CONTROL SYSTEM

FOR

SURFACE MOUNTED BOP STACKS

OPERATION MANUAL

Shanghai Shen Kai Petroleum & Chemical Equipment Co., Ltd.

Table of contents

1.0 General

2.0 Model designation

3.0 Technical parameters

4.0 Construction & features

4.1 Remote control panel

4.2 Driller’s panel

4.3 Air interconnect cable

4.4 Hydraulic control line

5.0 Operation principle and description

5.1 Controlling for the “start” or “stop” of electric oil pump

5.2 The control principle of hydraulic control system

5.3 Controlling for pneumatic oil pump

5.4 Hydraulic principle of FKQ640-6 control system for surface mounted BOP stacks

6.0 Installation and Pilot run

6.1 Installation

6.2 Pilot run

6.3

7.0 Operations, Maintenance and Lubrication

7.1 Operation instruction

7.2 Maintenance

7.3 Lubrication Instruction

8.0 Troubleshooting

9.0 Order instruction

Appendix A: Conversion table

Appendix B: Recommended hydraulic fluid for BOP stacks

1.0 GeneralControl system for surface mounted BOP stacks (hereafter called hydraulic control system) is very important equipment which controls BOP stacks and gate valves controlled by hydraulic pressure especially in drilling and repairing well operations. It is necessary to accurately operate and maintain hydraulic control system.The hydraulic control system is divided into two types. One is the type liquid controlled by air with a driller’s panel to remotely open or close BOP equipment. The type is often used for drilling operation. The other type is directly operated by hand and often used for drilling or workover operation.

2.0 Model designation

FK Q 640 6

Number of objects controlled: (6)

Total capacity of accumulator (640L)

Remote control type (“Q” means liquid controlled by air)

Product code of control system of surface mounted BOP

3.0 Technical parameters

Working pressure: 21MPa 3000PsiAdjusting pressure range: 0-14MPa 0-2000PsiNitrogen pressure of accumulator: 7+0.7MPa 1000+100PsiPressure control units range: 18.9-21MPa 2700-3000PsiHydraulic/pneumatic switch range: 18.9-21MPa 2700-3000PsiAir supply pressure: 0.65-0.8MPa 93-115PsiPower supply: 380±19V/50Hz

3.1 Main technical parameter of control system for surface-mounted BOP stacks

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Mode

Numbers of controlled object Accumulator Effective

Volume

of oil

tank (L)

Annular Ram Choke Backup

Total

Volume

(L)

Useful

liquid (L)Installation

FKQ 1208-

81 3 2 2 80×16 640 Side 1800

FKQ 800-7 1 3 2 1 40×20 400

Side/Back

1800

FKQ 800-6 1 3 2 40×20 400 1600

FKQ 640-6 1 3 2 40×16 320 1600

FKQ 640-5 1 3 1 1 40×16 320 1400

FKQ 480-5 1 3 1 1 40×12 240 1400

FKQ 480-4 1 3 1 40×12 240 1200

FK200-4 3 1 40×5 100Side

700

FK 160-3 3 40×4 80 550

ModeMotor

power (KW)

Flow-rate of pumps Rated

working

pressure

(MPa)

Maximnm

working

pressure

(MPa)

Triplex

(ml/r)

Pneumatics

(ml/stroke)

FKQ 1208-8 18.5×2 80×2 60×2 21 31.5

FKQ 800-7 18.5 80 60×2 21 31.5

FKQ 800-6 18.5 80 60×2 21 31.5

FKQ 640-6 18.5 80 60×2 21 31.5

FKQ 640-5 18.5 80 60×2 21 31.5

FKQ 480-5 15 60 60×2 21 31.5

FKQ 480-4 15 60 60×1 21 31.5

FK200-4 15 60 21 31.5

FK 160-3 15 60 21 31.5

3.2 The model and arrangement of the control system for surface-mounted BOP stacks

ModeElectric

pumpPneumatics

Manual

oil punp

Alarm

system

Nitrogen

Backup

system

Protect

house

Insulated

House

&

air-condition

Driller’s

panel

Auxiliary

Control

panel

Pipe

Racks

&

hose

FKQ 1208-8 ● ● ○ ○ ○ ● ○ ● ○ ○

FKQ 800-7 ● ● ○ ○ ○ ● ○ ● ○ ○

FKQ 800-6 ● ● ○ ○ ○ ● ○ ● ○ ○

FKQ 640-6 ● ● ○ ○ ○ ● ○ ● ○ ○

FKQ 640-5 ● ● ○ ○ ○ ● ○ ● ○ ○

FKQ 480-5 ● ● ○ ○ ○ ● ○ ● ○ ○

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FKQ 480-4 ● ● ○ ○ ○ ● ○ ● ○ ○

FK200-4 ● ● ○ ● ○

FK 160-3 ● ● ○ ● ○

Note：1. All above are all model of our coMPany. “●”is basal arrangement, “○”is optional arrangement.

2. The arrangement above not mean each model can be choose. It must confirm by negotiate when sign the

contract.

3. All above arrangement or function can design and manufacture according to the request of custom.

4.0 Construction and featuresFKQ series control systems for surface mounted BOP stacks consist of the followings:1. Remote control panel (normally equipping with protecting house)2. Driller’s panel3. Air interconnect cable4. Hydraulic control lines including hose bundle or pipe racks

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Driller’s panel

Air junction box

Auxiliary remote control panel

Master hydraulic control manifold

Auxiliary electric pump

Auxiliary air pump

Accumulators

Pipe Racks

Drill’s panel interconnect cable

Remote control interconnect cable

Air junction box

4.1 Remote control panel Remote control panel consists of reservoir, pump units, accumulator units, manifold various valves & gauges and electric boxes. The primary function of the remote control panel is to receive high-pressure fluid from the pump unit and to store the fluid in accumulator bank. The high-pressure fluid flowed though 3-positon and 4-way hydraulic valve controls the “OPEN” or “CLOSE” of BOP.The remote control panel has the following features:(1) FKQ series equipping with two separate motive power supply systems, electric pump and pneumatic pump, can ensure the operation of system even if electric power supply is shut-off.(2) Accumulator unit should be provided with sufficient high-pressure fluid to open or close BOP stacks. Accumulator system is divided into four groups, the loss of capacity is less than twenty-five percent of the total accumulator system capacity when an individual accumulator or one group loses effectiveness, and pressure isolation valves and bleed valves shall be provided on each group accumulator line and bleed valves can drain the pressure out from the accumulators to the control fluid reservoir.(3) Electric oil pump and pneumatic oil pump can be automatically started up or shut down. Relief valve can immediately overflow even if the automatic control unit fails to start or stop during work.(4) Each BOP is controlled by a relevant 3-position and 4-way hydraulic valve to open or close. FKQ series hydraulic control systems can be changed direction by either hand or pneumatic remote control equipment.

4.2 Driller’s panelFKQ series hydraulic control system equip with driller’s panel placed on drill platform, so that it is convenient for driller to remotely control BOP stacks.The features of driller’s panel are as follows:(1) Working media is compressed air to safely operate.(2) “Y” type valve bushing of air-operated valve can automatically come back to normal place so that the remote operation can’t be influenced in any case.(3) Memory function. Every 3-position and 4-way air-operated valve is individually connected with a cylinder. When the air-operated valve is placed on “open” or “close”,

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Air junction box and shuttle valve assembly

Figure 1 Connecting of control system for surface mounted BOP stacks

the show window appears “o” or “c”. The show isn’t changed after the handle of air- operated valve comes back so that operator can understand the last state.(4) Two steps operation is used in valves of driller’s panel to ensure correct operation

of BOP stacks. The first step is to turn air supply valve to open air supply switch, then turn air control valve at the same time so as to control related objects.

4.3 Air interconnect cableAir interconnect cable is connected remote control panel to driller’s panel. The air interconnect cable consists of protector and multicore with flanges on its both ends sealed rubber rings connecting remote control panel and driller’s panel.

4.4 Hydraulic control line In general, the remote control panel is 40 meters away from BOP stacks. They are connected with hydraulic control lines, hose and pipe.The pipes include pipe rack and flexible pipeline. To connection with pipe is reliable and safe for operation, but inconvenient for installation. To connection with hose is simple and convenient, but not safe enough. You can use hose and pipe together according to actual site situation.

5.0 Operation principle and description5.1 Controlling the “start” or “stop” of electric oil pumpWhen turning the main switch of electric box (figure 2) on remote control panel to “automatic” position, the system is in automatic state. In this time, pressure controller will automatically start the electric oil pump, if the pressure of system is blow 18.9MPa(2700Psi). The pressured oil is flowed from check valve to accumulator bank after the isolate valve of accumulator bank is opened. When the system of pressure is up to 21MPa(3000Psi), the pressure controller automatically shut up power to stop oil supply.When the system is in “automatic” state, the pressure controller makes the pressure of accumulator bank 18.9-21MPa(2700-3000Psi) in order to open or close BOP in any time.When turning the main switch to “manual” position, the electric oil pump will immediately work no mater what the system pressure is. Operator must turn the main switch to “stop” position, when the system pressure id up to 21MPa(3000Psi).

Note: the electric oil pump cannot be stopped, when the main switch is in “manual” position. Operator shall watch the system pressure and turn the main switch to “stop” position to stop electric oil pump.

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Connection power （380 V / 50 HZ ）

Air switch

--------------------

Manual Stop

Contactor Automatism --------------------

Main switch

Heated electric

Connection Connection light Connection

Motor pressure valve

Figure 2: Electric principle of control system for surface mounted BOP stacks

5.2 The control principle of hydraulic control systemThe pressured oil stored in accumulator bank flow from isolate valve (high-pressure ball valve), filer, and relief valve into control manifold, then to 3-position and 4-way valve, final to inlet. In the same time, the pressured oil from accumulator bank to filer, then to the relief bleed valve of annual BOP. The relief pressure oil is only used by annual BOP. Operator just easily pushes the handle of 3-position and 4-way valve to “open” or “close” BOP.

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Operator can remotely control the turning of 3-position and 4-way valve in driller’s panel. Firstly, turning 2-position and 2-way air-supply valve of driller’s panel to “open”, and turning the other 3-position and 4-way air-operated valve at the same time. The compressed air flows from air connection cable to remote control panel in order to control relevant cylinder to turn changing way handle, then to turn 3-position and 4-way valve in remote control panel. In the turning air-operated valve of driller’s panel, the compressed air makes the piston of cylinder move. Operator of driller’s panel can watch the window show “o” or “c” on every air-operated valve to judge BOP “open” or “close”.

Note: Turning valve must be two steps operation. In other words, when turning valves of each controlled objector, operator must turn air supply valve at the same time. Turning valves must maintain 3 seconds to make the valves of remote control panel in proper position.The outlet pressure range of relief bleed valve on controlling manifold is 0-14MPa(2000Psi). In generally, operator adjusts pressure 10.5MPa(1500Psi). The pressure of controlling manifold will be the same as the pressure of the system, when turning pass-by valve from “close” to “open”. At this time, the relief bleed valve does not work.The relief bleed valve of controlling annual BOP is selected as “manual” or “pneumatic/manual” valve. When the system is installed with “pneumatic/manual” valve, operator can pneumatically adjust the outlet pressure of the “pneumatic/manual” valve on remote control panel or driller’s panel. The position of pneumatic pressure is selected by distribution valve on remote control valve. The distribution valve is placed in remote control panel or in driller’s panel.In manual operation, turning the handle of relief bleed valve can adjust the outlet pressure to the pressure what operator need. Turning down is to up the outlet pressure. Turning up is to down the outlet pressure.Pneumatic/manual adjusting operation description is followed:(1) When the air pressure is zero, manually adjusting the pressure 10.5MPa or the pressure what the operator need, then locking adjusting rod.(2) Turning the handle of distribution valve to the position of “driller’s panel”, operator can adjust the controlling pressure of annual BOP in driller’s panel by remotely control Pneumatic/manual relief bleed valve. The Pneumatic handle of remote control panel does not work in this time.(3) Turning the handle of distribution valve to the position of “remote control panel”, operator can adjust the controlling pressure of annual BOP in remote control panel by remotely control Pneumatic/manual relief bleed valve. The Pneumatic handle of driller’s panel does not work in this time.

Note 1: In Pneumatic adjusting operation, the air pressure must be zero. Turning the handle of relief bleed valve down, setting the annual BOP pressure what the manufacture recommend such as 10.5MPa(1500Psi). then locking the adjusting rod to adjust pressure.

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Note 2: When the pneumatic adjusting operation does not work, the controlling pressure of annual BOP will automatically come back to the setting pressure such as 10.5MPa(1500Psi) to safeguard the system.Note 3: In Pneumatic adjusting operation, the outlet pressure of relief bleed valve cannot be changed immediately because of longer air control line. Operator shall carefully watch and slowly operate.

The “O” type 3-positong and 4-way valve can be used in remote control panel. When the handle is in middle place, the room of valve is not connected. While the handle is in “open” or “close” position, the compressed oil flows into the side of oil tank of BOP, the other sides of oil flow into reservoir by 3-position and 4-way valve.The “Y” type 3-position and 4-way valve can be used in driller’s panel.

5.3 Controlling pneumatic oil pumpControl units are equipped with a pneumatic oil pump. The system pressure can be adjusted with pneumatic oil pump in no power or stopping using power.To open air supply switch, then to close pass-by valve, the compressed air flow from pneumatic cells into air/liquid switch in system with pneumatic oil pump. When the manifold pressure is blow 18.9MPa(2700Psi), the air/liquid switch will automatically open. The compressed air flows into pneumatic oil pump to drive it start. The relief oil flow into manifold by check valve. When the system pressure is up to 21MPa(3000Psi), the air/liquid switch will automatically shut-off. Then the power is shut-off. The pneumatic oil pump is stopped.In special, when the pressure what the system need is over 21MPa(3000Psi), operator only use the system with pneumatic oil pump. Firstly, shutting down isolate valve of accumulator bank to prevent compressed oil into accumulator bank. Turning pass-by valve of relief bleed valve to “open” at the same time. Opening the pass-by valve of air/liquid switch so that the air/liquid switch does not work. The compressed air can directly flow into pneumatic oil pump.

Note 1: Operator must make sure the relief bleeds valve work normally, when using pneumatic oil pump. In necessarily, operator shall test complete relief in 34.5MPa(5000Psi).Note 2: When the manifold pressure is up to 21MPa(3000Psi), the isolate valve of accumulator bank (ball valve) must be closed to make equipment normal and make persons safe.

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5.4 Hydraulic principle of FKQ640-6 control system for surface mounted BOP stacks

Item Product name Qty. Drawing No. Type Notes

1 Gate valve 7 1”

2 Pneumatic cells 1 set AF5000, AR500, AL5000

3 Gate valve 1 2”

4 Air/liquid switch 1 Y10-00 QKY21-25

5 Check valve 2 DIF-L10H2 31.5 40l/min

6 Pneumatic oil pump 2 Y04-00A QYB40-60L

7 Oil filter 2 1”

8 Oil filter 1 2”

9 Flame-proof electric

Motor

1 YB180M-4 18.5KW

10 Electricity box 1 BQC83-40

11 Check valve 1 DIF-L20H1 31.5 100l/min

12 Plunger pump 1 Y15-00 QB21-80

13 Relief valve 1 Y08-00 Y25-20

14 Pressure controller 1 YTK-02

15 Isolation valve

(ball valve)

1 Q11NS-31.5-1” 1”

16 Relief valve 1 Y09-00 Y40-20

17 Cylinder 7 K4-01-51-00

18 3-position and 4-way

valve

6 Y01-00 34ZS21-25

19 2-position and 3-way

valve

1 Y01-00A 23ZS21-25

20 Quake-proof

pressure gauge

2 YN100BF 0-40MPa

21 Filter 3 Y14-00

22 Manually adjusting

valve

1 Y02-00 JYS21-25

23 High pressure ball

valve

4 YQ2-32H-Z1” 1”

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24 Accumulator 8 NXQ1-L80/31.5/H

25 Pneumatic pressure

transmitter

3 YPQ400B 0-40MPa

26 Air filter relief valve 1 QFH-261 0-0.6MPa

27 Quake proof pressure

gauge

1 YN100BF 0-25MPa

28 Pneumatic/manual

adjusting pressure

valve

1 Y16-00 JYSQ21-25

29 Distribution valve 1 Remade by Q34SR2-

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30 Unloading valve 1 Y06-00 φ10

31 Pneumatic cells 1 AW4000,AL4000

32 Pneumatic adjusting

valve

2 QTY-8 0.05-0.63MPa

33 Pressure gauge 3 Remade by Y-100ZT 0-0.2MPa

34 Pressure gauge 1 Y-100ZT 0-2.5MPa

35 3-position and 2-way

valve

1 Remade by 34XR6Y-

L8-F

36 3-position and 4-way

valve

7 Remade by 34XR6Y-

L8-F

37 Cylinder 7

6.0 Installation and Pilot run6.1 Installation (1) Smoothly safely install remote control panel. (2) The remote control panel is located a place away from wellhead over 30m according to standard and requirements. The driller’s panel is located in a convenient place for driller on drill floor.(3) Connecting oil pipe Connecting oil pipe from BOP it is good for arranging oil pipe and changing oil pipe. It is important to clean every oil pipe with compressed air before the oil pipes are connected. Every oil pipe is welded on “o” or “c” mark over channel steel on the base of remote control panel. “o” means open, “c” means close. When the oil pipes are connected, operators watch not only the mark “blind ram”, “pipe ram” and “annular” the same with the show of valve on remote control panel, but also the mark “o” or “c” corresponding the open or close of BOP.Note 1: carefully check about control object and switch direction before connecting pipe.Note 2: checking pipe without stuff or leakage before connecting pipe.(4) Connecting air pipeThe air supply pipes and air connect cables are connected to the FKQ hydraulic control system. Be careful flanges direction, flanges seal, and tight bolts& nuts when connecting pipes.

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ID 25mm hose is used in air supply of remote control panel. ID 13mm hose is used in air supply of driller’s panel. Be good tight between hoses and connections to prevent loosing. The hoses are no default especially no rifts and no ageing to prevent from explosion in use. Note 1: There no dead angle when connecting pipe to prevent from broken pipe.Note 2: when connecting air connection cables flanges, the air will go though everywhere in cables if the seal rings do not work.(5) Connecting power lines The power shall be 440V, 60Hz alternating current. Connecting power line according to relevant regulations.The main switch of electric power control box on remote control panel shall be turned on the stop to prevent from electric accident before connecting power line.Note: Be sure about the main switch is turned on the stop to prevent from accident before connecting.Carefully checking all connection of pipes, flexible joints and connections without loosing and defaults after the equipment is completely installed.6.2 Pilot run The preparation of pilot run according to the following procedures:(1) Precharging Nitrogen or checking pressure of accumulators. The pressure is 7+0.7MPa (1000+100Psi). Refilled again if the Nitrogen is not enough.(2) Adding oil into reservoirThe oil is added from inlet on the top of reservoir or sucking oil with sucking pump. The oil volume shall be controlled on the level of oil mark.Using YA-N32 hydraulic pressure oil or other proper oil under circumstances temperature over 0oC.Using YC-N32 low temperature hydraulic pressured oil or other proper oil under circumstance temperature below 0 oC.(3) Lubrication motion parts according to lubrication requirements.(4) Open isolates valves on pipe and accumulators.Open bleed down valves on control manifold.Turn the handle of 3-position and 4-way hydraulic valve and by-pass valve on the middle place.(5) Turn main switch to “manual ” then turn main switch to “stop” after starting motor. Be careful if the direction of motor and chain protector is the same, otherwise changing the electric phase.The procedures of pilot run are followed:

(1) Testing start-up or shut-off of electric oil pump.Turning main switch to “automatic” position, making the motor oil pump run without load 10 minutes, then closing bleed down valve on control manifold to make accumulator pressure up to 21 MPa (3000Psi), result in the pump automatically stopped. Turning main switch to “ stop” if the pumps is fail to automatically stop.Gradually open bleed down valve to slowly down pressure to 18.9 MPa (2700Psi), result in electric oil pump automatically stopped.In operation, checking and adjusting pressure controller to automatically stop or start.

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Watching about the each joint on remote control panel in the pressure rising up.(2) Testing start-up or shut-off pneumatic oil pump.

When using pneumatic oil pump, closing by-pass valve of fluid / air switch and opening air supply valve acting on pneumatic oil pump to make accumulator’s pressure up to 21MPa(3000Psi). Then watching about if the air supply is automatically shut-off to stop pneumatic pump.Gradually open bleed down valve to slowly down pressure to 18.9MPa(2700Psi), result in the pneumatic oil pump automatically stopped.

(3) Adjusting relief valvesWatching about if the outlet pressure of manifold or annular is 10.5 MPa (1500Psi), otherwise adjusting to 10.5 MPa (1500Psi).

(4) Direction changed testWhen the accumulator pressure is up to 21MPa(3000Psi) and the by-pass valve of control manifold is in middle place, changing handle direction of 3-positin and 4-way hydraulic valves, then watching about if “open” or “close” of BOP is the same with “ open” or “close of 3-position and 4-way hydraulic valve, otherwise checking pipe connecting.

(5) Relief valve testTo close the isolate valves of accumulator bank on pipes and, turn 3-position and 4-way hydraulic valve in a middle place, then turn main switch of electric box to “manual”, finally start electric motor to make the pressure of accumulator up to 23MPa (3300Psi), and watch about if the relief bleed valve on the outlet of motor oil pump fully kick off. If fully kick, to turn main switch to the “stop” position and stop motor oil pump. The relief valve completely is closed with the pressure not less than 18.9 MPa.To close isolate valve of accumulator on pipes, then turn by-pass valve of control manifold on open. To open air supply switch valve and by-pass of fluid and air switch, then to start pneumatic oil pump to make the manifold pressure up to 345MPa(4900Psi) and watch about if the relief valve is fully kick off. After fully kick, to close air supply and stop pneumatic oil pump. The relief valves shall be fully closed with pressure not less than 29MPa(4200Psi).Note: when testing and adjusting relief valves, the isolate valve of accumulators on pipes must be closed to prevent from pressure rising accident.

(6) Pneumatically adjusting testing in annual BOP.Turning the handle of manual adjusting valve on annual BOP down. Setting the outlet pressure of the

valve in 10.5MPa.

Turning the handle of distribution valve on remote control panel in “driller’s panel’ position. Then

adjusting pneumatic handle in driller’ panel, and watch about the reader of pressure gauge on

driller’s panel is the same with the reader of pressure gauge on remote control panel.

Turning the handle of distribution valve in “remote control panel” position, then adjusting pneumatic handle in remote control panel and watch the reader of pressure gauge on annual BOP.

(7) Testing reservoir heightAdding oil into reservoir if there leakage oil too much in above mentioned procedure.

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7.0 Operations, Maintenance and Lubrication

Because the hydraulic control system is more important equipment in well control system, relevant person must be technically trained, managers and operators shall understand the principle, installation, operation and maintenance.7.1 Operation instruction1) In normal drilling operation, BOPS are open, blowout valves are closed, and by-pass valves are in middle place.2) Two-steps operation is used in turning valve of driller’s panel. 3) Don’t go through transport vehicles on hydraulic or pneumatic line between control units and BOP stacks to prevent from damaged.4) Operator must check control system at least once week. Check control system every shift work once when drilling approach to oil or gas. The following contents should be inspected:

- The height of reservoir is in normal - Electric cells and wire are safe- No leakage on oil or gas line- The control units are reliable and accurate- The range of pressure gauges are in normal- Testing “open” or “close” of BOP according to safe requirements.

5). Suggesting customers to establish operation and maintenance records. Write down the work of operations, shutdowns and maintenance at any time.

7.2 Maintenance1) Monthly carefully checking strainers of reservoir or the other parts.2) For diverter strainer of air supply elements: Everyday discharging water in cup. Every one-week cleaning strainer cup and disposed water cup with gasoline then to dry cup.3) Oil part of pneumatic cells: everyday checking the water lever, and adding lubrication oil such as N32 gasoline in time. Cleaning it with stuffed.4) Periodically check precharging Nitrogen pressure. At the beginning, weekly check Nitrogen pressure once. Monthly check it once in normal operation.Checking the Nitrogen pressure under only the accumulator bank completely relief pressure.5) When transportation hydraulic controls equipment in long distance, the Nitrogen pressure of accumulator shall be in 1MPa(140Psi).6) Checking the oil lever of reservoir and cleaning the bottom of reservoir covered sands and mud in any time.7) Periodically check the pack-off of and pneumatic oil pump.8) Keep the “o” seal rings well in unloading pipe lines.9) Often cleaning the surface of remote control panel and driller’s panel.10) Correcting the pressure gauge after completion a well.7.3 Lubrication Instruction1) Adding grease or machine oil weekly to two nozzles of air cylinder with grease

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gun.2) Monthly checks the grease oil of crankshaft box. Add N32 machinery oil under insufficient oil circumstance.3) Monthly checks the grease lever in motor oil pump. Add N32 machinery oil under insufficient oil circumstance.4) Monthly take off chain protector to check grease. Add N32 machinery oil under insufficient oil circumstance.8.0 Troubleshooting

1 Running noise from control units.Cause: mixed gas in oil.Remedy: Running equipment with unload to circulate gas out. Checking the bladder of accumulator to ensure it is good otherwise changing it.

2 Electric motor can not be started.Cause (1): The power parameter is closed in bad.Remedy (1): Checking and repairing power circuit.Cause (2): Electric elements in electric control box are broken down or the fuse is blown.Remedy (2): Inspecting and repairing electric control box or changing the fuse.

3 The pressure rises slowly or stop and the noise of pump are in abnormal.Cause (1): The oil of reservoir is below normal level to make pump suck nothing.Remedy (1): Adding oil into reservoirCause (2): The gate valve of sucking oil is closed or the sucking mouth of the oil strainer is blocked.Remedy (2): Checking pipe, then opening gate valve and cleaning the strainer.Cause (3): The bleed valve of control manifold does not close.Remedy (3): Closing bleed down valveCause (4): The electric oil pump broken down.Remedy (4): Checking the electric oil pump.

4 The electric oil pump can not automatically stoppedCause (1): Oil pipe or connection of pressure controller is blocked or leakage.Remedy (1): Checking the pipe lines of pressure controller.Cause (2): The pressure controller does not work.Remedy (2): Adjusting or changing pressure controller.

5 The outlet pressure of relief valve is too highCause (1): Dirt on the surface of seal ring.Remedy (1): Revolving the adjusting pressure handle to make sealing box up and down several times to push dirt out.

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6 Driller’s panel can not close or open BOP or the action of “close” or “open” is inconsistent.

Cause (1): The cable core is wrongly connected, or broken or blocked. The rubble ring of flange is not sealed.Remedy (1): Checking air interconnect cable or changing seal parts.

9.0 Order instructionControl systems for surface BOP stacks have various structural models. Please provide the technical parameters and requirements required, including:

1 Number of objects controlled and model Manufacturer:

The type of BOP stacks:Liters required Liters required

-Annular __________ Open ____________ (L) Close ____________ (L) -Blind ram _____ __ Open ____________ (L) Close ____________ (L)

-Pipe ram ____ _ Open ____________ (L) Close ____________ (L)

-Pipe ram __________ Open ____________ (L) Close ____________ (L) -Preventer __________ Open ____________ (L) Close ____________ (L)

-Preventer __________ Open ____________ (L) Close ____________ (L)

-Spare parts

2 Order scopePlease choose the following parts what you need, and write down details about your chose parts.

- Driller’s panel- Air interconnect cable- Hydraulic control lines (pipe rack, flexible lines and hose bundle)- Others

3 Special requirementsPlease describe the special requirements of products or parts when ordering:

-Protect house pattern-Painting -Connecting-Others

Our factory manufactures the hydraulic control system according to national standard, industrial standard.

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APPENDIX ACONVERSION TABLE

1. Mass1kg=2.2lbs1lbs=0.45kg

2. Volume1L=0.264 US. Gal=61 cu.in1 US. Gal=3.785L=231 cu.in

3. Pressure1MPa=145 Psi1Psi=0.0069 MPa

4. Length1m=3.28ft=39.37 in1ft=0.305 m

5. Temperature1OC=5/9 (OF-32)1 OF=1.8X OC+32

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6. Power1kw=1.34 hp1hp=0.746kw

APPENDIX BRECOMMENED HYDRAULIC FLUID FOR BOP STACKS

ISO Brand: HM32 (used for plunger pump system with low or no Zn)

Mobil Brand: D.T.E24 (used for plunger pump system with low or no Zn)

Shell Brand: Tellus32 (used for plunger pump system with low or no Zn)

Note: The moving viscosity of hydraulic fluid oil is 17-33mm2/s when the temperature is at 50oC.

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