leaks.

Regulator 1. Stop pumps.

Leaking 2. Bleed fluid system pressure by
Slowly opening bleeder valve.
3. Listen for poppet valves to close
while observing accumulator
pressure gauge.
4. If poppet valves do not close at
precharge pressure, and pressure
continues to drop to zero, at least
one accumulator has lost its
precharge.
5. Check and record precharge
pressures of each accumulator.
6. Those with zero precharge may
have faulty bladders.
To check this:
a. Tighten valve cores snuggly
with valve core tool.
b. Precharge with 200 psi of
nitrogen.
7. If an accumulator does not sustain
200 psi precharge, the bladder is
ruptured and must be replaced
(See Section 7.0).
8. Close manifold bleeder valve.
9. Start pumps.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-8
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BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-9 of 25

Problem Possible Cause Remedy

6.4.2 Pumps Shut Air pump pressure 1. Stop pumps.

Down At Wrong switch is out of 2. Closes accumulator Isolator
Pressure adjustment. valves.
3. Make sure air bypass valve Is
tightly closed.
4. Open manifold bleeder valve to
relieve system pressure.
5. Close manifold bleeder valve.
6. Open air pump supply valves.
7. Adjust pump shutoff pressure
setting (See Maintenance Section)
unti1 pump stops running when
desired fluid pressure has been
reached on accumulator pressure
gauge.
8. Bleed off manifold pressure
through bleeder valve and repeat
procedure to check accuracy of
setting.
9. Open accumulator isolator valves.
10. Turn motor starter to AUTO
position.

Electric pressure Switch is Pressure switch settings have a

out of Adjustment.
tendency to drift and require periodic
Calibration. This is especially true
when the Equipment has been moved
to a different location. To adjust the
setting, see Maintenance Section.

If pump discharge pressure reaches a

certain point and pump still continues
to run, the check valve in the pump is
stuck in open position or has been
damaged:

6.4.3 Pump Cannot Faulty Check Valve In Air 1 .Stop pumps.

Reach Full Pump(s) 2. Close isolator valves with
Pressure pressured up accumulators

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-9
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-10 of 25

Problem Possible Cause Remedy

6.4.3 (Continued) Faulty Check Valve In 3. Open bleeder valve and bleed off
Air Pump(s) manifold pressure.
(Continued) 4. Remove suspected air pump,
5. Clean, repair, or replace as
Necessary.
6. Install pump.
7. Start air pump and operate with
bleeder valve open to make sure
that the pump is properly primed.
8. Close bleeder valve.
9. Open isolator valves.
10. Start pumps and. pressure up
system.

Low Air Supply 1. Check rig air supply gauge for

proper air supply (See Installation
Data Section 2.5.2.
2. Correct air supply at main air
compressor.

6.4.4 Pumps Produce Loss of pump prime to restore fluid level:.

No Pressure because of low fluid level. 1. Close accumulator isolator Valves
if accumulator pressure Gauge
shows pressure is contained.
2. Stop pumps.
3. Open manifold bleeder valve and
bleed system pressure.
4. Add fluid to at least twelve (12)
inches above pump suction lines.
5. Start one pump and operate at full
pressure.
6. Observe fluid flow through
inspection ports.
7. Stop pumps.
8. Open isolator valves.
9. Check reservoir fluid level.
Add oil if needed.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-10
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BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-11 of 25

Problem Possible Cause Remedy

6.4.4 (Continued) Loss of pump Prime 10. Close bleeder valve.

because Of low fluid 11. Start system.
Level. (Continued)

Suction Valve closed Check that pump suction valves are in

full open position.

Fluid Contamination 1. Close accumulator isolator valves

if accumulator pressure Gauge
shows pressure is contained.
2. Stop pumps.
3. Open manifold bleeder valve.
4. Open air pump supply valves and
start air-operated pumps.
5. Observe fluid flow through
inspection ports. If slight or no
fluid flow is observed:
6. Stop air pumps.
7. Close pump suction valve(s).
8. Remove Y-type strainer plugs.
9. Remove strainer elements.
10. Open pump suction valves and
flush out debris from piping.
11. Close pump suction valves.
12. Clean and replace strainer and
plug.
13. Start pump and observe fluid flow
through inspection ports.
14. Repeat procedure until system
is clean.
15. Close manifold bleeder valve.
16. Open accumulator isolator valves.
17. Start pumps.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-11
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-12 of 25

Problem Possible Cause Remedy

6.4.5 Pumps Leaking Plunger packingIs on the older style pumps (Model
worn ordamaged on no. 88550):
airpump(s).
1. Tighten packing nut.
2. If leak stops: Check for proper
plunger lubrication. The plunger
should be coated with a thin film of
hydraulic fluid.
3. If leak persists: Remove pumps
and replace.

Worn packing on Replace packing.

Electric drivenPump.

Damaged valvecover 1. Stop pumps,

gasket orloose coverplate 2. Close pump suction valve,
on electricdriven pump. 3. Remove valve cover plate
4. Remove and inspect valve cover
Gaskets.
5. Replace gaskets if they appear to
be distorted, washed out or
compressed excessively.
6. If the gaskets appear to be good,
invert and reinstall.
7. Replace cover plate and tighten
bolts.
8. Open. Suction valve.
9. Open manifold bleeder valve.
10. Turn motor starter Co AUTO
position.
11. Operate pump and check for new
leaks.
12. Open air supply valves.
13. Close manifold bleeder valve.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-12
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BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-13 of 25

5.5 Electric Motor Problems

Problem Possible Cause Remedy

6.5.1 Motor Fails To Pressure switch faulty 1. Turn motor starter to OFF position
start. 2. Turn off power at rig main
generator panel.
3. Remove pressure switch
explosion -proof cover.
4. Disconnect leads from electrical
pressure switch to starter.
5. Check resistance across terminals
of pressure switch with an
ohmmeter. If resistance to
observed, the switch is working
properly.
6. If no resistance Ls found , replace
the limit switch or, if time is limited,
replace the entire pressure switch
assembly (See Section 7.0).
7. Replace the leads from starter to
pressure switch (See Starter
Wiring Diagram in Equipment
Section).
8. Turn on power at rig main
generator panel.
9. Turn motor starter to AUTO
position.
10. Check for proper adjustment of
settings (See Maintenance
Section) .
11. Replace pressure switch
explosion-proof housing cover.

Starter tripped If power supply had a thermal

Overload:
1. Turn motor starter to OFF position.
2. Press reset button on motor
starter.
3. Turn motor starter to AUTO
position.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-13
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 BOP Control System
6 Troubleshooting Instructions Revision A
Page 6-14 of 25

Problem Possible Cause Remedy

6.5.1 (Continued) Loss Of Power supply 1. Turn motor starter to OFF position
2. Check voltage of power supply to
scarcer at rig main generator
panel.
3. Restore power supply from rig
main generator panel.
4. Turn motor starter to AUTO
position.

6.5.2 Motor Runs Voltage Fluctuation If pump pressure is at proper setting

Erratically and pump stops frequently, Input
voltage may be too low.
1. Turn motor starter to OFF position.
2. Check and correct voltage at rig
main generator panel.
3. Turn motor starter to AUTO
position.

Pressure switch Span If pump continues to stop and start

is out of Adjustment. after reaching the proper Setting,
switch adjustment may be Necessary.
1. Close air supply valves.
2. Check that starter switch is in
AUTO position.
CAUTION : ELECTRICAL CONTACTS
HAVE LIVE POWER.
3. Remove pressure switch cover.
4. Move white adjustment wheel
down or toward the front.
5. Open manifold bleeder valve and
reduce pressure to desired pump
starting pressure.
6. Close manifold bleeder valve.
7. Move adjustment lever back (Up
or towards rear) until pump starts.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-14
Sara
BOP Control System
Revision A Troubleshooting Instructions 6
Page 6-15 of 25

Problem Possible Cause Remedy

6.5.2 (Continued) Pressure switch Span 8. After pump stops, check results to
is out of Adjustment. make sure that proper set ting has
been obtained.
9. Replace pressure switch cover.
10. Open air supply valves.

6.6 Four-way Valve Problems

Problem Possible Cause Remedy

6.6.1 Interflowing Debris In The valve 1. Stop pumps.

2. Open manifold bleeder valve.
3. Dislodge debris by manually
shifting the valve handle through
the full range.
4. Repeat shifting several times until
interflow has been cleared up.
5. Close manifold bleeder valve.
6. Start pumps.

Washed Out Or 1. Remove and replace the valve.

damaged seals 2. Use special repair kits containing
necessary parts for overhaul (See
Parts Section).
3. The maintenance instructions
supplied with the kit must be
consulted for proper assembly.
Improper or reverse assembly can
result in high pressure and cause
injury.

Actuator rod is Out of 1. Adjust clevis locknut so actuator

adjustment. rod obtains full travel.
2. Check lever travel.
a. Start pumps.
b. Pressure up system.
c. Operate function from remote
panel.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-15
Sara
 BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-16 of 25

Problem Possible Cause Remedy

6.6.l (Continued) Actuator Faulty 1. Remove cylinder.

2. Inspect for debris, wear or other
damage.
3. If dirt wiper is blown out, either:
a. The rod seal is leaking.
b. There is excess grease in
the grease fitting.
4. Repair or replace as necessary.
5. Install cylinder.

Insufficient Pressure Check all interface points forleaks or

open connections.

6.7 GAUGE PROBLEMS

Problem Possible Cause Remedy

6.7.1 Out Of Shock Due To Rough 1. Non-fluid filled pressure gauges

Adjustment Treatment (Note: When checking The
accumulator pressure gauge does
not close the accumulator isolator
valve.):
a. Close accumulator isolator
valves.
b. Stop pumps.
c. Open bleeder valve and
bleed
off manifold pressure,
d. Remove gauge face covering.
e. Adjust gauge indicator to
zero setting with a thin
screwdriver blade.
f. Replace, gauge face cover.
g. Loosen gauge fitting and
bleed off any trapped air.
h. Retighten fitting,
i. Close bleeder valve.
j. Open accumulator isolator
valves.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.
6-16
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-17 of 25

Problem Possible Cause Remedy

6.7.1 Continued Shock Due To Rough k. Start pumps and pressure

Treatment (Continued) up system.
1. After full pressure is indicated
1) Close accumulator isolator
valves.
2) Stop pumps.
3) Open manifold bleeder valve
and bleed off pressure at 500
psi increments,
4) Observe gauge reaction
each time. -
5) When no manifold pressure
remains, gauge should read
zero (0) psi.
m. Close manifold bleeder valve.
n. Open accumulator isolator
valves.
o. Start pumps and restore
system pressure.
2. Fluid filled gauges:
a. Remove defective gauge and
replace with a workable unit.
b. Send the defective gauge to
vendor for factory calibration.
3. An alternate method of checking
a faulty gauge can be used:
a. Connect the faulty gauge
supply line to a common
manifold with a gauge of
known accuracy.
b. Adjust faulty gauge if
possible.
c. Acceptable indication limits
are +50 psi from true
pressure.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-17
Sara
 BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-18 of 25

Problem Possible Cause Remedy

6.7.2 Responds Slowly Supply line or snubber is When gauge responds slowly or in an
clogged (Accumulator erratic manner during operation:
Pressure ) 1. Stop pumps.
2. Close accumulator isolator valves.
3. Open manifold bleeder valve to
relieve system pressure.
4. Disconnect gauge supply line. If
pressure gauge is installed with
snubber:
a. Remove snubber from gauge
and connect to gauge supply
line.
b. Start air operated pump,
c. Slowly close bleeder valve.
d. If fluid does not pass through
snubber it is blocked and
should be replaced.
1) Stop pump.
2) Open the manifold bleeder
valve.
3) Remove snubber and install a
new one on the gauge.
5. Purge supply line with hydraulic
fluid by starting one air operated
pump only.
6. Reconnect supply line to gauge
assembly.
7. Close bleeder valve.
8. Open accumulator isolator valves.
9. Operate air pump.
10. If gauge is still sluggish or erratic,
replace the gauge.

Supply line or snubber 1. Place valves in center position.

is clogged (Manifold
2. Reduce hydraulic pressure to zero
and annular pressure).
by adjusting regulators,

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-18
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-19 of 25

Problem Possible Cause Remedy

5.7.2 (Continued) Supply line or Snubber 3. Remove tubing and snubber from
is Clogged (Manifold
gauge.
and annular Pressure).
(Continued) 4. If gauge indicates pressure,
recalibrate to zero,
5. While hydraulic tubing is
disconnected from gauge,
increase Pressure from regulator.
If:
a. Fluid flows freely from open
tube:
1) Reduce pressure back to
zero.
2) Attach snubber to-the
hydraulic. Tubing.
3) Increase pressure.
b. No fluid escapes, the snubber
is blocked and should be
replaced.
6. Reassembly tubing, snubber,
and gauge.
7. Cycle regulated fluid pressure
to 1000 psi and back down again
to zero.
8. Check chat gauge indicates zero.
If it does not, replace gauge with a
workable unit,

6.8 REGULATOR PROBLEM

Problem Possible Cause Remedy

5.8.1 Regulator will not Smaller adjust-ment 1.
adjust to zero spring (1"Diameter) in
pressure. the Spring control
Head is too long. 2.
Check spring for length. For
disassembly instructions see
Maintenance Section.
1" diameter spring specifica--
tions:
a. TR-1500 - 5-1/2" Long (Blue)
b. TR-3000 - 5" Long (Red)

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-19
Sara
 BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-20 of 25

Problem Possible Cause Remedy

5.8.1 (Continued) Smaller adjust-ment NOTE: Heavy springs (2" diameter)

spring (1"diameter) in Do not effect minimum set
the Spring control pressure.
Head is too long.
(Continued)

5.8.2 Regulator will not Positive stop is set too 1. Remove adjusting actuator
adjust to maximum set high. (Manual handle and lock or power
pressure: drive unit) by turning handle
counterclockwise.
2. Loosen lock nut, set stop nut
TR-1500: 1600 psi lower and tighten Lock nut.
TR-3000: 3100 psi

Heavy springs (2" 1. Check spring for length. For

diameter) are too disassembly instructions see
short. Maintenance Section.
2.2" diameter spring specifications:
a. TR-1500 - 5" Long (Red)
b. TR-3000 - 4-1/2" Long
(Yellow)

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.
6-20
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-21 of 25

Problem Possible Cause Remedy

5.8.3 Regulated pres- Leakage in Hydraultc 1. Visually inspect hydraulic inanifold

sures cycles up down. Manifold downstream for piping or tubing connection
Up to set point and of regulator. leaks. Repair as necessary.
down to bottom of 2. Ensure that 4-Way valves on
search band (Search hydraulic manifold are properly
band is equal to lowest positioned. Incorrect positioning of
pressure in adjustable the valve handles will cause
pressure range of interflowing,
regulator. See TR™
3. If valves are positioned propearly,
Regulator Specification
open inspection ports or break
Sheet in Equip ment
common return line and inspect
Section.)
for leakage. Repair or replace
leaking valve.

Internal leakage from Replace missing or damaged orings

secondary region from seal kit. See Maintenance
(Regulated pressure) Section for disassembly Instructions
to vent; and the Parts Section for reference
drawings.
1. Damaged o-ring under
flow plate around vent
port.
2. Damaged seal plug o-
ring in flow plate.
3. Damaged o-ring seal
in vent seat

Worn (Scored) Replace worn (Scored) vent seat

vent seat or flow and/or flow plate from repair kit. See
plate. Maintenance Section for disassembly
instructions and the Part Section for
reference drawings.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-21
Sara
 BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-22 of 25

Problem Possible Cause Remedy

5.8.4 Regulated Internal leakage from Replace missing or damaged orings,

pressure cycles up primary (Accumulator
hydra seat and/or flow plate
down. Up to vent pressure ) to
secondary ( Regulated from repair kit. See Maintenance
pressure and down
to top of search pressure): Section for disassembly
band. (Search instructions and the Parts Section
band isequal to 1.No o-ring or
damaged o-ring under for reference drawings.
lowest pressure in
adjustable flow plate around
pressure range of primary port or ports.
regulator. See TRÔ 2.Damaged o-ring in
Regulator hydra seat.
Specification 3.Scored hydra seat
Sheetin E seal surface and/or
quipment Section.) scored flow plate at
seal point.

Orifice plug in seal Remove 1/4"pipe plug in bottom

5.8.5 Excessive
chatter, hammer container tail piece flange. Use 5/32"alien wrench and
or vibration when is missing. install orifice plug, part number
4-way valve son 0150-1172 and replace 1/4"pipe
hydraulic manifold
are operated. plug. This operation can be
performed without removing
regulator if it is accessible. Relieve
system pressure while servicing
any high-pressure component.

5.8.6 External Damaged o-ring seal Replace with new o-ring seal and
leakage from on control piston.
back-up rings from seal kit. See
venthole
( 1 / 8 " dia. ) in Maintenance Section for
spring control disassembly instructions and the
head. Parts Section for reference
drawings.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-22
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-23 of 25

Problem Possible Cause Remedy

5.8.7 External leakage Damaged o-ring Replace with new o-ring seal and
from vent hole seal or seals on back-up rings from seal kit. See
(1/8"dia.) in override plunger. Maintenance Section for disassembly
Internal override instructions and the Parts Section for
housing. reference drawings.

5.8.8 Excessive and Seal plug missing Remove bottom flange and check
continuous from TR-5 valve that brass plugs are installed. If not,
exhaust flow from flow plate.
the regulator must be disassembled
secondary
( Regulated ) and part.no.0150-1143 plugs installed.
pressure out vent See Maintenance Section for
pore of TR-5 valve disassembly instructions and the Parts
only. Section for reference drawing.

5.8.9 Excessive and Seal carrier 1. Remove flange from side opposite
continuous flow Installed sub plate.
from primary Incorrectly . 2. Remove bottom flange from end
(Accumulator) Primary and vent opposite spring control head.
pressure to both hydra seats do not
3. Extract seal carrier, rotate 180 °
secondary and line up with their
and re-install.
vent ports of the respective ports
4. Re-install side and bottom flanges.
TR-4 valve on1y.
NOTE: See Maintenance Section
for detailed Instructions and
Parts
Section for reference
drawings.

Lock lever is not Turn the lock lever clockwise and

5.8.10 Air or hydraulic
operator does not engaged which tighten securely.
change regulated allows the gearbox
pressure when hub to turn while
motor is running. the adjustment
handle and lock
lever do not.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-23
Sara
 BOP/Diverter Control System
6 Troubleshooting Instructions Revision A
Page 6-24 of 25

Problem Possible Cause Remedy

5.8.10 (Continued) Motor drive shaft key is Disengage drive motor from gearbox
not engaged in worm and check drive key. A snug fit of key
keyway thus neither in keyway facilitates proper insertion
the drive hub nor the into worm bore keyway.
adjustment handle and
lock, lever turns while
the motor is running.

Damaged threads on Examine drive threads for galling or

5.8.11 Air or hydraulic
driver will not adjustment screw or in binding. Drive screw and head cap
reverse after spring head cap, should be file hard-
reaching minimum
or maximum set
pressure.

5.8.12 Air driver will Airsupply pressure is Set air regulator to 60 psi minimum.
not drive o too low,
maximum set
pressure. Smaller adjustment
spring (1" diameter) in See Troubleshooting Section 6.8.1
the spring control
head is too long.

5.8.13 Air driver motor Air motor rusted or

Disassemble motor, inspect. Clean,
will not run when gummed up.
recondition and assemble
disengaged from
gearbox. Per motor service instructions in
Maintenance Section. Ensure that
filter/strainer and Lubricator are
installed in the air motor supply line.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-24
Sara
BOP/Diverter Control System
Revision A Troubleshooting Instructions 6
Page 6-25 of 25

Problem Possible Cause Remedy

5.8.14 Hydraulic driver Hydraulic motor scored Disassemble motor, inspect, clean,
motor won't run when or jammed with foreign remove burrs or interference and
disengaged from Particles. assemble. Motor should turn freely
gearbox. by hand.

5.8.15 Leakage from Damaged or

Replace seals from seal kit.
interface between missing o-ring
valve body and seals in port plate
sub plate. face:

TR-4 (3) o-rings

TR-5 (4) o-rings

Missing or damaged
seal plug o-ring in Extract port plate and replace oring
flange of port plate to seal and back-up rings from seal kit.
seal cross-drilled vent See Maintenance Section for
passage. disassembly instructions and Parts
Section for reference drawings.

DRILLING OPERATIONS SHOULD CEASE WHILE

REPAIRS ARE BEING MADE TO THE BOP
CONTROL SYSTEM.

6-25
Sara
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009

1 1000-3195 PORT ASSY. FOR 1-1/4" TOP 24

LOADING BLADDER
******items reqd for each Assly.***

8842-8338 BACK UP RING 1

01-0222-4B (VD297)
1000-4106 WASHER BACK UP 1
01-0221-4
8717-2338 'O ' RING 1
01-0219-4A
1000-4105 RING ANTI EXTRUSION 1
01-0227-3B (IR030) (VD195)
1000-4107 SPACER 1
01-0224-4A
1000-4110 LOCK NUT PLUG 1
01-0223-4C
1000-4103 POPPET (MACHINED) 1
01-0225-4B
1000-4104 SPRING POPPET 1
01-0220-4
1000-3111 PLUG BODY 1
01-0230-3F
1000-4108 PISTON POPPET 1
01-0232-4A
1000-4111 STOP NUT POPPET (NUT HEX 1
01-0226-4 NY LOCK 3/8"-24 UNF
8017-0200 PLUG, HEX, 1/4", CS3M 1
01-1115-4.2
1000-4105-01 RING 1
01-0228-4C

2 PORT ASSLY, TOP 24

******items reqd for each Assly.***

NIC 0050 PLUG 1

01-0384-3C
8717-2338 'O ' RING 1
01-0219-4A
8842-8338 BACK UP RING 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-0222-4B (VD297)
1000-4105 RING ANTI EXTRUSION 1
01-0227-3B (IR030) (VD195)
1000-4106 WASHER BACK UP 1
01-0221-4
1000-4107 SPACER 1
01-0224-4A
1000-4110 LOCK NUT PLUG 1
01-0223-4C
1000-3102 VALVE NUT 1
01-2924-4
1000-3101 VALVE GUARD 1
01-2589-4
1000-4105-01 RING 1
01-0228-4C

3 8120-0300 MALE CONNECTOR,1/2T X 1/2 8

MPT,BRASS
4 3500-2100 TRIPLEX CHAIN 5/8" PITCH 3
ROLLER #-0.4" D-10203
5 8120-0100 MALE CONNECTOR, 1/4" T x 15
1/4" MPT, BRASS
6 8120-0200 MALE, CONNECTOR, 3/8T X 6
3/8 MPT, BRASS
7 8121-0100 ELBOW, 90 DEGREE, MALE, 20
1/4T TP 1/4 MPT, BRASS
8 8121-2100 ELBOW, 90 DEGREE, FEMALE, 5
1/4T X 1/4 FPT, BRASS
9 8121-2100 ELBOW, 90 DEGREE, FEMALE, 5
1/4T X 1/4 FPT, BRASS
10 8121-1300 ELBOW, 90 DEGREE, MALE, 10
3/8T X 1/4 MPT, BRASS
11 8121-1300 ELBOW, 90 DEGREE, MALE, 2
3/8T X 1/4 MPT, BRASS
12 8121-0300 ELBOW, 90 DEGREE, MALE, 6
1/2T TO 1/2MPT, BRASS
13 LEVEL INDICATOR GAUGE 1
SGR-14
14 MTG.KIT 1-1/2"SAE CODE 62 2

******items reqd for each Assly.***

 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009

CAP SCREW HEX SOCKET HEAD 4

5/8"-11 UNC X 3"
WASHER, SPRING LOCK 5/8" 4

5003151 O-RING,90 DURO 1

15 3500-2101 CHAIN LINK TRIPLEX 50-3 1

5/8" PITCH
16 LUGS 0.75MM E-7508-GH 50

17 LUGS 1.00MM E-1008 RD 25

18 7410-0500 NAME PLATE BLIND RAMS 2

01-1090-3 OPEN-CLOSE, UNIT
19 7410-0400 NAME PLATE, KILL LINE 1
01-1086-3 OPEN-CLOSE, UNIT
20 7410-0800 NAME PLATE BY PASS LOW- 1
01-1091-3 HIGH PRESSURE,(0.250 KG)
21 7410-0100 NAME PLATE CHOKE LINE 1
01-1088-3 OPEN-CLOSE, UNIT
22 011245 NAME PLATE" API-16D-0003" 3
01-1245-3A FOR ACCUMULATOR UNIT
23 7405-0202 NAME PLATE "OPEN" 1
01-1140-4.2A
24 7405-0203 NAME PLATE "CLOSE" 1
01-1140-4.1A
25 7402-3100 NAME PLATE 2
01-1149-4 "AIR SUPPLY PRESSURE"
26 7403-0300 NAME PLATE "AIR SUPPLY" 1
01-1150-4A (0.100 KG)
27 7403-0300 NAME PLATE "AIR SUPPLY" 1
01-1150-4A (0.100 KG)
28 7402-0100 NAME PLATE 1
01-1151-4 MANIFOLD PRESSURE "
29 7402-1100 NAME PLATE 1
01-1152-4 "ACCUMULATOR PRESSURE"
30 7404-0500 NAME PLATE 1
01-1153-4 "AIR LUBRICATOR"
31 7403-1200 NAME PLATE "ANNULAR REGU- 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-1154-4 LATOR INCREASE-DECREASE"
32 016511 NAME PLATE "NOV SARA" 3
01-6511-3A
33 016512 NAME PLATE 3
01-6512-4A
34 011238 NAME PLATE UPPER PIPE 1
01-1238-3 RAM
35 011239 NAME PLATE LOWER PIPE 1
01-1239-3 RAM
36 011280 NAME PLATE "EARTHING" 1
01-1280-4
37 011303 NAME PLATE FOR "NOTE" 1
01-1303-4
38 011304 NAME PLATE FOR "ATTENTION 1
01-1304-4 "
39 511218 NAME PLATE "SPARE 1" 1
51-1218-3
40 019144 NAME PLATE 'ANNULAR' 1
01-9144-3 (OPEN CLOSE) FOR 1 1/2"
41 011192 SPROCKET, 23 TEETH 1
01-1192-3 TRIPLEX
42 012878 STICKER "ACCUMULATOR PRE- 22
01-2878-3 CHARGE MAINTANENCE"
43 011212 SPROCKET, 86 TEETH 1
01-1212-2A TRIPLEX (REF-IS937)
44 017588-6 STICKER,NORMALLY CLOSED 4
01-7588-2.6
45 017588-7 STICKER,NEEDLE VALVE-1 2
01-7588-2.7
46 017588-8 STICKER,(THIS PUMP CAN 1
01-7588-2.8 START AUTOMATICALLY)
47 017588-9 STICKER,PNEUMATIC 1
01-7588-2.9 PRESSURE SWITCH (2750PSI)
48 017588-11 STICKER,NEEDLE VALVE-2 2
01-7588-2.11
49 017588-1 STICKER,RELIEF VALVE 1
01-7588-2.1 (SET AT 3300 PSI)
50 017588-2 STICKER,BYPASS VALVE 1
01-7588-2.2 (NORMALLY CLOSED)
51 017588-3 STICKER,RELIEF VALVE 1
01-7588-2.3 (SET AT 5500PSI)
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
52 017588-4 STICKER,BLEEDER VALVE 1
01-7588-2.4
53 017588-5 STICKER,NORMALLY OPEN 1
01-7588-2.5
54 017588-12 STICKER,HYDRAULIC 5
01-7588-2.12 STRAINER
55 017590-2 STICKER,STRAINER (CLEAN 1
01-7590-1.2 EVERY 30 DAYS)
56 017590-3 STICKER,ELECTRICAL POWER 1
01-7590-1.3 SUPPLY (440 VOLTS)
57 017590-4 STICKER,ELECTRICAL POWER 1
01-7590-1.4 SUPPLY (220 VOLTS)
58 017590-5 STICKER,ELECTRICAL POWER 1
01-7590-1.5 SUPPLY (120 VOLTS)
59 017590-6 STICKER,CAUTION(NEVER-OPE 1
01-7590-1.6 N AN ELECT.ENCLOSURE WHEN
60 017591-1 STICKER"CAUTION"(CONFIRM 1
01-7591-2.1 BEFORE OPERATE)
61 017591-3 STICKER"CHAIN GUARD OIL 1
01-7591-2.3 TYPE"
62 017591-4 STICKER"CAUTION"(NEVER TR 1
01-7591-2.4 Y TO SERVICE AN ACCUM.WHI
63 8123-2600 TEE MALE 3/8"T x 3/8" T 2
x 1/4" MPT BRASS
64 8123-0100 TEE MALE 1/4" T x 1/4" T 2
x 1/4" MPT BRASS
65 8123-4300 TEE, UNION 1/2"T x 1/2"T 2
x 1/2"T, BRASS
66 8123-4200 TEE UN,3/8" T x 3/8" T 2
x 3/8" T BRASS
67 TEE MALE 1/2"x1/2"x1/4" 2
NPT,BRASS
68 5751118 UNIVERSAL TERMINAL BLOCK, 2
RED, UK5NRD
69 UNIVERSAL TERMINAL BLOCK, 4
GRAY, UK5NGY
70 5751147 UNIVERSAL TERMINAL BLOCK, 2
BLACK, UK5NBK
71 8124-0100 UN. 1/4"x1/4" BRASS WITH 4
2 NUT + 2 OLIVE.
72 8123-4100 COMPLETE TEE UNION 10
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1/4 x 1/4 x 1/4 BRASS
73 1500-1100 VALVE BALL,1" FPT,5000 2
PSI C.S
74 1500-3100 VALVE, BALL, 1-1/2" FPT, 4
5000 PSI C.S.
1 NIC0757 PROTECTOR FOR 1" MALE 6
07-0114-4 FIG 602
2 NIC0758 PROTECTOR FOR 1" FEMALE 6
07-0115-4 FIG 602
1 THIMBLE 25 MM COPPER 5

1 9053-0040 PIPE, 1-1/2", SCH 160, 20

SEAMLESS
2 SEAMLESS PIPE SCH 80 4
3/4" NB WALL THICK 0.154"
3 9053-0010 PIPE, 1/2", SCH 160, 4
SEAMLESS, CS
4 SEAMLESS PIPE 2-1/2" 1
SCH-80 5MTR.
5 9053-0030 PIPE,1",M.S.SCH 160, 135
SEAMLESS 5MTR
6 9230-2400 TUBING,3/4"ODx0.065 WALL 6

7 9230-2100 TUBING SS,1/4" X 0.035" 350

WALL THICKNESS 316,
8 9230-2350 TUBING SS,3/8" X 0.035" 20
WALL THICKNESS 316,
9 70000137 TUBING SS,1/2" X 0.049" 60
WALL 316 SS,SMLS
1 8502-0100 BOLT HEX HEAD, 1/4" x 20 50
UNC, 1/2" CD, PLATED
2 8500-0012 BOLT HEX HEAD 1/4" -20UNC 50
x 3/4"
3 BOLT HEX HEAD, 1/4"-20 10
UNC x 1"
4 8540-0024 BOLT, HEX HEAD, 1/4"-20 25
D-5004-12-17 UNC x 1-1/2" LONG
5 BOLT HEX HEAD 5/16" - 18 5
UNC x 3/4"
6 101539 BOLT HEX HEAD 3/8"-16 UNC 8
x 1-1/4"
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
7 8504-2016 BOLT HEX HEAD, 3/8"-16UNC 15
x 1-1/2"
8 8540-1032 BOLT HEX HEAD, 3/8"-16UNC 15
x 2"
9 101555 BOLT HEX HEAD, 1/2" x 50
13 UNC x 3/4"
10 BOLT HEX HEAD, 1/2" - 50
13 UNC x 1-1/4"
11 101559 BOLT HEX HEAD, 1/2" x 13 10
UNC x 1/2" LONG MS
12 8540-3032 BOLT HEX HEAD, 1/2"- 50
13 UNC x 2" (REC)
13 BOLT HEX HEAD, 1/2"-13UNC 5
2-1/2" (REC)
14 BOLT HEX HEAD 1/2" -13UNC 5
x3" (REC)
15 BOLT HEX HEAD, 1/2" - 10
13 UNC x 5" (REC)
16 101583 BOLT HEX HEAD, 5/8" - 15
11 UNC x 2" IDLER PAD
17 BOLT HEX HEAD 5/8" - 10
11 UNC x 2-1/2" (REC)
18 BOLT HEX HEAD 5/8" -11UNC 10
x 3" (REC)
19 BOLT HEX HEAD, 5/8" - 4
11 UNC x 6"(REC)
20 BOLT HEX HEAD, 5/8" - 10
11 UNC x 10" (REC)
21 BOLT HEX HEAD, 3/4"-10UNC 8
x 1-1/4"
22 BOLT HEX HEAD 3/4" - 10 5
UNC x 5"
23 BOLT HEX HEAD 3/4" - 10 2
UNC x 5"
24 BOLT HEX HEAD 3/4" - 10 5
UNC x 6"
25 BOLT HEX HEAD 1"X8 UNC, 4
4-1/2" LONG,CADMIUM
26 50706-7A SET SCREW HEX SOCKET 3/8" 5
STD. -16 UNC X 3/4", FLAT
27 8580-0300 NUT, HEX, NO.10,24 UNC, 50
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
CAD PLTD
28 8580-1100 NUT, HEX, 1/4" 20 UNC, 20
D-51804 CAD PLATED
29 8580-1200 NUT, HEX, 3/8" -16 UNC 15
CAD PLATED
30 8580-1400 NUT, HEX, CAD, PLTD, 50
UNC 1/2"
31 945724-7 NUT HEX 5/8"-11 UNC (REC) 15

32 NUT HEX 1"-8 UNC 4

33 101764 NUT HEX THIN LOCK 7/8"- 16

02-0173-4A 14 UNF
34 NUT HEX 3/4" 10 UNC 20

35 NUT 3/16" UNC SS. 40

36 RIVET, SNAP HEAD KNURALED 50

DIA 1/8" x 5/16"
37 8514-2012 MACHINE SCREW SLOTTED 30
3FILLISTER HEAD NO.10-24U
38 MACHINE SCREW SLOTTED 30
FLAT COUNTERSUNK HEAD NO
39 MACHINE SCREW CHEESE HEAD 10
1/4" -20 UNC x 3/4"
40 101638. CAP SCREW HEX SOCKET HEAD 5
3/8" - 16 UNC x 3/4" S.S.
41 CAP SCREW HEX SOCKET HEAD 5
3/8"-16 UNC x 1-1/2"
42 HEX HEAD SCREW 3/16"-24 40
UNC X 3/4",SS316
43 SCREW 3/16" X 2-1/2" UNC 40
SS
44 8575-0300 WASHER, LOCK, No.10, CAD 30
PLTD
45 8575-1100 WASHER LOCK, CAD PLATED, 20
1/4"
46 8575-1200 WASHER LOCK, CAD PLATED, 10
3/8"
47 NIC 0750 WASHER SPRING LOCK, 3/8" 10
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
48 1320-4122 WASHER, SPRING LOCK, 1/2" 5
01-2672-4 (YELLOW ZINC PLATED)
49 WASHER, SPRING LOCK 5/8" 35

50 WASHER SPRING LOCK 1" 4

51 8570-1100 WASHER FLAT, CAD PLATED, 20

1/4"
52 8570-1200 WASHER, FLAT, CAD PLATED 20
3/8"
53 8570-1400 WASHER, FLAT, 1/2", 316SS 100

54 WASHER PLAIN 5/8" 30

55 NIC 0448 WAHSER PLAIN 3/4" 5

56 WASHER PLAIN 1" 4

57 101699 WASHER, SPRING LOCK 3/8" 8

58 939349-4 WASHER, SPRING LOCK 1/2" 50

1 3033-0100 FLUID END ASSY,8-1/2" 4

01-0296-1 AIR PUMP
******items reqd for each Assly.***

3033-0105-2 PISTON BODY 1

01-2583-4B
3033-0107-1 BALL ,SEAL RING FOR FOOT 1
01-0295-4B VALVE ASSY
3030-0106-1 STEEL BALL 1" DIA S.S. 1

1320-4108 STEEL BALL 1/2" DIA STD 1

01-0278-4.2A
3033-0113 BALL STOP, FLUID END 1
01-2915-4 8-1/2"
3033-0111 PUMP BODY,8-1/2" AIR PUMP 1
01-0293-3D
8717-2137-1 `O ' RING FOR SEAL(VD416) 2
01-0284-4A
8717-2137-2 SEAL RING FOR SEAL 2
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-0285-4A
3033-0110 WASHER 1
01-0283-4.1A (RP129)
3033-0102 SPRING UPPER PACKING 1
01-0279-4.2C
3033-0103 LOWER PUMP BLOCK 1
01-0292-3C
3033-0107-2 FOOT VALVE 1
01-2582-3
3033-0105-1 BALL ,SEAL RING 1
01-0291-4B FOR PISTON BODY ASSY
3033-0108 PACKING SET FOR 8-1/2" 2
PUMP
NUT HEX 3/4" -16 UNF 2

3032-0102 STANCHION 2
01-1823-4A
3033-0109 LOWER PACKING SPRING 1
01-0279-4.1C
3033-0104 WASHER PISTON 1
01-0283-4.2A
3033-0101 PLUNGER ROD 1
01-0289-4F
3032-0119 NUT HEX JAM, 5/8"-11 UNC 1
x 3/8" THICK
3032-0120 COUPLING NUT 1
01-0288-4
3032-0118 CONNECTING ROD 1
01-0287-4A
3032-0101 STANCHION WASHER 6
01-1822-4A

2 2250-0100 PRESS SWITCH,HYDROPNEUMA- 1

01-0123-2C TIC 1"FPT AIRx3/4"FPT HYD
******items reqd for each Assly.***

2250-0113 ROD 1
01-0105-3B
2250-0115 FLUID INLET BODY 1
01-0107-4C
2250-0114 SPRING RETAINER 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-0108-4A
2250-0111 SLEEVE 1
01-0110-3B
2250-0110 ADJUSTMENT NUT 1
01-0111-4B
2250-0109 STOPPER 1
01-0112-4B
2250-0116 MALE THREADED INSERT 1
01-0113-4B
2250-0108 INLET BODY 1
01-0114-4C
2250-0107 SPACER 1
01-0115-4A
2250-0106 SLEEVE 1
01-0117-4B
2250-0103 RETAINER 1
01-0119-4B
2250-0105 OUT LET BODY 1
01-0122-4C
8717-2111 'O ' RING (VD266) 1
01-0103-4A
8841-2111 BACKUP RING TEFLON 1
01-0104-4B
8717-2012 'O ' RING 1
01-0106-4A
8718-2012-1 'O' RING 'VITON' 1
01-0116-4.2B
2250-0101 SEAL (VD263) 1
01-0118-4A
8575-1100 WASHER LOCK, CAD PLATED, 1
1/4"
8506-0012 CAP SCREW HEX SOCKET HEAD 1
1/4" 20 UNC x 3/4"
8717-2225 'O ' RING (VD312) 1
01-0121-4B
2250-0104 CAP SCREW HEX SOCKET HEAD 4
3/8"-13 UNC X 1"LONG
2250-0112 SPRING FOR HYD. PNEUMATIC 1
PRESSURE SWITCH, 3000 PSI

3 NIC 0026 ADOPTER FOR 1/4"x1/2" NPT 3

 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-1122-4
4 3023-0100 ASSY AIR OPERATED PUMP 4
01-1772-0.2 60:1 RATIO,8-1/2"DIA
******items reqd for each Assly.***

3023-0108 BALL,SS 440 C 5/8" 2

3023-0110 CIRCLIP INT.B-52,IS 3075- 1

1978 THICK 2 MM OD-56.2MM
3023-0103 GASKET 2
01-1801-4A
8717-2133 'O ' RING (VD264) 5
01-1776-4A
8717-2115 'O ' RING (VD274) 2
01-1780-4C
3022-0120 SPRING 2
01-1779-4A
3023-0112-4 SPRING 1
01-1788-4A
3023-0112-3 TUBE 1
01-1787-4
NUT HEX 1/4" UNF NYLON 2

3022-0122 ADOPTER,EXHAUST PLATE 2

01-1807-4A
3022-0104 ADOPTER 4
01-1812-4A
3022-0118 BOLT,HEX HEAD 1/4"-20 UNC 2
x 1-3/4"
3022-0105 BUSHING 1
01-1795-4B
3023-0113 MOTOR BASE 1
01-1814-1D
3023-0111 BOLT 8
01-1804-4A
3023-0112-2 COLLER 2
01-1786-4
3023-0106 CYLINDER 1
01-1802-4B
3022-0111-3 FERRULE 4
01-1811-4B
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
3023-0102 CYLINDER HEAD 1
01-1773-1E
3023-0109 LOWER VALVE KEEPER 1
01-1798-4A
3022-0115 UPPER VALVE KEEPER 1
01-1799-4
NUT,HEX,1/4",20 UNC, 2
NYLOCK
3022-0107 PISTON NUT 1
01-1794-4
3022-0112 HEX NUT,3/8"- 24 UNF 10
01-1805-4
3022-0111-2 COUPLING NUT 4
01-1810-4B
3023-0105 PISTON 1
01-1791-4E
3022-0121 EXHAUST PLATE 2
01-1808-3A
3022-0117 TRIP SPRING RETAINER 2
01-1781-4B
3022-0126-1 VALVE ROD 1
01-2679-3
3022-0113 PISTON ROD 1
01-1784-4F
3022-0102 VALVE SLEEVE 1
01-1774-2H
3022-0111-1 AIR TUBE 2
01-1809-4
3022-0103 AIR VALVE 1
01-1775-3F
3023-0104 PISTON NUT WASHER 1
01-1793-4A
NIC 0359 NUT DOME CAP 3/8" 24 UNF 8

8717-2445 'O' RING (VD232) 1

01-1792-4B
3022-0127 VALVE, TRIP COLLAR 1
01-1813-4A
8717-2011 'O ' RING (VD262) 1
01-1796-4B
8717-2216 'O ' RING (VD265) 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-1803-4B
8757-2128 `O ' RING (VD275) 2
01-1777-4F
012677 RING FOR MOTOR BASE 1
01-2677-4

5 012803 ADAPTER, 1-1/4" MALE X 24

01-2803-4 1-1/4" MALE NPT ENDS
6 1522-2100. NEEDLE VALVE 1/2" FPT, 5
01-2829-3A 10000 PSI
******items reqd for each Assly.***

013154 HANDLE FOR STEM 1

01-3154-4A
012831 PACKING NUT 1
1-2831-4A
013166 HEXAGON SOCKET HEAD CAP 1
SCREW,SIZE 1/4"-20 UNC x
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100
012834 PACKING, TEFLON 1
01-2834-4A
012839 BODY 1
01-2839-3A
012836 SUPPORT RING 2
01-2836-4
012837 BONNET 1
01-2837-3A
012838 STEM 1
01-2838-3I

7 2000-1100 CYLINDER,AIR,2POS,3"BORE, 7
01-1201-3 2-1/8"STROKE, 200 PSI,
8 0150-1576 MANUAL,ADJUSTMENT,HANDLE 1
AND LOCK LEVER ASSY,
******items reqd for each Assly.***

8522-5000 SET SCREW HEX SOCKET FLAT 1

POINT 3/8" 16 UNC 21/64"
0150-1156 ADJUSTMENT SCREW 1
01-0471-4A
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
RIVET, SNAP HEAD KNURALED 2
DIA 1/8" x 5/16"
0150-1593 ADJUSTMENT HANDLE 1
01-0457-4
0150-1155 LOCK LEVER 1
01-0472-3A

9 8015-4200 BUSHING, HEX, 1"x1/4", 5

01-1110-4 CS3M
10 8015-4500 BUSHING, HEX, 1"x3/4", 5
01-1109-4 CS3M
11 8015-7600 BUSHING, HEX, 2" x 1", 2
01-6013-4 CS3M
12 8035-7800 HEX BUSH 2" x 1-1/2" 2

13 8550-0100 BOLT-U, 1/4" 20 UNC x 15

01-6014-4 1-1/2" ID x 2.5" LONG
14 3024-0200 AIR PUMP MOUNTING BRACKET 4
01-1067-3 # 8-1/2"
15 8550-4100 U BOLT,1/2" 13UNC, 9-1/2" 24
01-1031-3 ID x 11-1/2" LG, CAD
16 8015-6600 BUSHING, HEX, 1-1/2" 2
01-1108-4 x 1", CS3M
17 8015-6600 BUSHING, HEX, 1-1/2" 3
01-1108-4 x 1", CS3M
18 8015-6400 N BUSHING, HEX, 1-1/2" X 3
1/2", CS3M
19 8005-4400 BUSHING HEX HEAD 1"X1/2" 12
01-1111-4 MI
20 8005-3400 BUSHING, 3/4" X 1/2" 1
01-1112-4 (REFER CODE IB010)
21 8005-3200 BUSHING HEX HEAD 3/4" X 1
01-1113-4 1/4" MI
22 8005-2200 BUSHING HEX HEAD 1/2" X 6
01-1114-4 1/4" MI
23 808007 BOLT, U, 1/2"-13 UNC, 8
01-1157-3 4-9/16" I.D x 6-3/4" LG.
24 011210 BUSHING FOR SPROCKET 86 1
01-1210-3 TEETH TRIPLEX
25 011223 BUSHING 1.5 x 0.25 M 4
01-1223-4
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
26 019208 MOUNTING BRACKET FOR 1
01-9208-3 JUNCTION BOX
27 013000 `U' BOLT 2
01-3000-4
28 019221 MOUNTING BRACKET FOR GAUG 2
01-9221-4 E HOUSING
29 019237 MOUNTING BRACKET FOR 1
01-9237-3 INCREASE DECREASE VALVE
30 019238 MOUNTING BRACKET FOR 1
01-9238-3 PLC MASTER PANEL
31 8010-0600 COUPLING, FULL, 1" CS3M 12
01-0247-4
32 8010-0600 COUPLING, FULL, 1" CS3M 12
01-0247-4
33 011226 COUPLING FULL,1-1/2" 2
01-1226-4A NPT
34 011226 COUPLING FULL,1-1/2" 2
01-1226-4A NPT
35 510164.1 TUBING CLIPS (M.S)(2NOS) 1
51-0164-4.1
36 TUBING CLIPS (M.S)(4NOS) 1

37 510164.3 TUBING CLIPS (M.S)(6NOS) 1

51-0164-4.3
38 510164.4 TUBING CLIPS (M.S)(8NOS) 1
51-0164-4.4
39 510164.5 TUBING CLIPS (M.S)(10NOS) 1
51-0164-4.5
40 510164.6 TUBING CLIPS (M.S)(12NOS) 1
51-0164-4.6
41 510164.7 TUBING CLIPS (M.S)(14NOS) 1
51-0164-4.7
42 019269 FLANGE,1.5"NPT,4BOLT, 2
01-9269-3 WITH'O'GROOVE,6000#,
43 017535 CHAIN GUARD ASSY. FOR 1
01-7535-1 BUXTON TRIPLEX PUMP TO
******items reqd for each Assly.***

8380-0200 FLANGE 1/2" 1

01-1102-4
8017-0400 PLUG, HEX, 1/2", CS3M 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-1115-4.3
8380-0100 FLANGE 1/4" 2
01-1101-4
8017-0200 PLUG, HEX, 1/4", CS3M 2
01-1115-4.2
8500-0012 BOLT HEX HEAD 1/4" -20UNC 26
x 3/4"
8575-1100 WASHER LOCK, CAD PLATED, 26
1/4"
GASKET FIBER 2.5
3.2 MM THICK

44 013156 ASSY.SHEAR RAM GRAD,BOP 1

01-3156-2 CONTROL UNIT
******items reqd for each Assly.***

013164 L - SUPPORT 2
01-3164-4
013158 TOP PLATE,SHEAR RAM GRAD 1
01-3158-3
HINGE SINGLE ACTION 1

013160 MOUNTING PLATE,SHEAR RAM 1

01-3160-4 GRAD

45 0150-1577 SPRING CONTROL HEAD 1500 1

01-0433-2A PSI, MTR-5
******items reqd for each Assly.***

0150-1158 STOP NUT 1

01-0434-4A
0150-1168 LOCK NUT 1
01-0435-4
0150-1154 HEAD CAP 1
01-0436-4
805395 SET SCREW HEX SOCKET FLAT 1
POINT 1/4"-20 UNCx 25/64"
8717-2226 'O` RING (VD470) 1
01-0437-4A
0150-1152 SPRING GUIDE 1
01-0438-4A
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100
0150-1153 HEAD TUBE 1
01-0439-3A
7010-0900 COMPRESSION SPRING 1

7010-0800 COMPRESSION SPRING 1

0150-1151 SPRING PLATE 1

01-0442-4A
8504-4024 CAP SCREW HEX SOCKET HEAD 4
1/2"-13 UNCx1-1/2"
0150-1173 HEAD FLANGE 1
01-0443-4
0150-1153-1 RETAINING RING (INTERNAL 1
CIRCLIP 58x2N IS:3075)-II
0150-1151-1 PIN CYLINDRICAL 1
01-2555-4A (INP)

46 017021 STRUCTURAL GAUGE HOUSING 2

D-1877208 FOR 2 NO'S., 4" FLUID
47 SPRING CONTROL HEAD 1
1500 PSI, PTR-5
******items reqd for each Assly.***

8717-2113-1 'O'RING 'VITON' 1

01-1128-4.2B
3150-0300 AIR MOTOR FOR PTR REG. 1
01-0394-3 VALVE
0150-1918 WORM 1
01-0466-3A
805492 BEARING (SKF-6004) 2
T-048-0.13
805491 CAP SCREW HEX SOCKET HEAD 4
3/8" 16 UNC x 3/4" (REC)
8717-2223 'O` RING 2
01-0460-4A
0150-1542 CAP 1
01-0465-4
8717-2232 'O' RING 1
01-2540-4B
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
0150-1919 WORM WHEEL 1
01-0464-3B
805493 BEARING SKF 6008 FOR FN2U 2

0150-1541 GEAR BOX BODY 1

01-0463-2A
8717-2226 'O` RING (VD470) 1
01-0437-4A
0150-1545 DISC 4
01-0462-4
0150-1925 DRIVE BUSHING 1
01-0461-3A
8717-2121 'O ' RING 1
01-0181-4.1C
0150-1921 LOCK LEVER 1
01-0458-3
8717-2114 'O ' RING (VD254) 1
01-1052-4.2A
0150-1178 DRIVE SHAFT 1
01-0459-3B
8522-5000 SET SCREW HEX SOCKET FLAT 1
POINT 3/8" 16 UNC 21/64"
0150-1593 ADJUSTMENT HANDLE 1
01-0457-4
805490 SET SCREW HEX SOCKET CONE 2
POINT 3/8" 16 UNC x 3/8"
0150-1589 NAME PLATE, HANDLE 1
01-2825-4
0150-1173 HEAD FLANGE 1
01-0443-4
8504-4024 CAP SCREW HEX SOCKET HEAD 4
1/2"-13 UNCx1-1/2"
8717-2224 'O' RING 1
01-2541-4B
RIVET, SNAP HEAD KNURALED 2
DIA 1/8" x 5/16"
8522-5000 SET SCREW HEX SOCKET FLAT 1
POINT 3/8" 16 UNC 21/64"

48 0150-1577-1 SPRING CONTROL HEAD 1500 1

PSI,PTR-5/PTR-4
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
******items reqd for each Assly.***

013147 STOP NUT (SMALL) 1

01-3147-4
0150-1168 LOCK NUT 1
01-0435-4
0150-1154 HEAD CAP 1
01-0436-4
805395 SET SCREW HEX SOCKET FLAT 1
POINT 1/4"-20 UNCx 25/64"
8717-2226 'O` RING (VD470) 1
01-0437-4A
0150-1152 SPRING GUIDE 1
01-0438-4A
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100
0150-1153 HEAD TUBE 1
01-0439-3A
7010-0900 COMPRESSION SPRING 1

7010-0800 COMPRESSION SPRING 1

0150-1151 SPRING PLATE 1

01-0442-4A
8504-4024 CAP SCREW HEX SOCKET HEAD 4
1/2"-13 UNCx1-1/2"
0150-1173 HEAD FLANGE 1
01-0443-4
0150-1153-1 RETAINING RING (INTERNAL 1
CIRCLIP 58x2N IS:3075)-II
0150-1151-1 PIN CYLINDRICAL 1
01-2555-4A (INP)

49 0576-2860 MACHNIED MANIFOLD FOR 1

01-1026-3.6 ACL UNIT. 6 STN.
50 0085-6060 ACCUM. MANIFOLD MACHINED 4
01-1025-3.5 (6 BOTTLES)
51 013143 MOUNTING PLATE(76X32X25MM 10
01-3143.4 THK.)
52 8270-0410 CLOSE NIPPLE 1/4" NPT 12
01-1124-4A
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
53 013040 HIGH NUT,1/2"-13 UNC 7
01-3040-4
54 8012-0800 HEX UNION 1-1/2",CS3M 14
01-2974-3
******items reqd for each Assly.***

8012-0800-1 MALE SUB FOR 1-1/2",HEX 1

01-2975-4 UNION
8012-0800-2 FEMALE SUB FOR 1-1/2",HEX 1
01-2976-4 UNION
8012-0800-3 NUT FOR 1-1/2"HEX UNION 1
01-2977-4

55 019201 NOV MAIN SKID 1

01-9201-1C
56 019202 NOV JUNK B/N 1
01-9202-1F
57 019203 NOV CONOPY 1
01-9203-2B
58 019214 STRAP ASSEMBLY-1 10
01-9214-4A
59 019215 STRAP ASSEMBLY-2 5
01-9215-4
60 019220 MOUNTING BRACKET FOR AIR 4
01-9220-4 LINE
61 510022 GAUGE HOUSING ASSY FOR 1
51-0022-2 MOUNTING PLATE
******items reqd for each Assly.***

510022 GAUGE HOUSING ASSY FOR 1

51-0022-2 MOUNTING PLATE
8020454 WASHER,FL,3/8",SS 4

8007710 SCREW,10-32x3/4",SS ROUND 9

HD 3/4"LGTH,SLOTTED
8020293 NUT,HX,#10-32 UNF, SS 9

1730-0100 SNUBBER OIL,303 SS,POROUS 3

01-0468-4 METAL, 1/4 MPT X 1/4" FPT
7402-2100 NAME PLATE 1
01-1148-4 "ANNULAR PRESSURE"
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
7402-0100 NAME PLATE 1
01-1151-4 MANIFOLD PRESSURE "
7402-1100 NAME PLATE 1
01-1152-4 "ACCUMULATOR PRESSURE"
NIC 1253 U BOLT FOR GAUGE HOUSING 2
01-2574-4A MOUNTING
8020960 WSHR,LK,3/8"HELICAL SPG, 4
SS

62 019248 STRUCTURAL ASSY.SKID 1

01-9248-1 184"X72"WITH 350 GAL
******items reqd for each Assly.***

019249 SKID ASSY.184"X72"FOR 1

01-9249-1 ACCUMULATOR UNIT 240 GAL
019242 MOUNTING BRACKET FOR PLC 1
01-9242-3 MASTER PANEL MASTER PANEL
O19207 N.O.V. BOTTLE RACK 1
01-9207-1C
017537 ASSY. MOUNTING BRACKET 1
01-7537-2 FOR UNIT MOUNTRD BUXTON
019210 ASSY.MOUNTING BRACKET 1
01-9210-2 FOR 50 H.P.E.P. ELECTRIC
808886 BOTTLE ACCUM MANIFOLD 4
01-0510-3 SUPPORT

63 019250 RESERVR.ASSY.350 GAL. 1

01-9250-1C 160"X36"X14"FOR(8) VALVES
******items reqd for each Assly.***

013073 MTG,BKT,FOR TWONO PNMT, 1

01-3073-4A PRSR,SWTH,
017577 BRACKET FOR CLEAN OUT MAN 1
01-7577-3 WAY
8380-0200 FLANGE 1/2" 6
01-1102-4
8380-0300 FLANGE 3/4" 7
01-1103-4
8380-0400 FLANGE 1" 10
01-1104-4
8380-0600 2" FLANGE 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-1106-4
011191 FLANGE 2 1/2" 1
01-1191-4
8380-0800 FLANGE 4" 8
01-1107-4
C-88-0498-0001 MNTG.BAR 60:1 SPEEFLOW 8
01-1044-4 AIR-OPERATED HYD.PUMP
017578 COVER PLATE CLEAN OUT MAN 1
01-7578-3 WAY
101555 BOLT HEX HEAD, 1/2" x 20
13 UNC x 3/4"
8570-1400 WASHER, FLAT, 1/2", 316SS 20

013149 FLANGE M20 X 2.5 2

01-3149-4
019228 MOUNTING PLATE FOR SS TUB 18
01-9228-4 E
8012-0600-3.1 FEMALE SUB FOR 1"COUPLING 2
01-0254-4C ,EN-8
8380-0500 FLANGE 1-1/2" 1
01-1105-4
013105 SQUARE PLATE (5X5MMX14" 1
01-3105-4 LONG)

64 8017-0400 PLUG, HEX, 1/2", CS3M 2

01-1115-4.3
65 8017-0600 PLUG, HEX, 1", CS3M 16
01-1115-4.5
66 8017-0700 PLUG, HEX, 1-1/4", CS3M 2
01-1115-4.6
67 8017-0800 PLUG, HEX, 1-1/2", CS3M 5
01-1115-4.7
68 8017-0900 PLUG, HEX, 2", CS3M 3
01-1115-4.8
69 C-83-0990-0060B MOUNTING PLATE 3X2 AIR 7
01-1038-3 CYLINDER 1" VLV.
70 019232 HEX PLUG-2 1/2" NPT 1
01-9232-3
71 016064 PLUG,4" NPT (MACHINING) 4
01-6064-3
72 019079 MOUNTING PLATE AIR 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-9079-3 CYLINDER FOR 1.5"
73 511248 NAME PLT.ACCUM.BANK 1 1
51-1248-4
74 511249 NAME PLT.ACCUM.BANK 2 1
51-1249-4
75 511250 NAME PLT.ACCUM.BANK 3 1
51-1250-4
76 5112170 NAME PLT,ACCUMULATOR- 1
51-1270-4 BANK 4
77 050733 PLUG 3/8"NPT (ALUM) 2
50-0733-4
78 011313 POINTER FOR DISC DETAINT 1
01-1313-4 1-1/2"
79 013012 MOUNTING PLATE FOR ALARM 1
01-3012-4 CONTROL PANEL
80 8577-0100 SPACER 21x9.5 MM FOR AIR 7
01-1123-4.1 CYLINDER
81 8577-0300 SPACER 21x15.5 MMM FOR 7
01-1123-4.2 AIR CYLINDER
82 012963 SPACER FOR BOX ENCLOSURE 4
01-2963-4 STARTER
83 8012-0400 UNION HEX 1/2" HP 12

******items reqd for each Assly.***

8012-0400-1 NUT 1/2" HEX UNION 1

01-0257-4A
8012-0400-3 FEMALE SUB 1/2" HEX UNION 1
01-0259-5
8012-0400-2 MALE SUB 1/2" HEX UNION 1
01-0258-4C

84 3620-4019 1" HAMMER UNION FIG 602 26

07-0146-4 (8022-1600)
******items reqd for each Assly.***

39004494N 1" LIP SEAL RING FIG 602 1

07-0107-3.2D (NITRILE) (VD443)
3620-4121 NUT 1" FIG. 602 (STD) 1
07-0103-3C 6000 CWP (GN001)
3620-4220 MALE SUB 1" FIG 602 (STD) 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
07-0102-4D LPT END.
3620-4329 FEMALE SUB 1"FIG 602(STD) 1
07-0104-3D LPT END FOR HMR UN.6000PS

85 8012-0600 UNION HEX 1" HP. 24

******items reqd for each Assly.***

8012-0600-1.1 NUT 1" COUPLING,EN-8 1

01-0252-4B
8012-0600-2.1 MALE SUB FOR 1"COUPLING, 1
01-0253-4D EN-8
8012-0600-3.1 FEMALE SUB FOR 1"COUPLING 1
01-0254-4C ,EN-8

86 072726 HAMMER UNION 1-1/2" FIG 4

07-2726-3 602 F/STD SEVC 6M, W.P.
******items reqd for each Assly.***

072728 UNION NUT 1-1/2" FIG-602 1

07-2728-3 (MACHINING)
072730 MALE SUB 1-1/2" FIG 602 1
07-2730-3 (MACHINING)
072729 FEMALE SUB 1-1/2" FIG 602 1
07-2729-3 (MACHINING)
072731 UP SEAL RING 1-1/2" 1
07-2731-3 FIG 6023 & 1002

87 1390-1100 VALVE 1" HYD 4 WAY 2 POS 1

3000 PSI
******items reqd for each Assly.***

1320-4122 WASHER, SPRING LOCK, 1/2" 4

01-2672-4 (YELLOW ZINC PLATED)
1320-4123 NUT HEX 1/2"-13 UNC 4
01-2671-4 (YELLOW ZINC PLATED)
1320-4121 BODY (MACHINING) 1
01-2614-2A
1320-4120 DOWEL PIN 2
01-2616-4A
1320-4119 WASHER 3
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-0245-4
8841-2116 BACKUP RING 6
01-0241-4
8717-2116 O-RING (VD303) 3
01-0244-4.4B
1320-4118 SHEAR SEAL SEAT 3
01-0242-4E
1390-1101 ROTAR,1" HYD.BY PASS 1
01-0246-3E VALVE
1320-4116-2 SHAFT 1
01-2618-3C
1320-4116-1 PIN FOR SHAFT 2
01-2619-4A
8717-2212 `O' RING (VD295) 1
01-0244-4.2A
8717-2115 'O ' RING (VD274) 1
01-1780-4C
1320-4113 THRUST WASHER 2
01-0243-4C
1320-4114 STEEL BALL 3/8" DIA STD 26
01-0240-4B SAE 52100
8719-2243M SEAL RING 1
01-2719-4
1320-4112 HOUSING (MACHINING) 1
01-2620-2B
1320-4112-1 RING, ANTI VELOCITY 1
01-2622-4A
012718 RETAINER 1
01-2718-4
1320-4110 STOP PIN 1
01-2624-4A
1320-4109 SPRING DETENT 1
01-2625-4
1320-4108 STEEL BALL 1/2" DIA STD 1
01-0278-4.2A
1320-4111 BOLT HEX HEAD, 1/2"-13 4
01-2670-4 UNC X 4"LONG,2" THREAD
1320-4107 DISC DETENT 1
01-2626-3B
1320-4115 RETAINING RING 1
01-2627-4B
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1320-4106 SPACER HANDLE 1
01-2628-4A
1320-4102 WASHER PLAIN 7/16" 1
01-2669-4 (YELLOW ZINC PLATED)
013024 HEX NUT NYLOCK 7/16"-20 1
01-3024-4 UNF X 5/16" LONG
1320-4103 HANDLE, MANUAL & CYL 1
OPERATED FOR 1" VLV
1320-4105 GRIP 1" HANDLE 1
01-2629-3 (VD197)
1688-B GREASE FTG,45 DEGREE 1/8" 1

88 1291-0200 VALVE AIR SHUTTLE ASSY. 2

01-0045-4 1/4" FPT 3-200 PSI
******items reqd for each Assly.***

1291-0200-3 BODY VALVE, 1

01-0260-4B
1291-0200-4 VALVE FLANGE 2
01-0261-4C (SHUTTLE VALVE)
807924 SHUTTLE 1

1291-0200-1 ORING FOR SHUTTLE VLV BIG 2

01-0047-4.1 (VD253)
1291-0200-2 'O ' RING FOR SHUTTLE VLV 2
01-0047-4.2 SMALL (VD326)
SCREEW CHEESE HEAD, 8
M5 x 0.8 x 12 MM

89 0150-1588 VALVE ASSY, MTR-5/PTR-5 1

01-0430-2A REGULATOR
******items reqd for each Assly.***

8717-2115 'O ' RING (VD274) 1

01-1780-4C
0150-1172 ORIFICE PLUG 1
01-0455-4A
0150-1141 BODY 1
01-0444-2D
8599-0216 DOWEL PIN 3/8" # x 1"LONG 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-2631-4
8599-0012 DOWEL PIN 1/4" # x 5/8" 1
01-2632-4 LONG
8506-0012 CAP SCREW HEX SOCKET HEAD 1
1/4" 20 UNC x 3/4"
0150-1140 PORT PLATE 1
01-0445-2A
8717-2019 'O' RING 4
01-2537-4B
8717-2014 'O' RING 2
01-2535-4A
8717-2218 'O' RING 1
01-2539-4B
8717-2222 'O ' RING (VD472) 1
01-0446-4B
0150-1143 SEAL PLUG 3
01-0449-4B
8717-2010 'O' RING 3
01-2534-4A
805394 PLUG HEX SOCKET 3/4" NPT 1

8717-2232 'O' RING 3

01-2540-4B
8841-2232 BACKUP RING 3
01-0379-4B
805391 CAP SCR.HEX SCK.HD.10-24 4
UNC X 3/4" LG (SS)
0150-1139 FLOW PLATE, TR-5 2
01-0373-3D
0150-1149 FLANGE 1
01-0451-3A
8841-2010 BACKUP RING 6
01-0450-4C
8504-4024 CAP SCREW HEX SOCKET HEAD 12
1/2"-13 UNCx1-1/2"
0150-1142 HYDRA SEAT TR-5 INLET 4
01-0374-4F
8717-2117-1 'O' RING 'VITON' 5
01-2538-4.2C
8841-2117 BACK-UP RING 6
01-2584-4C
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
0150-1161 SPRING SEAT INLET 2
01-0375-4
0150-1144 HYDRA SEAT VENT 2
01-0376-4C
8717-2113-1 'O'RING 'VITON' 4
01-1128-4.2B
8841-2113 BACKUP RING 2
01-2587-4D
0150-1162 SPRING SEAT VENT 1
01-0377-4
0150-1148 BOTTOM FLANGE 1
01-0452-4
805392 PLUG HEX SOCKET 1/4" NPT 1

0150-1150 PISTON GUIDE, TR-4, 1

01-2867-4 REGULATOR
8717-2226 'O` RING (VD470) 1
01-0437-4A
8717-2224 'O' RING 1
01-2541-4B
8841-2224 BACK-UP RING 1
01-2585-4C REFIR BR355
0150-1538 SEAL CONTAINER MACHINING 1
01-0447-3C
0150-1538-1 PISTON 1
01-0454-4B
0150-1548 NAME PLATE, TR-4/TR-5 1
01-2826-4
RIVET, SNAP HEAD KNURALED 4
DIA 1/8" x 5/16"
0150-1169 SUB PLATE, TR-5, 1" NPT 1
01-0432-2B
8504-5045 CAP SCREW HEX SOCKET HEAD 4
5/8" 11 UNC x 4"
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100
8717-2019 'O' RING 2
01-2537-4B

90 1700-8500 VALVE, POPET RELIEF, 3/4" 1

01-0090-3.1G MPT IN, 3/4" OUT, 3500
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
******items reqd for each Assly.***

1700-8909 'O ' RING (VD252) 1

01-0099-4A
1700-8904 BODY 1
01-0091-3E
1700-8910-2 SEAT CAP 1
01-0101-4F
1700-8901 THREAD CAP,RELIEF VALVE 1
01-0092-4A
1700-8907 GUIDE 1
01-0097-4A
1700-8506 SPRING 1

1700-8908 POPPET 1
01-0098-4C
1700-8905 SPRING REST,RELIEF VALVE 1
01-0095-4A
1700-8902 ADJUSTING SCREW,RELIEF 1
01-0094-4C VALVE
1700-8903 LOCK NUT,RELIEF VALVE 1
01-0093-5
8717-2112 O-RING 1
01-0235-4.1A
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100

91 1700-8700 RELIEF VALVE,5500 PSI 1

01-0093-3.2G
******items reqd for each Assly.***

1700-8909 'O ' RING (VD252) 1

01-0099-4A
1700-8904 BODY 1
01-0091-3E
1700-8910-2 SEAT CAP 1
01-0101-4F
1700-8901 THREAD CAP,RELIEF VALVE 1
01-0092-4A
1700-8907 GUIDE 1
01-0097-4A
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1700-8908 POPPET 1
01-0098-4C
1700-8905 SPRING REST,RELIEF VALVE 1
01-0095-4A
1700-8902 ADJUSTING SCREW,RELIEF 1
01-0094-4C VALVE
1700-8706 SPRING FOR RELIEF VALVE 1

1700-8903 LOCK NUT,RELIEF VALVE 1

01-0093-5
8717-2112 O-RING 1
01-0235-4.1A
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100

92 1601-1100 CHECK VALVE 1/2", 4

23-0015-3 5,000 PSI (SWAGE LOK)
******items reqd for each Assly.***

230016 OUTLET BODY 1

23-0016-3
230017 INLET BODY 1
23-0017-3
230018 INDICATOR RING 1
23-0018-4
230019 POPPET STOP 1
23-0019-4
230020 SPRING 1
23-0020-4
230021 BACK-UP RING 1
23-0021-4
230022 'O' RING, BODY SEAL 1
23-0022-4
230024 BONDED POPPET 1
23-0024-4

93 HYD CONTROL VALVE 1" FOUR 6

WAY SELECTOR TYPE WITH
******items reqd for each Assly.***

1320-4122 WASHER, SPRING LOCK, 1/2" 4

 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-2672-4 (YELLOW ZINC PLATED)
1320-4123 NUT HEX 1/2"-13 UNC 4
01-2671-4 (YELLOW ZINC PLATED)
1320-4121 BODY (MACHINING) 1
01-2614-2A
1320-4120 DOWEL PIN 2
01-2616-4A
1320-4119 WASHER 3
01-0245-4
8841-2116 BACKUP RING 6
01-0241-4
8717-2116 O-RING (VD303) 3
01-0244-4.4B
1320-4118 SHEAR SEAL SEAT 3
01-0242-4E
1330-4101 ROTAR,1"SELECTOR VALVE 1
01-0277-3E
1320-4116-2 SHAFT 1
01-2618-3C
1320-4116-1 PIN FOR SHAFT 1
01-2619-4A
8717-2212 `O' RING (VD295) 1
01-0244-4.2A
8717-2115 'O ' RING (VD274) 1
01-1780-4C
1320-4113 THRUST WASHER 2
01-0243-4C
1320-4114 STEEL BALL 3/8" DIA STD 26
01-0240-4B SAE 52100
8719-2243M SEAL RING 1
01-2719-4
1320-4112 HOUSING (MACHINING) 1
01-2620-2B
1320-4112-1 RING, ANTI VELOCITY 1
01-2622-4A
012718 RETAINER 1
01-2718-4
1320-4110 STOP PIN 1
01-2624-4A
1320-4109 SPRING DETENT 1
01-2625-4
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1320-4108 STEEL BALL 1/2" DIA STD 1
01-0278-4.2A
1320-4111 BOLT HEX HEAD, 1/2"-13 4
01-2670-4 UNC X 4"LONG,2" THREAD
1320-4107 DISC DETENT 1
01-2626-3B
1320-4115 RETAINING RING 1
01-2627-4B
1320-4106 SPACER HANDLE 1
01-2628-4A
1320-4102 WASHER PLAIN 7/16" 1
01-2669-4 (YELLOW ZINC PLATED)
013024 HEX NUT NYLOCK 7/16"-20 1
01-3024-4 UNF X 5/16" LONG
1320-4103 HANDLE, MANUAL & CYL 1
OPERATED FOR 1" VLV
1320-4105 GRIP 1" HANDLE 1
01-2629-3 (VD197)
1688-B GREASE FTG,45 DEGREE 1/8" 1

011312 POINTER FOR DISC DETAINT 1

01-1312-4A 1/2" & 1"

94 VALVE ASSY,MTR-5/PTR-5 1
REGULATOR FOR 1-1/2"
******items reqd for each Assly.***

8717-2115 'O ' RING (VD274) 1

01-1780-4C
0150-1172 ORIFICE PLUG 1
01-0455-4A
0150-1141 BODY 1
01-0444-2D
8599-0216 DOWEL PIN 3/8" # x 1"LONG 1
01-2631-4
8599-0012 DOWEL PIN 1/4" # x 5/8" 1
01-2632-4 LONG
8506-0012 CAP SCREW HEX SOCKET HEAD 1
1/4" 20 UNC x 3/4"
0150-1140 PORT PLATE 1
01-0445-2A
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
8717-2019 'O' RING 4
01-2537-4B
8717-2014 'O' RING 2
01-2535-4A
8717-2218 'O' RING 1
01-2539-4B
8717-2222 'O ' RING (VD472) 1
01-0446-4B
0150-1143 SEAL PLUG 3
01-0449-4B
8717-2010 'O' RING 3
01-2534-4A
805394 PLUG HEX SOCKET 3/4" NPT 1

8717-2232 'O' RING 3

01-2540-4B
8841-2232 BACKUP RING 3
01-0379-4B
805391 CAP SCR.HEX SCK.HD.10-24 4
UNC X 3/4" LG (SS)
0150-1139 FLOW PLATE, TR-5 2
01-0373-3D
0150-1149 FLANGE 1
01-0451-3A
8841-2010 BACKUP RING 6
01-0450-4C
8504-4024 CAP SCREW HEX SOCKET HEAD 12
1/2"-13 UNCx1-1/2"
0150-1142 HYDRA SEAT TR-5 INLET 4
01-0374-4F
8717-2117-1 'O' RING 'VITON' 5
01-2538-4.2C
8841-2117 BACK-UP RING 6
01-2584-4C
0150-1161 SPRING SEAT INLET 2
01-0375-4
0150-1144 HYDRA SEAT VENT 2
01-0376-4C
8717-2113-1 'O'RING 'VITON' 4
01-1128-4.2B
8841-2113 BACKUP RING 2
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
01-2587-4D
0150-1162 SPRING SEAT VENT 1
01-0377-4
0150-1148 BOTTOM FLANGE 1
01-0452-4
805392 PLUG HEX SOCKET 1/4" NPT 1

0150-1150 PISTON GUIDE, TR-4, 1

01-2867-4 REGULATOR
8717-2226 'O` RING (VD470) 1
01-0437-4A
8717-2224 'O' RING 1
01-2541-4B
8841-2224 BACK-UP RING 1
01-2585-4C REFIR BR355
0150-1538 SEAL CONTAINER MACHINING 1
01-0447-3C
0150-1538-1 PISTON 1
01-0454-4B
0150-1548 NAME PLATE, TR-4/TR-5 1
01-2826-4
RIVET, SNAP HEAD KNURALED 4
DIA 1/8" x 5/16"
0150-1138 SUB PLATE 1-1/2" PORT, 1
01-2986-2 TR-5 REGULATOR
CAP SCREW HEX SOCKET HEAD 4
5/8"-11 UNC x 5"
1320-4114 STEEL BALL 3/8" DIA STD 1
01-0240-4B SAE 52100
8717-2019 'O' RING 2
01-2537-4B

95 013004-1 PLAIN WASHER,38X14X2.5 10

01-3004-4.1 MM.THICK
96 017597 MOUNTING BRACKET FOR 1
01-7597-3 STARTER & PRESSURE SWITCH
1 817100 BLADDER ASSLY.,11 GALLONS 24
3000 PSI
2 8014-0600 CROSS,CS3M,1"FxFxFxF 2

3 8100-0101 CONNECTOR,MALE,1/4" T x 7
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
1/4 MPT STEAL
4 8100-2101 CONNECTOR,FEMALE,1/4" Tx 7
1/4 FPT STEAL
5 8004-0600 CROSS, 1", M.I 1

6 819277 CABLE,4 AWG, 4 CONDUCTORS 6

7 8110-5200 CONNECTOR, MALE, 1/2"T X 2

1/2"T MPT S-STEEL
8 8014-0800 CROSS, 1-1/2", CS3M 3

9 2000-2100 CYLINDER,AIR,2 POS,4"BORE 1

2-1/8"STROKE,200PSI,W/ROD
10 2115060 CONN,TUBE,3/4"T X 3/4" 2
MPT,SS3/4 TUBE,TUBE OR P.
11 2115060 CONN,TUBE,3/4"T X 3/4" 2
MPT,SS3/4 TUBE,TUBE OR P.
12 01P18I/S-OSBN CABLE,ELECTRIC,EXP,ARMOND 30
O.SHILDOD,18AWG-,1PAIR
13 8210-1301 ELL. CONDUIT SVCP, CAP 1
1" DIA,TYPE, LBY
14 8011-0400 ELBOW,90DEG,1/2"NPT,CS3M 8

15 8011-2400 ELBOW STREET,90 DEG,1/2", 8

CS3M
16 8011-0600 ELBOW,90 DEG, 1"NPT, CS3M 40

17 8011-0600 ELBOW,90 DEG, 1"NPT, CS3M 2

18 8011-0600 ELBOW,90 DEG, 1"NPT, CS3M 2

19 8011-2600 ELBOW STREET,90 DEG,1", 17

CS3M
20 8011-2600 ELBOW STREET,90 DEG,1", 2
CS3M
21 8011-2600 ELBOW STREET,90 DEG,1", 7
CS3M
22 8101-0101 ELBOW, 90 DEG, MALE, 1/4" 10
X 1/4"MPT, STEEL
23 8001-2500 ELBOW, STREET, 90 DEG, 8
3/4"MI
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
24 8001-0500 ELBOW,90 DEG,3/4" M-1 8

25 8001-0600 ELBOW,90 DEG,1", M-1 8

26 8001-1000 ELBOW,90 DEG,2 1/2",M.I., 2

NPT
27 8001-3000 ELBOW,ST.,2 1/2",M.I.,NPT 2

28 2115255 ELBOW,MALE,3/4"T X 3/4" 4

MPT,316 SS
29 8101-0301 ELBOW, 90 DEG, MALE, 1/2T 14
X 1/2 MPT STEEL
30 8011-0800 ELBOW, 90 DEG, 1-1/2" 10
CS3M
31 8011-2800 ELBOW, STREET, 90 DEG, 10
1-1/2" CS3M
32 8011-2800 ELBOW, STREET, 90 DEG, 2
1-1/2" CS3M
33 2620-3600 FILTER,AIR,AUTO DRAIN,50 1
MICRON,METAL BOWL,W/SIGHT
34 0500012 BREATHER,FLTR,3/4" NPT,HI 4
IMPACT TECHNOPOLYMER C
35 FLTR (H.P.)1-1/2",SAE 4- 1
BOLT FLANGE ASSY.(DONALD
36 4082-4500 GAUGE,6"DL FC,0-3000 PSI/ 1
21000KPA,1/2"LWR BACK PNL
37 4082-4600 GAUGE,6"DL FC,0-6000 PSI/ 2
42000KPA,1/2"LWR BACK PNL
38 4000-4100 GAUGE,DIRECTREADING,DUAL 1
FC 2-1/2",0-300 PSI/2100
39 4082-4100 GAUGE D/R DL,FC,0-6000PSI 4
/0-42000KPA 1/4"NPT LWR
40 753/A/1/2"NPT GLAND,TIBER CABLE FOR 5
EXPLOSION PROOF (NEMA
41 753/0/1/2"NPT GLAND.EXP,OD MIN-.37", 3
MAX-0.63"MAKE-HAWKE
42 GLAND,EXP,OD MIN-0.87'MAX 3
1.30')NO-753/C1'NPT/HAWKE
43 810261 LUBRICATOR,AIR,METAL BOWL 1
W/SIGHT GLASS,MANUAL
44 MOTER ELEETRIC EXP PROOF 1
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
50 HP,230V,460V,60HZ,3PH
45 3003-1300 PUMP,TRIPLEX 1
RECIPROCATING 1-1/4"
46 1153-1200 REGULATOR, AIR, 1/4", 1
W/GAUGE 0-125 PSI, GAUGE,
47 2200-0100 ELECTRIC PRESSURE SWITCH 1
BOURDON TYPE 3000 PSI
48 1730-0100 SNUBBER OIL,303 SS,POROUS 8
01-0468-4 METAL, 1/4 MPT X 1/4" FPT
49 SHELL,ACCUMULATER 24
GALLONS,3000 PSI TOP
50 2600-1100 STRAINER,Y-TYPE,250PSI 4
20MESH,3/4"FPT,MI
51 2600-5100 STRAINER,Y-TYPE,250PSI 1
20MESH,2-1/2"FPT,MI
52 STER,EXP.PRF,50HP,73A,480 1
V/60HZ,P.NO(XSIDH-73A4BEE
53 8013-0600 TEE,1",FxFxF,CS3M 10

54 8003-0600 TEE, 1" NPT, M-1 6

55 8103-4101 TEE,UNION 1/4Tx1/4Tx1/4T 4

STEEL
56 8013-0800 TEE, 1-1/2", CS3M 10

57 8104-0101 UNION 1/4"TUBE x 1/4"TUBE 2

STEEL
58 8002-0500 UNION,HEX, 3/4" NPT,M-1 8

59 UNION,2 1/2",M.I,NPT 2

60 8103-4300 TEE, UNION,1/2"x1/2"x1/2" 2

61 8211-1100 UNION CONDUIT,1/2"TYPE 2

UNY
62 1290-0400 VALVE QUICK RELEASE 1/4" 2
PT. 150 PSI FOR PTR-5
63 807054 1/2" MANUALLY OPERATED 1
DUAL AIR CONTRL PILOT VLV
64 1601-5100 VALVE, CHECK,5000 PSI 1
POPPET,STEEL 1-1/2" FPTx
 Bill Of Material NOV Ideal Rig
SL PART_DRAW DES UNIT_QTY
NOV ACC UNIT WITH PLC (P.O.-RII80709CM, RIG-95)
Bom date -: / / Po Date-:31/03/2009
65 1330-5100 VALVE 1-1/2" HYD,4-WAY, 1
3 POSITION,3000PSI W.P
66 1510-1100 VALVE,SHUT-OFF,COMBO, 5
200PSI,1/2"
67 1510-2100 VALVE,SHUT-OFF,COMBO, 4
200PSI,3/4"
68 1510-7100 VALVE,SHUT-OFF,COMBO, 1
200PSI,2-1/2"
69 4160700 WIRE HOOKUP 10 AWG 30
6MMSQ COLOUR GREEN/YELLOW