BOP CONTROL UNIT

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 TOPIC 1

CONTROL UNIT
ACCUMULATOR BOTTLES & CALCULATIONS.

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CONTROL UNIT

BOP control unit is to provide pressurized

hydraulic fluid that will promptly operate
the blowout presenters

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CONTROL UNIT CONSISTS OF :

 Accumulator bottles for storing pressurized fluid.

 Hydraulic control fluid and its reservoir tank
 Charging system to pump hydraulic fluid into
accumulator bottles.
 Pressure regulating valves and an operating
manifold to operate the BOPs , choke and kill valves.
 Remote control panels for operating BOPs , choke
and kill valves from remote locations.

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 SURFACE BOP CONTROL UNIT
Accumulator Guages
Bottles
Annular Regulator
Hi/Lo Bypass valve

4 way Valves

Manifold
Regulator

Electric
Starter

Hydro-Electric Electric Pump Pneumatic (Air) Hydro-Pneumatic

Pressure switch Pump Pressure switch
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NEED :-

1. To reduce the closing time of BOP functions

2. To enable the BOP’s to be closed in event of

power failure

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 Gas fluid
separation

Bladder

Shock
Dampner

Puppet
Spring
Safety
Relief Port
Assembly
Flow Port
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Fig 5.28 ACCUMULATOR BOTTLE WITH CHARGING & GAUGIING ASSEMBLY
 Nitrogen is used for precharge
 Pre charge pressure is 1000 + or – 100
psi
 Standard bottle capacity is 10 gals.
 Frequence for checking pre charge
pressure is before spudding of each well.

.
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11
 1. 2. 3.

N2 N2
P1 P2, V2
1000 + N2
100 psi P3, V3
------------
V1 ------------
------------
10 gal -V2
fluid-------
------------
------------
------------ --V3
------------ fluid---------
---- -------
P2 = 3000 psi,
FLUID V3 fluid = ( 10 – V3 ) gal
V2 = P1*V1/P2
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V2 fluid = ( 10 – V2 ) gal
USABLE FLUID
Usable fluid is defined as the fluid that can be recovered
from Accumulator Bottles.

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Usable
Fluid per
bottle

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Eg.1.
Operating Pr. To Close BOP < 1200 psi
P1 = 1000 psi
V1 = 10 gal
P2 = 3000 psi
V2 = P1V1 / P2
= 1000 x 10 / 3000
= 3.33 gal
P3 =?
= 1200 psi
V3 = P1V1 / P3
= 1000 x 10 / 1200
= 8.33 gal
USABLE FLUID = V3 – V2
= 8.33 – 3.33 = 5 gal 16
SIZING OF CONTROL UNIT ( for surface Stack )

Fluid vol. required to close all BOPs

Total Fluid = +
Fluid vol. required to open all HCRs

+ 50 % Safety Margin

No. of Bottles = Total Fluid

Usable fluid per bottle
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SIZING OF CONTROL UNIT ( for Subsea Stack )

Total Fluid = Fluid vol. required to close and open

all BOPs
+
Fluid vol. required to Close & open all
failsafe valves
+ 50 % Safety Margin

No. of Bottles = Total Fluid

Usable fluid per bottle
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Q. P1 = 1000 psi, V1 = 10 gal, P2 = 3000 psi,
Minimum Operating pr. – 1200 psi.
One Annular BOP to close 18 gal
Three Ram BOPs to close 5.8 gal each
One HCR to open 1 gal
Calculate the no. of bottles required as per API RP53 ?

Calculation:
Vol. required to Close BOPs & Open HCR
= 18 + ( 3 * 5.8 ) + 1
= 36.4 gal

Total Vol. required = 36.4 + 50 % Safety = 54.6 gal

No. of Bottles = 54.6 = 54.6 =

11 Fluid per bottle
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Q. A BOP stack contains one Annular, two Rams and one HCR.
Annular BOP requires 18 gals to close and 16 gals to open.
Ram BOP requires 6 gals to close and 5 gals to open.
HCR requires 1 gals to close and 1 gals to open.
Calculate the total fluid required to close , open and close all functions,
taking a safety factor of 20% ?

Operation :- close open close

Annular BOP 18 + 16 + 18 = 52 gals
Ram BOP (6 + 5 + 6) x 2 = 34 gals
HCR 1 + 1 + 1 = 3 gals
Total = 89 gals
S.F. (20 %) = 17.8 gals

Total Fluid required = 106.8 gals25

 TOPIC 2

RESERVOIR TANK, CHARGING SYSTEMS, etc.

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RESERVOIR TANK :
A reservoir tank provides means for storage of Hydraulic fluid.
The capacity of the reservoir tanks should be such when
system is not pressurised the level should be about one
inches below the inspection port and when the accumulator
bottles are charged fully at 3000 psi the level of the tank
should be at least one inch above the suction valves of the
pumps used in unit.
As per API recommendation the tank capacity should
be at least two times the usable fluid.
High quality SAE - 10W hydraulic oil should be used in the
system.
Prevent Hydrate formation - Methanol and Glycol
Antifreeze - Ethylene Glycol 27
CHARGING SYSTEM
At least TWO pump systems with independent power sources.
SIZING OF PUMP SYSTEM
• With the Accumulators isolated , each pump system .

shall have the capacity to close ANNULAR BOP on the .

Minimum size D/P being used, open HCR valve and provide .

the minimum system operating pressure within 2 minutes.

• The combined output of all pumps should be capable of
. charging the entire system from pre charge pressure to
. the control system RWP within 15 minutes.
• Each pump system should provide a discharge pressure
. at least equivalent to the system working pressure.
• Air driven pumps should reach RWP with 75 psi air supply.
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ELECTRICAL PUMP
The BOP control unit consist of one electric driven triplex or
duplex pump.
The pump output remains constant up to the maximum
pressure of 3000 psi, independent of system back pressure.
AIR PUMPS
The BOP control unit consist of two or three air pumps. It
consist of two main components, the air motor and the fluid
end.
The standard double action pumps are 60 : 1 or 50:1 ratio.
The pumps are double acting so air is exhausted on each
upstroke and down stroke of the pump.

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REGULATORS
The BOP control unit consist of two regulators,
 one manifold regulator
 one annular regulator.
Manifold regulator is one which regulates the accumulator
pressure from zero to 1500 psi and in some of the unit from zero to
3000 psi. for the manifold line.
Manifold pressure operates all the functions except annular
preventer in BOP stack.
The manifold pressure should not be less than the calculated value
on the basis of BOP rated pressure and closing ratio of the ram
preventer and in any case normally it should not be less than 1200
psi when BOP is in operational mode.
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ANNULAR REGULATOR
Annular preventer requires different operating pressure for
different requirements compared to other functions of BOP stack.
It regulates accumulator pressure to operate the annular preventer
from zero to 3000 psi.
There are two types of annular regulators, manual regulator with
air motor and air operated regulators.
The annular regulator should be operative from rig floor remote
panel. This is accomplished with the help of UNIT / REMOTE
Switch.  

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 PRESSURE REGULATORS
 MANIFOLD REGULATOR
 Operates Rams & HCRs
 Regulates Accumulator Pr.
From 0 – 1500 psi.
 ANNULAR REGULATOR
 Operates Annular BOP
 Regulates Accumulator Pr. From 0
– 3000 psi.

 Pressure depends upon RWP  Air motor / Air operated

& Closing Ratio of Ram BOP
 Pr. Normally 1500 psi but not  UNIT / REMOTE Switch to regulate
less than 1200 psi Annular Pr from Remote Panel

 Bypass valve in HIGH

position – Accumulator Pr. In
Manifold.
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THREE POSITION FOUR-WAY VALVE:
The operating manifold consists of several 3 position 4 way
valves, either manipulator or selector type.
All the manipulator or selector valve should be kept in neutral
when unit is not charged.
After charging, unit valves should be kept in
open position for all ram type and annular preventer
close position for choke and kill HCR valve.
To operate the valve move the handle in one swift motion.
Pausing will cause the valve to inter-flow, thus venting some of
the supply fluid and delaying operation.

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Manipulator Type Selector Type

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Manipulator Type Selector Type

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Manipulator Type Selector Type

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PRESSURE TRANSMITTERS
Control unit consists of three pneumatic pressure transmitters.
Three transmitters are for annular, accumulator and manifold
pressures.
Operating pressures can be monitored on the remote control panel.
The transmitters converts hydraulic pressure to air pressure and
sends a calibrated signal to corresponding air receiver gauges on the
remote control panel.
The air output is 3-15 psi, ensure that the air input to the transmitter
should not be more than 18 psi, if this pressure is more than 18 psi
it will rupture the diaphragm of the transmitter.

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AIR FILTER
Located on the air inlet line. This filter removes contaminants
from the air supply which may damage the air pumps.
It traps moisture to supply dry air to the accumulator unit. This
filter must be cleaned periodically to maintain maximum air
flow.  
AIR LUBRICATOR
Its function is to lubricate the pump during operation.
Ensure that the lubricator contains sufficient amount of SAE -10
oil.
Setting: Check the drip setting flows 6 drops per minute.

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RESPONSE TIME
Closing Response Time begins when a function is activated at any
control panel and ends when a BOP is closed , effecting a SEAL
(Regulated pressure recovers to normal value)
SURFACE STACKS
RAMS < 30 Sec.
ANNULAR BOP, smaller than 18 ¾” < 30 Sec.
ANNULAR BOP , 18 ¾” & Larger < 45 Sec.
HCR Valves ( Open or Close ) < Min. observed Ram
close response time

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 TOPIC 3

CONTROL UNIT FIGURES, REMOTE PANEL

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 BOP Operating Fluid Path (Low Position)

Accumulators

Annular
1500 Psi Regulator
3000 Psi
Isolation Valve Low High

Bypass Valve 600-1500 Psi

Pressure Gauges
Manifold Regulator
1500 Psi
MANIFOLD Open Close

RAMS HCR Annular

FOUR-WAY VALVES

Ram Assembly
Tail Rod
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Piston Ram Shaft
How it
works

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 BOP Operating Fluid Path (High Position)

Accumulators

Annular
3000 Psi Regulator
3000 Psi
Isolation Valve Low High

600-1500 Psi
Bypass Valve

Manifold Regulator Pressure Gauges

3000 Psi
MANIFOLD
Open Close

RAMS HCR Annular

FOUR-WAY VALVES

Ram Assembly
Tail Rod
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Piston Ram Shaft
 Accumulators

Annular
1500 Psi Regulator
3000 Psi
Isolation Valve Low High

Bypass Valve 600-1500 Psi

Pressure Gauges
Manifold Regulator
Activating Switches 1500 Psi
MANIFOLD
Open Close

RAMS HCR Annular

Air Lines
Driller’s Remote Pannel
Accumulator Manifold

2 3
Air Annular
Annular
1 4
O C
Master
Inc. Dec
Electrical Signals Valve Pipe Ram
O C

O C

O C 46
 Accumulators

Annular
1500 Psi Regulator
3000 Psi
Isolation Valve Low High

Solenoid Bypass Valve

Air Valve- Open 600-1500 Psi
Pressure Gauges
Manifold Regulator
1500 Psi
MANIFOLD
Open Close
Solenoid
Valve - Close

RAMS HCR Annular

Driller’s Remote Pannel

Accumulator Manifold

2 3
Pressure Switch
Junction Box Air Annular
Annular
1 4
Electrical Signal to Ram close Lamp O C

Inc. Dec
Electrical Signal to actuate solenoid valve-close Pipe Ram
O C

Master O
Blind Ram
C
Electro-Pneumatic Remote panel Push Pipe Ram
Button O C
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Operating Sequence Close Function
Drilling is in progress and none of the BOP has been
operated. Electrical pump of control unit is not running
and gauges are showing pressures as follows:

Accumulator Pr. - 2600 psi and constant

Manifold Pr. - 1500 psi
Annular Pr. - 1200 psi

Which of the following is correct:

1. Everything is OK
2. Leakage in the system
3. Electrical pump malfunctioning / Electrical pr.
Switch faulty.

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 When shutting in a well from the remote BOP panel, a number of
problems may occur that makes you wonder whether the selected
function has operated. From the chart below select the probable causes
Problem Master 3 Position Closed Leak in Air Bulb
valve not valve not line line or lost blown
held down moved blocked BOP
Close light does
not illuminate but
pressure drops
and later recovers
Light does not
illuminates and
pressure gauge
does not drop

Pressure gauge
drops but does not
rise back

Light illuminates
but pressure
gauge does not
drop
2 5 6 12 14 15 17 18 50
 TOPIC 4

MGS, VACUUM DEGASSER

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MGS
Device used for handling large amount of gas at the time of killing

VACUUM DEGASSER

Device used for handling small amount of gas during drilling /

circulation / coring etc.

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 IDv

Vent line Hv

IDb
Mud Line

Hb
Baffle Plate

Body
HL

Cleaning Port

Base

Figure 5.70 MUD GAS SEPERATOR 53

1. Pressure build up in MGS depends on
-- VENT TUBE dimensions
-- Hv & IDv

2. Maximum Allowable Pr build up depends on

( Pressure beyond which gas blow through occurs)
-- Height of Liquid Seal
-- HL

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