Hydril Advanced Hydraulics

Advanced
Hydraulics Course
Training Manual
copyright © 2007 by Hydril Company, LP

Houston, Texas
NOBL-NA-AHC2008A
Published by Hydril Company LP
Noble Corporation
Advanced Hydraulics Course
Training Manual
NOBL-NA-AHC2008A
Hydril Company LP makes no warranties of any kind, expressed or implied, including any war-
ranty of mechanical fitness for any particular purpose that the work performed pursuant to this
manual will be free from defects in workmanship or material. Hydril retains for itself all propriety
rights in and to all designs, engineering details, data, and procedures set forth herein. This man-
ual is intended for the sole use of Hydril customers, and they shall strictly control copying and dis-
tribution of same, as this manual and all paper and electronic copies thereof may be recalled by
Hydril at any time.
This manual makes recommendations only. The customer is at all times responsible for actual
disassembly, inspection, reassembly, and testing of the equipment. The customer also is solely
responsible for providing competent and qualified persons; equipment and facilities to perform
such operations; and for workmanship and safety. If at any time the customer is unable to under-
stand recommendations made in this manual or is unable to follow those recommendations, they
should consult the nearest Hydril location. Hydril reserves the right to make additions, changes or
deletions on the equipment described, at any time, without obligation.
No portion of this work may be reproduced by any means, electronic, mechanical, photocopying,
recording, or otherwise, without prior written permission from Hydril Company LP.
Copyright © 2007 Hydril Company LP

All rights reserved. Printed in the United States of America.
To contact Hydril:
Hydril Company LP
Pressure Control Systems
ATTN: Customer Service and Training
3300 North Sam Houston Parkway East
Houston, TX 77032-3411 USA
Phone (281) 449-2000 (USA)
(800) 231-0023 (USA and Canada)
Fax (281) 985-2828 (USA)
Web www.hydril.com
TABLE OF CONTENTS
Introduction
Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 1
System Overview
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Operational Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Chapter 2
Subsea Control Pod
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Rigid Conduits and the Rigid Conduit Manifold . . . . . . . . . . . . . . . 2-2
Pod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electro-Hydraulic (EH) Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Solenoid Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Shear Seal Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Solenoid Activations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Troubleshooting Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Flow Meter Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Lower Valve Control Unit (LVCU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SPM Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Adjustable Regulator Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Pod Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Pod Stab Extend and Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Auto Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Choke and Kill Test Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
LMRP Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Chapter 3
Pod Component Maintenance
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Advanced Hydraulics 1-1

Copyright © 2007 Hydril Company, LP
TABLE OF CONTENTS
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Shear Seal Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Solenoid Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
EH Housing Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Solenoid/Shear Seal Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Hydrostatic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Post Test Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Solenoid Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Test Record Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Sub Plate Mounted (SPM) Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Hydrostatic Test of the SPM Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Hydrostatic Test of the SPM Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . 3-36
Seal Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
SPM Valve Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Function Tests for Bi-Directional Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Post Test Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Post Test Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Test Completion and Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Chapter 4
Annular Blowout Preventer
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydril GX 18-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
1-2 Noble Roger Eason / Muravlenko

NOBL-NA-AHC2008A
TABLE OF CONTENTS
Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Stripping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Packing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Packing Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Testing Packing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Replacing Packing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Splitting Packing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Testing the Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Surge Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Teardown and Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Chapter 5
RAM Blowout Preventers
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
RAM BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Types of Ram BOPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Ram Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Multiple Position Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Packers and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Ram Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Shear Ram Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Variable Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Wear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Upper Seal Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fluid Hinge and Pin Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Other Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Compact Ram BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Multiple Position Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Ram Block Removal/Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
MPL Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
MPL Overhauling Nut and Thrust Bearing Replacement and Break-In . . . 5-43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

TABLE OF CONTENTS
Cylinder Seal Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Blind Shear Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Lower Blade Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Lower Blade Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Upper Blade Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Upper Blade Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Casing Shear Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Lower Blade Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Lower Blade Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Upper Blade Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Upper Blade Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Variable Pipe Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Variable Pipe Ram Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Variable Pipe Ram Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Fixed-Bore Pipe Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Fixed-Bore Pipe Ram Dissassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Fixed Bore Pipe Ram Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Chapter 6
High Pressure Test Unit
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Hydraulic Power Module (HPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Pump Control Console (with Eleven-Valve Test Manifold) . . . . . . . . . . . . . . 6-6
Remote Console (With Eight-Valve Test Manifold) . . . . . . . . . . . . . . . . . . 6-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Hydraulic Power Module (HPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Flow Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
System Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Triplex Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Power-End Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Fluid-End Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Pump Control Console (PCC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Remote Console (RC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

NOBL-NA-AHC2008A
TABLE OF CONTENTS
Chapter A
Glossary of Terms
Chapter B
Abbreviations and Acronyms

TABLE OF CONTENTS

NOBL-NA-AHC2008A
Introduction
Course Description
The Hydril® Advanced Hydraulics Course is for Hydraulic or Subsea Technicians on the rig or their
supervisors who want to have a better understanding of how the hydraulics subsystems function
and how to troubleshoot that system. It is meant to build on the Basic Mux Control System Course.
Each course is intended to give the student 1) an understanding of the hydraulic circuits in the Mux
Control Pod and the Control System on the stack, 2) techniques useful in troubleshooting the
system, and 3) hands-on experience in the disassembly, maintenance, and assembly of major
stack components.
Course Objectives
The Advanced Hydraulics Course is designed with several objectives in mind. When you complete
this course, you should have:
• An understanding of the purpose of the Hydril® MUX BOP Control System.
• An ability to identify the major hydraulic components of the system.
• An introduction to these components and their operation and interaction.
• A familiarization with the buildup and teardown of these components.
This manual has been developed to act as a guide during the classroom and serve as a handy
reference guide to the system. For exact system information, students should refer to the Hydril®
Operations & Maintenance Manual Set for the MUX Control System installed on their rig.
Advanced Hydraulics Course 1-1

CHAPTER 1
Introduction
How to Use This Manual
How to Use This Manual

Description
The chapter description provides a quick overview of the scope of the chapter and allows you
to quickly familiarize yourself with the subject matter.
Objectives
The learning objectives for each chapter are stated at the beginning of the chapter. Before
each lecture or practical exercise, review the objectives to ensure you are familiar with the
important points.
Conventions
This manual uses the following conventions:
NOTE
Notes provide additional useful information.
CAUTION
Cautions indicate procedures which can potentially damage
equipment if not performed properly.
WARNING
Warnings indicate procedures which can potentially injure
or kill personnel if not performed properly.

NOBL-NA-AHC2008A
Chapter 1
System Overview
Description
Hydril sells well control systems. These systems consist of power distribution, hydraulic fluid
generation and distribution, control signal generation and monitoring at the surface and a blowout
preventer stack subsea. A blowout preventer (BOP) stack is composed of control pods, annular
preventers, ram preventers, and large high pressure valves. Each of these components must be
operated hydraulically. The Hydril control system uses multiplexed electrical signals to operate
subsea solenoid valves which send hydraulic pilot signals to valves that operate the BOP Stack
functions.
Objectives
When you complete this chapter, you should have:
• An understanding of the purpose of the MUX BOP Control System.
• An ability to identify the major hydraulic components of the system.
• An introduction to these components and their operation and interaction.

CHAPTER 1
System Overview
Background
Background
To keep the well under control during drilling operations and completion, blowout prevention
equipment was pioneered by Hydril in the 1930’s with the introduction of the CP blowout preventer,
the forerunner of the annular-type hydraulicly-activated blowout preventer.
This equipment is attached to the wellhead and should be capable of the following operations:
• close the top of the well,
• control the release of mud and other fluids within the column,
• permit the pumping of mud into the hole, and
• allow the drill pipe to move.
• The equipment must be capable of fast operation and allow the crew doing the work to
be free of danger.
In the 1940’s, Hydril marketed the GK annular blowout preventer. It comes with a latched or
screwed head and provides greater uptime when compared to similar units. The compact design of
the GK is ideal for rigs with small substructures.
In the 1970’s, Hydril entered the ram market and introduced the GL line of annular blowout
preventers. Standard rams were re-engineered in 1995 when Hydril introduced the Compact RAM.
The GL annulars have specially molded packing units which reduced the closing volume and
increased closing cycles over the GK units.
The GX annular blowout preventer was introduced in the 80’s. It’s single packing unit has provided
continuous service for as long as a year, and it has continued to hold pressure after exposure to
extreme temperatures and extensive stripping operations. The GX has stripped 300,000 feet of 5”
drill pipe with 6-3/8” tool joints and held pressure in the field after 328 closing cycles plus
stripping.
In the 1990’s, Hydril introduced the Subsea Test Valve (SSTV). The SSTV comprises a ram blowout
preventer that seals in the downward direction. This configuration enables rig crews to complete
testing in about one hour, without pulling the drill pipe and setting a test plug.
In the 2000’s Hydril introduced the Quik-Loq ram blowout preventer. The Quik-Loq ram has boltless
bonnets. This minimizes personnel exposure to safety hazards that are inherent to BOP
maintenance on the rig by eliminating the need for tools and rigging. Quik-Loq rams allow
changeout of rams and operator assemblies in a matter of minutes instead of hours.
There are three main types of control systems used to control well pressures. DIRECT HYDRAULIC
CONTROL uses hydraulic fluid to directly open and close valves on the BOP stack and is good to 500
ft. PILOTED HYDRAULIC CONTROL, good to 4,000 ft., uses pilot fluid to actuate larger valves subsea to
open and close BOP stack valves. MULTIPLEX HYDRAULIC CONTROL systems use electrical signals from
the surface to control the subsea piloted valves and operates in depths up to 10,000 ft.
Figure 1-1 Direct, Piloted, and Multiplexed Control Systems

NOBL-NA-AHC2008A
CHAPTER 1
System Overview
System Operational Summary
At the time the Hydril MUX Control System was designed, it was realized that when drilling in
10,000 foot of water, the rig down time and revenue lost from pulling the LMRP due to a problem
with the pod would be intolerable (estimated in excess of a week’s worth of time).
To reduce the possibility of failure, Hydril has built many redundancies into the system. Some of
the hydraulic redundancies the system employs include:
• Two independent pumping subsystems for supplying hydraulic fluid to the system.
• Two independent subsea control pods - one is configured as the active pod and the other
as the standby pod. Both pods perform all of the same BOP control functions.

The Multiplex BOP Control System is designed to operate the wellhead control equipment installed
on the stack and the lower marine riser package (LMRP) attached to the stack.
In order for the system to work properly, it must have the right fluid mixture. There are two
approved fluids for use in the Hydril MUX BOP system - Houghton Offshore’s Stack Magic 200 and
Cannon Erifron’s HD603 HP. These should be used as part of a water mixture, consisting of 2 - 5%
fluid concentrate. The mixture may contain up to 40% glycol, as an anti-freeze. These fluids were
chosen based on several important properties -
• Lubricity of the fluid
• Compatibility with elastomers, other materials
• Biodegradeability
• Resistance to biological attack and
• Resistance to foaming.
At the surface, a skid-mounted Hydraulic Pumping Unit (HPU) and skid-mounted Fluid Reservoir/
Mixing Unit (FRU), have been provided to produce and pressurize the hydraulic fluid used for
system operation. The FRU has a 220-gal fluid concentrate tank, a 550-gal glycol tank, and a 900-
gal mixing tank. Each tank is made of stainless steel. The fluid levels in the tanks must be above
the low-level float-actuated sutdown switches in order for the FRU to operate. Rig water pressure
must be at least 3 psi and the mixing system must be set to AUTO at the Central Control Unit
(CCU). The FRU may be safe or hazardous-area rated.
The FRU Motor Control Panel is
powered by 480 VAC from rig power.
It is converted to 120 VAC via an
internal transformer. Inside the FRU
Motor Control Panel there is a 24 VDC
power supply to power the media
converters (analog and RS485-to-FO).
Three Flux Vector Controllers are in
the panel, one each to turn on and off
the pumps for the concentrate, glycol,
and water. Refractometers in the fluid
help determine that the fluid ratios are
maintained to their desired levels. Figure 1-2 Fluid Reservoir/Mixing Unit
Refer to Figure 1-3 on the following
page for a hydraulic schematic of the FRU.
On each injector assembly, check the gear box every 500 hours or 3 months for leaks, wear, and
proper oil level. Periodically check each of the pumps for signs of wear. Ensure the actuators open
and close completely and do not oscillate. Ensure the flow control valves open and close completely
and do not leak. Trouble spots include the stem, seat surfaces and a worn ball.

CHAPTER 1
System Overview
Figure 1-3 Fluid Reservoir Hydraulic Schematic
The Hydrualic Pumping Unit (HPU) has four ball valves for supplying fluid at 5,000 psi to storage
Accumulator Banks, Hot Line Hose (via a regulator at 3,000 psi), both rigid conduits, and a diverter
control system. Two 100-HP motors drive two quintuplex pumps. Quintuplex means the pumps are
equipped with five positive displacement plungers driven by a single crankshaft. Periodically check
the V-belt on the motor/pump assembly for proper tension and wear. The HPU may be constructed
for safe or hazardous area usage.
Upstream of the pumps is a 100-mesh screen to clean the
fluid entering the system. Downstream from the pumps
there are two 40-micron filters. To smooth out the
pulsations from the pump there is a pulsation dampener.
The HPU Interface Panel controls the start/stop of the
system as well as controlling the fluid mix from the FRU.
The HPU Interface Panel also controls the distribution of
the fluids in the system. Inside the HPU Interface panel is
the HPU Controller, fiber optic converters, Adapta
Figure 1-4 Hydraulic Pumping Unit
swithces, and a heater. Redundant 24 VDC power supplies
power the switches and converters. Pressure switches and transducers help to control and monitor
the flow of fluid. Refer to Figure 1-5 for the hydraulic schematic of the HPU.

NOBL-NA-AHC2008A
CHAPTER 1
System Overview
Figure 1-5 Hydraulic Pumping Unit Hydraulic Schematic

CHAPTER 1
System Overview
Fluid is stored on the surface in Accumulator Racks. Each Hydril

accumulator bottle is a 15-gal, top-loading container rated to
6,000 psi. Top-loading allows for easier maintenance. Racks may
hold 10, 12, 16, or 20 bottles. Hydril’s unique flanged design
allows each bottle to be removed and installed more easily. Each
manifold may be isolated and has a gauge showing manifold
pressure.
There is a Blue and a Yellow Cable Reel. Each are hazardous-area
rated. The reel uses a slip joint ring to transfer power and signals
from the staitonary J-Box to the Mux Cable. The cable on the
reels is 1.5” and come sequipped with a Schroeder valve. This
valve allows the connector become filled with dialectric fluid,
fiiling the void between connector halves.
The Hotline Hose Reel carries a spooled hydraulic hose connected
to the HPU and the pod. It is rated to 3,000 psi and maintains
hydrualic communication with the pod during stack installaiton
Figure 1-6 Accumulator Rack and removal.
To supply the stack with fluid once it is installed on the wellhead, the rigid
conduit connects from the HPU and extends downward from the drilling rig
alongside the riser. The conduit terminates at a Rigid Conduit Manifold.
The manifold is used to direct fluid flow as commanded from the surface.
Fluid pressure is reduced to 3,000 psi by a regulator. Hydraulic fluid from
the regulator enters the MUX Control Pods through the riser receiver. Each
control pod has an electro/hydraulic (E/H) section attached to a lower
hydraulic valve control (LHVC) section.
Hydraulic communication between the pod, the LMRP and stack
components occurs through flow passages in an extendable pod stab and
receiver assemblies on the stack and LMRP. Two other extendable stabs,
external to the pods, supply hydraulic fluid to Subsea Accumulator Bottles
stored in racks on the stack.
As shown in Figure 1-8, three surface stations - the Driller’s Panel, the
Central Control Unit’s (CCU) monitors, and the Toolpusher’s (Remote)
Control Station - are provided for operator control. Commands generated
from these consoles operate the two identical subsea control pods
Figure 1-7 Cable Reels
installed on the LMRP. These pods can be operated from any of the three
consoles individually or in combination; however, only the CCU is in direct communication with the
control pods. This communication is achieved through umbilical cables which are lowered to the
sea floor from the MUX Cable Reels located on the rig.
The MUX cable connects to the E/H section of each pod, and commands from the CCU pass to
identical subsea electronics modules (SEMs) A and B, within each pod for processing and
distribution to electrically operated solenoid valves. The solenoid valves respond by applying or
removing pilot pressures to subplate mounted (SPM) valves in the lower hydraulic valve control
section. These SPM valves then operate accordingly to apply or remove hydraulic pressures at the
BOP control components on the stack and LMRP.
Subsea Electronic Riser Angle (ERA) System components are in the two pods and the flex joint at
the bottom of the riser, and a Surface ERA System is located at the top of the riser. The
navigational instruments in these systems monitor the alignment and orientation of the stack and
riser relative to the rig.
Electrical power is supplied through two Uninterruptible Power Supply (UPS) Systems. This power
is routed to each component of the system through two Power Distribution Panels. Other support
equipment includes a Data Logger System for record keeping, and portable Testing Systems to
allow for easier access to the MUX pod controls for troubleshooting or testing.

NOBL-NA-AHC2008A
CHAPTER 1
System Overview
Figure 1-8 MUX BOP Control System

CHAPTER 1
System Overview

NOBL-NA-AHC2008A
Chapter 2
Subsea Control Pod
Description
The subsea components of the MUX Control System play an important part in the operation and
control of the BOP stack. The surface equipment generates electronic communications and
hydraulic fluid and passes them to the pod via the MUX cable (electronics) and the rigid conduit
(hydraulics). The cable and the rigid conduit terminate in the stack at the MUX control pod, which
serves as the central point of control for the subsea components. The control pod is comprised of
two primary sections: the electro-hydraulic (EH) unit, and the lower valve control unit (LVCU).
The EH unit receives the electric communication and power signals from the surface through the
MUX cable via a VCC 29-pin connector which communicates with the pod’s subsea electronics
modules (SEMS). These signals are converted to hydraulic communications that constitutes
operation of the pod’s functions. Each function is assigned a matched solenoid/shear seal valve
combination which is responsible for this conversion.
In the LVCU, regulators and sub-plate mounted (SPM) valves control the flow of hydraulic signals
from the control pod to the various components on the BOP stack.
Objectives
When you complete this chapter, you should be able to:
• Identify the components of the subsea subsystem.
• Explain the function and the purpose of the communications subsystem.
• Explain the role of the EH unit in the subsea subsystem.
• Explain the role of the LVCU in the subsea subsystem.
• Explain the operation of the solenoid/shear seal valve combination.
• Explain the operation of the pod regulator.
• Explain the operation of the SPM valves.
• Explain the function and the purpose of the subsea electronics module (SEM).
• Explain the auto-shear hydraulic circuit.
• Explain the pod stab extend and retract function circuits.
• Explain the LMRP disconnect hydraulic circuit.

CHAPTER 2
Subsea Control Pod
Rigid Conduits and the Rigid Conduit Manifold
Rigid Conduits and the Rigid Conduit Manifold

There are two rigid condiuts on the BOP control system that are
designated Blue and Yellow. These 2” diameter metal tubes are
attached to the riser and carry hydraulic fluid from the surface to the
Low Marine Riser Package (LMRP).
The Blue and Yellow rigid conduits connect to the Rigid Conduit Manifold
on the LMRP. The manifold distributes the surface generated fluid to the
BOP control pods, LMRP components, and the lower stack components.
The fluid may also be routed to the stack accumulators. There are two
identical hydraulic circuits. The manifold is a network of valves, filters,
check valves, and pressure regulators. The filters are 40-micron filters
to help maintain the cleanliness of the fluid. The check valve prevents
Figure 2-1 Rigid Conduit the fluid from flowing back into the rigid conduit. The pressure regulator
Manifold (Rear View) reduces the line pressure from 5,000 psi to 3,000 psi.
TO 1” HOTLINE
YELLOW RIGID
CONDUIT LINE
CONDUIT LINE
BLUE RIGID
FLUSH LINE
TO BLUE
5K STAB
TO YELLOW Blue Accumulator TO RIGID

5K STAB
Charge/Dump Valve CONDUIT FLUSH
Yellow Accumulator
Charge/Dump Valve Yellow Accumulator Blue Rigid Conduit
Isolation Valve Isolation Valve
Figure 2-1 Rigid Conduit Manifold Schematic

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Pod Overview
Figure 2-2 Flow from Blue and Yellow Rigid Conduit Manifolds
Pod Overview
As shown in Figure 2-3, the MUX subsea control pod consists of two primary assemblies, the
electro-hydraulic (EH) section and the lower valve control unit (LVCU). These two components join
together via a junction plate, which facilitates the flow of fluid from the EH section to the LVCU.
The control pod executes stack control commands issued from operator control panels at the
surface. The control pod also supports stack control from the surface by confirming command
executions, indicating stack equipment configurations, and providing subsea temperature data,
pressure data, and the orientation of the stack and riser.
The control pod selectively applies and removes hydraulic pressures to operate BOP components on
the stack and lower marine riser package (LMRP). These applications and removals occur in
response to software commands from the central control unit (CCU)

CHAPTER 2
Subsea Control Pod
Electro-Hydraulic (EH) Section
Two pods identified as Blue and Yellow are

employed in the typical MUX BOP control system.
The pods are installed on the lower marine riser
package (LMRP) in parallel mountings separated
from each other by the drill stem penetration. .
The pod extends a hydraulic stab or wedge into
the LMRP receiver. Hydraulic ports on the LVCU EH Section
pod stab match up with hydraulic ports on the
LMRP receiver. The LMRP receiver connects to the
BOP receiver, which conducts hydraulic fluid to
the various BOP stack functions.
Junction Plate
While both pods are energized with power, each
operates independent of the other. Only one pod
is needed to execute all functions associated with
stack BOP control. The system operators select
Lower Valve
one pod for BOP control (i.e., the “active” pod),
Control Unit
and the other one is kept energized in case of
(LVCU)
failover (i.e., the “standby” pod).
The MUX control pod is made from stainless
steel. Virtually all components included in the LMRP Receiver
assembled pod are also fabricated from stainless
BOP Receiver
steel. This feature enables the pod to withstand
the corrosive affects of the marine environment.
Figure 2-3 MUX Subsea Control Pod

The EH Unit is comprised of five (5) major sub-assemblies: 1) the subsea electronics enclosure,
which contains components to transmit and receive surface digital data; 2) the subsea transformer
enclosure, which contains transformers to modify the received surface voltage; 3) the VCC-29
connector, which connects the MUX cable to the pod, and 4) two solenoid housings, which contain
the solenoid/shear seal valve and pressure transducer assemblies. The electronics and transformer
enclosures serve as heat sinks during operation, and are connected to the one atmosphere
housing. The one atmosphere housing and the enclosures are not pressurized. They withstand
external pressures solely by the strength of their construction
The control pod EH section is connected to the surface CCU via the MUX cable and the VCC-29
connector. Individual conductors inside this cable provide (1) AC voltages to the power transformer
and a relay board and (2) data communication with the electronics package. At the surface, the
data conductors communicate with the CCU through umbilical junction boxes (J-boxes).
Figure 2-4 shows the EH section separated from the LVCU. When the EH section settles onto the
LVCU, four cylindrical stabs on the section slip into four receptacles at each end of the LVCU. The
stabs and the receptacles have holes that align when the EH section is placed onto the LCVU, and
bolts are inserted through the holes to mechanically lock the two sections together.
Additionally, as shown in Figure 2-5 and Figure 2-6, as the EH section lowers onto the LVCU, small
receptacles in the four junction plates of the EH section slip over small diameter stabs contained in
the four junction plates on the LVCU. The stab/receptacle interfaces are O-ring sealed to provide
leak-proof fluid flow passages between the EH section and LVCU. The junction plates on the EH
section have spring loaded suspensions to compensate for any misalignment that may occur as the
EH section is joined to the LVCU. These hydraulic passageways allow communication of fluid
between the pod pilot circuits on the EH section and the function valves located in the LVCU.
Pairs of receptacles on top of each solenoid housing provide attachment points for a pod lifting
assembly. The lifting assembly is used to hoist the EH housing by itself or the fully assembled
control pod.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Electronics
Transformer Package
Enclosure Enclosure
Solenoid VCC-29 Connector

Housing Cover
Shear Seal Solenoid

Valve Cover
Shear Seal
Valve
Solenoid ERA
Maintenance Connector
Cover
Fluid Supply
Tube
Pressure
Transucer
Drain
Valve
One Atmosphere Solenoid Housing

Housing RTU Flow Meter
Connector Connector
Figure 2-4 EH Section
Subplate Solenoid
Shear Seal Valve

Pilot
Fluid In
Junction Plates
E/H Section
Lower Hydraulic Seal Sub Stab Stainless

Control Section Receptacle Steel Tube
(Typical)
SPM Valve
Junction Plate
Working Fluid
Supply In Junction Plate
Seal Sub
Stab
Figure 2-5 Typical Solenoid Valve Circuit

CHAPTER 2
Subsea Control Pod
Umbilical Connector
Solenoid Housing
E/H Section
Valve Cover
Solenoid
Shear Seal
Valve
Lower Fluid
Hydraulic Supply
Valve Manifold
Section
Flow
Tube
Transducer
Bolt
E/H
Section
Spacer
Retainer Screw
w/Spring
Upper J-Plate
Stab Receptacle
Stab
Guide Pin Lower J-Plate
Figure 2-6 EH Section - Hydraulic Section Interface

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Electronic Control Module

The electronic control module (ECM) is responsible for processing commands and distributing
power from the surface to other EH section circuits, including those that energize the
solenoids for the shear seal valves. The ECM also processes subsea pod configuration,
instrumentation data, and control pod command responses for transmission to the surface.
The ECM comprises the following components:
• A stepdown power transformer stack
• Redundant voltage rectifiers
• Relay control board
• Dual redundant subsea electronics modules (SEMs)
• Computer processing PCBs as follows
• Solenoids
• Pressure transducers
• Water detector
• Fluid leakage detector
• Temperature sensors.
These components are distributed among
five stainless steel enclosures: the domed
electronics package enclosure, power
transformer enclosure, the electronics
enclosure, and the two solenoid housings at
either end of the EH section. The domed
electronics package enclosure, the power
transformer housing, and the electronics
enclosure are all one atmosphere
environments. The two solenoid housings
are filled with DC-200 dielectric fluid for
subsea pressure compensation.
Both solenoid housings are isolated from the
electronics enclosure by bulkheads sealed
with O-rings. Wiring passes through these Figure 2-7 ECM Wiring Bundles
bulkheads by means of feed-through
penetration connectors equipped with O-ring seals.
The subsea electronics modules (SEMs) are the major signal processing assembly in the
ECM. Each pod contains two SEMs (SEM A and B) which both support control system
operation by (1) distributing BOP function commands for execution in the control pod and (2)
providing data regarding the status and configuration of the control pod electronics and valve
circuits. The computers are redundantly tasked to:
• Respond to system operator commands from the surface.
• Distribute solenoid firing commands to the appropriate solenoid driver circuits.
• Fire the appropriate solenoids.
• Furnish data regarding pod configurations and subsea status data to the CCU.
Both computers receive identical data simultaneously. The data consists of information
regarding control pod valve status, solenoid firing currents and voltages, and configuration
matching data from their respective electronics circuits.

CHAPTER 2
Subsea Control Pod
Solenoid Housings
The solenoid housings contain the solenoids and pressure
transducers used to control the pod functions and the
pressure transducers which provide pressure data to the
surface equipment.
Figure 2-8 shows one of the two pressure compensated
solenoid housings located at the ends of the EH section.
Each housing has 58 receptacles, 48 for the solenoid valve
assemblies and 10 for the transducers.
Some of the receptacles will not have solenoids or
transducers. Unused receptacles are sealed with blanking
plates. The transducers and solenoid valve assemblies are
installed with their electrical ends inside the enclosure and
their mechanical portions on the outer faces of the
enclosure. The valve has an actuator rod that extends into
the solenoid through an opening in the housing wall.
Figure 2-8 Solenoid Housing

Each solenoid housing is filled with DC-200
dielectric fluid and sealed with a cover
containing an internal bladder. The bladder
is immersed in the electrolyte and
connects to a flow port which is open to
sea water invasion.
As the pod is lowered to the sea floor,
water flows to and from the bladder to
maintain the DC-200 pressure equal to the
ambient marine environment. The outer
faces of both enclosures are protected
with a stainless steel cover bolted to the
EH section frame. The housing/cover
interface is not sealed, and sea water is Figure 2-9 Solenoid Housing Lid and Bladder
allowed to circulate around the valves and
transducers.
Solenoids
At the core of the solenoid is a copper coil inside an iron core. These components are
inserted into a stainless steel housing and vacuum-filled with DC-200 dielectric fluid. The
solenoids energize at a 60VDC rating. Each solenoid is matched with a shear seal valve. This
assembly is assigned a specific position on the MUX control pod related to a particular
hydraulic function on the BOP stack.
Figure 2-10 Assembled Solenoid

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Shear Seal Valves

The shear seal valve is composed of a stainless steel body fitted with a check valve on one
end and a bushing and filter element on the other. An inlet plate and outlet plate, each with
corresponding seal plates, are installed on opposite sides of the body. The inlet and outlet
plates are each equipped with a seal sub which interfaces with the solenoid housing. Inside
the shear seal valve body, a seal cage contains two metal-to-metal seals separated by a
spring. One seal contacts the inlet seal plate, and the other contacts the outlet seal plate.
The spring provides the necessary tension to ensure the seals contact the seal plates
completely.
The seal cage is held in place by the seal carrier spool, which connects to the rod spool via a
dowel pin. A spring creates a tension sufficient to keep the shear seal valve normally closed.
The iron armature screws on to the rod spool. The armature’s position on the rod spool is
maintained through the use of a cotter pin.
An energized solenoid pulls the armature out, aligning the seals with the ports in the inlet
and outlet plate. Fluid passes from the inlet port to the outlet port until the armature is
released by the solenoid.
Figure 2-11 Shear Seal Valve Assembly
Solenoid Activations
Surface Initiations
From the panels at the surface, system operators initiate solenoid firing commands.
Commands are issued from the CCU by simultaneously depressing its PRESS AND
HOLD TO OPERATE push button and clicking a mouse on the function control icon in
the graphic display. System operators observe various graphic displays to verify that
the targeted solenoid(s) responded appropriately. The verifications include momentary
fluid flow increases through the control pod flow meter or amperage and voltage
changes in the solenoid windings.
As the command is issued, the selected function icon illumination begins blinking and
the panel processor encodes the command with the address(es) of the targeted
solenoid(s). The address identifies (1) the specific solenoid firing circuit(s) and (2) the
board(s) on which the circuit(s) is located.

CHAPTER 2
Subsea Control Pod
Troubleshooting Screens
There are a few screens
that may prove useful to
the technician when
troubleshooting the
system. The first is the
SOLENOIDS DIAGNOSTIC
screen. It displays the
various solenoids by
number and function
name. When a solenoid
fires, a trickle current
flows through a sensor,
feeding the information
back to the surface and
displayed on the screen in
mAmps.
Figure 2-12 Solenoid Diagnostic Screen
While the Solenoid

Diagnostic screen may tell
you if the solenoid has
fired, it does not tell you if
the corresponding shear
seal valve opened and
allowed pilot fluid to flow.
The flow meter indicators
on the FLUID AND POWER
CONTROL screen notify the
technician when fluid flows
via the flow meter in the
individual pods (Blue and
Yellow).
Figure 2-13 Fluid and Power Control Screen
2 - 10 Noble Roger Eason / Muravlenko

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Flow Meter Port

A flow meter is located downstream from the
pod select valve. The flow meter monitors the
flow rate of the working fluid in the pod and
BOP stack working fluid circuits. A connector
port on the bottom of the EH section one
atmosphere housing provides a communication
connection from the flow meter to the CCU at
the surface. The flow meter uses an insulated
and pressure compensated cable filled with DC-
200 dielectric fluid to communicate with the
pod.
Figure 2-14 Flow Meter (Right) Connectors
Pressure Transducers
The pressure transducers are mounted in a line
below the shear seal valves. Each transducer has
a 0 to 10,000 PSIA measurement range and
provides pressure data for the surface panels
from an assigned location in the control pod.
Both the transducers and solenoid valve
assemblies are constructed with stainless steel
components, and the solenoids are rated for
60 VDC and 30 watts. Figure 2-15 and Figure 2-
16 illustrates a typical transducer assembly.
Figure 2-15 Pressure Transducer
Spring Pin
10,000 PSI
Pressure Sensor Hole Plug Hole Plug
Socket Head
Cap Screw
Male Connector
Fitting
Pressure
Mounting Ring Sensor Cap
Dust Plug
Figure 2-16 Pressure Transducer Assembly Drawing
Advanced Hydraulics Course 2 - 11

CHAPTER 2
Subsea Control Pod
Lower Valve Control Unit (LVCU)

In the lower valve control unit,
hydraulically piloted valves,
shuttle valves and filters
comprise the hydraulic circuits.
Some of these components are
combined with regulators and
small volume accumulator
bottles to form four pressure-
adjustable circuits.
Figure 2-17 shows the LVCU
with its side plates removed. A
total of 84 fluid flow ports are
located in the base and
extendable stabs. One port
(#60) accepts fluid from the
rigid conduit manifold. The
remaining ports pass hydraulic
fluid to the BOP components on
Figure 2-17 Lower Valve Control Unit Photo the stack and LMRP.
The LVCU contains piloted SPM valves and shuttle valves that apply and vent hydraulic pressures to
the BOP equipment. The SPM valves receive piloting fluid from the solenoid valve assemblies in the
E/H section via the junction plate interface, and fluid for the BOP equipment comes from several
working fluid circuits in the LVCU. In four of the fluid circuits, fluid pressures can be adjusted to
ranges below 3,000 psi by operator controls in the surface panels. Within the LVCU, hydraulic fluid
is conveyed through hard pipes, tubes, and passages - there are no hosed connections.
The riser receiver is located on top of the LMRP base plate. The pod bolts to the riser receiver.
When the pod base stab or wedge extends, the wedge interfaces with the riser receiver. Stab seals
form a seal between the ports on the pod base stab block and the ports on the riser receiver.
The stack receiver is bolted in place on the top of the lower stack. Hoses from the stack receiver
ports connect to the hydraulic actuators for the lower stack components. When the LMRP is placed
on top of the lower stack, the LMRP plate and the lower stack plate are oriented so the riser
receiver is directly on top of the stack receiver.
Once the LMRP is connected to the lower stack, the operator fires the Extend Pod Stab function.
This action will energize a solenoid valve which moves the pod stab wedge down and out of the pod
and into contact the face of the stack receiver and the riser receiver.
The contacting faces of the stabs and the receivers are sloped from top to bottom. When fully
extended, the pod stab wedge contacts the stack receiver and the riser receiver faces. As a result,
the weight of the pod stab resting in the receivers forces a tight seal at the stab/receiver
interfaces. The force exerted by the stab extension ensures tight sealing of the packer seals
against the receiver seal face. In each stab, the external ports are threaded to accept screw-in
packer seal retainers of varous sizes. A wave spring installed behind the packer seal provides the
outward force necesary to maintain the seal once it is compressed.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
SPM Valves
Inside the Hydraulic Unit are three sizes of hydraulically piloted SPM Valves (Sub-Plate
Mounted hydraulic valves); ½”, 1" and 1½”. Refer to Figure 2-18. Their individual body
housings are manifold mounted and of a low inter flow cage design. These valves route the
hydraulic fluid to most of the BOP stack functions.
Upper Seat Spool Rod

Body Cage
Inner Spring
Piston Housing
Piston
Backup Outer Spring

Lower Spool Spring
Valve Seat Plate Retainer
Figure 2-18 SPM Valve Assembly Drawing
As the SPM valves and regulators operate, hydraulic fluid is vented from the pod and collects
behind the exterior plates of the LVCU. Since the hydraulic fluid is heavier that sea water, it
displaces sea water from vent ports and around the assemblies.
Figure 2-19 Pressure Regulator

CHAPTER 2
Subsea Control Pod
Discharge Cap Socket Head

Cap Screw
Handle
Regulator Slide
1.5” OD
Seal Sub
Inlet Seal (2 PLCS)

Spring (4 PLCS)
Vent Seal (2 PLCS)
Piston Lock Pin
Seal Housing
(4 PLCS)
.75” OD
Seal Sub
Piston
Piston Head
Figure 2-20 Adjustable Regulator Assembly Drawing

Figure 2-20 shows a typical adjustable regulator. Hydril’s pressure regulators use the pilot pressure
to regulate the output pressure of the regulator. The output pressure is proportional to the pilot
pressure.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Figure 2-21 Pod Function Map

CHAPTER 2
Subsea Control Pod
Adjustable Regulator Circuits

The pod supplies much of the working fluid for BOP functions at 3,000 psi; however, some
fluid is supplied at lower pressures because of the specific functions served or the design
limitations of the targeted components. Accordingly, four working fluid circuits have been
equipped for remote pressure adjustment from the surface panels. These are identified on
the pod hydraulic schematic as the Upper Annular, Subsea Manifold, Lower Annular, and
Stack Connector circuits.
Figure 2-22 shows how the four circuits
work. Each has two solenoid valves - (A) Prsr Prsr
and (B) - with adjustable flow restrictors XDCR XDCR
A B (a) (b)
(1) and (2), a pilot operated regulator,
and two accumulators. Transducers (a)
and (b) provide fluid pressure readback
data for gauges at the surface panels.
The accumulator bottles are added to the
pilot circuit of the regulator to add
1 2
additional volume to the pilot circuit. 3000 PSI Pod
These accumulators allow fluid to flow in Pilot Supply
E/H Sec.
and out of the area above the piston.
Otherwise the regulator could very easily Ctrl Sec.
develop a pressure lock and malfunction. Working
Fluid
Three of the regulator circuits, upper 2.5L 1QT
annular, lower annular and wellhead
connector, have a 2.5 liter and a 1.0
quart accumulator bottle attached, as
shown in Figure 2-22. These circuits must To LMRP
work on the surface and at the sea floor. and Stack
The 1.0 quart bottle is a piston type Functions
accumulator and is pre-charged for
surface applications. This allows the pod Surface
to function quickly at the surface without Panel
having to change the pre-charge in the Control
accumulators.
Regulator
Figure 2-22 Adjustable Pressure Circuit
As this bottle descends to the sea floor the sea

head pressure overtakes the low pre-charge
pressure and pushes the accumulator’s piston
into contact with the accumulator’s head, making
the 1.0 quart accumulator non-functional at the
sea floor. The 2.5 liter bottle is pre-charged to
take over operation as the pod is moved subsea.
It is pre-charged at a higher pressure and as a
result is ineffective at the surface. The larger
Figure 2-23 Metering Valve volume is needed for subsea operation because
of the increased pressure. The bottles are
mounted on swing out arms for easy of maintenance.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Figure 2-24 Regulators Screen

The regulator functions are activated through the MUX Control System software at the CCU,
driller’s panel, or tool pusher’s panel using the Regulators screen as shown in Figure 2-24. To
increase (or decrease) the pressure for a specified regulator, press the INC (DEC) button
ONCE for that regulator. Allow the system a few seconds to stabilize.
If the regulator does not reach the pressure desired, press the appropriate button a second
time and allow the system to stabilize. Proceed in this manner until the desired pressure is
reached. Once the desired pressure is reached, press the SET button. This will allow the
system to generate an alarm range for the pressure set.
Subsea, to increase the pressure, the software will fire solenoid A (see Figure 2-22) for two
seconds. The amount of pressure transferred to the regulator during this two second burst
will depend upon the setting of metering valve 1 (see Figure 2-23). This valve is located on
the pod in front of the shear seal valves.
To decrease the pressure, the software will fire solenoid B (see Figure 2-22) for two seconds.
the solenoid will vent fluid to the atmosphere. The amount of pressure vented during the two
second burst will depend upon the setting of metering valve 2 (see Figure 2-23). This valve
is also located on the EH section of the pod in front of the shear seal valves.

CHAPTER 2
Subsea Control Pod
Figure 2-25 Manifold Regulator Increase
Figure 2-26 Manifold Regulator Decrease
The fourth circuit (Subsea Manifold Regulator) has two 2.5-liter bottle accumulators. This
regulator must be functional during the entire trip from surface to sea floor and therefore
needs both regulators to be larger. The accumulators are pre-charged so that one
accumulator works at the surface and part of the way down to the sea floor. The other
accumulator works at the sea floor and part of the way up to the surface. The pre-charges
should be set to allow the bottles operational distance to overlap. These accumulators are
located opposite the pilot system accumulator bottles.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Hydraulic Circuits
Pod Select
Surface commands open and close the targeted shear seal valves in both pods
simultaneously, and both pods are continuously monitored to ensure that their respective
valve configurations match in case a changeover is necessary. However, the BOP functions
involved are executed in only one pod, not both. What prevents the commands from
executing in both pods simultaneously is the status of the POD SELECT VALVE. The system is
designed to open the valve in only one pod at a time.
Figure 2-27 Pod Select Circuit
Figure 2-27 illustrates the Pod Select circuit. When the Pod Select button is pressed at the
surface, a signal is sent to the active SEM which fires, in this case, solenoid 28 of the Blue
Pod. This allows pilot pressure to flow through SV2 and actuate its corresponding shear seal
valve. This valve allows pod supply pressure to flow to the SPM valves in the LVCU at 3,000
psi. An inline flowmeter measures the fluid flow and pressure then sends this data back to
the surface.

CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Pod Stab Extend and Retract

Hydraulic circuits in the MUX BOP control pod extend and retract the pod stabs, the stabs for
the choke and kill lines, and the two 5,000 psi fluid supply stabs. This section describes pod
stab operation only. Figure 2-28 diagrams the stab extend and retract circuits for the Blue
and Yellow pods. As illustrated, the stab operating circuits are identical and communicate
from pod to pod through shuttle valves. The stab extend circuits utilize a check valve to lock
the extended stabs solidly in their receptacles until unlocked by a retract command.
Pilot pressure circuits are identified by orange lines, working pressure circuits by purple
lines, and venting pressures by red lines. For this description, the terms initiating and
opposite are substituted for Blue and Yellow designations. The initiating pod will be the one
to which surface commands are directed. The stab in the initiating pod is the internal pod
stab; the stab in the other pod is the opposite pod stab.
INITIATING POD OPPOSITE POD

INTERNAL POD
INTERNAL POD
INTERNAL POD
INTERNAL POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB EXTEND
STAB EXTEND
STAB EXTEND
STAB EXTEND
LEGEND
PILOT PRESSURE
WORKING PRESSURE
VENTING PRESSURE
ENERGIZED SOLENOID
DE-ENERGIZED SOLENOID
POD STAB RETRACT
POD STAB EXTEND

INTERNAL POD
INTERNAL POD
STAB EXTEND
POD STAB RETRACT
POD STAB EXTEND
POD STAB
POD STAB
POD STAB EXTEND
POD STAB RETRACT
INTERNAL POD
STAB EXTEND
INTERNAL POD
POD STAB EXTEND
POD STAB RETRACT

STAB RETRACT
STAB RETRACT
TO OPPOSITE
TO OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
TO OPPOSITE
TO OPPOSITE
Figure 2-28 Pod Stab Extend and Retract Circuits

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Internal Pod Stab Extend

Refer to Figure 2-29. In the initiating pod, this command opens the INTERNAL POD STAB
EXTEND shear seal valve to apply pilot fluid to open the INTERNAL POD STAB EXTEND SPM
valve. Working fluid passes from this valve through a check valve and a shuttle valve
(SV6) to extend the pod stab.
The INTERNAL POD STAB EXTEND solenoid valve remains in the shifted position until
returned to its normal state by a stab retract command from the surface. The check
valve, normally closed adjacent SPM valve, and piloted check valve lock the stab
hydraulically in the extended position.
Fluid from the stab cylinder retract port flows through shuttle valve SV5 to vent
pressure out of the circuit. Depending on the position of the shuttle valve SV5,
hydraulic pressure vents to seawater either from the internal pod stab extend SPM
valve, or from the opposite pod stab retract SPM valve on port 11 in the opposite pod.

INTERNAL POD
INTERNAL POD
INTERNAL POD
INTERNAL POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB EXTEND
STAB EXTEND
STAB EXTEND
STAB EXTEND
LEGEND
PILOT PRESSURE
WORKING PRESSURE
VENTING PRESSURE
ENERGIZED SOLENOID
POD STAB RETRACT
POD STAB EXTEND

INTERNAL POD
INTERNAL POD
STAB EXTEND
POD STAB RETRACT
POD STAB EXTEND
POD STAB
POD STAB
POD STAB EXTEND
POD STAB RETRACT
INTERNAL POD
STAB EXTEND
INTERNAL POD
POD STAB EXTEND
POD STAB RETRACT

STAB RETRACT
STAB RETRACT
TO OPPOSITE
TO OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
TO OPPOSITE
TO OPPOSITE
Figure 2-29 Internal Pod Stab Extend

CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Opposite Pod Extend

Refer to Figure 2-30. In the initiating pod, this command energizes the opposite pod
stab extend shear seal valve solenoid. Pilot fluid from this valve energizes an SPM
valve, applies to an identical stab extend and locking circuit in the other pod.
Working fluid from stab port 09 in the initiating pod enters the opposite pod through
stab port 52. From this port, the fluid passes through shuttle valve SV6 to the extend
port on the opposite pod stab. The check valve in the internal pod stab locks the
opposite pod stab in the extended position.
The retract circuit for the opposite pod stab vents through shuttle valve SV5 and the
stab retract valve in the opposite pod. The opposite pod stab also remains extended
until retracted by an OPPOSITE POD STAB RETRACT command from the surface.

INTERNAL POD
INTERNAL POD
INTERNAL POD
INTERNAL POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB EXTEND
STAB EXTEND
STAB EXTEND
STAB EXTEND
LEGEND
PILOT PRESSURE
WORKING PRESSURE
VENTING PRESSURE
ENERGIZED SOLENOID
POD STAB RETRACT
POD STAB EXTEND

INTERNAL POD
INTERNAL POD
STAB EXTEND
POD STAB RETRACT
POD STAB EXTEND
POD STAB
POD STAB
POD STAB EXTEND
POD STAB RETRACT
INTERNAL POD
STAB EXTEND
INTERNAL POD
POD STAB EXTEND
POD STAB RETRACT

STAB RETRACT
STAB RETRACT
TO OPPOSITE
TO OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
TO OPPOSITE
TO OPPOSITE
Figure 2-30 Opposite Pod Stab Extend

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Internal Pod Stab Retract

Refer to Figure 2-31. In response to this command, pilot fluid from the Initiating Pod
Stab Retract shear seal valve opens two SPM valves and applies to shuttle valve SV3.
The Internal Pod Stab Retract SPM valve passes fluid via shuttle valve SV5 to the
Retract port on the pod stab, and the second valve opens a vent path for fluid from the
Extend port on the stab. This path circumvents the locking function of the check valve
in the Internal Pod Stab Extend circuit. Fluid passes from shuttle valve SV3 to perform
identical functions in the opposite pod.

INTERNAL POD
INTERNAL POD
INTERNAL POD
INTERNAL POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB EXTEND
STAB EXTEND
STAB EXTEND
STAB EXTEND
LEGEND
PILOT PRESSURE
WORKING PRESSURE
VENTING PRESSURE
ENERGIZED SOLENOID
POD STAB RETRACT
POD STAB EXTEND

INTERNAL POD
INTERNAL POD
STAB EXTEND
POD STAB RETRACT
POD STAB EXTEND
POD STAB
POD STAB
POD STAB EXTEND
POD STAB RETRACT
INTERNAL POD
STAB EXTEND
INTERNAL POD
POD STAB EXTEND
POD STAB RETRACT

STAB RETRACT
STAB RETRACT
TO OPPOSITE
TO OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
TO OPPOSITE
TO OPPOSITE
Figure 2-31 Internal Pod Stab Retract

CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Opposite Pod Stab Retract

Refer to Figure 2-32. In the initiating pod, this command opens the Internal Pod
Retract shear seal valve, and pilot fluid applies to the Opposite Pod Stab Retract SPM
valve and shuttle valves SV2 and SV3. The Opposite Pod Stab Retract valve passes
fluid to the Retract port on the opposite pod stab, and fluid from shuttle valve 3 opens
two SPM valves. One of these valves opens a vent path for fluid from the opposite pod
stab, the other opens a vent path from the shuttle valve SV6 in the internal pod stab.

INTERNAL POD
INTERNAL POD
INTERNAL POD
INTERNAL POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
OPPOSITE POD
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB RETRACT
STAB EXTEND
STAB EXTEND
STAB EXTEND
STAB EXTEND
LEGEND
PILOT PRESSURE
WORKING PRESSURE
VENTING PRESSURE
ENERGIZED SOLENOID
POD STAB RETRACT
POD STAB EXTEND

INTERNAL POD
INTERNAL POD
STAB EXTEND
POD STAB RETRACT
POD STAB EXTEND
POD STAB
POD STAB
POD STAB EXTEND
POD STAB RETRACT
INTERNAL POD
STAB EXTEND
INTERNAL POD
POD STAB EXTEND
POD STAB RETRACT

STAB RETRACT
STAB RETRACT
TO OPPOSITE
TO OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
FROM OPPOSITE
TO OPPOSITE
TO OPPOSITE
Figure 2-32 Opposite Pod Stab Retract
ROV All Stabs Retract Function

The internal MUX pod stabs in both pods can be retracted by the ROV All Stabs Retract
function. Fluid from the ROV pressurizes this circuit, which is connected to the All Stab
Retract function. For the MUX pod stabs, this ROV circuit is connected to the TO-FROM
circuit in Figure 2-31, though, for clarity purposes, it is not illustrated.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Auto Shear
Auto Shear is a safety feature that has been included to secure the wellbore during an
emergency. When activated by a sudden loss of hydraulic and electrical power in the subsea
control pods, the Auto Shear feature immediately and automatically closes the shear rams
and secures the wellhead connector locking mechanism on the stack.
The Auto Shear feature utilizes 3,000 psi fluid from stack-mounted accumulators and two
stack-mounted valves - Auto Shear Arm and Hydraulic Auto Shear. These valves control a
flow path between the accumulators and the CLOSE ports on the shear rams. The fluid
pressure resulting from Auto Shear activation also applies to the stack wellhead connector
lock.
Two circuit configurations, Dis-Armed and Armed, can be established from the operator
control panels at the surface. These configurations are shown in Figure 2-33. Hydraulic pilot
pressures applied from solenoid valves in the control pod establish the Dis-Armed and Armed
configurations. The Armed configuration is the normal operational status.
Activation
The armed Auto Shear feature activates automatically when hydraulic pilot pressure is
removed from the spring actuated Hydraulic Auto Shear valve. Such an event occurs
when both control pods experience a loss of electrical power or hydraulic pressure
simultaneously.
Catastrophic hydraulic pressure losses would occur during unplanned LMRP
disconnects or pod stab retractions.
Configurations
Solenoid valves in the E/H section of the control pod are used to establish the Arm and
DisArmed configurations. The status of these valves is controlled by system operators
from the surface panels.
Disarmed
As shown in Figure 2-33, the Disarmed configuration is established by
simultaneously energizing the DisArm and Control Reset solenoid valves and de-
energizing the Arm valve. This closes the pod Auto Shear Control valve and
opens the Auto Shear Arm valve on the stack. Pilot pressure vents from the
Hydraulic Auto Shear SPM valve, and the valve assumes its normally open
status. The closed Auto Shear Arm valve interrupts the flow path between the
shear ram accumulators and the wellhead connector secondary lock port and the
close ports on the shear rams.
Armed
Figure 2-33 also shows the Auto Shear feature in the Armed state. In the EH
section, the Arm solenoid valve is energized and the DisArm and Control Reset
Valves are de-energized. Pilot pressure from the pod Arm valve opens the stack
mounted Auto Shear Arm Valve. PIlot pressure from the pod Arm valve also
opens the pod Auto Shear Control Valve, allowing working fluid pressure from
the pod to close the Hydraulic Auto Shear Valve.

CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Isolator Valves Control Control

Isolator Valves
Open DisArm Reset Arm DisArm Reset Arm
Open
5,000 PSI 5,000 PSI

From Rigid From Rigid
Conduit Conduit
Manifold Manifold
3,000 PSI 3,000 PSI

Pilot Fluid Pilot Fluid
Autoshear
Pod 3,000 PSI Control Valve
Working Fluid
Pod 3,000 PSI
Autoshear
Working Fluid
Control Valve Control Control
Pod Pod
Shear Ram Stack Shear Ram Stack
Close Supply Hydraulic Close Supply Hydraulic
Autoshear Autoshear
Valve Valve
Regulator Autoshear Regulator

3,000 PSI Arm Valve 3,000 PSI
Autoshear
Relief Valve Relief Valve Arm Valve
5,500 PSI 5,500 PSI
Relief Valve To Shear Ram Relief Valve To Shear Ram

Accumulator Accumulator
5,500 PSI Close Port 5,500 PSI Close Port
Isolator Valves Isolator Valves
Disarmed Armed
Figure 2-33 Auto Shear Circuit
Activation
Once the Auto Shear feature is armed, the loss of pilot pressure from the
Hydraulic Auto Shear valve will allow that valve to assume its normally open
status. This permits hydraulic fluid to flow from the stack accumulators to the
shear ram and wellhead connector lock. The loss of hydraulic pressure can be
due to either an interruption on the hydraulic fluid supply to the pod (i.e.,
inadvertent pod stab retraction, etc.) or electrical power to the control pod (all
solenoid valves resume their normal states).
Stack Accumulators
The shear ram accumulators receive hydraulic fluid at 5,000 psi from the
surface. This fluid is admitted into the accumulators by dual SPM isolator valves
that are opened and closed by solenoid valves in the control pod. The fluid
pressure at the accumulator output is reduced to 3,000 psi by a regulator
located upstream from the Auto Shear Arm valve.

NOBL-NA-AHC2008A
CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Choke and Kill Test Valve
Figure 2-34 Choke and Kill Test Valve Circuits
Figure 2-34 illustrates the Choke and Kill Test Valve circuits. The green lines identify the pilot
pressure for the standby pod while the purple lines identify the pilot pressure for the active
pod. When the CLOSE button for the Choke and Kill Test Valves icon is pressed at the
surface, a signal is sent subsea to fire the corresponding solenoids (in this case, solenoid 12)
in both the active and the standby pod. The shear seal valves open and allow pilot fluid to
flow to the gate of the appropriate SPM valves.
The Pod Select circuit, previously discussed, sends pod supply pressure to the active pod’s
SPM valves. The pilot fluid opens the SPM valve and sends operating fluid through a shuttle
valve to the close sides of the Kill test valve and Choke test valve.
When the OPEN button for the Choke and Kill Test Valves icon is pressed at the surface, a
signal is sent subsea to fire the corresponding solenoid (solenoid 13) in both pods. Pilot fluid
is sent to the gate of the SPM valves in both pods. The active pod’s SPM valve opens and
allows operating fluid to flow to the open sides of the Kill test valve and the Choke test valve.

CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
LMRP Disconnect
Figure 2-35 shows the two configurations of the mechanism that monitors the connection
between the LMRP and the stack. The mechanism comprises two assemblies: the LMRP
Disconnect Actuator and a Shear Seal Valve.
In assembly AC128, the bottom end of the lower trip rod extends through an aperture in the
LMRP; the top end contacts the actuator in the side bar. The actuator is in contact with the
rod in valve assembly AC223.
Depending on its position, the valve can open or close a fluid flow path leading to the LMRP
Disconnect Pressure Transducer and the pressure switch for LMRP Disconnect Valve
Indication.
Operation
Coil springs expand the trip rods in the LMRP disconnect actuator and the rod in the
shear seal valve. This opens a fluid flow path in the valve.
As the LMRP connects with the stack, the lower trip rod contacts the upper surface of
the stack. As the LMRP settles, the lower trip rod is forced upward against the actuator.
The upward movement of the actuator forces the rod in valve AC223 upward, which
closes the valve.
When the LMRP Disconnect Arm shear seal valve in the E/H section of the control pod
is activated, fluid at 3,000 PSI is applied to closed valve AC223.
Should the LMRP separate from the stack, spring pressure will extend the rods in
the valve and disconnect assembly. This will open the shear seal valve and
produce a pressure signal for transmission to the surface panels. As a result, a
pressure switch at the surface will activate to signal the riser recoil system
(furnished by others) that a separation has occurred.

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CHAPTER 2
Subsea Control Pod
Hydraulic Circuits
Expandable
O-Ring Interrupted
Flow Path
Shear Seal
Cage
Retracted
Figure 2-35 LMRP Disconnect Actuator

CHAPTER 2
Subsea Control Pod
Hydraulic Circuits

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Chapter 3
Description
Proper maintenance of the shear seal valve, solenoid, regulator, and SPM valve extends the life of
these components, and ensures optimal operation of the subsea control pod. General maintenance
consists of removing the component part from the pod, disassembling it (in most cases), replacing
worn or damaged parts, assembling the component, and installing it on the subsea control pod. In
some instances, the component will undergo one or more tests to verify it is suitable for
operations.
Objectives
Upon completion of this chapter, you should be able to:
• Remove, disassemble, maintain, assemble, install, and test the shear seal valve.
• Remove, maintain, install, and test the solenoid.
• Replace lost dielectric fluid in the solenoid.
• Remove, disassemble, maintain, assemble, install, and test the regulator.
• Remove, disassemble, maintain, assemble, install, and test the sub plate mounted (SPM)
valve.
• Properly fill the solenoid housing with dielectric fluid.

CHAPTER 3
Shear Seal Valves
Shear Seal Valves

Maintenance
The following procedures are recommended to extend the working life and maintain the
reliability of the solenoid/shear seal valves.
After a Subsea Trip

1. Function each shear seal valve a few times to ensure that most of the seawater
is purged from the solenoid/armature cavity. This functioning will replace the
seawater, which ingresses into this cavity while subsea, with control fluid.
Control fluid, when properly mixed, has corrosion inhibitors.
During Troubleshooting or Routine Maintenance

If a shear seal valve is removed from the pod as part of a troubleshooting or routine
maintenance procedure, the following steps should be performed:
1. Remove the shear seal valve from the solenoid/control pod housing.
2. Inspect the armature and the solenoid bore for corrosion. If there is little or no
corrosion, clean the armature and the solenoid bore with a cloth rag (or similar)
and dry the parts.
NOTE
The solenoid bore and the armature are manufactured from
nearly pure iron and are very susceptible to corrosion, thus
both are specially coated.
Figure 3-1 Moderate (Left) and Minor (Right) Corrosion

3. If there is some corrosion, but it is not extensive, it may be cleaned with emery
cloth. Use care not to remove any remaining coating. Clean the armature and
the solenoid bore and dry the parts.
4. If there is extensive corrosion, replace the parts. If it is not possible to replace
the parts that have corrosion, then clean the parts with emery cloth to remove
the corrosion. Use care so as not to remove any remaining coating. Clean the
armature and the solenoid.

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Shear Seal Valves
NOTE
Armatures can easily be replaced on the rig. Solenoids involve
more work and time, but a few solenoids can easily be
replaced on the rig. Solenoids can not be rebuilt on the rig,
due to specialized assembly processes. Solenoids must be
sent to Hydril for refurbishment or rebuild.
5. It is recommended that the indicator pistons be installed on all solenoids. The

indicator piston provides a quick and easy means of verifying the dielectric fluid
level in the solenoid. If the indicator is in the proper position, the solenoid
envelope is sound.
6. Coat the solenoid bore and the solenoid armature (which is attached to the
shear seal valve) with LPS 3 Heavy Duty Rust Inhibitor or similar product. Apply
liberal amounts to any parts that had corrosion.
7. Reassemble the shear seal valve assembly into the solenoid/control pod bore
and dry the parts.
Removal
WARNING
Do not attempt to service a shear seal valve while the
system is pressurized. Hydraulic fluid ejected from a
system component at operating pressure can cause
serious injury to personnel and damage to equipment.
1. Depressurize the MUX control pod.

2. Mark the shear seal valve with its position number on the pod.
Figure 3-2 Labelling Shear Seal Valves

3. Using a 3/16” Allen wrench, remove both screws and washers that secure the shear seal
valve in the pocket of the EH section.

CHAPTER 3
Shear Seal Valves
Figure 3-3 Removing the Cap Screws

4. Remove the shear seal valve from the EH section.
Figure 3-4 Removing the Shear Seal Valve
Disassembly
1. Remove the two seal subs from the shear seal valve.
2. Remove the two O-rings from each seal sub.
3. Support the plunger on a padded wooden block or other firm surface that is the same
height as the shear seal valve when it is laid on its side. Be sure to keep the plunger
and the valve level during cotter pin removal.
CAUTION
The solenoid armature position is critical to the solenoid shear
seal valve assembly. If the position is off by as little as .015 inch,
the solenoid may not function. Excessive pressure on the
armature will bend the spool rod and effect armature position.
4. Straighten the armature cotter pin. Do not apply excessive pressure.

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Shear Seal Valves
Figure 3-5 Straightening the Cotter Pin

5. Remove the cotter pin from the armature.
Figure 3-6 Removing the Cotter Pin

6. Unscrew the armature from the spool rod using a counter-clockwise motion.
Figure 3-7 Removing the Armature

7. Using a 1/4”
Allen wrench, remove the four, 1/4”-20UNC x 21/4” cap screws holding the
outlet plate to the assembly.
8. Remove the four 1/4” lock washers.
9. Set the screws and lock washers aside.
Figure 3-8 Removing the Cap Screws

CHAPTER 3
Shear Seal Valves
10. Remove the inlet plate from the valve body.

11. Remove the O-ring from the inlet plate.
12. Remove the outlet plate from the valve body.
13. Remove the O-ring from the outlet plate.
Figure 3-9 Outlet and Inlet Plates Removed

14. Remove the inlet and outlet shear seal plates.
Figure 3-10 Inlet and Outlet Shear Seal Plates

15. Remove the O-rings from the inlet and outlet shear seal plates.

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Shear Seal Valves
16. Remove the shear seal cage and seals from the seal carrier spool.
Figure 3-11 Removing the Shear Seal Cage

17. Remove one of the shear seals from the cage.
18. Remove the spring from the cage.
19. Remove the other shear seal from the cage.
20. Remove the O-rings from the inside diameter of the cage.
21. Using an adjustable wrench, remove the seal bushing.
Figure 3-12 Removing the Seal Bushing

22. Remove the filter element from the seal bushing.
23. Remove the O-ring from the seal bushing.
24. Remove the rod seal from the seal bushing.
25. Remove the shear seal rod spool and carrier assembly from the body.
Figure 3-13 Removing the Rod Spool and Carrier Assembly

26. Remove the dowel pin from the seal carrier spool.
27. Separate the rod spool from the seal carrier.
28. Using an adjustable wrench, remove the check valve from the body.

CHAPTER 3
Shear Seal Valves
29. Remove the O-rings from the check valve.

30. Remove the O-rings from the shear seal valve body.
31. Inspect all seal surfaces for damage.
Figure 3-14 Shear Seal Valve Components
Assembly
This assembly procedure applies to both new builds and to re-builds where the valve is re-
assembled with a new seal kit and/or a new repair kit. The repair kit contains new shear
seals, inlet and outlet seal plates, seal cage spring, check valve, filter element, dowel pin,
spool spring, and a seal kit. The seal kit contains all the shear seal valve assembly O-rings, a
rod seal, and a cotter pin.
There are two valve types: The surface shear seal valve has only two main differences from
the subsea shear valve: the vent assembly and check valve is a straight tube connection,
and the function port has a tube connection rather than a seal sub.
1. Lubricate all seals with Vaseline.
2. Lubricate all threads prior to assembly, including the collar contact area.
3. Prior to assembly, ensure that all parts are on hand and are in good condition:
• Inspect all parts for cleanliness. Clean and dry if necessary.
• Inspect all O-rings for damage and replace if necessary. If the valve is to be
rebuilt, always replace elastomer seals; these are contained in the seal kit.
• Ensure that all valve interior and mating surfaces are free from damage, dirt,
metal shavings, burrs, or any other foreign material before assembly.
4. If a shear seal valve is to be re-assembled with a new seal kit, perform the following
steps:
• Inspect the shear seals for any indications of wear or surface imperfections. The
shear seals must NOT have anything unusual on the shear seal surface. If there
are any indications of wear, replace the shear seal. Do not attempt to ‘polish’ or
‘buff out’ any imperfections on the shear seal surfaces; such a procedure would
not meet the flatness requirements to operate properly.
• Clean the shear seal plates with non-residual cleaner. Inspect the shear seal
surface for scoring, galling, or distortion. The shear seal surface is very flat, and
should have a mirror-like finish. If there are any indications of wear, replace the
shear seal plates. Do not attempt to ‘polish’ or ‘buff out’ any imperfections on the
shear seal surface; such a procedure would not meet the flatness requirement to
operate properly.

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Shear Seal Valves
NOTE
If the shear seals indicate any wear, replace the shear seals
AND the shear plates. If the shear seal plate indicates any
wear, replace the shear seals AND the shear seal plates. (If
one of the parts is worn, the other is also worn). Replacing
only the shear seals or only the shear seal plate will lead to
premature wear and reduced service life. The repair kit
includes both the shear seals and the shear seal plates.
5. Install O-rings onto the check valve assembly.

6. Install the check valve into the valve body until it is snug. It is not necessary to over
tighten this part.
Figure 3-15 Installing the Check Valve

7. Attach the spool rod to the spool seal carrier using the dowel pin.
Figure 3-16 Assembling the Spool Seal Carrier

8. Insert the spool carrier into the valve body until it is stopped by the check valve.
Figure 3-17 Installing the Spool Seal Carrier

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Shear Seal Valves
9. Install the filter element onto the seal bushing.
Figure 3-18 Installing the Filter Element

10. Install O-ring onto the seal bushing.
11. Install the rod wiper seal into the seal bushing.
12. Install the spring into the seal bushing.
13. Install the seal bushing with spring into the valve body by threading the rod spool
through the seal bushing and spring.
Figure 3-19 Installing the Spool Seal Carrier

14. Tighten to 40 ft-lbs to ensure that the seal bushing is bottomed into the seal body.
NOTE
The filter is designed to be retained once the seal bushing is
tightened. If the filter is not secure, verify that the seal bushing
is properly tightened. If the filter is still loose, replace the filter.
15. Install two O-rings into the seal cage.
CAUTION
When assembling the seal cage, do not push the shear seals
through the cage, as they will damage the O-rings inside the
cage.

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Shear Seal Valves
16. Taking care not to damage the seals, install one shear seal, the spring, and the other
shear seal into the center of the seal cage.
Figure 3-20 Seal Cage Assembly

17. Install this assembly into the spool seal carrier through the opening for the inlet seal
plate.
18. Install O-ring into the valve body at the seal plate outlet.
19. Install the outlet seal plate and the orientation pin into the valve body.
Figure 3-21 Seal Plate Installation

20. Install O-ring into the valve body at the seal plate inlet.
21. Install the inlet seal plate into the valve body.
Figure 3-22 Seal Plate Installation

22. Install face seal O-ring into the outlet plate.
23. Install face seal O-ring into the inlet plate.
24. Reposition the valve body assembly and carefully align the inlet plate and the outlet
plate with the body.

CHAPTER 3
Shear Seal Valves
25. Verify that the inlet plate and outlet plate port orientations are correct.
Figure 3-23 Inlet (Left) and Outlet (Right) Plates

26. Apply Bostik Regular Grade High Nickel NEVER-SEEZ thread lubricant to the four, 1/4”-
20UNC x 21/4” cap screws.
27. Install the four lock washers and four cap screws.
Figure 3-24 Installing the Cap Screws

28. Using a 1/4” Allen wrench, install the four, 1/4”-20UNC x 21/4” cap screws
29. Using a torque wrench and a 1/4” Allen wrench socket, torque the cap screws to
40 in-lbs.
30. Thread the solenoid armature onto the rod spool.
Figure 3-25 Installing the Armature
NOTE
The MUX system installation tool kit (P/N 3135439) includes
an armature gauge tool (P/N 3136192).

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Shear Seal Valves
31. Use the armature gauge tool and screw on the armature so that the gauge is
‘touching’, with no play. Do NOT over tighten.
Figure 3-26 Armature Gauge Tool

32. Remove the gauge tool. There should be no movement between the armature and the
valve when the gauge tool was removed. If there was, or if not sure, re-gap the
armature using the gauge tool.
33. Install cotter pin. If the cotter pin does not line up with the hole in the valve stem,
rotate the armature CLOCKWISE (toward the valve) until the cotter pin can be
inserted. This will take less than ¼ of one turn. If the armature is rotated more than ¼
turn, re-gap the armature using the gauge tool.
Figure 3-27 Installing the Cotter Pin

34. Center the cotter pin in the armature. It is only necessary to bend one ear of the cotter
pin, bending both just makes it more difficult to remove.
35. Verify the cotter pin does not extend past the armature; if it does it will remove the
coating from the solenoid bore and cause corrosion and valve sticking.
36. Install two O-rings onto each seal sub. Install the seal subs into their ports.
Figure 3-28 Installing the Seal Subs
NOTE
The subsea valve has two seal subs while the surface valve
has one seal sub.
37. Install O-ring onto the valve body.

CHAPTER 3
Shear Seal Valves
38. Perform a quick check that the valve is assembled properly by pulling on the armature.
Actuation force is typically less than 35 lbs.
39. Perform the acceptance tests (in later sections of this document):
• All new build shear seal valves shall be hydrostatically proof and function tested.
• All rebuilt shear seal valves shall be function tested.
Installation
NOTE
For subsea control systems, ensure that the manifolds are
centered on the solenoid housing openings. If the manifolds
are not correctly centered, it may not be possible to install the
armature or the armature may not function properly. Use the
following procedures to ensure that the manifolds are
centered. Manifold alignment procedures do not apply to
surface control pods.
1. If the manifold and solenoids have been removed from the solenoid housing, use an
alignment tool provided by Hydril. Place one alignment tool at one end of the manifold
and another at the other end, and mount the manifold to the solenoid housing. Go to
step 4.
2. If the manifold and solenoids are still mounted on the solenoid housing, perform the
following:
• Remove the shear seal valves.
• Ensure that the manifold is ‘loose’. If re-installing the manifold, only use 4 cap
screws, and tighten hand tight (only 2 cap screws are needed for a small
manifold). Each manifold has 8 to 40 cap screws to mount the manifold to the
solenoid housing. If adjusting a manifold, loosen all of the cap crews, and remove
the corner cap screws.
• Using two alignment tools, place one alignment tool at one end of the manifold and
another at the other end, and tighten some cap screws.
3. If it is absolutely necessary to align the manifolds without an alignment tool:
• Remove the shear seal valves.
• Ensure that the manifold is ‘loose’. If re-installing the manifold, only use 4 cap
screws, and tighten hand tight (only 2 cap screws are needed for a small
manifold). Each manifold has 8 to 40 cap screws to mount the manifold to the
solenoid housing. If adjusting a manifold, loosen all of the cap crews, and remove
the corner cap screws.
• Visually line up the bolt holes in the manifold with the tapped holes in the solenoid
housing. Perform this alignment for all corner bolt holes as a minimum. For a large
manifold, also remove some of the cap screws from the center of the manifold to
ensure proper alignment.
• Once the manifold is aligned, tighten the cap screws to around 100 in-lbs. Verify
that alignment is still correct and install the remaining cap screws. Torque all cap
screws to 150-160 in-lbs, starting from the center of the manifold and moving out.
4. To install the solenoid into the solenoid housing (or surface control pod): ensure that
the solenoid is clean, with no grease or dirt.
5. Install two O-rings.

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Shear Seal Valves
NOTE
Do NOT use Vaseline to lubricate the inside O-ring. Use DC-
200 or a silicone based lubricant compatible with DC-200.
6. Lubricate the cap screws with Molylube TS70 or equivalent.

7. Position the solenoid inside the solenoid housing and install the cap screws with lock
washers into the solenoid.
Figure 3-29 Installing the Solenoid

8. Tighten the cap screws to 40 in-lbs.
9. Coat the solenoid bore and the solenoid armature (which is attached to the shear seal
valve) with LPS 3 Heavy Duty Rust Inhibitor or similar product.
10. Lubricate the cap screws with Moly-lube TS70 or equivalent.
11. Install the shear seal valve into the solenoid using the cap screws and lock washers.
The armature should fit snug, but should slide freely and not bind.
Figure 3-30 Installing the Shear Seal Valve

12. If the armature does not fit correctly, inspect the parts and verify the manifold is
correctly aligned. Correct any deficiencies. Note that the shear seal valve cap screws
pass through the manifold and thread into the solenoid.
13. Tighten these cap screws evenly (to prevent binding) to 140 in-lbs.

CHAPTER 3
Solenoid Fluid Replacement

1. Visually inspect the indicator piston to determine the solenoid fluid level. If 1/2” of the
piston is not visible, the solenoid requires fluid.
Figure 3-31 Fluid Level Indicator not Visible

2. If the solenoid is currently installed on the pod, remove the solenoid from the solenoid
housing using the appropriate removal procedure.
NOTE
Complete assembly of the solenoid requires a vacuum fill
procedure, which is not performed in the field. This procedure
assumes the fluid level is low and disassembly is not required.
3. Stand the solenoid up on a flat surface with the pressure balance cap facing up.
4. Use a screwdriver to remove the two pan head screws from the pressure balance cap.
5. Remove the pressure balance cap from the pressure balance holder.
6. Remove the indicator piston and the spring from the pressure balance holder.
7. Locate the self-sealing screw on the side of the pressure balanced solenoid base.
Remove the screw using a flat head screwdriver.
8. Lay the solenoid on its side with the fill port facing up.
9. Fill a syringe with DC-200.
10. Screw the syringe onto the solenoid oil fill port. Ensure the connection is sealed to
prevent the fluid from leaking as the syringe is compressed.
11. Using your finger, press on the top of the diaphragm seal to compress it.

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CHAPTER 3
Figure 3-32 Manually Compressing the Diaphragm

12. Pull gently on the syringe plunger to apply a vacuum to the solenoid. As fluid is pulled
from the solenoid, watch for air bubbles coming into the syringe.
13. Press gently on the syringe plunger to inject fluid into the syringe.
Figure 3-33 Adding Fluid to the Solenoid

14. Repeat steps 11 - 13 until no more air bubbles appear.
15. Unscrew the syringe from the solenoid.
16. Check the O-ring on the self sealing screw. Replace the O-ring if necessary.
17. Using a flat head screwdriver, install the self sealing screw on the pressure balanced
solenoid base. Hand tighten the screw.
18. Install the indicator piston in the pressure balance holder.
19. Install the compression spring in the pressure balance holder.
20. Install the pressure balance cap on the solenoid.
21. Install the two screws on the pressure balance cap. Hand tighten the screws.
22. Verify that 1/2” of the indicator piston is visible. If the solenoid requires additional
fluid, repeat steps 4 - 21 until the indicator piston is in the appropriate position.
Figure 3-34 Correct Fluid Level Indicator Position

CHAPTER 3
EH Housing Component Testing

Solenoid
The solenoid armature position is critical to the proper functioning of the solenoid shear seal
valve assembly. If the position is off by as little as .015 inch, the solenoid may not function
as intended. The assembly procedures used in this document are sufficient for the majority
of the solenoid shear seal valve assemblies to function within the desired parameters.
However, due to minute differences in solenoid coil properties and armatures, the only
method to ensure that all solenoid armatures are optimally positioned is to perform the
electrical signature test. This test measures the amount of voltage required to pull-in the
armature (causing the shear seal valve to open) and the amount of current present when the
armature drops out (shear seal valve closes). The requirements are that the pull-in voltage
shall be 38.5 Volts or less, the drop out current shall be greater than 30 mA and should be
less than 50 mA. Each solenoid shear seal valve is tested; if the electrical specifications are
met, no adjustment is required. If the pull-in voltage is higher than the specification, the
armature needs to be repositioned. The armature is repositioned by turning the armature
counter clockwise ¼ turn (toward the solenoid, away from the valve), and re-tested.
Similarly, if the current drop out is too low, the armature is re-positioned closer to the valve,
away from the solenoid, by turning the armature clockwise. The procedure is repeated if
necessary, until the solenoid shear seal valve assembly meets the electrical requirements. If
the drop out current is above 50 mA, the armature is repositioned counter clockwise ¼ turn
(toward the solenoid, away from the valve) to reduce power consumption. In the few cases
where this final adjustment causes the drop out current to fall below 30 mA, the armature is
returned to its former position and the drop out current just over 50 mA is deemed
acceptable. In rare cases where the pull in voltage is too high AND the drop out current is too
low at one position, the armature should be changed. Simply changing the armature has
alleviated the problem in the rare case where it has occurred. In all cases the cotter pin is
reinstalled. The change is recorded (e.g. solenoid XX armature position is gauge + ¼
turn counter clockwise) with the results of the test (in document X-1009370).
Preparation
1. Collect the necessary test equipment.
2. Record the shear seal valve assembly part number and serial number.
3. Attach the calibration certificates for the pressure gauges/transducers/chart recorder
to this test procedure (copies are acceptable). Record the range, serial number,
calibration number, and calibration date of each device in the TDDR.
4. On shear seal valves that are solenoid operated, screw armature onto threaded shaft
and set with feeler gauge to a gap approximately 0.050”. Armature should be snug
against the gauge. Then lock into place with cotter key. This may require that the
armature screwed in a little bit to align the key and the hole in the shaft.
5. If applicable, ensure that the solenoid assemblies and the shear seal valve assemblies
are properly assembled together with mounting screws part number 1900324-06024
and lock washers 1900500-08.
Solenoid/Shear Seal Valve Test

1. Assemble the solenoid, the shear seal valve, and the test equipment. It is acceptable
to test more than one solenoid/shear seal valve assembly at a time.
2. Fill the test circuit with test fluid. The test fluid shall be Hydril’s approved BOP control
fluid unless stated otherwise by the customer. Cycle the valve(s) to remove any
trapped air.

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CHAPTER 3
CAUTION
Place personnel protection devices around the assembly during
all high pressure tests. Failure to place protective barriers
around the test equipment and the tested assembly could result
in serious injury should the equipment fail.
Hydrostatic Test
NOTE
The hydrostatic test of the shear seal valve is NOT required
for shear seal valves that are to be installed on Hydril MUX
pods at Hydril. The MUX pod shear seal valves are
hydrostatically tested when the MUX pod is hydrostatically
tested; if this is the case, this portion of the test procedure
may be skipped. However, any shear seal valve assembly that
is to be shipped separately (loose, such as a replacement
unit) MUST be hydrostatically tested. The hydrostatic test is
included in this test procedure for those valve assemblies
ONLY.
1. If leakage occurs during the hydrostatic test, the source of the leakage must be
identified. Once the source of the leakage has been found the pressure must be
reduced to zero. Fittings that leak shall be tightened and/or replaced. Other
components found to be leaking shall be repaired or replaced. The hydrostatic test
shall then be restarted from the beginning.
2. Dry all flanges, tubing, piping, and piping components.
3. Position the shear seal valve in the OPEN position.
4. The test pressure for the shear seal valve is 4,500 psi, + 200 psi / - 0 psi.
5. Start the test chart recorders and/or the data acquisition system.
6. Gradually increase the pressure to the hydrostatic test pressure. Allow the pressure to
stabilize. If necessary, it is permissible to apply additional pressure during the
stabilization process. Pressure shall be considered stabilized when there is no
noticeable change in pressure.
7. Record the pressure readings of the test transducer/gauge in the TDDR.
8. After pressure stabilization, the test pressures shall be held for five (5) minutes
without visible leakage (Hydrostatic Hold Period). The timing shall not start until the
assembly and the pressure-monitoring gauge have been thoroughly dried, the
pressure stabilized and the test pressure source has been isolated for the equipment
under test. The pressure shall not fall below the minimum test pressure and there shall
be no noticeable change observed on the pressure measuring device during the hold
period.
9. At the end of the test period, record the pressure reading of the transducer/gauge and
the actual length of the hold period in the TDDR.
10. Bleed the test pressure to 0 psig.
11. Stop the chart recorders or data acquisition devices. On the charts, identify the
test(s), the assembly serial number, the test date, and sign the chart(s). The test

CHAPTER 3
technician, Hydril. QA representative, and the customer representative, if required,

shall also sign and date the chart(s). The charts are to be attached to this TDDR.
12. Ensure that all pressures have been bled to 0 psi.
Function Tests
All shear seal valves shall be function tested.
1. Assemble the solenoid, manual operator or hydraulic supply, the shear seal valve, and
the test equipment. This test will not require a chart recorder.
2. Cycle the solenoid to open and close the shear seal valve.
3. Apply 3,000 to 3,200 supply pressure to the inlet of the shear seal valve.
4. Cycle the solenoid, manual operator or hydraulic supply to open and close the shear
seal valve several times. Verify that the shear seal valve functions properly and does
not leak.
5. Reduce all pressures to 0 psi.
6. Remove the solenoid, manual operator or hydraulic supply and shear seal valve from
the test assembly.
7. Enter results into the TDDR.
Post Test Preparations

1. Remove all test equipment.
2. Remove as much test fluid from the assembly as possible.
3. Re-install all socket weld flange connections, as applicable.
4. Where applicable, install thread protectors or flange covers.

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CHAPTER 3
Solenoid Calibration
The Hydril Solenoid Assembly Test Set is used to verify
proper electro/mechanical operation of the Hydril EH
section assemblies. The test set is useful in
determining the operational profile of each solenoid.
This unit also checks for proper operation of the
solenoid and valve pair by simulating the output of the
solenoid driver boards. Testing is typically done by
energizing the solenoid at the worst case pull-in
voltage and the worst case drop-out current. Use of
this tool is not limited to profile testing. The test unit's
top panel gives a convenient break-out point for
accessing all solenoids for resistance checks and meg
testing. Additionally, there is a Diode Check circuit
which verifies the integrity of the internal diodes on EH
function solenoids.
Setup
1. Remove all hydraulic supply pressure from
the EH section and bleed off any residual
pressure on the shear seal valves.
2. Disable 720 volt AC power to the SEM.
Figure 3-35 Hydril Solenoid Assembly Test
3. Verify that the A/B SEM power switches Set
are in the "ON" position on the CCU. This
ensures that there is no AC voltage on the
A/B relay board.
NOTE
For additional safety, removing the VCC29 (Mux cable)
connector from the base of the 1 atmosphere housing
guarantees there is no input voltage to the electronics section.
4. Remove the one atmosphere dome from the electronics.

5. Remove the Hypertronics connector from the solenoid bay in test (Low side/High side)
and connect to the Hypertronics connector on the test set (see Figure 3-36).
6. Connect test set DC power supply to the VOLTAGE IN FROM POWER SUPPLY jacks
using cable 1, with proper polarity (see Figure 3-36).

CHAPTER 3
Figure 3-36
Hypertronics Connector on the Test Set
NOTE
If you are using an external current monitor, connect cable 3
from the EXTERNAL CURRENT MONITOR jacks on the test
set to the external metering.
7. Connect cable 2 to the VOLTAGE OUT TO SOLENOIDS jacks to the first solenoid in test
jacks on the back panel, with proper polarity (see Figure 3-37). Testing can begin at
this point.
Figure 3-37 Cable 2 connected on the Test Set
Testing
With voltage level controls turned fully CCW on power supply, turn on supply. Gradually turn
the coarse voltage control CW until you get to 60 VDC. The current meter should show
energizing current (approximately 500 mA). Turn voltage back down to zero. Repeat twice
before recording readings on drop-out and pull-in voltage and current. Record the readings
for pull-in and drop out for each of the system solenoids.

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NOTE
When testing EH function and shear seal valve solenoids,
refer to the cable connections diagrams for proper cable
usage and end terminations.
Solenoid Pull-In/Drop-Out Testing
NOTE
Use of a mechanics stethoscope will aid in detection of
actuation and dropout.
Figure 3-38 Monitoring Solenoids Using a Mechanic’s Stethoscope

1. With voltage increasing to the solenoid in test, record the point at which the
solenoid energizes.
2. Slowly decrease the voltage and record where the solenoid de-energizes (drop-
out).
Table 3-1 Acceptable Levels
Reading Voltage
PULL - IN 38.5 VDC or less
DROP - OUT 30 mA DC or greater
EH Function Solenoid Testing

On some control systems, there are 4 EH solenoids which are controlled directly from
an EH Controls J-Box on the surface. Typically these are solenoid numbers 1, 2, 49 &
50. These solenoids are accessed through the VCC 29 (Mux cable) connector. Checking
these solenoids requires that the Mux cable be removed from the system. Verify
proper connector pin-outs using the Hydril Controls System Manuals that come with
the equipment.
1. Connect cable 2 to the VOLTAGE OUT TO SOLENOIDS jacks to the EH function
solenoid in test jacks on the back panel, with proper polarity. Connect one end

CHAPTER 3
of cable 4 to the EH function solenoid in test jacks in the lower section of the
back panel with proper polarity (see Figure 3-39).
Figure 3-39 Solenoid Test Hookup

2. Connect the other end of cable 4 (two single female connectors) to the proper
pins on the VCC 29 connector. Testing can begin at this point (see Figure 3-40).
Figure 3-40 Solenoid Test Hookup (cont’d)

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3. Attach the other end of cable 4 (with the two single female connectors) to cable
5 (with the two single male connectors) with proper polarity. Connect the four
pin connector of cable 5 (male) to the mating 4 pin female connector from the
shear seal valve in the lower electronics section (see Figure 3-42 and Figure 3-
43).
Solenoid Diode Testing

The EH function solenoids have an integrated diode in parallel to the coil which is
connected reversed bias, and is used for solenoid current kickback protection. With the
solenoid under test wired in, switch the DIODE CHECK switch in the diode check mode
[up]. Increase the voltage to the solenoid to 30 VDC. Note the current value. Turn off
power to the solenoid. Reverse the polarity on cable 2 to the solenoid, then increase
the voltage back to 30 VDC. The current reading should indicate approximately
DOUBLE the current since now the diode is forward biased in the solenoid and the coil
is bypassed. Record any variation to this indication.

CHAPTER 3
Solenoid Fire Testing

With the solenoid under test wired in, switch the FIRE / PROFILE MODE switch to the
fire position [down]. Increase the voltage to the solenoid to 38.5 VDC. Switch the FIRE
/ PROFILE MODE switch to the Idle position [up]. Adjust the 20mA ADJUSTMENT
potentiometer to get a reading of 20 mA on the current meter. Return the FIRE /
PROFILE MODE switch to the Fire [down] position and record a pass/fail on the pick-up
operation on the form. Return the FIRE / PROFILE MODE switch to the Idle [up]
position and record a pass/fail on the drop-out operation on the form.
Solenoid Resistance Testing

The solenoid coils in the solenoid housing should be tested for proper DC resistance
With the appropriate Hypertronics connector connected into the test set, attach cable
2 from the RESISTANCE METER jacks on the test set [green jacks] to the solenoid
jacks on the back panel and read ohms directly from the Ohmmeter (see Figure 3-44).
Figure 3-44 Solenoid Resistance Testing Hookup

Record the actual resistance value on the test form. If the resistance reading is less than 129 Ohms
or greater than 139 Ohms, further investigation and troubleshooting will be required to determine
of there is a wiring problem or if the solenoid winding needs replacement.
Table 3-2
Coil Voltage Coil Resistancea
60 VDC <= 139 ohms

>= 129 ohms
48 VDC <= 77 ohms

>= 70 ohms
a. Stated values are referenced to 25°C at 1 ATM.
Normal operating values should be adjusted to
meet field conditions.
Test Record Form

Record all data on the Test Record form and include Date, Location, EH Housing SN, and
Technician name.

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Sub Plate Mounted (SPM) Valves

Three sizes of hydraulically piloted sub plate mounted (SPM) valves are installed on the LVCU
section of the MUX Control Pod: 1/2”, 1”, and 11/2”. Their individual body housings are manifold
mounted and of a low interflow cage design. These valves route the hydraulic fluid to the BOP
functions.
Troubleshooting
When a function is fired at the CCU, driller’s panel or tool pusher’s panel, and there is no
response from the system, the SPM valve is suspect as part of the hydraulic system. To
check the appropriate SPM valve, locate the faulty function on the hydraulic system
schematic, and match that function to its corresponding valve. The SPM valves are labelled
on the LVCU. Locate the correct valve and begin maintenance or repair procedures.
Disassembly
1. Depressurize hydraulic system.
2. If the valve is accessible, the valve can be rebuilt while connected to a manifold or
piping. If not accessible, remove the valve from the manifold or piping.
CAUTION
If mounting SPM in a vise, protect the body against damage.
3. Use the valve cap tool from the tool kit to unscrew and remove the piston housing.
Carefully remove housing to avoid damaging housing threads.
4. Remove spring/spool assembly from valve body. Care must be taken not to damage
the spool face seal surface.
Figure 3-45 Removing the Spring/Spool Assembly

5. Use the cage removal tool to remove the cage from the valve body.
6. Use the seat removal tool to remove the lower valve seat from valve body.
Figure 3-46 Removing the Lower Valve Seat

7. Place spring/spool assembly in the spring compression base tool.
8. Place spring compression cap tool from the tool kit on end of the spool.

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9. Place assembly in press.
Figure 3-47 Spring/Spool Assembly in Press
WARNING
Use press with extreme caution to avoid injury when
removing split collet halves as they are highly compressed.
10. Apply pressure to compress valve springs until split collet halves are accessible.
11. Carefully remove split collet halves from spring retainer.
Figure 3-48 Removing the Collets

12. SLOWLY decompress the springs
13. Remove assembly from press and disassemble.

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Figure 3-49 Disassembling the Spring/Spool Assembly

14. Hold valve stem at flats and remove lock nut.
15. Remove piston from piston housing.
Figure 3-50 Piston, Piston Housing, and Lock Nut

16. Remove elastomers and back-up rings from components.
17. Clean all parts with non-residual cleaner.
18. Inspect each component for deformation and mechanical damage. Specifically
examine the sealing surfaces on both ends of the spool, spool to cage interface and
piston rod.
Figure 3-51 SPM Valve Component Parts

19. Replace components showing excessive wear or damage. Replace all seals and back-
up rings. Inspect the upper and lower seats for surface scratches and cracking. A
minor impression from the spool is common in the seats but if cracking is evident
replace the seats. If only surface scratches are evident the seats can be rotated once
before replacement. Obtain Part numbers for each component from the BOM. Remove
minor surface damage on non-critical components with fine emery cloth.
Assembly
1. Hold valve stem at flats and install new lock nut on stem.

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2. Tighten lock nut until it bottoms out on stem shoulder. Tighten nut in accordance with
Table 1.
Table 3-1 Lock Nut Torque Values
SPM Size In-lbs N-m
½” Valve 35 4.0
1” Valve 115 13.0
1 ½” Valve 265 30.0
3. Verify spool rotates freely after nut is tightened.
Figure 3-52 Installing the Lock Nut on the Stem

4. Lubricate and install T-seal in ID groove on new upper seat.
NOTE
Use only petroleum jelly to lubricate SPM valve components.
Do not use PTFE or other sealing-type lubricants on stainless
steel components exposed to saltwater. PTFE and sealing
type lubricants cause oxygen deprivation that accelerates the
corrosive affects of saltwater.
5. Orient and install back up rings above and below T-seal.

6. Lubricate and install new O-ring in OD groove of new upper seat.
7. Install upper seat on valve stem.
Figure 3-53 Installing the Upper Seat

8. Install back up plate on valve stem.

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Figure 3-54 Installing the Backup Plate

9. Install inner spring on valve stem.
Figure 3-55 Installing the Inner Spring

10. Install outer spring on valve stem.
Figure 3-56 Installing the Outer Spring

11. Install spring retainer on valve stem.
Figure 3-57 Installing the Spring Retainer

12. Place spring/ spool assembly in spring compression base tool from tool kit.

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13. Place spring compression cap tool from the tool kit on end of the spool.
14. Place assembly in press.
Figure 3-58 Spring/Spool Assembly in Press

15. Apply pressure to compress inner and outer valve springs. Ensure spring retainer does
not hang in collet groove on valve stem as spring compresses.
Figure 3-59 Compressing the Spring

16. Install split collet halves in spring retainer. When correctly installed collets are flush (to
within 1/32”) with spring retainer.
Figure 3-60 Installed Collets

17. Lubricate and install new T-seal in ID groove on cage.

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18. Orient and install back up rings with T-seal.

19. Lubricate and install new O-ring on OD groove of cage.
20. Place installation tool in valve spool.
Figure 3-61 Installation Tool

21. Lightly lubricate valve spool.
22. Lightly lubricate installation tool. The installation tool is specified in the SPM valve
repair kit.
Figure 3-62 Lubricating the Installation Tool

23. With valve spool facing up and large diameter of cage facing down, hand press cage
onto spool.
Figure 3-63 Hand Pressing Cage onto Spool

24. Remove installation tool from valve spool.
25. Inspect bore of SPM body for damage and debris.
26. Lightly lubricate bore of SPM body.

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27. Install new lower seat.

28. Press spring/spool assembly into SPM body ensuring that cage OD O-rings pass
undamaged through supply and vent ports of body.
Figure 3-64 Hand Pressing Spring/Spool Assembly

29. Lubricate and install new T-seal in OD groove on piston.
30. Orient and install back up rings with T-seal.
31. Install piston on valve stem.
Figure 3-65 Lubricating Piston Seal Grooves

32. Screw piston housing into SPM body and tighten in accordance with Table 3-2.
Table 3-2 Piston Housing Torque
Size Working Pressure (psi) Torque (ft-lbs) Torque (N-m)
½” Valve 3,000 40 55
5,000 40 55
1” Valve 3,000 50 68
5,000 80 110

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Table 3-2 Piston Housing Torque
Size Working Pressure (psi) Torque (ft-lbs) Torque (N-m)
1 ½” Valve 3,000 100 140
5,000 40 55
Figure 3-66 Installing Piston Housing
Testing
1. Record the SPM valve assembly part number, serial number, and description in the Test
data Documentation Report (TDDR).
2. Collect the necessary test equipment based on the test pressures listed in Table 3-3.
In accordance with API, the test pressure readings shall be in the range of 25% to
75% of the full scale of the pressure gauges and chart recorders.
3. Record the range, serial number, calibration number and date of the pressure gauges /
transducers, and data acquisition device(s) and / or chart recorders, as applicable, in
the Test Data Documentation Record (TDDR).
Table 3-3 Test Pressures
Working Hydrostatic Function

Description
Pressure Rating Test Pressure Test Pressure
3,000 psi SPM Valve 3,000 psi 4,500 - 4,700 psi 3,000 - 3,150 psi
5,000 psi SPM Valve 5,000 psi 7,500 - 7,700 psi 5,000 - 5,200 psi
Actuator 3,000 psi 4,500 - 4,700 psi 1,500 - 1,550 psi
4. The hydrostatic test of the SPM valve is performed with the valve in the open position.
For normally closed SPM valves, connect a hydraulic supply source to provide actuator
pressure to keep the valve in the open position during the hydrostatic test.
5. The hydrostatic test is performed with a blind test flange or plug in the function port.
Use a test flange to connect the hydraulic supply source to the supply port for two way
valves. Connect the hydraulic supply source to the supply port and to the vent port for

CHAPTER 3
three way valves. Connections shall be made such that the pressure source can be
isolated and any of the valve ports can be vented. The data acquisition device (chart
recorder) and a test gauge shall be connected to the supply side for the hydrostatic
test.
6. Fill the assembly with test fluid. The test fluid shall be Hydril's standard BOP/Control
System test fluid unless otherwise specified by the customer.
7. Open the pressure source isolation valve. Fill the SPM Valve and SPM Actuator with
test fluid. Cycle the valve to remove trapped air in the valve.
Hydrostatic Test of the SPM Valve

1. If leakage occurs during the hydrostatic test, the source of the leak must be identified.
Once the source of the leakage has been found, reduce the pressure to zero. Fittings
that are leaking shall be tightened and/or replaced. Other components found to be
leaking shall be repaired or replaced. The hydrostatic test shall then be restarted at
the beginning.
2. Ensure that a chart recorder or data acquisition device suitable for recording the test
pressure is connected between the pressure source isolation valve and the SPM valve
assembly. Place a new chart onto the chart recorder and wind the clock, if applicable.
3. Start the recorder or data acquisition device.
4. For a normally closed SPM valve only: apply 1,500 psi pilot pressure to open the SPM
valve.
5. Increase the pressure to the hydrostatic test pressure listed in Table 3-3. Close the
pressure source isolation valve. Allow the pressure to stabilize. If necessary, it is
permissible to apply additional pressure during the stabilization process, but pressure
shall not exceed the maximum listed in Table 1. Pressure shall be considered stabilized
when there is no noticeable change in the pressure reading. If pressure transducers
are used, a maximum pressure loss of 6 psi per minute is acceptable.
6. Record the pressure for the system at the beginning of the hold period in the TDDR.
7. The test pressure shall be held for a minimum of five (5) minutes after stabilization
without visible leakage. The pressure must not drop below the minimum hydrostatic
test pressure listed in Table 3-3 and there shall be no noticeable change in pressure
observed. If pressure transducers are used a maximum pressure loss 6 psi per minute
is acceptable. The timing shall not start until the valve assembly and the pressure
gage/chart recorder have been isolated from the pressure source, the external
surfaces of the valve assembly have been thoroughly dried and the pressure stabilized.
8. Record the pressure at the end of the hold period and the length of the hold period in
the TDDR.
9. Bleed the system pressure to 0 psi. Open the pressure source isolation valve.
10. Stop the chart recorder or data acquisition device. On the chart(s), identify the test(s),
the SPM valve assembly serial number, and the test date. The test technician, the
Hydril QA representative, and the customer representative (if applicable) shall sign
and date the chart(s).
Hydrostatic Test of the SPM Valve Actuator

1. If leakage occurs during the hydrostatic test, the source of the leak must be identified.
Once the source of the leakage has been found, reduce the pressure to zero. Fittings
that are leaking shall be tightened and/or replaced. Other components found to be
leaking shall be repaired or replaced. The hydrostatic test shall then be restarted at
the beginning.

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2. Connect a hydraulic pressure source to the SPM valve actuator. Connect a chart
recorder or data acquisition device suitable for recording the test pressure between
the pressure source isolation valve and the SPM valve actuator. Ensure that the SPM
valve actuator has been filled with fluid and trapped air has been removed from the
circuit. Place a new chart onto the chart recorder and wind the clock, if applicable.
3. Start the recorder or data acquisition device.
4. Increase the pressure to 4,500 - 4,700 psi. Close the pressure source isolation valve.
Allow the pressure to stabilize. If necessary, it is permissible to apply additional
pressure during the stabilization process. Pressure shall be considered stabilized when
there is no noticeable change in the pressure reading. If pressure transducers are
used, a change rate of no more than 4 psi per minute is acceptable.
without visible leakage. The pressure must not drop below 4,500 psi. and there shall
be no noticeable change in pressure observed. If pressure transducers are used a
pressure loss of less than 4 psi per minute is acceptable. The timing shall not start
until the valve assembly and the pressure gage/chart recorder have been isolated from
the pressure source, the external surfaces of the valve assembly have been thoroughly
dried and the pressure stabilized.
the TDDR.
8. Bleed the system pressure to 0 psi. Open the pressure source isolation valve.
Seal Function Test

1. Connect the hydraulic supply source to the supply port. Connect a chart recorder or
data acquisition device suitable for recording the test pressure between the pressure
source isolation valve and the supply port. Connect a test flange with a bleed valve
and pressure gauge to the function port. Open the bleed valve. Ensure that the SPM
valve has been filled with fluid and trapped air has been removed from the circuit.
Place a new chart onto the chart recorder and wind the clock, if applicable.
2. For a normally closed SPM valve, verify that the valve is closed. For a normally open
SPM valve, apply 1,500 psi pilot pressure to the SPM valve actuator to close the SPM
Valve.
3. Start the chart recorder or data acquisition device.
4. Increase the pressure to the function test pressure listed in Table 1. Close the pressure
source isolation valve. Allow the pressure to stabilize. If necessary, it is permissible to
apply additional pressure during the stabilization process, but do not exceed the
maximum operating pressure listed in Table 1. Pressure shall be considered stabilized
when there is no noticeable change in the pressure reading. If pressure transducers
are used, a change rate of no more than 4 psi per minute is acceptable.
without visible leakage. The pressure must not drop below the minimum function test
pressure listed in Table 1 and there shall be no noticeable change in pressure
observed. If pressure transducers are used a maximum pressure loss of 4 psi per
minute is acceptable. The timing shall not start until the valve assembly and the
pressure gage/chart recorder have been isolated from the pressure source, the

CHAPTER 3
external surfaces of the valve assembly have been thoroughly dried and the pressure
stabilized.
7. Ensure that no leakage appears at the function port or the vent port (if applicable)
while the SPM valve is closed and sealing from the supply port.
the TDDR.
SPM Valve Operation Test

1. While the SPM valve is still closed and pressurized, perform the following:
2. For a normally closed SPM valve, apply 1,500 psi pilot pressure to the SPM valve
actuator to open the valve.
3. For a normally open SPM valve, vent the pilot pressure from the SPM valve actuator to
open the valve.
4. Read the pressure gauge to verify that pressure is present at the function port. Record
the results in the TDDR. If a three way valve is being tested, verify that no fluid is
exiting the vent port. (SPM Valve Opened).
5. If necessary, increase pressure in the valve to the function test pressure listed in Table
1. While the SPM valve is still pressurized, perform the following:
6. For a normally closed SPM valve, vent the pilot pressure from the SPM valve actuator
to close the valve.
7. For a normally open SPM valve, apply 1,500 psi pilot pressure to the SPM valve
actuator to close the valve.
8. Read the pressure gauge at the function port to verify that pressure is NOT present at
the function port.
9. For a two way valves, open the bleed valve a the function port, reduce pressure to
zero, then close the bleed valve. Pressure reading should remain at 0 psi. Record the
results in the TDDR. (SPM Valve Closed).
10. For a three way valve, verify that fluid exited the vent port, and that there is pressure
at the supply port. Record the results in the TDDR. (SPM Valve Closed).
11. Bleed the valve circuit pressure to 0 psi and vent the actuator pressure.
Function Tests for Bi-Directional Valves

(This section is in addition to the previous section. If the valve being tested is not a bi-
directional valve, skip this section. Note that the only difference is that this test is performed
with the supply and function ports switched from the previous test))
Seal Test - Function Side

1. Connect the hydraulic supply source to the function port. Connect a chart
recorder or data acquisition device suitable for recording the test pressure
between the pressure source isolation valve and the function port. Connect a
test flange with a bleed valve and pressure gauge to the supply port. Open the
bleed valve. Ensure that the SPM valve has been filled with fluid and trapped air
has been removed from the circuit. Place a new chart onto the chart recorder
and wind the clock, if applicable.

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2. For a normally closed SPM valve, verify that the valve is closed. For a normally
open SPM valve, apply 1,500 psi pilot pressure to the SPM valve actuator to
close the SPM Valve.
3. Start the chart recorder or data acquisition device.
4. Increase the pressure to the function test pressure listed in Table 1. Close the
pressure source isolation valve. Allow the pressure to stabilize. If necessary, it is
permissible to apply additional pressure during the stabilization process, but do
not exceed the maximum operating pressure listed in Table 1. Pressure shall be
considered stabilized when there is no noticeable change in the pressure
reading. If pressure transducers are used, a change rate of no more than 4 psi
per minute is acceptable.
5. Record the pressure for the system at the beginning of the hold period in the
TDDR.
6. The test pressure shall be held for a minimum of five (5) minutes after
stabilization without visible leakage. The pressure must not drop below the
minimum function test pressure listed in Table 1 and there shall be no noticeable
change in pressure observed. If pressure transducers are used a maximum
pressure loss of 4 psi per minute is acceptable. The timing shall not start until
the valve assembly and the pressure gage/chart recorder have been isolated
from the pressure source, the external surfaces of the valve assembly have been
thoroughly dried and the pressure stabilized.
7. Ensure that no leakage appears at the supply port or the vent port (if applicable)
while the SPM valve is closed and sealing from the function port.
8. Record the pressure at the end of the hold period and the length of the hold
period in the TDDR.
SPM Valve Operation Test

1. While the SPM valve is still closed and pressurized, perform the following:
2. For a normally closed SPM valve, apply 1,500 psi pilot pressure to the SPM valve
3. For a normally open SPM valve, vent the pilot pressure from the SPM valve
4. Read the pressure gauge to verify that pressure is present at the supply port.
Record the results in the TDDR. If a three way valve is being tested, verify that
no fluid is exiting the vent port. (SPM Valve Opened).
5. If necessary, increase pressure in the valve to the function test pressure listed in
Table 3-3. While the SPM valve is still pressurized, perform the following:
6. For a normally closed SPM valve, vent the pilot pressure from the SPM valve
7. For a normally open SPM valve, apply 1,500 psi pilot pressure to the SPM valve
8. Read the pressure gauge at the supply port to verify that pressure is NOT
present at the supply port.
9. For a two way valves, open the bleed valve a the supply port, reduce pressure to
zero, then close the bleed valve. Pressure reading should remain at 0 psi. Record
the results in the TDDR. (SPM Valve Closed).
10. For a three way valve, verify that fluid exited the vent port, and that there is
pressure at the supply port. Record the results in the TDDR. (SPM Valve Closed).
11. Bleed the valve circuit pressure to 0 psi and vent the actuator pressure.

CHAPTER 3
12. Stop the chart recorder. On the chart(s), identify the test(s), the SPM valve
serial number, and test date. The test technician, the Hydril QA representative,
and the customer representative (if applicable) shall sign and date the chart(s).
Post Test Activities

2. Remove as much test fluid from the valve as possible.

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Regulators
Regulators
Removal
1. Depressurize the MUX BOP Control Pod (both EH and Lower Valve Unit sections).
2. Depressurize pod valves, fluid supply lines, and pressure fluid storage vessels.
3. Verify control panel pod pressure gauge indicates zero pressure.
4. Loosen all ten 1/2”-13UNC x 7” screws and washers about 2 turns. Verify all of the
screws are loose before proceeding.
CAUTION
If the screws are not loose, verify there is no hydraulic pressure
in the regulator before proceeding!
5. Make provisions to support the weight of the regulator. The regulator weighs about
110 lbs. (50 kg.).
6. Remove the ten screws and washers from the regulator.
7. Grasp handles and carefully pull regulator from the manifold.
8. Place the regulator on clean work surface.
Figure 3-67 Regulator

9. Remove any seal-subs remaining in the pod manifold.
10. Remove the seal-subs from the regulator base plate.
Figure 3-68 Regulator Seal Subs

11. Remove and discard the seal-sub O-rings.
Disassembly
1. Clean the seal-subs with non-residual cleaner.
2. Turn regulator over and remove the six, 11/4” screws securing the top plate to the
regulator body.

CHAPTER 3
Regulators
Figure 3-69 Removing the Top Plate

3. Remove the top plate.
Figure 3-70 Removing the Top Plate

4. Remove eight, 1/2”-13 UNC x 11/4” screws securing the discharge cap to the regulator
body.
Figure 3-71 Removing the Discharge Cap

5. Remove the discharge cap and discard the O-ring.
Figure 3-72 Removing the Discharge Cap

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Regulators
6. Remove the ten, 11/4” screws securing the base plate to the regulator body.
Figure 3-73 Removing the Base Plate

7. Remove the base plate.
Figure 3-74 Removing the Base Plate

8. Remove eight, 1/2”-13 UNC x 1-1/4” screws securing the piston head to the regulator
body.
9. Remove the piston head and discard the O-ring.
Figure 3-75 Piston Head and O-Ring

10. Hand-press assembled regulator slide and piston out of regulator body.
NOTE
Regulator slide and piston should exit regulator body through
end covered by piston head.

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Regulators
Figure 3-76 Removing the Piston

11. Remove lock pin, piston, spiral retaining ring, and bushing from regulator slide.
Figure 3-77 Disassembling the Piston

12. Remove the vent shear seal from the regulator body.
Figure 3-78 Removing the Inlet Shear Seal
Figure 3-79 Seal Housing and Inlet Shear Seal

13. Remove the inlet shear seal from the regulator body.
Figure 3-80 Removing the Vent Shear Seal

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Regulators
Figure 3-81 Seal Housing and Vent Shear Seal

14. Remove O-rings and back-up rings from shear seals.
15. Remove O-rings from shear seal housings.
16. Discard elastomers and clean springs, seal housings, and shear seals with non-residual
cleaner.
17. Flip the regulator body over and perform steps 12-16 for the other side.
18. Remove the SAE plugs from the base plate and top plate.
19. Remove and discard O-rings from SAE plugs.
Figure 3-82 Regulator Component Parts
Maintenance
1. Inspect the shear seals for any indications of wear or surface imperfections. The shear
seals must NOT have anything unusual on the shear seal surface. If there are any
indications of wear, replace the shear seal. Do not attempt to ‘polish’ or ‘buff out’ any
imperfections on the shear seal surfaces; such a procedure would not meet the
flatness requirements for the regulator to operate properly.
2. Inspect the shear seals for any indications of wear or surface imperfections. The shear
seals must NOT have anything unusual on the shear seal surface. If there are any
indications of wear, replace the shear seal. Do not attempt to ‘polish’ or ‘buff out’ any
imperfections on the shear seal surfaces; such a procedure would not meet the
flatness requirements for the regulator to operate properly.
3. Clean regulator slide with non-residual cleaner. Inspect the shear seal surface on the
slide for scoring, galling, or distortion. The shear seal surface is very flat, and should
have a mirror-like finish. If there are any indications of wear, replace the slide. Do not
attempt to ‘polish’ or ‘buff out’ any imperfections; such an attempt would not meet the
flatness requirement for the regulator to operate properly. If unsure, send the slide to
Hydril for inspection.
NOTE
If the shear seals indicate any wear, replace the shear seals
AND the slide. If the slide indicates any wear, replace the
shear seals AND the slide. (If one of the parts is worn, the

CHAPTER 3
Regulators
other is also worn). Replacing only the shear seals or only the
slide will lead to premature wear and reduced service life of
the regulator.
4. Clean regulator bushing with non-residual cleaner. Inspect the bushing for scoring,
galling, or distortion. Replace the bushing if defective.
5. Inspect the spiral retainer ring groove for pitting. Minor surface damage may be
removed with emery cloth. If damage cannot be removed in this manner, replace the
component.
6. Clean the regulator body with non-residual cleaner. Carefully inspect the inside
diameter of the regulator body for imperfections. The circular inside diameter should
be smooth to prevent the valve slide from hanging as it travels through body. If
necessary, use ultra-fine (600-grade) emery cloth to remove minor surface damage.
Replace regulator body if damage cannot be removed in this manner.
7. Clean discharge cap, piston, piston head, bushing, and spiral retaining ring with non-
residual cleaner.
8. Remove and discard the T-seal and back-up rings from inner diameter of regulator
body.
9. Remove/discard four 2-115 O-rings from regulator body.
10. Inspect all O-ring seal grooves for any pitting or surface discontinuities. If necessary,
remove minor surface damage with fine emory cloth. If damage cannot be removed in
this manner, replace the part.
Assembly
NOTE
Use only petroleum jelly to lubricate wetted components.
PTFE, copper-based, or other sealing-type lubricants should
not be applied to stainless-steel components that are exposed
to saltwater. Sealing type lubricants cause oxygen deprivation
that accelerates the corrosive effects of saltwater.
Figure 3-83 Regulator Component Parts

1. Lightly lubricate two new #2-230 O-rings with petroleum jelly.
2. Install lubricated O-rings in grooves on discharge cap and piston head.
3. Install slide bushing in regulator slide
4. Lightly lubricate a new #335 T-seal and back-up rings with petroleum jelly and install
in ID groove in regulator body.

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CHAPTER 3
Regulators
5. Assemble piston onto regulator slide and secure assembly with lock pin.
Figure 3-84 Assembling the Piston

6. Assemble bushing onto regulator slide and secure in place with spiral retaining ring.
7. Lubricate exterior surfaces of regulator slide and piston with petroleum jelly.
NOTE
Regulator slide should enter regulator body through end
covered by piston head.
8. Hand-press regulator slide assembly into regulator body.
Figure 3-85 Inserting the Piston

9. Verify assembled regulator slide and piston travel freely back and forth inside regulator
body. If regulator slide travel is impeded, check the following:
• ensure piston body is level inside regulator body and
• no debris exists between regulator body and slide assembly.
10. Install the discharge cap into the regulator body.
Figure 3-86 Installing the Discharge Cap

11. Lubricate sixteen 1/2-13UNC x 11/4-inch cap screws with thread lubricant that is
suitable for stainless steel (e.g. ‘pure nickel special’).

CHAPTER 3
Regulators
12. Install eight 1/2-13UNC x 11/4-inch cap screws and lock washers to secure discharge
cap to regulator body.
13. Tighten screws, using a cross-over pattern, to 54 ft-lbs torque (73 N-m).
Figure 3-87 Torquing the Discharge Cap Screws

14. Install piston head into regulator body.
Figure 3-88 Preparing the Piston Head

15. Install eight1/2-13UNC x 11/4-inch cap screws and lock washers to secure piston head
to regulator body.
Figure 3-89 Securing the Piston Head

16. Tighten screws, using a cross-over pattern, to 54 ft-lbs torque (73 N-m).
Figure 3-90 Torquing the Piston Head Cap Screws

17. Lightly lubricate four new #2-124 O-rings and four new #8-124 back-up rings with
petroleum jelly.

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CHAPTER 3
Regulators
18. Install lubricated O-rings and back-up rings on two inlet shear seals and two vent
shear seals. Verify that the back-up rings and O-rings are properly installed.
19. Position regulator body with base plate side up.
20. Lightly lubricate the inlet and vent ports in regulator body with petroleum jelly.
21. Lightly lubricate inlet and vent shear seals with petroleum jelly.
Figure 3-91 Lubricating Shear Seals

22. Orient shear seals so that tungsten-carbide surface on each will contact regulator slide
when installed in regulator body.
Figure 3-92 Shear Seal Orientation

23. Hand-press shear seals into their respective housings as shown.
24. Insert shear seal housings into the supply and vent ports on the regulator body.
Figure 3-93 Inserting Seal Housings

25. Ensure seal housing assemblies are level in the regulator body.
26. Lightly lubricate new #2-225 O-rings with petroleum jelly and install in grooves on
shear seal housings.

CHAPTER 3
Regulators
27. Install lubricated O-rings in O-ring grooves on the regulator body.
Figure 3-94 Installing Regulator Body O-Rings

28. Install compression springs into the installed housings/cavities.
Figure 3-95 Installing Compression Springs

29. Install the base plate on the regulator body.
Figure 3-96 Installing the Base Plate

30. Lubricate ten 1/2-13UNC x 11/4-inch cap screws with thread lubricant that is suitable
for stainless steel (e.g. ‘pure nickel special’).
31. Install ten 1/2-13UNC x 11/4-inch cap screws and lock washers to secure the base plate
to the regulator body.
Figure 3-97 Securing the Base Plate

32. Tighten screws to 54 ft-lbs torque (73 N-m). Tighten the screws in the center first,
then work towards the ends of the plate.

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Regulators
Figure 3-98 Torquing the Base Plate Cap Screws

33. Position regulator body so the side with the top plate is up.
34. Lightly lubricate the top plate side inlet and vent ports with petroleum jelly.
35. Lightly lubricate inlet and vent shear seals with petroleum jelly.
36. Orient shear seals so that tungsten-carbide surface on each will contact regulator slide
when installed in regulator body.
Figure 3-99 Shear Seal Orientation

37. Hand-press shear seals into their respective housings as shown.
38. Insert shear seal housings into the supply and vent ports on the regulator body.
Ensure seal housing assemblies are level in the regulator body.
Figure 3-100 Seal Housings in the Regulator Body

39. Install compression springs into the installed housings/cavities.
40. Lightly lubricate new #2-225 O-rings with petroleum jelly and install in grooves on
shear seal housings.
41. Install lubricated O-rings in O-ring grooves on the regulator body.
42. Install the top plate on the regulator body.

CHAPTER 3
Regulators
Figure 3-101 Installing the Top Plate

43. Lubricate six, 1/2-13UNC x 11/4-inch cap screws with thread lubricant that is suitable
for stainless steel (e.g. ‘pure nickel special’).
Figure 3-102 Lubricating Cap Screws

44. Install six cap screws and lock washers to secure the top plate to the regulator body.
Figure 3-103 Securing the Top Plate

45. Tighten screws to 54 ft-lbs torque (73 N-m). Tighten the screws in the center first,
then work towards the ends of the plate.
46. Lightly lubricate eight new #2-113 O-rings with petroleum jelly.
47. Install the lubricated O-rings on the 3/4” seal subs.
48. Lightly lubricate eight new #2-125 O-rings with petroleum jelly.
49. Install the lubricated O-rings on the 11/2” seal subs.
50. Lightly lubricate the four seal-sub ports in base plate with petroleum jelly.
51. Lightly lubricate the seal-subs with petroleum jelly.
52. Hand-press all four seal subs into the seal sub ports.
53. Lightly lubricate new O-rings and install them on each SAE plug.
54. Lightly lubricate SAE plugs and install them into the base and top plates
55. Lubricate four 1/2-13UNC x 11/4” cap screws with thread lubricant that is suitable for
stainless steel (e.g. ‘pure nickel special’).
56. Install two each 1/2-13UNC x 11/4” cap screws and lock washers through the regulator
handles into the regulator top plate.

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CHAPTER 3
Regulators
57. Tighten screws to 20 ft-lbs torque (27 N-m).

58. Carefully install regulator on manifold. Avoid damaging seal sub O-rings when pressing
seal subs into manifold receptacles.
59. Install ten 1/2-13UNC x 7” screws and washers to secure regulator to manifold.
60. Tighten screws to 20 ft-lbs torque (27 N-m). Tighten the cap screws in the center of
the regulator first, then towards the ends.
Testing
1. Operate repaired regulator from a remote control panel. If regulator does not function
properly, refer to troubleshooting information at beginning of this procedure.
2. Energize the solenoid for regulator pressure decrease and decrease regulator pressure
to the minimum pressure.
3. Position the Increase and Decrease Metering Valves to the half open position.
4. Energize the solenoid for regulator pressure increase and increase regulator pressure
to 3,000 psi and observe the rate of pressure increase of the regulated pressure. The
rate of pressure increase should be about 100 psi per second. (Adjust the Increase
Metering valve for the proper pressure increase rate, if required).
5. Energize the solenoid for regulator pressure decrease and decrease regulator to the
minimum pressure. Observe the rate of pressure decrease of the regulated pressure.
The rate of pressure decrease should be about 100 psi per second. {Adjust the
Decrease Metering valve for the proper pressure decrease rate, if required).
6. Repeat steps 4 and 5 until proper pressure change rate is obtained.
7. Energize the solenoid for regulator pressure increase and set regulator pressure to
1,550 psi – 1,600 psi for a target pressure of 1500 psi. Simulate function operation by
opening the test valve for a few seconds. Verify that there is fluid exiting the test
valve. Close the test valve. Verify that regulator pressure has stabilized at the set
pressure (± 5% of the target pressure). Hold this pressure for 5 minutes and verify
that there no visible leakage. Record the pressure hold time and pressure readings in
the table on the next page. Also record the following pressure readings:
• Regulator pilot pressure.
• Regulated pressure.
8. For the next two tests, energize the solenoid for regulator pressure increase and
increase regulator pressure to:
• 2,050 - 2,100 psi for a target pressure of 2,000 psi.
• 3,050 psi - 3,100 psi for a target pressure of 3,000 psi.
9. Simulate function operation by opening the test valve for a few seconds. Verify that
there is fluid exiting the test valve. Close the test valve. Verify that regulator pressure
has stabilized at the set pressure (± 5% of the target pressure). Record the following
pressure readings for each test:
10. For the next two tests, energize the solenoid for regulator pressure increase and
increase regulator pressure to:
• 2,050 - 2,100 psi for a target pressure of 2,000 psi.
• 3,050 psi - 3,100 psi for a target pressure of 3,000 psi.

CHAPTER 3
Regulators
12. For the next four tests, energize the solenoid for regulator pressure decrease and
decrease regulator pressure to:
• 1,900 psi – 1,950 psi for a target pressure of 2,000 psi.
• 1,400 psi – 1,450 psi for a target pressure of 1500 psi.
• 900 psi – 950 psi for a target pressure of 1000 psi.
• 650 psi – 700 psi for a target pressure of 750 psi.
14. Energize the solenoid for regulator pressure increase and increase regulator pressure
to 1,550 psi – 1,600 psi for a target pressure of 1500 psi. Simulate function operation
by opening the test valve for a few seconds. Verify that there is fluid exiting the test
valve. Close the test valve. Verify that regulator pressure has stabilized at the set
pressure (± 5% of the target pressure). Record the following pressure readings for
each test:
15. Reduce all pressures to 0 psi.
Post Test Activities

2. Remove as much test fluid from the assembly as possible.
3. Re-install all socket weld flange connections, as applicable.
Test Completion and Documentation

1. All sheets in the FAT/TDDR shall be reviewed for completeness. They shall have been
filled out, signed, and dated by the Hydril test technicians who performed the tests,
and the Hydril Quality Assurance personnel who witnessed and documented the test. A
Customer Representative (when requested by the customer) shall sign the TDDR.
2. Documentation from vendors shall be included in the TDDR, and remain as part of the
FAT/TDDR record. Include certificates of conformance (COCs); copies are acceptable.
3. Tests that were not completed must be approved by the customer representative as
waived (signature required) or a written explanation added to the TDDR.
4. All test charts and printed data shall be identified with the assembly tested and tests
performed. They shall be signed and dated by the test technician Hydril Quality
Assurance and a Customer Representative (when requested by the customer).
5. Copies of these tests shall be retained in Hydril’s documentation system for a period of
five (5) years after shipment of the unit.

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CHAPTER 3
Solenoid Housing Fill Procedure
6. Copies of these tests shall be sent to the customer with individual units, if applicable.

Assumptions
This procedure assumes that:
• Contaminants, debris, and foreign matter are flushed from the MUX pod hydraulic
circuits and from the fluid lines that supply the MUX pod.
• All the solenoids passed testing in accordance with Hydril test procedures.
• All of the MUX control pod transducers are calibrated, tested, and installed.
• The interior of the solenoid electronics housing is free of debris and inspected for
damage and correct component installations.
• Except for the cover of the solenoid electronics housing, all control pod
components are installed and are ready for operation.
• The solenoid electronics housing is uncovered.
Required Equipment and Materials

The following equipment and materials are required for this procedure:
• Two vacuum pump(s)
• Dow Corning DC-200® dielectric fluid or equivalent
• Torque wrench, 200 in-lb capability
• Torque wrench, 300 ft-lb capability
• Bostik Never Seez® Pure Nickel Special (NSN-165) or equivalent fastener lubricant
• Petroleum jelly (Vaseline® or equivalent)
• New O-rings for the solenoid electronics housing cover and orifice plugs
• SAE feed-through fittings for 1/2”-1/4 Inch SAE receptacle
• ¼” fitting for seal test port receptacle
• fitting for the compensator plug receptacle (see Figure 3-109)
• *Filtering Flask, Erlenmeyer form with heavy wall detachable side arm secured by
neoprene grommet (and rubber stopper with single perforation for glass feed-
through tube); Kimax® brand or equivalent
• Air filter with moisture trap (for vacuum filling procedure)
• Lint free rags.
Procedure
1. Verify the cleanout ports are bolted securely to the sides of the solenoid pressure
compensator housings.

CHAPTER 3
Figure 3-104 Solenoid Housing Cleanout Ports

2. On the EH section, remove the cover from one solenoid housing.
3. Inspect the seals and the seal grooves and:
Figure 3-105 Cleaning the Solenoid Housing O-Ring Grooves

• Remove dirt and other foreign matter from the sealing grooves.
• Replace any seals showing damage or evidence of excessive wear.
• Coat the seals with petroleum jelly.
Figure 3-106 Installing the Solenoid Housing Seals

4. As required, remove scratches or blemishes from the sealing surface and grooves of
the cover with a fine emery cloth. If scratches and blemishes can not be removed in
this manner, replace the cover.
5. Re-mount and fasten the cover to the solenoid housing, using 3/8-16UNC stainless
steel bolts.
6. Torque the bolts to 120 in-lbs.

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CHAPTER 3
Figure 3-107 Torquing the Solenoid Housing Cover Bolts

7. At the solenoid housing cover, remove the plugs from the vacuum and the
compensator ports. Store the plug for the bladder access port. The plug is only used to
protect the port and bladder during transport and storage.
Figure 3-108 Vacuum Port
Figure 3-109 Compensator Port

8. At the bottom of the solenoid housing:
• Remove the tube cap from the end of the ball valve.
• Close the ball valve. The ball valve is closed when the handle is rotated fully
perpendicular to the flow path through the valve.
9. Attach a hose from the dielectric fluid source to the ball valve.
Figure 3-110 Attaching the Dielectric Fluid Source Hose

10. Screw leak-proof fittings with feed-throughs into the compensator and vacuum ports.
The compensator port threads are 9/16-18UNF-2B. The vacuum port threads are SAE
1/2 (3/4-16UNJF-3A).

CHAPTER 3
11. Connect a vacuum pump with shutoff valve to the feed-through fitting on the
compensator port. The tube must be able to hold a vacuum without collapsing.
Figure 3-111 Vacuum Pump (Typical)

12. For the compensator port, operate the vacuum pump to draw the bladder flat against
the underside of the solenoid housing cover.
Figure 3-112 Compensator Port Valve (Typical)

13. Verify no air is being drawn from the bladder at the vacuum pump that. When bladder
has flattened against solenoid housing cover:
• Close the shutoff valve between the pump and the compensator port.
• Allow the bladder to sit 30 minutes to verify no leaks in the seals.
• Terminate the pump operation.
14. Operate the vacuum pump on the vacuum port until the gauge reads 20-25 bars.

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CHAPTER 3
Figure 3-113 Vacuum Port Gauge and Valve (Typical)

15. Close the shutoff valve between the pump and the vacuum port.
16. Allow the housing to sit for 30 minutes to verify there are no leaks in the housing,
solenoids, or shear seal valves.
17. Open the ball valve to admit the dielectric fluid into the solenoid housing.
18. Continue pumping until the dielectric fluid appears in the filtering flask.
19. When the fluid appears in the flask, perform the following tasks below in sequence:
• Close the ball valve at the bottom of the solenoid housing.
• Turn off the vacuum pump to terminate the dielectric fluid flow in the transparent
tube.
20. Remove the tube and the feed-through fitting from the vacuum port.
21. As necessary, add dielectric fluid until it overflows from the lip of the port.
22. Remove the pump, shutoff valve, and feed-through fitting from the compensator port.
The bottom of the bladder should be visible through the port.
CAUTION
Coat stainless steel fastener threads with NEVER SEEZ or
equivalent lubricant to minimize the possibility of galling.
23. Replace the stainless steel 9/16-18UNF-2B vacuum port plug and torque to 35 ft-lbs
(405 in-lbs).
WARNING
Sea water must flow into the pressure compensating
bladder as the MUX BOP Control Pod lowers to working
depth. Therefore, the access port must be unplugged for
underwater service. Failure to observe this precaution will
result in severe damage to the EH section structure and
render the enclosed electronics package inoperative.
24. Repeat steps 1 to 23 for the other solenoid housing.

CHAPTER 3

NOBL-NA-AHC2008A
Chapter 4
Description
A blowout preventer (BOP) is basically a large valve that can be closed if there is a loss of control of
formation fluids. By closing the valve, an operator may regain control of the well, then procedures
may be started to increase the mud density until it is possible to open the BOP and retain control of
the formation.
Annular BOPs use a doughnut-shaped elastomeric sealing element, which is mechanically squeezed
inward, to seal the space between the tubular and the wellbore or an open hole. The ability to seal
on a variety of pipe sizes is an advantage the annular BOP has over ram-type BOPs.
Hydril invented the annular BOP in 1947 and has applied 70 years of experience to develop a
complete product line to match a broad range of operating requirements. Hydril annulars are best
known for their exceptional ability to handle extremely high pressures and temperatures on the
surface and subsea.
Objectives
• An understanding of the purpose of annulars in well pressure control.
• An ability to identify the major components of an annular.
• An introduction to these components and their function.
• An understanding of how to remove, disassemble, inspect, maintain, assemble, and
install the Hydril GX annular.
• An understanding of how to remove, maintain, and install an annular packing unit.

CHAPTER 4
Hydril GX 18-15
Hydril GX 18-15
The Hydril GX 18-15 blowout preventer is an
annular blowout preventer as defined by API R.P.
53. It has been developed for use on both surface
and subsea installations. It will close and seal off
on anything in the well bore or completely seal off
the open hole to full rated working pressure.
Seal-off is affected by raising the piston which
causes the rubber packing unit to be squeezed
inward to a sealing engagement with anything in
the bore (pipe, tool joints, casing, square or hex
Kellys, etc.), or with itself on the open hole.
The piston is raised by applying hydraulic
pressure to the closing chamber. The optimum
closing pressure is the minimum pressure that
will maintain a complete seal under existing
operational conditions. Drill pipe can be rotated
and tool joints stripped through a closed packing
unit while maintaining a full seal on the pipe. Figure 4-1 Annular Packer in Test Cell
Any normal closing unit having a separate
regulator valve for the annular blowout preventer and sufficient accumulator volume can be used
to operate the GX blowout preventer. The closing time of the preventer is determined by the rate at
which the hydraulic fluid can be delivered to the closing chamber. Minimum closing time will be
achieved by using short, large-diameter control lines and a large accumulator volume.
The Hydril GX has a latched head design for easy access. For simplicity, there are only two moving
parts. The piston has been designed to prevent binding. The packing rubber is reinforced with
flanged steel segments. The seals are large lipped-type for improved reliability.
Table 4-1 Operating Data
Description Data
Bore Size 18 3/4 in (476 mm)
Working Pressure 10,000 psi (689.476 bar)
Operating Pressure, Maximum 3000 psi (207 bar)
Operating Temperature (w/Nitrile Packing Unit) 20 F to 180 F (-7 C to 82 C)
Top and Bottom Connection Gasket BX-164
Hydrostatic Shell Test Pressure (Factory Test Only) 15,000 psi (1035 bar)
Closing Chamber Test Pressure (Factory Test Only) 10,000 psi (690 bar)
Opening Chamber Test Pressure (Factory Test Only) 10,000 psi (690 bar)
Piston Stroke 11.5 in (292.1 mm)
Body Lift Eye Safe Working Load - Each Shackle 17.5 Ton (15.88 Tonnes)
Packing Unit Closure Range 18 3/4 in (476 mm)
Hydraulic Connections 1 1/2 SAE Code 62
Opening and Closing Chamber Volume 58 gal (219.55 Liters)

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CHAPTER 4
Hookup
Table 4-2 Weight Data
Component Weight
Annular BOP Assembly 28.618 Tons (25.813 Tonnes)
Head 6.148 Tons (5.545 Tonnes)
Piston 4.94 Tons (4.054 Tonnes)
Inner Sleeve 500 lbs (227 Kg)
Body 14.715 Tons (13.35 Tonnes)
Packing Unit 1600 lbs (726 Kg)
Hookup
The hookup for the GX 18-15 connects hydraulic control lines to the opening and closing chambers.
Pressure applied to the closing chamber raises the piston and causes the seal off between the
packing unit and tubular. This pressure must be maintained in order to maintain the seal off.
The GX piston is completely balanced. The opening and closing chamber areas are of equal size.
This equalizes the hydrostatic forces exerted on the piston by the marine riser drilling fluid column
in subsea operations. The result is a BOP that utilizes a constant closing pressure regardless of
water depth or mud weight. Closing pressure requirements are independent of well bore pressures.
Figure 4-2 Operating Curve for the GX Annular
Stripping Operations
Drillpipe can be rotated and tool joints stripped through a closed GX packing unit while maintaining
a full seal-off on the pipe. Longest life for the packing unit is obtained by adjusting the closing
chamber pressure low enough to maintain a seal with a slight amount of drilling fluid leakage
around the pipe. This leakage indicates the lowest usable closing pressure for minimum packing
unit wear and provides lubrication for the drillpipe motion through the packing unit Slow tool joint

CHAPTER 4
Packing Units
stripping speeds reduce surge pressures, thus prolonging packing unit life. The pressure regulator
valve should be set to provide and maintain the proper closing chamber pressure.
If the pressure regulator valve does not respond fast enough for effective control, an accumulator
(surge absorber) should be installed in the closing chamber control line adjacent to the blowout
preventer. In subsea installations, the closing chamber surge absorber is necessary and an opening
chamber surge absorber should be added if the control system does not permit free bi-directional
control fluid flow from the opening chamber during stripping operations.
Packing Units
The heart of the GX 18-15 blowout preventer is the packing unit. The packing unit is manufactured
by Hydril from high quality rubber, reinforced with flanged steel segments. Each unit has a large
volume of tough, feedable rubber.
The molded-in steel segments have flanges at the top and the bottom of the unit. The segments
anchor the packing unit within the blowout preventer and control rubber extrusion and flow when
sealing off well pressures. Since the rubber is confined and kept under compression, it is resistant
to tears, cuts, and abrasions.
Packing Unit Selection

Because of the importance of the packing unit to the operation of the blowout preventer and
to the safety of crew and rig, only genuine Hydril packing units should be used as
replacements for original equipment. All Hydril packing units are tested to full rated pressure
inside a test BOP at the factory as part of rigid standard acceptance tests before being
furnished to the consumer. Packing units for Hydril BOP’s are manufactured from
compounded natural rubber, or nitrile rubber.
Natural rubber is compounded for drilling with water-based drilling fluids. Natural rubber
can be used at operating temperatures between - 30 F to 225 F (-35C to 170C). When
properly applied, the compounded natural rubber packing unit will usually provide the
longest service life. The all-black packing unit is identified by its singular color and a serial
number with an “NR” suffix.
Nitrile rubber (a synthetic compound) is for use with oil-
based or oil-additive drilling fluids. It provides the best service
with oil-based muds when operated at temperatures between
20F to 190F (-7C to 88C). The nitrile rubber packing unit is
identified by a red color band and a serial number with an
“NBR” suffix.
Seals for Hydril BOPs are manufactured from a special nitrile
rubber material which provides long, trouble-free service in
Figure 4-3 Nitrile Packer
sealing against oil, gas, or water.
H2S service does not affect selection of packing unit material. H2S service will reduce the
service life of rubber products, but the best overall service life is obtained by matching the
packing unit material with the requirements of the specific drilling fluid.
Performance of elastomeric materials can vary significantly, depending on the nature and
extent of exposure to hydrogen sulfide. The operator should monitor pressure sealing
integrity frequently to ensure no performance degradation has occurred.
Storage conditions are important for realizing the maximum life of the packing unit. Packing
units should be stored in a cool, dry, dark storage area. Atmosphere, light, and heat
accelerate deterioration of rubber goods. It is also essential to practice “first-in, first-out”
when storing packing units.

NOBL-NA-AHC2008A
CHAPTER 4
Packing Units
Testing Packing Units

Install the GX BOP on the test stump, ensuring that the BOP is open. Insert a test pipe into
the test stump and fill the wellbore with tap water. Close the packer around the test pipe.
Increase the wellbore pressure to 200 - 300 psi (14 - 21 Bar). Allow the pressure to stabilize
and hold for ten minutes. Check for leaks. Next, increase the wellbore pressure to 15,000 psi
(1034.213 Bar). Allow the pressure to stabilize and hold for ten minutes. Check for leaks.
WARNING
The rated working pressure of the GX® ANNULAR BOP is
15,000 psi. Use extreme caution when working with high
pressure. Take every precaution to protect personnel from
coming in contact with pressure during testing.
Decrease wellbore pressure to zero. Open the packing unit. Drain potable water from the
wellbore. Remove the test pipe and return the annular BOP to service.
Replacing Packing Units

Back off the radial latches to release the head. Loosen the clamping screws by rotating them
counterclockwise for four full turns or until the latches shoulder against the body. Then,
remove the four sleeve assemblies containing the pulldown bolts.
CAUTION
Take care not to continue turning the screws after the latches
have shouldered. Excessive torque may cause thread damage.
NOTE
If a latch does not retract, remove the pipe plug to gain access
to the shoulder screw. Tighten the shoulder screw
counterclockwise (left-hand thread) to approximately 150 lb-ft
(203 N•m) torque. Reinstall the pipe plug after tightening.
Install three 2"-4.5UNC hoist rings into the head. Attach a Hydril sling (1900179-0560) to
the rings and lift the head straight up and off the body. Remove the rings.
Install three 3/4"-10 NC eyebolts into the packing unit. Attach a Hydril sling to the eyebolts
and lift the packing unit out of the piston. Remove the eyebolts.
Lubricate the piston bowl and the new packing unit with castor oil.
Install three 3/4"-10NC eyebolts into the new packing unit and place it into the piston bowl
using a Hydril sling. Remove the eyebolts and lift the head onto the body.
Install the four pull-down bolt assemblies to pull the head fully into place. Tighten the pull-
down bolt assemblies until they bottom fully against the head flange and torque to 300 lb-ft
(407 N•m). Check for "standoff" gaps between the head flange and the body. Gaps should
not be more than 0.05 inch (1.3 mm) maximum.
Turn the clamping screws clockwise to engage the radial latches fully into the locking rings of
the head and torque to 350 lb-ft (475 N•m).

CHAPTER 4
Testing the Seals
CAUTION
To prevent unequal clearance between the head and the body,
tighten the latches alternately in a criss-cross pattern.
Remove the lifting apparatus from the annular head and remove the eyebolts.
Splitting Packing Units
CAUTION
The practice of splitting a packing unit should be done only in
the case of an emergency. The packing unit should be replaced
as soon as possible with a unit that has not been split.
Packing unit replacement is possible with pipe in the

hole. After removing a worn packing unit, cut the new
packing unit completely and smoothly through one
side between any two steel segments - preferably 90
degrees from eyebolt holes to achieve easier
handling. The cut should be made with a sharp knife
as this will not affect the efficiency of the packing
unit. Spread cut segments apart with a pry bar to put
the rubber in tension for easier cutting. Do NOT use a
saw or other rough cutting tool. Spread the packing
unit open sufficiently to pass around the pipe, drop
Figure 4-4 Splitting a Packer the unit into position in the BOP body, and replace the
BOP head.
Testing the Seals

The seal rings for the Hydril® GX® Annular BOP are manufactured from a special synthetic rubber
material for long trouble-free sealing service. To prevent seal damage, do NOT use synthetic fluids
in the hydraulic operating system. The hydraulic operating fluid may be clean, light petroleum
hydraulic oil, or water with soluble oil added. In cold climates, antifreeze should be added to
prevent freezing. The dynamic seals are all molded, lip-type, pressure-energized rings.
Hydril recommends that all seals be replaced when it is known or suspected that a seal within the
GX® Annular BOP is leaking. However, if only the seal in question is to be replaced, it must first be
determined which seal is leaking. Use the following procedure for testing the seals in the GX®
Annular BOP.
NOTE
The upper and lower piston seals are double U-seals that can
be tested in both directions.

NOBL-NA-AHC2008A
CHAPTER 4
Testing the Seals
Install the annular BOP on the test stump, ensuring that the
BOP is open. Insert a test pipe into the test stump. Apply
1500 psi (104 Bar) operating pressure to the Close port to
close the packing unit around the test pipe. Open the opening
chamber to atmosphere.
If closing fluid is seen at wellbore, then the lower U-seal is
leaking. If closing fluid is seen at the opening chamber, then
the middle U-seal is leaking. Refer to Figure 4-5.
Figure 4-5 Lower and Middle U-

seals
Reduce the closing pressure to zero and open the closing

chamber to atmosphere. Apply 1500 psi (104 Bar) operating
pressure to the opening chamber to open the packing unit.
If fluid is seen coming from the Close port, the middle double U-
seal is leaking. If fluid is seen in the wellbore or coming from the
relief valve, the Upper U-seal (lower) ring is leaking, or the head
gasket seal is leaking, or both the upper U-seal (lower) and the
head gasket are leaking. Refer to Figure 4-6.
Figure 4-6 Middle Double U-

seal, Upper U-seal Ring and
Head Gasket

CHAPTER 4
Surge Accumulator
WARNING
Use extreme caution when working with high pressure.
Take every precaution to protect personnel from coming in
contact with pressure during testing.
Reduce the opening pressure to zero and open the opening

chamber to atmosphere. Open the closing chamber to
atmosphere. Remove the test pipe and attach a blind flange to the
top of the annular BOP. Fill the wellbore with water and pressurize
the wellbore to 10,000 psi maximum and check for leaks.
If wellbore fluid is seen at the opening chamber, the upper U-seal
(upper) is leaking. If wellbore fluid is seen at the closing chamber,
the lower double U-seal is leaking. Refer to Figure 4-7.
The head O-ring and clamping screw O-ring seals exclude sea
water and are not feasible to test. Reduce the wellbore pressure to
zero and drain the wellbore fluid. Remove the blind flange. Return
the BOP to service.
Surge Accumulator
The connection of a surge accumulator to the Close chamber to
improve the control and speed of closing pressure during stripping
operations is optional.
WARNING
Do NOT attempt to service an accumulator
while the system is under pressure. The surge
accumulator is a pressure vessel rated to 6000 Figure 4-7 Upper U-seal and
psi working pressure, and hydraulic fluid or Lower Double U-seal
nitrogen gas ejected from an accumulator at
working pressure can cause serious injury to
personnel and damage to equipment.
Check to ensure the locknut, jam nut, and bleeder plug are tight. Calculate the nitrogen precharge
required (Precharge = 0.80 x Closing Pressure) and verify the accumulator has retained its
precharge using a charging assembly.
To change a bladder in the accumulator, first depressurize the accumulator. Replace bladder and
install a repair kit. Calculate the nitrogen precharge required and recharge the accumulator.

NOBL-NA-AHC2008A
CHAPTER 4
Teardown and Rebuild

Disassembly
WARNING
This is VERY heavy equipment, and extreme safety
procedures must be followed during lifting operations. Be
sure that lifting equipment is in good condition and capable
of handling the load.
Stand clear of escaping pressure to avoid injury.
To help make the BOP safe, open the closing and opening chambers to the atmosphere to
vent pressure. Ensure that no trapped pressure exists that will cause injury to personnel or
damage the equipment. Open the valves in the control system to vent the pressure and
loosen the hydraulic connections to allow the pressure to bleed off.
CAUTION
Take care not to continue turning the screws after the latches
have shouldered. Excessive torque at shouldering may cause
thread damage.
Unscrew the clamping screws by rotating them counterclockwise four turns or until the
latches shoulder against the body. This releases the annular head by backing off the radial
latches.
NOTE
If a latch does not retract, remove the pipe plug to gain access
to the shoulder screw. Tighten the shoulder screw counter-
clockwise (left-hand thread) to approximately 150 lb-ft (203
N•m). Reinstall the pipe plug after tightening.
Loosen the four pull-down bolts in a cross-pattern to unload the annular head evenly.
Remove the four pull-down bolts from the head. Install three hoist rings (2"-4.5UNC) into
the three holes in the head. Attach a Hydril chain sling (1900179-0560) to the hoist rings
and lift the head out of the body.
WARNING
Keep hands, feet, and body out from under the suspended
annular head if the opening chamber head sticks to the
bottom of the annular head. The opening chamber head
can fall off unexpectedly and cause injury or death.

CHAPTER 4
If the opening chamber head sticks to the

bottom of the annular head, separate the two
parts safely by placing nonmetallic spacers or
wood timbers across the bore of the BOP body
about 1 cm or 1/2" below the suspended
opening chamber head to catch and cushion it.
Carefully drive nonmetallic or wood wedges
between the parts to separate them.
Remove the six cap screws and the wear plate
from the annular head. Remove the annular
head.
Install two eyebolts (3/4"-10UNC) into the
packing unit. Attach a Hydril chain sling
(1900179-0160) to the eyebolts and lift the
packing unit out of the piston. Remove
eyebolts.
Install three hoist rings (7/8"-9UNC) into the
opening chamber head. Attach a Hydril chain
sling (1900179-0160) to lift the opening
chamber head out of the body. Remove the
hoist rings.
If the opening chamber head binds as the lift
begins, tap the opening chamber head with a
mallet. If binding is excessive or a good
vertical lift is not possible. Fill the opening
chamber with hydraulic oil—DO NOT USE AIR
OR GAS. Slowly apply low (50 PSI) hydraulic
pressure to the opening chamber until the
opening chamber head is free, then lift it out.
Install three piston eyebolt assemblies (1"-
8UNC) into the piston, ensuring that the
retaining ring and spacer block are snug
against the piston. Attach a Hydril chain sling
(1900179-0560) to the eyebolts and gently lift
the piston out of the preventer body. Remove
the eyebolt assemblies.
If a vertical lift is not possible or the piston does not lift out freely, slowly apply low (50 psi)
hydraulic pressure to the closing chamber—DO NOT USE AIR OR GAS.
Remove the twelve capscrews from around the inner sleeve. Install two eyebolts (1/2"-
13UNC) into inner sleeve. Attach a Hydril chain sling (1900179-0160) to the eyebolts and lift
the inner sleeve out of the body. Remove the eyebolts.
NOTE
NOTE: Keep the latches in sequence so that they can be
returned to their original position.
To remove each radial latch, hold the clamping screw and remove the pipe plug. Remove the
shoulder screw from the clamping screw, then remove the clamping screw from the body.
Remove the radial latch from the inside of the body.

NOBL-NA-AHC2008A
CHAPTER 4
Inspection
Clean all components thoroughly. Clean the exterior as well as the interior parts of the BOP
assembly with high pressure water or steam.
Inspect the upper and lower connections for pitting, wear, and damage, especially in ring
grooves and stud bolt holes. Minor pits and scores in a ring groove can be removed in the
field by polishing with 240-grit or finer emery cloth. Apply light machine oil to the ring
groove and wipe it clean, leaving only a film of oil on the surface. Severe pits and scores
requiring welding, machining, and stress relieving must be repaired at a Hydril Authorized
Repair Facility (ARF). Also, damaged or worn stud bolt holes requiring welding, machining,
and stress relieving must be repaired at a Hydril ARF.
Check the body for wear and damage, especially for pits and vertical scores in the internal
cylinder walls. Minor pits and scores can be removed in the field with emery cloth. Repaired
surfaces should be coated with castor oil. Severe pits and scores requiring welding,
machining, and stress relieving must be repaired at a Hydril ARF.
Inspect the vertical bore for wear and damage from drill string and drill tools, especially in
the area of the ring grooves. If wear is excessive, the area must be repaired at a Hydril ARF.
Check the inner body sleeve for wear, damage, and looseness. Check slots in sleeve for
cuttings which may restrict piston movement.
Check for piston damage and wear. Examine the inner and outer walls for pits and vertical
scores and examine the tapered bowl for pits and gouges. Minor pits and scores on the walls
can be removed in the field with emery cloth. Repaired surfaces should be coated with castor
oil. Severe pits and scores must be repaired at a Hydril ARF. Pits and gouges in the tapered
bowl should be filled with a permanent type adhesive, such as epoxy. Sharp or rolled edges
should be removed with emery cloth or a grinder. Repair is satisfactory if a relatively smooth
surface is achieved.
Check the wear plate on the inner bottom face of the head for wear. Severe wear is exhibited
in the form of grooves or channels shaped by the steel segments of the packing unit. The
inner bottom face of the head serves as a wall to prevent upward movement of the packing
unit. Friction between these metal surfaces is controlled at a level which does not impair
horizontal movement of the packing unit. Repair of this surface is accomplished by
replacement of the wear plate.
Inspect the packing unit for wear, cracking, hardness, and correct elastomer composition.
Replace if necessary. Check seal rings for nicks, cuts, fraying of lips, and abrasion. Worn or
damaged seal rings must be replaced.
NOTE
Hydril recommends all seals be replaced whenever a BOP is
disassembled and assembled. Coat packing unit, seals, and
non-extrusion rings with castor oil before installation.

CHAPTER 4
Assembly
WARNING
This is VERY heavy equipment, and extreme safety
procedures must be followed during lifting operations. Be
sure that lifting equipment is in good condition and capable
of handling the load.
Ensure that working surfaces are free of burrs, rough edges, or other defects. Inspect all
seals and replace any damaged seals or seals in use over one year.
NOTE
Hydril recommends that all seals be replaced whenever a
BOP is disassembled and assembled. Seals must be installed
as shown in assembly drawing. Coat packing unit, seals, and
non-extrusion rings with castor oil before installation.
CAUTION
Use of a petroleum-based oil or grease will adversely reduce
seal life.
Lubricate all fastener threads with TS Moly Paste thread lubricant, except where noted. Coat
interior surfaces with castor oil.
Insert the radial latches into the annular body with the short side of the teeth down and in
the same sequence as disassembled.
NOTE
If a new latch is installed within a set of well worn latches,
ensure equal load sharing by polishing the new latch to match
the existing latches.
Install an O-ring in the external groove of each clamping screw. Install the clamping screws
and thread them hand tight all the way in.
CAUTION
Be careful not to overtighten the clamping screws, or the radial
latch will extend beyond the sides of the body.
NOTE
Do not lubricate shoulder screws.
Insert the shoulder screw into each clamping screw and turn them into the latches until tight
(approximately 150 lb-ft/203 N•m). Apply teflon tape to the threads of the pipe plug. Hold

NOBL-NA-AHC2008A
CHAPTER 4
each clamping screw and install the pipe plug. Ensure that all of the latches are retracted
fully by turning the clamping screws counterclockwise until the latches are shouldered
against the body.
Install two sleeve eyebolts (1/2"-13UNC) into the inner sleeve. Attach a Hydril chain sling
(1900179-0160) to the eyebolts and install the inner sleeve into the counterbore of the
upper body. Secure the inner sleeve with twelve capscrews. Torque the screws to 150 lb-ft
(203 N•m). Remove the eyebolts.
Install double U-seal and non-extrusion rings on the upper and lower segments of the piston.
Install three piston eyebolt lifting assemblies (1"-8UNC) into the piston, ensuring that the
retaining ring and spacer block are snug against the piston. Attach a Hydril chain sling
(1900179-0560) to the eyebolts and gently lift the piston. Lubricate all mating surfaces with
castor oil before lowering the piston into the body.
Ensure that the piston is aligned vertically with the body prior to lowering the piston into the
BOP cavity. Open the Close port(s) to atmosphere. With proper vertical alignment, the piston
will slide the length of its normal full stroke to the bottom of the preventer body. Remove the
eyebolt assemblies from the piston.
CAUTION
Be careful not to damage the seals during assembly.
Install a head gasket in the seal groove on the outside of the opening chamber head. Install
the U-seal in the seal groove on the inside diameter of the opening chamber head, ensuring
that the lips are facing downward. Install three hoist rings (7/8"-9UNC) into the opening
chamber head. Vent the Open port.
Attach a Hydril chain sling (1900179-0160) to the hoist rings and lift and lower the opening
chamber head into the body of the BOP, ensuring that the opening chamber head is square
with the body and has a straight start. Remove the hoist rings.
Lubricate the bowl of the piston and the packing unit with castor oil. Install two 3/4"-10UNC
eyebolts into packing unit. Attach a Hydril chain sling (1900179-0160) to the eyebolts and
lift the packing unit and set it into the bowl of the piston. Remove the eyebolts.
Install a wear plate on the inner face of the annular head. Secure the wear plate with
capscrews. Torque the capscrews to 50 lb-ft (68 N•m).
Install an O-ring in the seal groove on the outside diameter of the head, just below major
diameter and above the locking rings. Install a U-seal in the seal groove on the inside bottom
of the head. Ensure that the lips are facing upward.
Install three hoist rings (2"-4.5UNC) into the head. Attach a Hydril chain sling (1900179-
0560) to the hoist rings and install the head into the annular body. Remove the hoist rings.
Secure the head with four pull-down bolt assemblies to pull the head fully into place. Tighten
the pull-down bolt assemblies until they bottom fully against the head flange and torque to
300 lb-ft (407 N•m). Check for "standoff" between the head flange and the body. "Standoff"
gaps should not be more than 0.05 inch (1.3 mm) maximum.
CAUTION
To prevent unequal clearance between the head and the body,
tighten the latches alternately on opposite sides or in a
crisscross pattern.
Turn the clamping screws clockwise to engage the latches fully into the locking rings of the
preventer head and torque them to 350 lb-ft (475 N•m).

CHAPTER 4
Storage
Storage
The ideal storage situation for rubber goods (which includes synthetic compounds such as Nitrile
Copolymers as well as natural rubber parts) would be in vacuum-sealed containers maintained in a
cool, dry, dark storage area. The following recommendations will allow vendors and users of oil
field equipment to maximize normally available storage facilities for rubber goods:
1. Keep the rubber storage area as dark as possible — preferably indoors and away from direct
sunlight, skylights, windows, and direct artificial lighting.
2. Select a cool location (approximately 65oF) that is away from heaters, stoves, and direct blasts
of space heaters.
3. Keep rubber goods away from electrical machinery (motors, switch gear, or any high-voltage
equipment). Avoid locations susceptible to drafts that will carry the atmosphere from electrical
machinery to the rubber goods storage area.
4. The practice of first-in, first-out is essential with rubber goods.
5. Store rubber goods in a relaxed position in their normal shape. For example, do not hang O-
rings on nails. Do not keep assemblies in stretched attitudes, e.g., O-rings on glands, BOP testers,
and operator parts.
6. Rubber goods storage areas should be kept as dry as possible. Remove oil, grease or other
foreign materials from the storage area to preclude spillage on rubber goods.
7. Sealed containers are recommended if storage is for extended periods. Impervious surface
coverings such as waxing will increase shelf life.

NOBL-NA-AHC2008A
Chapter 5
Description
A ram BOP is a valve that uses metal blocks with integral elastomer seals to seal off pressure on a
wellbore with or without tubulars in the bore. A ram-type BOP may be used to quickly seal off a
well in the event of an under balanced or induced kick. A ram BOP consists of two fitted blocks,
normally retracted. Pistons force the halves together, sealing the well. The blocks may be flat to
seal over an open hole, or semi-circular to seal around pipe. Blocks may also be fitted with a
cutting edge to allow the ram BOP to shear through drillpipe.
Objectives
• An understanding of the purpose of ram BOPs in well pressure control.
• An ability to identify the various types of rams and their purposes.
• An ability to identify the major components and features of a ram BOP.
• An introduction to these components and their function.
• An understanding of how to remove, disassemble, inspect, maintain, assemble, test and
install a Hydril ram.
• An understanding of how to remove, maintain, and install an annular packing unit.

CHAPTER 5
RAM BOP
RAM BOP
The Hydril ram-type blowout preventer is essentially a specialized type of valve used to close in a
wellbore. Similar in operation to a gate valve, the ram-type blowout preventer has gates called
rams which meet at the center of the hole, which they close.
The faces of the rams are equipped with large
rubber packers which are made in shapes to close
around tubing, drill pipe, casing, or to close off
the open hole. The ram upper seal closes off the
area between the ram and the blowout preventer
seal seat. Hydril rams provide a large volume of
feedable rubber in the front packer and upper
seal system. As upper seal and/or front packer
wear occurs, more rubber is compressed into a
sealing engagement to maintain a seal off.
Each set of rams seal off on only one size of pipe.
Hydril variable rams are available which close and
Figure 5-1 Single Ram BOP seal on a range of pipe sizes. When pipe rams are
closed, they seal off the annulus between the
outside of the pipe and the wellbore. Pipe centering guides in the face of the pipe rams contact the
pipe in a manner to center the pipe within the bore as the rams close. Hydril ram-type blowout
preventers can also be equipped with blind rams which seal off the well bore when there is no pipe
in the hole. Blind/Shear rams are available that shear drill pipe, then seal off the wellbore.
All Hydril ram blowout preventers are closed and opened hydraulically. Each ram is attached to a
piston rod which extends through the bonnet on each side of the blowout preventer to a piston in
an operating cylinder. The application of hydraulic pressure to the operating cylinders pushes the
pistons inward or outward to close or open the rams. The ram operators are sometimes equipped
with an automatic functioning lock (MPL). The primary purpose of the MPL is to lock the rams in
place, after they are closed hydraulically.
Hinged bonnets are provided for ease of ram change. Ram changes are accomplished by operating
the rams to a fully open position, unbolting the bonnets, then swinging both bonnets open. The
rams are then energized hydraulically to the closed position. The ram is then lifted straight up to
disengage it from the piston rod. A new ram is seated on the piston rod, the lifting eyebolt is
removed and the ram is retracted into the bonnet recess. The bonnet is then swung closed and the
bonnet bolts secured, thus making the blowout preventer ready for use.
Types of Ram BOPs

There are several types of ram BOPs in use: compact, single, double, Quik-Loq and subsea test
valve (SSTV). Compact rams are lighter in weight, shorter, and more economical than regular
rams. They are typically used on existing wells where the average wellbore pressures are known
and maintained normally. Rams may come in single, double, or even triple body configurations.
Each one of these types of rams may use one of several types of blocks: pipe, blind, shear, casing,
etc. Pipe rams are designed to seal over specific sized tubulars. Blind rams are designed to seal
over open holes in which there is no toolstring. Shear rams are used to cut through tubulars in the
wellbore. There are pipe shear rams and casing shear rams. Shear rams may not actually seal over
a hole once the tubular is cut. If a shear ram is designed to seal over a hole, it is referred to as a
blind shear ram.
Refer to Figure 5-2. This dual compact ram BOP provides blowout prevention with blind/shear and
casing shear rams installed in the two ram compartments. The upper ram BOP is equipped with 22"
Multiple Position Lock (MPL) operators that close the shear rams with enough force to shear the
pipe and seal off the wellbore in the event of a blowout during operations. The blind/shear rams
can also seal off the wellbore if no drillpipe is in the wellbore.

NOBL-NA-AHC2008A
CHAPTER 5
Types of Ram BOPs
The Middle Hydril® Dual Compact Ram BOP provides

blowout prevention with Hydril® Variable rams
installed in the two ram compartments. The middle
dual compact ram BOP is equipped with 15 1/2"
Multiple Position Lock (MPL) operators that close the
variable pipe rams around the drillpipe in the wellbore
in the event of a blowout during drilling operations.
The Lower Hydril® Single Compact Ram BOP provides
blowout prevention with Hydril® Fixed-Bore rams
installed in the one ram compartment. The lower
single compact ram BOP is equipped with 15 1/2"
Multiple Position Lock (MPL) operators that close the
pipe rams around the drillpipe in the wellbore in the
Figure 5-2 Upper Hydril Dual Compact Ram event of a blowout during drilling operations.
The Quik-Loq BOP is unique in that it features a

boltless bonnet attached to slide rods. The
design eliminates the need for tools during ram
and operator changeouts. It permits 360°
rotation of ram blocks for easy access and
service so that change-outs can be done 90%
quicker - in minutes instead of hours.
A subsea test valve (SSTV) allows a crew to
pressure test the rest of the stack. When closed
around drill pipe, the SSTV test ram seals the
lower ram cavity. Test pressure is applied
internally above the test ram, allowing testing of
the stack.
Figure 5-3 Quik-Loq Ram
The SSTV is a Hydril® compact SRBOP. It is used

for pressure testing the stack without the need to
withdraw the total length of the drill pipe. This is a
huge savings in terms of otherwise lost rig time. It
even comes equipped with the Hydril Variable Ram
(HVR) which allows the SSTV to close on tubulars
anywhere from 4.5” - 7”
It can be transformed at the surface from a SRBOP
to a SSTV and back again. The transformation is
accomplished by changing the internal ram block
sets. The SRBOP ram blocks seal the well bore
around the drill pipe; the SSTV ram blocks close
off the well bore after the drill pipe has been
removed.
Figure 5-4 Subsea Test Valve (SSTV)

CHAPTER 5
Ram Features
Ram Features
The ram-type BOP has many useful features. It
is designed to be field maintainable. It comes
with inter-changeable rams, a patented bonnet
seal, low torque bonnet bolts, replaceable
manifold hinge assembly, a replaceable top
seat, and replaceable cavity wear pads. The
bonnets may be hinged from either side and
have an elevation adjustment.
Hydraulic Circuit
An opening and closing line is required to
operate each set of rams. These control lines Figure 5-5 Ram BOP Components
are connected to the one inch NPT ports on the hinge side of the blowout preventer. The regulated
pressure source to operate this ram preventer should be from a regulator separate from that used
for the annular blowout preventer(s).
The operator hydraulic chambers and seals are rated for 3000 psi continuous operation. The
operating cylinders may be operated to 3000 psi, and have been tested to 4500 psi. Hydraulic
closing pressures from 100 - 300 psi against zero psi well pressure indicates satisfactory operation.
Refer to Figure 5-6. Hydraulic pressure applied to
the closing port initiates fluid flow in drilled passages
in the BOP body. The fluid flows from the body to the
fluid hinge, through the fluid hinge sub, and into the
bonnet hinge. From there, it flows through a drilled
passage in the bonnet and exits between the
cylinder and cylinder liner. The fluid then acts upon
the back side of the operating piston and moves it
toward the wellbore. This closes the rams.
As the piston assembly moves toward the wellbore,
the hydraulic fluid in the opening chamber flows out
of the porting in the bonnet. The fluid flows through
a drilled passage in the bonnet and into the bonnet
Figure 5-6 Hydraulic Fluid Flow
hinge. The fluid then passes through the fluid hinge
sub and into a drilled passage in the preventer body and out through the opening chamber port.
When opening pressure is applied, the hydraulic fluid flow is exactly the reverse of the process just
described. The closing time of the preventer is determined by the rate at which the hydraulic
closing can be delivered to the operating cylinders. Minimum closing time will be achieved by short,
large-bore hydraulic control lines and large accumulator volume.
Multiple Position Lock.

Once hydraulic closing pressure is applied, the ram
automatically closes, locks, and seals off. With
multiple position lock (MPL), opening and closing of
the ram is controlled by a unidirectional clutch
mechanism and lock nut. The clutch maintains the
nut and ram in a locked position until the clutch is
disengaged by hydraulic pressure to open the ram
Hydraulic opening pressure disengages the front
and rear clutch plates, thus allowing the lock nut to
rotate and the ram to open. As the ram and piston
move to the open position, the lock nut and front
clutch plate rotate freely. Figure 5-7 Multiple Position Lock Mechanism

NOBL-NA-AHC2008A
CHAPTER 5
Packers and Seals
Packers and Seals

Ram Assembly
The ram is designed to combine strength with the most effective seal assemblies, providing a
large volume of feedable rubber in the front packer and upper seal. The upper seal and front
packer are separate, and each can be replaced independently.
The ram upper surface is recessed to prevent seal seat wear while opening and closing the
rams and to prevent scoring from a damaged ram. A unique technique of energizing the
upper seal increases contact pressure with the upper seal seat only during the final seal off
portion of the ram stroke.
The standard ram operator is 15.5”. It takes approximately 19.5 gal (73.8l) of fluid to close
and 16.82 gal (63.7l) to open. There is a 19” operator which takes approximately 29.31 gal
(110.9l) to close and 26.62 gal (100.8l) to open. The 22” operator takes 39.29 gal (148.7l)
to close and 36.61 (138.6l) to open.
Pipe rams for the 18-15 ram blowout preventer are designed to hang off drill pipe up to
700,000 lbs. while retaining a seal to full rated working pressure. The rams contain a
hardened inlay in the corners of the pipe bore, which support the pipe when hanging load is
applied. Pipe rams have a fatigue life of greater than 78 wellbore pressure cycles (546
closures) and temperature rating of 20°F - 500°F.
All rams meet API16A performance tests including:
Sealing characteristics Hangoff Tests
Shear Tests Ram Locking Device
Ram Access Test Temperature Verification
Fatigue Life Tests and Stripping Tests.
As an option, rams may come equipped with a position indicator. A position indicator sends a
signal to the surface displaying where the operator is in its travel position.
Figure 5-8 Pipe Ram Closing Ratios

CHAPTER 5
Packers and Seals
Shear Ram Operation

The shear ram assembly is designed to shear drill pipe and seal off the wellbore. Shear rams
may also be used as blind rams for open hole closures. The closed rams will seal against full
rated working pressure in the wellbore.
The shear blades’ design minimizes the required shearing load. The dual v-blade
arrangement with sharp rake angles concentrates the deforming forces so that the drill pipe
is crimped only on the shear plane. Once shearing is initiated, the blades’ rake angles impose
an additional tensile load to aid in separation. The sheared lower fish has an opening large
enough to allow pumping drilling fluid down the drill pipe to the bit.
Following a pipe shear or when closing on an open hole, a seal against wellbore pressure is
obtained in a similar manner as that in a blind ram. The difference is the lateral “T”-seal used
with the shear ram, taking the place of the front packer in the blind, seals on the horizontal
plane rather than the vertical.
There are two individual assemblies in each shear ram assembly set - the lower blade shear
ram and the upper blade shear ram assemblies. Blind rams or blind shear rams seal
repeatedly on open hole to full rated pressure. They have a fatigue life of 104 wellbore
pressure cycles (728 closures) and an operating range of 20°F - 350°F.
Figure 5-9 Shear Ram Closing Ratios

NOBL-NA-AHC2008A
CHAPTER 5
Packers and Seals
Variable Rams
A Hydril Variable Ram (HVR) is a ram
assembly designed to close and seal on a
range of pipe diameters. Using the HVR
eliminates the need to change ram sizes
when changing pipe sizes within the HVR’s
range. The current ranges are 3.5” - 5.5”,
4.5” - 7”, and 5.5” - 7 5/8”.
The HVR packer has interlocking I-beam
inserts molded into the rubber. These
inserts confine the rubber within the Figure 5-10 Hydril® Variable Ram
packer and against the pipe thus
preventing extrusion of the sealing element. During seal off on small diameter pipe, the
inserts move radially inward to contact. On large diameter pipe, the inserts are displaced into
the front packer. Its automatic adaptation to the pipe size as the ram closes is a key feature.
The HVR operates inside standard Hydril ram blowout preventers and utilizes the standard
hydraulic operator. This design permits interchangeability with fixed size pipe rams, casing
rams, and/or blind rams at anytime. The fatigue life of HVR’s are 78 wellbore pressure cycles
(546 closures). The operating ranges for the HVR varies.
Wear Plate
The wear plate is a field
replaceable pad set in a
machined recess groove of the
ram compartment. It
compensates for ram cavity
wear. It is normally held in place
by three stainless steel screws.
The wear plate comes in three
different styles. There is the
replaceable bolt-down,
replaceable rod-retention, and
the integral cast-in styles.
Figure 5-11 Wear Plate
Upper Seal Seat

The upper seal seat is a replaceable metal seat located above the ram bore cavity inside the
preventer body. It provides the sealing surface for the upper seal of the ram assembly.
Figure 5-12 Ram Cavity Upper Seal Seat

The seal seat is held in place by a stainless steel lock ring expanded into a groove in the
blowout preventer body. The lock ring is expanded by sixteen specially-coated stainless steel
socket head set screws. The seal seat contains the seat to body upper and lower seals and
lower seal backup ring.

CHAPTER 5
Packers and Seals
Fluid Hinge and Pin Seals

The fluid hinge allows fluid flow from the
input port through the bonnet hinge and to
the operators to open and close the rams.
The bonnet elevation may also be adjusted
using the hinge pins.
There are three O-ring seals located on the
hinge pin. The HINGE PIN SEAL is an O-ring
used to prevent the entry of outside
contaminants to the hinge pin threads. The
HINGE PIN THREAD SEAL located directly
below the hinge pin threads is an O-ring
used to prevent the entry of outside
contaminants to the hinge pin threads. The
HINGE PIN BEARING SEAL O-ring is used to
prevent the entry of outside contaminants Figure 5-13 Fluid Hinge and Seals
to the Hinge Pin Bearing and Thrust Washer.
Other Seals
The BONNET HINGE SEAL is an O-ring located between the bonnet and bonnet hinge. It seals
the operating fluid path between the bonnet and the bonnet hinge.
The BONNET SEAL is a special seal shaped to fit the groove in the face of the bonnet. This seal
prevents wellbore fluids from escaping between the body and the bonnet to the
environment. The integrity of the bonnet seal is as important as the ram seals to the safe
operation of the blowout preventer.
The Piston Rod Mud Seal is a lip-type seal located in the bonnet on the wellbore side. Its
purpose is to prevent the wellbore fluids from escaping to the environment.
The Bonnet-to-Piston Rod Seal prevents leakage of hydraulic opening fluid from the cylinder
opening chamber. This seal is a molded lip-type packing.
The Cylinder Liner to Bonnet Seal is an O-ring located at the end of the cylinder liner nearest
the wellbore. There are two backup rings, one on either side of the O-ring, associated with
this seal. The O-ring prevents closing pressure from entering the opening side of the cylinder
liner and opening pressure from entering the closing side.
The Cylinder-to-Bonnet Seal is an O-ring and backup ring located on the end of the cylinder
nearest the wellbore and prevents closing hydraulic pressure from entering the environment
or outside contamination and/or seawater from entering the cylinder.
The Piston Seal is a 3-piece bi-directional seal fitted into a groove in the piston. This seal is
flanged by two composite wear rings. The wear rings are split for easy installation. The
piston seals may be placed in hot water to ease installation.

NOBL-NA-AHC2008A
CHAPTER 5
Compact Ram BOP
The Cylinder Head Seal is an O-ring located on the pilot diameter of the cylinder head. This
seal prevents closing pressure from leaking to the environment.
The Cylinder Head Dirt Seal is an O-ring located on the inside face of the cylinder head. This
seal prevents dirt or sea water from entering the cylinder.
The Lockout Stem Seal is an O-ring with one backup ring located in a groove on the lockout
stem.
Compact Ram BOP

The Hydril® 183/4"-15,000 compact ram blowout preventer (BOP) is a hydraulically operated ram
type BOP as defined in API Specification 16A entitled Specification for Drill Through Equipment,
Second Edition, June 1, 1998. The ram BOPs are manufactured in dual and single configurations
(refer to Figures 5-14, 5-15, and 5-16).
The top connection for the compact ram BOP is a 183/4"-15,000 API type 6BX studded flange with a
BX-164 Inconel ring groove. The bottom connection is a 183/4"-15,000 API type 6BX flange with a
BX-164 Inconel ring groove. The compact ram BOP has two side outlets per ram cavity, one on
each side, for connection of the choke and kill valves. Each side outlet is a 41/16"-15,000 studded
flange with BX-155 Inconel ring groove. Side outlets not in use are fitted with blind flanges. Two 1"
Code 62 outlets in each manifold/hinge of the BOP are provided for connection of the hydraulic
lines.
The BOP body is drilled to allow mounting of the manifold/hinges on either side, making it possible
to install the bonnets so that they swing open in the either direction. In addition, the seal seat and
wear plate in each ram compartment are field replaceable without removal of the BOP from the
stack.
All surfaces exposed to wellbore fluids meet requirements of NACE Standard MR-01-75. This BOP
also contains Inconel weld overlays at the following locations:
• Ring Grooves
• Bonnet Seal Sealing Area on Body Face
• Seal Connector Ring and Bonnet Door
• Piston Rod Seal Surface
• Upper Seal Seat
• Ram Seal Seat
The bonnets of the 183/4"-15,000 compact ram BOP are equipped with 151/2 and 22-inch MPL
operators. Normally, the BOP containing pipe rams is equipped with 151/2 MPL operators and the
BOP containing the blind/shear rams or casing shear rams is equipped with 22-inch operators. In
addition, the bonnets are interchangeable, allowing different/same size operators to be used.
Single and dual configurations of the Hydril® 183/4"-15,000 ram BOP that are equipped with the
151/2 and 22-inch MPL operators are shown in Figures 5-14, 5-15, and 5-16.

CHAPTER 5
Compact Ram BOP
3
18 /4”-15,000 API Type 6BX
Studded Flange with BX-164
Inconel Ring Groove
Body
Upper Bonnet
1
15 /2” Operator
1” Code 62
151/2” Operator
Hydraulic Connections
Lower Bonnet 183/4”-15,000 API 6BX

1
4 /16”-15,000 API Studded Flange with BX-164
Flange with BX-155 Inconel Ring Groove
Inconel Ring Groove
Figure 5-14 183/4”-15,000 Dual Compact Ram with 151/2” MPL Operators
183/4”-15,000 API Type 6BX

Inconel Ring Groove
Body
Bonnet
22” MPL Operator
41/16”-15,000 API Studded

Flange with BX-155
NOTE: Two, 1” Code 62
Inconel Ring Groove
Hydraulic Connections on
Hinge Side not shown. 183/4”-15,000 API 6BX
Flange with BX-164
Inconel Ring Groove
Figure 5-15 18 /4”-15,000 Single Compact Ram with 151/2” MPL Operators
3

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CHAPTER 5
Compact Ram BOP
3
18 /4”-15,000 API Type 6BX
Inconel Ring Groove
Body
Upper Bonnet
22” MPL Operator
1” Code 62
22” MPL Operator Hydraulic Connections
Lower Bonnet 183/4”-15,000 API 6BX

1
4 /16”-15,000 API Studded Flange with BX-164
Flange with BX-155 Inconel Ring Groove
Inconel Ring Groove
Figure 5-16 183/4”-15,000 Dual Compact Ram with 22” MPL Operators
Principle of Operation
Similar in operation to a gate valve, the
compact ram blowout preventer has gates
called rams which meet at the center of the
wellbore when they close (refer to Figure 5-17). Top Seal
Each ram attaches to a piston rod. The piston
rod extends through the bonnet on each side of
the blowout preventer where it connects to the
piston inside the operating cylinder. The
application of hydraulic pressure to the
operating cylinders pushes the pistons and TOP VIEW
attached piston rods inward to close or outward
to open the rams. Attached to the other side of
the pistons, the multiple position lock
assemblies (MPL) lock the rams in the closed
position at the end of the close stroke. Packer
This compact ram BOP can operate pipe rams,
variable pipe rams, and/or shear rams (refer to FRONT VIEW
Figures 5-17, 5-18, and 5-19).
Figure 5-17 Pipe Ram, Operation

CHAPTER 5
Compact Ram BOP
Pipe rams (refer to Figures 5-17) seal-off on

only one size of pipe. When the pipe rams are
closed, they seal-off the annulus between the
outside of the pipe and the wellbore. Pipe
centering guides in the face of the pipe rams Top Seal
contact the pipe in a manner to center the
pipe within the bore as the rams close. The
faces of the rams are equipped with large
rubber packers which are made in shapes to
close around tubing, drill pipe, and casing or
to close off the open hole. The ram upper seal TOP VIEW
closes off the area between the ram and the
blowout preventer body. Hydril rams provide
a large volume of feedable rubber in the upper
seal and in the front packer. As upper seal
and/or front packer wear occurs, more rubber Packer
is compressed into a sealing engagement to
maintain a seal off. The pipe ram is installed
below the shear rams so that the drill string FRONT VIEW
can hang-off after the pipe above has been Figure 5-18 Variable Pipe Ram, Operation
sheared, preventing the drill string from
falling down the wellbore.
The variable ram (refer to Figures 5-18) is a pipe ram assembly designed to close and seal
on a range of pipe diameters. Using the variable ram eliminates the need to change ram
sizes when changing pipe sizes in the range of the variable ram.
The variable ram packer has interlocking I-beam inserts molded into the rubber. These
inserts confine the rubber within the packer and against the pipe thus preventing extrusion
of the sealing element. During seal-off on smaller diameter pipe, the inserts move radially
inward to contact. On larger diameter pipe, the inserts are displaced into the front packer.
Application of load by the BOP operator squeezes the sealing element within the confines to
the inserts and the pipe O.D. This action establishes a steel contained sealing element. A
key feature is automatic adaptation to the pipe size as the ram closes and seals off. Like the
pipe rams, the variable pipe rams allow sheared pipe to hangoff in the wellbore.
The ram block upper seal provides a large volume of feedable rubber to deliver a long and
dependable service life. This design permits interchangeability with fixed size pipe rams,
casing rams, and/or blind rams at any time.
The blind/shear rams (refer to Figures 5-19) cut through the drill pipe and seal-off the
wellbore. Shear rams also act as blind rams for open hole closures. The closed shear rams
seal against full rated working pressure in the wellbore.
The design of the shear blades minimizes the required shearing load. The dual V-blade
arrangement with sharp rake angles concentrates the deforming forces to crimp the drill
pipe only on the shear plane. Once shearing begins, the blades rake angles impose an
additional tensile load to aid in separation. As a result, the lower part of the sheared drill
pipe (fish) has an opening large enough to allow the pumping of drilling fluid down to the bit.
Following a pipe shear or closure on an open hole, the shear ram seals against wellbore
pressure.The lateral T-seal on each shear ram acts as a packer and seals on the horizontal
plane. The upper seal on the top of the shear ram closes off the area between the ram and
the body of the BOP. Each shear ram assembly consists of two individual assemblies, the
lower blade carrier assembly and the upper blade carrier assembly.

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CHAPTER 5
Compact Ram BOP
Lateral T-Seal
Top Seal
UPPER LOWER
BLADE BLADE
CARRIER CARRIER
TOP VIEW
Upper Shear
SIDE VIEW Lower Shear Blade
Blade
Figure 5-19 Shear Rams, Operation

Another type of shear ram is the casing shear rams (refer to Figures 5-20). These rams act
as shear rams to cut through casing; however, they do not have wellbore sealing capability.
UPPER LOWER
SHEAR SHEAR
RAM RAM
TOP VIEW
Upper Shear Lower Shear Blade
Blade
SIDE VIEW
Figure 5-20 Casing Shear Rams, Operation

CHAPTER 5
Compact Ram BOP
Bonnet
Piston Rod
Multiple Position
Lock (MPL)
Piston
Bonnet Hinge
Closing Chamber
Manifold/Hinge
Opening Chamber
Figure 5-21 Typical Hydril Dual Compact Ram, Interior
Multiple Position Lock

The compact ram BOP is equipped with multiple position lock (MPL) assemblies (refer to
Figures 5-21). The MPL automatically locks and maintains the ram closure, providing
optimum rubber pressure required for seal-off of the packer and the upper seal. Due to the
wear of the packer, the MPL also locks the ram in a different position with each closure to
ensure an effective seal-off. Furthermore, multiple position locking is required to ensure
retention of the seal-off position.
The mechanical lock is automatically set each time the ram is closed. Applying hydraulic
pressure to the close side of the piston in the operating cylinder closes the ram to a seal-off
position. The locking system maintains the ram mechanical lock whether closing pressure is
present or not. The ram opens only by application of hydraulic pressure to the open side of
the piston which automatically releases the locking system and opens the ram
simultaneously. A unidirectional clutch mechanism and a overhauling nut control the locking
and unlocking of the MPL. The clutch maintains the overhauling nut and ram in a locked
position until the clutch is disengaged by hydraulic pressure to open the ram. Hydraulic
opening pressure disengages the front and rear clutch plates to permit the overhauling nut
to rotate and the ram to open. As the ram and piston move to the open position, the
overhauling and front clutch plate rotate freely.
Hydraulic Circuit
The operation of the Hydril compact ram blowout preventer requires an oil field accumulator
unit of sufficient volume and pressure capacity. Hydraulic lines from the accumulator unit
connect to the 1 - inch SAE Open and Close ports in the manifold/hinge. Use a regulated
pressure source separate from that used for the annular BOP.
Hydraulic pressure applied to the Close port initiates fluid flow in drilled passages in the
manifold/hinge (refer to Figures 5-14). The flow continues from the manifold to the fluid
hinge, through the fluid hinge sub, and into the bonnet hinge. From the bonnet hinge,
hydraulic pressure flows through a drilled passage in the bonnet and enters into the

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CHAPTER 5
Compact Ram BOP
operating cylinder on the close side of the piston. Then, the hydraulic pressure moves the
piston toward the wellbore and closes the rams.
As the piston assembly moves toward the wellbore, the hydraulic fluid in the open side of the
piston flows out of the operating chamber and into the drilled passage in the bonnet. Flow
continues into the bonnet hinge, through the fluid hinge sub , and into the drilled passage in
the manifold/hinge. Finally, the fluid exits through the Open hydraulic port. When opening
pressure is applied, the flow of hydraulic pressure is exactly the reverse of the flow of closing
pressure just described.
The closing time of the preventer is determined by the rate at which the hydraulic closing
fluid can be delivered to the operating cylinders. Minimum closing time will be achieved by
short, large-bore hydraulic control lines and large accumulator volume.
Any clean, light petroleum hydraulic oil will serve as a hydraulic fluid. Fresh water may be
used if water soluble oil or corrosion inhibitor is added. Prevention from freezing in cold
climates may be accomplished by the addition of antifreeze to the fluid.
CAUTION
Do not use synthetic or fuel oils. These types of fluids will
damage the seals. For additional discussion and specific
hydraulic fluid recommendations, refer also to Hydril
Engineering Bulletin EB 99-009. This bulletin is available on
Hydril's website, www.hydril.com.
Operating Procedures
Opening the Rams

To open the rams, vent operating pressure from the Close chamber.
Apply operating pressure to the Open chamber.
Closing the Rams

To close the rams, vent operating pressure from the Open chamber.
Apply operating pressure to the Close chamber.
WARNING
HYDRIL IS NOT RESPONSIBLE FOR ANY ALTERATIONS,
MODIFICATIONS OR REPAIRS TO THE SYSTEM, ITS
INTERCONNECTS AND COMPONENTS, UNLESS
PERFORMED WITH HYDRIL SUPPLIED PARTS AND THE
WORK PERFORMED BY A HYDRIL AUTHORIZED
REPRESENTATIVE. ALTERATIONS, MODIFICATIONS, OR
REPAIRS PERFORMED OTHERWISE MAY RESULT IN
DAMAGE TO THE EQUIPMENT OR FAILURE OF THE
CONTROL SYSTEM TO OPERATE AS DESIGNED AND MAY
RESULT IN SERIOUS PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH. UNAUTHORIZED ALTERATIONS,
MODIFICATIONS, REPAIRS OR USE OF PARTS OTHER
THAN THOSE SUPPLIED BY HYDRIL WILL VOID THE
STANDARD WARRANTY OF THE CONTROL SYSTEM AS
OUTLINED IN THE TERMS AND CONDITIONS
AGREEMENT.

CHAPTER 5
Compact Ram BOP
BEFORE THE INITIAL START UP, OR PRIOR TO POST

REPAIR START UPS, VERIFY CONTAMINANTS, DEBRIS,
AND OTHER FOREIGN MATERIALS HAVE BEEN FLUSHED
FROM THE FLUID SUPPLY LINES. FAILURE TO DO SO MAY
RESULT IN DAMAGE TO THE EQUIPMENT OR FAILURE OF
THE CONTROL SYSTEM TO OPERATE AS DESIGNED AND
MAY RESULT IN SERIOUS PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
Ram Block Removal/Installation Procedure

Use the following procedure to remove and install the rams.
WARNING
DO NOT OPEN THE BONNETS OF A RAM BOP UNLESS IT
IS INSTALLED ON A TEST STUMP OR SUPPORTED SO
THAT IT CANNOT FALL OVER. THE WEIGHT OF AN OPEN
BONNET COULD TIP OVER AN UNSUPPORTED BOP AND
CAUSE AN INJURY.
Ram Removal
1. Gather the following tools and materials:
• Bonnet bolt socket
• Two lifting eyes, 1"-8UN
2. Open the rams fully with hydraulic pressure. Inspect to ensure that rams have
retracted fully.
3. Unscrew the bonnet bolts on each bonnet. The bonnet bolts are retained by O-
rings. Ensure that they are fully disengaged from the body.
4. Swing bonnets open approximately 90°.
WARNING
DO NOT OPEN THE BONNETS OF THE RAM BOP UNLESS
IT IS INSTALLED ON A TEST STUMP OR SUPPORTED SO
CAUSE AN INJURY.
5. Close (extend) the rams fully with hydraulic pressure.
CAUTION
Ensure that the bonnet doors are open. Do not apply closing
pressure while bonnet bolts are loose and a bonnet is against
the body or damage to the piston rod will result.

NOBL-NA-AHC2008A
CHAPTER 5
Compact Ram BOP
6. Install a 1"-8UN lifting eye into the ram block and lift it straight up to remove it
from the piston rod.
7. Remove the ram block from the other side in the same manner.
Ram Installation
• Castor oil
• TS Moly Paste 70
• Light machine oil, Gulf "Harmony No. 46" or Exxon "Coray 100" or
equivalent
• Cortec VCI-369 grease or equivalent
• Lint-free cloth
• Torque wrench
• Two lifting eyes, 1"-8UN
2. Insert a lifting eye into the ram and install it on the piston rod in one side of the
ram BOP.
3. Install the other ram into the other side in the same manner
4. Lubricate rams with castor oil.
NOTE
The flats on the piston rods must be aligned vertically to mate
with slots on the rams. The bonnets are equipped with guide
pins below the rams to prevent the rams from rotating out of
position while the bonnets are open.
5. Remove the lifting eyes.

6. Open (retract) the rams fully.
7. Clean the ram compartments thoroughly and lubricate them with castor oil.
8. Inspect the bonnet seal in each bonnet and clean the surfaces where the bonnet
seals contact the body. Replace the bonnet seals if required. Lubricate the
bonnet seals with castor oil.
9. Wipe the sealing surfaces with a clean lint-free cloth.
10. Apply Cortec VCI-369 grease to the sealing surfaces on the body.
11. Lubricate the threads of the bonnet bolts with TS Moly Paste 70 thread lubricant.
12. Close the bonnets.
13. Tighten all bonnet bolts using 2,000 lb-ft (2712 N•m) torque.

CHAPTER 5
Compact Ram BOP
Disassembly
Because the hydraulic circuits feed both bonnets of each BOP, it is necessary to disassemble
both bonnets from the body of each BOP at the same time. Do not attempt to disassemble
this BOP unless it is installed on a test stump or supported so that it cannot fall over.
WARNING
BONNET COULD CAUSE AN UNSUPPORTED BOP TO TIP
OVER.
Upper Seal Seat
Body Wear Plate
Bonnet
Bonnet Bolt
MPL Cylinder
Cylinder Head
MPL Assembly
Bonnet Hinge
Fluid Hinge
Piston
Manifold/Hinge
Figure 5-22 Ram BOP - Cutaway View

Except for the tools listed below, disassembly of the compact ram BOP can be performed
with standard tools.
• Two 11/2"-8UN eyebolts (for bonnet)
• 1/4" hex key wrench
• MPL lockout wrench
• Two all threaded bolts, 3/4"-10UNC x 5" long
• Bonnet Seal Carrier Ring Installation/Removal Tool Kit containing:
• Two cap screws, 1/2"-13UNC X 21/2" long
• Two 1"-8UN eyebolts (for packing unit)

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CHAPTER 5
Compact Ram BOP
• Two all threaded rods, 5/16"-18UNC x 31/2" long

• Two hex nuts, 5/16"-18UNC
• Two washers, flat, 5/16"
MPL Cylinder
Cylinder Head
Lockout Gland
Cylinder Head Lockout Stem

Cap Screws
Retainer Plate and Lockout Segment

Locating Pin
O-Ring and Backup Rings
Retainer Plate and O-Ring and Backup Rings

Locating Pin
O-Ring and Backup Rings
MPL Transfer Ring

Overhauling Nut Spring
Bearings Front Clutch Plate Close Port
Rear Clutch Seal Retainer
Overhauling Nut Cap Screw
Plate and Keys
Cylinder O-Ring
Piston Seals and and Backup Ring
Wear Rings Cylinder Nuts &
Lockout Device
Bolts/Cap Screws
MPL Cylinder Piston
Overhauling Nut and
Clutch assembly
Cylinder Head
Overhauling
Screw
Figure 5-23 MPL Cylinder Disassembly/Assembly
MPL Cylinder Assembly Removal

Refer to Figures 5-22 and 5-23 while following this procedure.
1. Open the rams by applying Opening pressure.
2. Remove the cylinder head cap screws.
3. Remove the cylinder head from the cylinder. Remove the overhauling nut
bearing from the cylinder head. Leave the O-rings installed.
4. Remove the overhauling nut/clutch assembly by rotating the overhauling nut
counterclockwise. If it is necessary to disassemble the overhauling nut/clutch
assembly, use the following procedure:
• Remove the socket head cap screws from the front clutch plate.
• Remove the front clutch plate from the overhauling nut.

CHAPTER 5
Compact Ram BOP
• Remove the rear clutch plate and keys from the retainer plate.
• Remove the clutch springs.
• Remove the retainer plate and locating pin.
• Remove the overhauling nut bearing from between the overhauling nut and
retainer plate.
5. Install the cylinder head. Tighten cap screws using 550 lb-ft (745 N•m) torque.
6. Disengage all bonnet bolts from the body. The bolts are retained in the bonnet
by O-rings and are intended to remain in in the bonnet unless replacement is
required.
7. Open the bonnet at least 90°.
8. Apply Closing pressure to extend the rams.
9. Remove the ram assembly by installing a 1"-8UN eyebolt in the hole provided
and lifting straight up.
10. Using the MPL lockout wrench, engage the two lockout devices by rotating
lockout stems (clockwise 6-8 turns.
11. Apply 100 psi (6.9 Bar) Opening pressure. Vent Opening pressure and
disconnect hydraulic pressure source from BOP.
12. Disengage lockout devices. Remove lockout devices. Remove O-ring and back-
up ring from lockout stem.
13. Remove the cylinder head. Remove the O-rings from the cylinder head.
14. Remove the MPL cylinder and transfer ring by removing the cylinder cap screws.
Remove the bonnet to cylinder O-ring and back-up ring from the bonnet.
15. Remove the close port seal retainer from the cylinder. Remove the O-rings from
the retainer.
16. Remove the O-rings and the back-up rings from the transfer ring.
17. Remove the piston and overhauling screw assembly by sliding it out of the
bonnet. Remove the piston seal(s) and wear rings from the piston.
CAUTION
Disassembly of the overhauling screw from the piston is not
normally performed in the field and requires factory service.
Contact Hydril or refer to Hydril website, www.hydril.com, for a
list of worldwide service locations.
18. Close the bonnet and screw in all bonnet bolts until tight.
Fluid Hinge Removal

Follow the procedure below for each of the bonnets. Refer to Figure 5-24.
1. Remove the nuts from the studs holding the fluid hinge to the bonnet hinge.
2. Remove the fluid hinge assembly from the bonnet hinge.
CAUTION
The springs in both ends of the seal sub spool are strong. As
the seal sub assembly comes out of the bonnet hinge, take care
that the springs do not eject the seal subs.

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CHAPTER 5
Compact Ram BOP
Seal Sub
O-Ring
Spool
Spring
Fluid Hinge O-Ring

O-Ring
Molded O-Ring
Figure 5-24 Fluid Hinge Disassembly/Assembly

3. Remove the seal sub assembly from the fluid hinge.
4. Remove the springs from the seal sub spool.
5. Remove the seals from the seal sub spool and seal subs.
NOTE
The seal subs have an O-ring molded into the top groove. It is
not necessary to remove this seal.
6. Remove the O-rings from the fluid hinge.
Bonnet Removal
1. Install two 1 1/2"-8UN eyebolts into the threaded holes in the top of the bonnet.
Attach lifting apparatus to the eyebolts.
CAUTION
The lifting apparatus must be capable of supporting the weight
of the bonnet and capable of allowing enough movement of the
bonnet to clear the manifold hinge on the BOP body.
2. Unscrew the bonnet bolts previously installed and open the bonnet enough to
disengage the bonnet guide pin from the body.
3. Remove the lower hinge pin by tunring it clockwise (viewing the pin from the top
of the preventer). Remove the O-rings.

CHAPTER 5
Compact Ram BOP
Retainer Ring Bonnet

Bonnet
Wear Ring Cap
Screw
Bonnet Hinge
Cap Screws
Connecting
Rod Seal
O-Ring
Upper
Piston Rod to Hinge Pin
Bonnet Seal Bonnet Hinge
and O-Ring
Lower Hinge Pin
Figure 5-25 Bonnet Disassembly/Assembly

4. With the weight of the bonnet supported by the lifting apparatus, remove the
upper hinge pin by turing it counterclockwise (viewing the pin from the top of
the preventer). Remove the O-rings.
5. Remove the bonnet by sliding it clear of the manifold hinge. Place the bonnet
where it can be disassembled. Remove the lifting apparatus.
6. Remove the retainer ring screws, the retainer ring, the connecting rod seal, the
piston rod to bonnet seal, and the wear ring from the bonnet.
7. Remove the O-ring from the retainer ring.
8. Remove the bonnet bolt O-rings and the bonnet bolts.
Bonnet Hinge Removal

1. Attach a lifting apparatus to the bonnet hinge for support.
2. Remove the cap screws that hold the hinge to the bonnet.
3. Remove the bonnet hinge and place it where it can be disassembled. Remove
the lifting apparatus.
4. Remove the O-ring seal from the bonnet hinge.
Bonnet Seal Carrier Ring Removal

1. Remove the two shoulder screws from the seal carrier ring.
2. Install two cap screws (1/2"-13UNC X 21/2" long from the tool kit) into the
threaded holes in the front of the seal carrier ring. Turn them until they contact
the bonnet.
3. Back the seal carrier ring out of the groove by turning the two cap screws in
equal increments.
4. Remove the cap screws from the seal carrier ring and the seals.

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CHAPTER 5
Compact Ram BOP
Backup Ring
Bonnet
O-Ring
Carrier Ring
Spring Seal Bonnet Seal
Shoulder Screw
Figure 5-26 Bonnet Seal Carrier Ring Disassembly/Assembly
Upper Seal Seat Removal

Follow the procedure below for each of the ram cavities. Refer to Figure 5-27.
1. Support the seal seat so that it cannot fall when the set screws are removed as
follows:
• Center a suitable 4"X4" board in the ram cavity of the BOP.
• Lower a line through the bore of the BOP and attach it securely around the
center of the board.
• Lift the board until it rests firmly against the seal seat.
2. Remove the socket head set screws using a 1/4" hex key wrench.
3. Slip the upper seal seat and retainer ring down and out the ram cavity.
4. Remove the seat to body seal.

CHAPTER 5
Compact Ram BOP
BOP Body
Retainer Ring
Set Screws
Seat to
Body Seal
Upper Seal
Seat
Wear Plate
Shoulder
Cap Screw Screw
Figure 5-27 Upper Seal Seat and Wear Plate Disassembly/Assembly
Wear Plate Removal

Follow the procedure below for each of the ram cavities. There are two wear plates in
each ram cavity, one on each side of the wellbore.
Follow the procedure below for each wear plate. Refer to Figure 5-27.
1. Remove the cap screws from wear plate.
2. Install two 3/4"-10UNC all threaded bolts, 5" long into the threaded holes on
each side of the cap screw hole in the center of the wear plate. Screw the bolts
in until they bottom out against the body of the BOP. From this point on, turn
the bolts in equal increments to raise the wear plate out of the body recess.
3. Remove the wear plate from the BOP.
Maintenance
Periodic maintenance is a very important part of keeping the Hydril 18 3/4"-15,000 compact
ram BOP in good operating condition. Not only will regular maintenance extend the service
life of the equipment, but it will also help to eliminate unnecessary down time. Furthermore,
the compact ram BOP is designed to allow scheduled maintenance and routine repair without
removal from the BOP stack.
Clean, Inspect, and Lubricate

Perform the following inspections as required or between wells. Ensure that all
pressure has been removed from the BOP.
WARNING
BONNET COULD CAUSE AN UNSUPPORTED BOP TO TIP
OVER.
DO NOT DISCONNECT HYDRAULIC CONNECTIONS

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Compact Ram BOP
BEFORE CONFIRMING THAT HYDRAULIC PRESSURE IS

NOT PRESENT.
Gather the following materials:

• Emery cloth, 240 grit or finer
• Castor oil
• TS Moly Paste thread lubricant (0.069
coefficient of friction) B
• Light machine oil, Gulf "Harmony No.
A
46" or Exxon "Coray 100" or equivalent
• Teflon filled grease, Magnalube-G or
Aqualube
• Bonnet bolt wrench
1. Clean the exterior of the ram BOP with
water.
2. Inspect the hydraulic line connections to the
Open and Close ports (Refer to Item A of
Figure 5-28) on the manifold/hinge for signs C
of leakage and apparent damage. Remove
hydraulic pressure from the lines and make B
necessary repairs if leakage or damage is
present.
3. Check the top and bottom nut and bolt Figure 5-28 BOP Exterior
connections (Item B of Figure 5-28) for Inspection Points
condition and tightness. Check the torque to
be sure that the top and bottom connections are tightened to specifications.
Refer to the Operation and Maintenance (O&M) Manual for torque values.
4. Check the side outlet nut and bolt connections (Item C of Figure 5-28) for
condition and tightness. Check the torque to be sure that the side outlet
connections are tightened to specifications. Refer to the Operation and
Maintenance (O&M) Manual for torque values.
5. Check remaining bolting, both studs and nuts, for proper type, size, condition,
and tightness.

CHAPTER 5
Compact Ram BOP
6. Open one bonnet and inspect

(refer to Figure 5-29). Check
the sealing surface on the
ram piston rod for wear,
pitting, and damage. (NOTE:
Extend piston rod and remove
ram assembly to inspect
Ram Piston Rod
sealing surface on the ram Bonnet
piston rod.
If Closing pressure is used to
extend the piston rod, ensure
that bonnet is open at least
Ram
90° to prevent damage to
piston rod.
Remove minor pits and scores
in the bonnet seal area or
bonnet seal groove with
emery cloth. Coat the
repaired surfaces with castor BOP Body
oil. If the bonnet seal groove
is severely worn or damaged,
replace the bonnet seal ring
carrier assembly. Surfaces Figure 5-29 Ram Piston Rod Inspection
that require welding,
machining, and stress
relieving must be repaired in a Hydril authorized repair facility (refer to Hydril
website, www.hydril.com, for a list of worldwide service locations). If the ram
piston rod shows wear, pitting, or other damage, replace it. If the ram piston
rod does not require replacement, continue to Step 7.
If the ram piston rod requires replacement, follow the procedure below.
• Disassemble the ram BOP.
• Inspect the bonnet to piston rod seal for wear and damage. Replace if
necessary. Install the seal into the bonnet. Lubricate the seal with light
machine oil before installation.
• Replace the ram piston rod with a new one. Removal and installation of the
piston rod from and onto the overhauling screw MUST be performed at a
Hydril authorized repair facility. Contact Hydril for nearest location or refer
to Hydril's website, www.hydril.com, for a list of worldwide service
locations.
• Assemble the BOP; however, leave the bonnets open. Replace seals as
required.
NOTE
Hydril recommends replacement of all seals.

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Compact Ram BOP
7. Remove the bonnet seal from

the bonnet seal carrier ring (see Bonnet Seal
Figure 5-30) installed in the face Carrier Ring
of the bonnet. Inspect the seal Groove
groove for wear, pitting, or other
damage. Remove minor pits
and scores in the bonnet seal Bonnet Seal
area groove with emery cloth.
Coat the repaired surfaces with
Cortec VCI-369 grease or
Bonnet Seal
equivalent. Replace the bonnet
Carrier Ring
seal ring carrier assembly if the
bonnet seal groove is severely
worn or damaged. Surfaces
that require welding, machining, Bonnet
and stress relieving must be
repaired in a Hydril authorized
repair facility. Contact Hydril for
the nearest repair facility
location or refer to Hydril's
website, www.hydril.com for a
list of worldwide locations.
8. Inspect the sealing surface
(Figure 5-31 where the bonnet
seal contacts the BOP body for
Figure 5-30 Ram Piston Rod Inspection
wear, pitting, and other damage.
Remove minor pits and scores in
the bonnet seal area groove with emery cloth. Coat the repaired surfaces with
Cortec VCI-369 grease or equivalent. Surfaces that require welding, machining,
and stress relieving must be repaired in a Hydril authorized repair facility.
Contact Hydril for nearest location or refer to Hydril website, www.hydril.com,
for a list of worldwide locations..
9. Clean the ram compartment
(Figure 5-31) thoroughly
and inspect for wear, pitting,
and damage. Remove minor
pits and scores in the field Bonnet Seal
with emery cloth. A Sealing Area
severely worn or damaged
ram compartment that
requires welding, machining, Bonnet
and stress relieving must be Face
repaired in a Hydril
authorized repair facility.
Contact Hydril for the
nearest location or refer to Ram
Hydril website, Compartment
www.hydril.com, for a list of
worldwide service locations. Figure 5-31 Ram Piston Rod Inspection

CHAPTER 5
Compact Ram BOP
10. Measure the maximum

Seal Seat
vertical clearance between
the rams and the upper
seal seat in the ram
compartment as shown by Top Seal
dimension "C" in Figure 5-
C
32. The surfaces subject
to wear which generate
this gap between the ram
Compartment
block and the seal seat are
the bottom of the ram
Ram
block, the upper bearing A B
surface of the ram block,
the seal seat sealing
surface, and the wear
plate of the ram Front Packer
compartment. Depending
on the surface(s) worn
Wear Plate
and the severity of the
wear, the wear plate, the
seal seat, the ram block, Measurement Tolerances
or all three may be
replaced. All three A MIN. B MAX. C MAX. NEW C MAX. WORN
components are
replaceable in the field. 10.742 10.793 0.051 0.113
This measurement should
be made if the life of the A MIN. Minimum ram height, new.
top seal is short, and
rubber loss due to B MAX. Maximum ram compartment height, new.
extrusion is severe, or C MAX. NEW Maximum gap between ram block bearing
leakage past the top seal surface and seal seat sealing surface, new
is suspected during
routine pressure tests. C MAX. WORN Maximum allowable gap between ram block
and seal seat, worn.
Figure 5-32 Ram Compartment Measurement

11. If the BOP is equipped
with pipe rams or variable rams (see
Figure 5-33), inspect the front packer
and top seal for wear, cracking, and Top Seal
excessive hardness by comparison
with new packer/top seal. Replace the
seal(s) if necessary.
If equipped with blind shear rams (see
Figure 5-34), inspect the seal(s) on
the shear ram for wear, cracking, and
excessive hardness by comparison TOP VIEW
with new seal(s). Replace the seal(s)
if necessary. Inspect the shear blades
for wear and damage. Replace if
necessary.
Packer
FRONT VIEW
Figure 5-33 Pipe/Variable Ram Inspection

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Compact Ram BOP
Lateral T-Seal
Top Seal
UPPER LOWER
BLADE BLADE
CARRIER CARRIER
TOP VIEW
Upper Shear
SIDE VIEW Lower Shear Blade
Blade
Figure 5-34 Blind/Casing Shear Ram Inspection
If equipped with casing shear rams, inspect the shear blades for wear and
damage. Replace if necessary.
12. Install the ram assembly onto the piston rod and remove the lifting eye.
Lubricate the ram assembly and the ram bore with castor oil. Retract the ram
assembly into the bonnet.
13. Inspect the bonnet seal for wear, cracking, and brittleness. Replace the bonnet
seal if required. Lubricate the surface where the bonnet contacts the body with
Cortec VCI-369 grease to prevent rust and corrosion. Lubricate the threads and
shoulders of the bonnet bolt threads with Moly Paste 503 lubricant.
14. Close the bonnet and torque the bonnet bolts to 2000 lb-ft (2710 N•m).
15. Repeat steps 6 through 14 for the remaining bonnet(s).
Assembly
Because the hydraulic circuits feed both bonnets of each BOP, it is necessary to assemble
both bonnets onto the body of each BOP at the same time. Do not attempt to assemble this
BOP unless it is installed on a test stump or supported so that it cannot fall over.
WARNING
CAUSE AN INJURY.
Gather the following tools.

• Castor oil
• TS Moly Paste 70 lubricant (0.069 coefficient of friction)

CHAPTER 5
Compact Ram BOP
equivalent
• Two 11/2"-8UN eyebolts (for bonnet)
• MPL lockout wrench
• Heavy grease
• Lint-free cloth
• Rubber mallet
• Two C-clamps
• Bonnet Seal Carrier Ring Installation/Removal Tool Kit, Hydril Part No.
3117785, containing the following Items:
• Two cap screws, 11/2"-13UNC X 211/2" long
• Two 1"-8UN eyebolts (for packing unit)
• Two all threaded rods, 5/16"-18UNC x 311/2" long
• Two hex nuts, 5/16"-18UNC
• Two washers, flat, 5/16"
• Seal kits and spare parts
• Teflon filled grease, Magnalube-G or Aqualube
• Loctite Dri-Lok #204 (red)
Cleaning and Inspection

Ensure that working surfaces are free of burrs, rough edges, or other defects. Remove
minor pits and scores in the field with emery cloth (240 grit or finer). Coat the
repaired surface with light machine oil. Severe pits and scores that require machining
and/or welding must be repaired in a Hydril authorized machine shop. Contact Hydril
or refer to Hydril website, www.hydril.com, for a list of worldwide service locations.
Inspect all seals and replace any damaged seals or seals in use over one year.
Lubrication
Lubricate all parts during assembly using the following lubrication guide:
1. Lubricate threads as follows (Torques are based on lubricants used):
• Lubricate the following threads with TS Moly Paste 70 thread lubricant:
• Bonnet bolt threads
• Cylinder bonnet studs and nuts
• Manifold/hinge cap screws
• Bonnet hinge cap screws
• Top, bottom, and side connection studs
• Wear plate shoulder screws
• Connecting rod seal retainer ring screws

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Compact Ram BOP
• Lubricate all other threads with light machine oil except for the upper seal
seat set screws and the MPL overhauling nut and screw (see below).
2. Coat O-rings, seals, internal metal parts, and machined surfaces with light
machine oil unless instructed otherwise in the procedure.
3. Lubricate ram packers and top seals with castor oil.
4. Coat surfaces of BOP body where bonnet contacts with Cortec VCI-369 grease.
5. Coat contact surface between upper seal seat and body with TS Moly Paste 70.
6. Apply a light coat of teflon filled grease (Magnalube-G or Aqualube) to the MPL
threads of the overhauling nut and screw as well as the thrust bearings with
teflon filled grease, Magnalube-G or Aqualube.
7. Apply Loctite Dri-Lok #204 (red) to threads of upper seal seat set screws.
Wear Plate Installation

Follow the procedure below for each wear plate. Refer to Figure 5-27.
1. Install wear plate top side up through the ram cavity into the recessed surface
next to the bore. The slot in the wear plate must be towards the bore where it
fits over the shoulder screw
2. Install the cap screws to secure the wear plate to the recessed surface in the
ram cavity. Tighten screws using 110 lb-ft ( 149 N•m) torque.
CAUTION
This is a critical torque. Ensure that the cap screws are
tightened using the torque specified.
3. Inspect the torque of shoulder screw, 110 lb-ft (149 N•m).
CAUTION
This is a critical torque. Ensure that the shoulder screws are
tightened using the torque specified.
Upper Seal Seat Installation

Follow the procedure below for each ram cavity. Refer to Figure 5-27.
1. Install seal ring and retainer ring into the seal seat.
2. Install the seal seat through the ram compartment into the recess in the upper
body bore of the BOP as follows:
• Center the seal seat on a suitable 4" X 4" board and slide in into the ram
cavity until the seal seat and board are centered in the bore of the BOP.
• Lower a line through the bore of the BOP and attach it securely around the
board through the inside diameter of the seal seat.
• Lift the seal seat and position it into the recess in the upper body bore of
the BOP.
• Install and tighten the socket head set screws using 75 lb-ft (102 N•m)
torque.

CHAPTER 5
Compact Ram BOP
CAUTION
Do not lubricate the threads of the set screws with light machine
oil. Coat the entire thread area of the screws with Loctite Dri-
Lok #204 (red) prior to installation.
• Remove the board and line.
Bonnet Hinge Installation

Follow the procedure below for each bonnet. Refer to Figure 5-25.
1. Attach a lifting apparatus to the bonnet hinge for support.
2. Lift the hinge and align it to the bonnet.
3. Install the O-ring seal into the groove in the bonnet hinge.
4. Install the cap screws that hold the hinge to the bonnet. Ensure that the bonnet
hinge key is in the hole in the bonnet. Tighten the screws using 340 lb-ft (460
N•m) torque.
Bonnet Installation
1. Install the bonnet bolts and O-rings into the bonnet.
2. Install the wear ring, the piston rod seal, and the connecting rod seal into the
bonnet.
3. Install the O-ring onto the piston rod seal retainer ring and install the retainer
ring onto the piston rod. Tighten the cap screws using 28 lb-ft (38 N•m) torque.
4. Install two 11/2"-8UN eyebolts into the top of the bonnet and attach a lifting
apparatus.
CAUTION
The lifting apparatus must be capable of supporting the weight
of the bonnet and capable of allowing enough movement of the
bonnet to engage the manifold hinge on the BOP body.
5. Lift the bonnet and position it against the body of the BOP so that the bonnet
bolts align with the threaded holes and the bonnet hinge fits over the manifold
hinge on the body.
WARNING
DO NOT PLACE HANDS WHERE THEY CAN BE INJURED
WHEN INSTALLING THE BONNET HINGES ONTO THE
MANIFOLD/HINGE.
6. Screw all of the bonnet bolts into the body. Tighten the bolts hand tight.
Remove lifting apparatus and eyebolts.
7. Install the O-ring seals onto the hinge pins. Install the hinge pins. Tighten the
hinge pin until snug.

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Compact Ram BOP
8. Unscrew all bonnet bolts and open the bonnet. Close the bonnet again to see if it
aligns with the body. If the bonnet locating pin enters the mating hole in the
body smoothly, the bonnet is aligned properly. Otherwise, open the bonnet and
adjust the hinge pins until bonnet is aligned.
• To raise the bonnet, loosen the lower hinge pin first. Then tighten the
upper hinge pin until alignment is made. Now, tighten the lower hinge pin
until snug.
CAUTION
Overtightening of hinge pins will cause the thrust washers to
bind, making the bonnet difficult to swing open.
• To lower the bonnet, loosen the upper hinge pin first. Then, tighten the
lower hinge pin until alignment is made. Tighten the upper hinge pin until
snug.
CAUTION
Overtightening of hinge pins will cause the thrust washers to
bind, making the bonnet difficult to swing open.
9. Close bonnet and screw in one bonnet bolt until snug.
Fluid Hinge Installation

1. Install the seals onto the seal subs.
2. Install the seal sub assemblies into the fluid hinge. Use two C-clamps to
compress the seal subs.
CAUTION
Compress the seal subs into the fluid hinge bore so that the top
of the seal subs are flush with the fluid hinge.
3. Install O-rings into the grooves in the fluid hinge.

4. Slide the fluid hinge onto the studs and between the manifold hinges. Remove
the C-clamps once the compressed seal subs are between the hinges. Continue
to slide the fluid hinge until it is against the bonnet hinge.
5. Install the nuts onto the fluid hinge studs. Tighten the nuts using 340 lb-ft (460
N•m) torque.
MPL Cylinder Assembly Installation

1. Install the wear ring(s) on the piston. Install the piston seal(s) into the grooves
in the piston (refer to assembly drawing for seal orientation).
2. Install piston and overhauling screw assembly into bonnet.
3. Install cylinder back-up ring and cylinder O-ring into the groove in the bonnet.
Install the O-rings and the close port seal retainer. Refer to assembly drawing
for seal orientation.

CHAPTER 5
Compact Ram BOP
4. Orient the cylinder with dowel pin matching hole in bonnet. Install cylinder over
the piston and onto the bonnet. Tighten cap screws using 550 lb-ft (745 N•m)
torque.
5. Install lockout stem seals and backup rings on the lockout stems. Refer to
assembly drawing for seal orientation.
6. Install the lockout devices into the cylinder. Retract segments fully by turning
counterclockwise 6 to 8 turns. Tighten gland nut using 25 to 50 lb-ft (34 to 68
N•m) torque.
7. Install the O-ring seals and the back-up rings onto the transfer ring and install
the transfer ring into the cylinder. Refer to assembly drawing for seal
orientation.
8. Open the bonnet and fit the ram assembly onto the piston rod. Remove the
lifting eye.
9. Install the cylinder head dirt seal, and the cylinder head seal onto the cylinder
head. Tighten the hex head cap screws using 550 lb-ft (745 N•m) torque.
10. Using the MPL lockout wrench, engage lockout devices by rotating lockout stem
clockwise 6-8 turns.
11. Apply 100 psi (6.9 Bar) opening hydraulic pressure to draw rams back into the
bonnet. Reduce the pressure to zero and disconnect hydraulic line.
12. Close the bonnet and screw in one bonnet bolt (opposite hinge side) until snug.
13. Remove the cylinder head.
14. Assemble the overhauling nut/clutch assembly if necessary as follows:
CAUTION
Take care in the assembling of the overhauling nut/clutch
assembly to protect it from damage. Use a table with a smooth
wooden work surface or cardboard mat.
• Place the rear clutch plate on the table, teeth down. Slip retainer ring
through the four rear clutch plate keys and position keys and ring in the
slots in the rear clutch plate.
• Insert the clutch springs into the rear clutch plate.
• Place the retainer plate, locating pin up, over the rear clutch plate. Engage
the slots with the clutch keys. Ensure that the retainer ring is trapped
under the lip of retainer plate.
• Place the overhauling nut, large O.D. down onto the table. Install one of
the MPL bearings into the overhauling nut.
• Hold together the retainer plate, clutch springs, and rear clutch plate and
turn the assembly over so that the teeth of the rear clutch plate are up.
Install the assembly into the overhauling nut so that the retainer plate rests
on the MPL bearing. Move the assembly to the edge of the table to allow
the locating pin to clear the table so that the retainer plate and rear clutch
plate rest squarely on the overhauling nut.
• Install the front clutch plate, teeth down, onto the overhauling nut.
• Install the socket head cap screws through the front clutch plate into the
overhauling nut. Tighten the screws using 70 lb-ft (95 N•m) torque.
15. Install the overhauling nut/clutch assembly onto the overhauling screw.

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Compact Ram BOP
CAUTION
Take care not to damage the outside diameter of the
overhauling nut/clutch assembly during installation.
Lubricate the threads of the overhauling screw and overhauling nut with a light
coat of Magnalube-G or Aqualube teflon filled grease.
NOTE
If the MPL overhauling nut has been replaced, perform a MPL
Overhauling Nut Break-In Procedure in this section after the
BOP is assembled.
• Turn the overhauling nut/clutch assembly until it shoulders on the cylinder

counterbore. Mark with a suitable marker, the top (twelve o'clock position)
of the overhauling nut
CAUTION
Do not mark on the bearing surface.
• Turn the overhauling nut/clutch assembly in the other direction until it is

located on the end of the overhauling screw.
NOTE
A new nut may be placed on an overhauling screw in any one
of the thread starts. However, after a nut has gone through
the break-in prodedure, the nut must always be timed to the
same thread start.
• Use two C-clamps

(refer to Figure 5-35
for positioning) to
depress the rear
clutch plate. Turn
the retaining plate so
that the mark on the
overhauling nut
aligns with locating
pin. Release the two
C-clamps and rotate
the overhauling
nut/clutch assembly
clockwise until it
shoulders on the
cylinder. The hole in Figure 5-35 C-Clamp Positioning on Rear Clutch Plate
the cylinder head will
now align with locating pin.
• Install the remaining MPL bearing into the cylinder head.

CHAPTER 5
Compact Ram BOP
16. Install cylinder head. Tighten the hex head cap screws using 550 lb-ft (745
N•m) torque.
17. Using the MPL lockout wrench, disengage the lockout devices by turning the
lockout stems counterclockwise until each stem stops (6 to 8 turns).
18. Check the alignment of the bonnets with the BOP body as outlined above and
adjust the hinge pins if necessary.
Bonnet Seal Carrier Assembly Installation

Follow procedure below for each of the bonnets (see Figure 5-26).
1. Using the installation/removal tool kit, install the bonnet seal carrier ring
assembly as follows:
• Install the bonnet seal O-ring and the back-up ring into the bonnet seal
carrier ring. Lubricate the groove with castor oil prior to installation.
• Install the spring O-ring into the seal carrier ring.
NOTE
Use heavy grease that is sticky to hold the O-ring in place
until the seal carrier is installed in the bonnet. After the seal
carrier is installed in the bonnet, the O-ring is trapped.
• Lubricate the bonnet seal ring carrier with castor oil and install it into the
recess in the face of the bonnet.
• Install the two 1/2" cap screws into the threaded holes in the front of
the carrier ring until about one inch of each screw sticks out of the
back side of the carrier ring.
NOTE
These screws keep the carrier ring from cocking.
• Install a 5/16" threaded rod into each threaded retaining hole in the
bonnet seal carrier ring recess in the bonnet face. Their position
should coincide with the counterbored holes in the carrier ring.
• Slide the carrier ring over the two threaded rods. Push the carrier ring
into the bonnet seal carrier recess until the bonnet seal O-ring evenly
contacts the entry bevel on the bonnet seal carrier recess. Install the
two washers and nuts onto the rods.
• Push the carrier ring into the recess in the bonnet face by tightening
the two nuts and loosening the two cap screws. Take care not to
damage the bonnet seal O-ring and back-up ring. Also keep the
carrier ring from cocking by adjusting the cap screws and nuts
alternately in equal increments (for example, one turn each). Once
the bonnet seal O-ring and back-up ring have cleared the entry bevel
and are fully installed in the recess bore, remove the cap screws and
threaded rods. Look into the space between the carrier ring and the
bonnet and inspect the spring O-ring to be sure that it is not
dislodged from the seal groove. Push the carrier ring the rest of the
way into the recess by hand or gently tap with a rubber mallet.

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CHAPTER 5
Compact Ram BOP
• Install the two carrier retaining screws through the counterbored

holes in the carrier ring and into the threaded holes in the bonnet.
Tighten the retaining screws until snug.
• Wipe the bonnet seal groove in the seal ring carrier clean with a lint-free
cloth.
• Lubricate the bonnet seal and groove with castor oil.
• Install the bonnet seal into the bonnet seal ring carrier.
• Wipe the face of the body clean with a lint-free cloth.
• Lubricate the face of the body with Cortec VCI-369 grease.
• Close the bonnet and screw in all bonnet bolts. Tighten bonnet bolts using
2000 lb-ft (2710 N•m) torque.
MPL Overhauling Nut Break-In
CAUTION
Make sure that pipe is in bore when opening and closing fixed-
bore pipe rams or variable rams. However, remove pipe when
closing shear rams.
1. Using the minimum pressure, cycle the operator closed and open three times.
Record the minimum pressure required. The operator pressure required will be
typically less than 200 PSI (14 Bar).
2. Cycle the operator fully closed and open five times with 500 PSI (35 Bar)
operator pressure.
operator pressure.
operating pressure.
5. Cycle the rams fully closed and open one time with minimum operator pressure.
The pressures should be recorded for comparison with later minimum pressure
cycles. If the minimum pressure exceeds 200 PSI (14 Bar), the MPL assembly
should be removed and component parts examined for the possible cause of the
increase.
Testing
Testing Precautions
Perform the following inspections prior to all blowout preventer hydraulic testing.
1. Verify wellhead type and rated working pressure.
2. Check for wellhead bowl protector.
3. Verify blowout preventer type and rated working pressure.
4. Verify drilling spool, valve types, and rated working pressures.
5. Verify ram placement in preventers and casing/variable pipe ram size.
6. Verify drill pipe connection size and type in use.
7. Open casing valve during test, unless pressure on the casing or hole is intended.
8. Test pressure should not exceed the rated working pressure of the body or the
seals of the assembly being tested.

CHAPTER 5
Compact Ram BOP
9. Test pressure should not exceed the values for tensile yield, collapse, and
internal pressure tabulated for the appropriate drill pipe as listed in API RP 7G,
Recommended Practice for Drill Stem Design and Operating Limits.
10. Verify the type and pressure rating of the preventer tester to be used.
BOP Operating Test

A preventer operating test should be performed on each round trip, but not more than
once a day.
NOTE
Periodically observe and record the minimum pressure to fully
close and open the MPL operators. Comparison to prior
minimum pressure cycles can be be used to determine the
relative operating condition of the actuator. If the minimum
pressure exceeds 200 PSI (14 Bar), the MPL assembly should
be removed and component parts examined for the possible
cause of the increase.
Hydraulic System Pressure Test

The hydraulic system should be pressure tested each time a wellbore pressure test is
made. The procedure is as follows:
1. Isolate the accumulator bottles from the hydraulic system.
2. Apply 3000 PSI (207 Bar) closing hydraulic pressure, stop pumping, and allow
the pressure to stabilize.
3. Observe pressure gauge. A drop in pressure indicates leakage. If leakage
occurs, reduce pressure to zero and disconnect the opening line either at the
blowout preventer or at the accumulator unit.
4. Reapply closing pressure to 3000 PSI (207 Bar) and stop pumping. If fluid flows
out of the Open port or line from the blowout preventer, the leak is at the piston
seals or the bonnet to cylinder port seal.
5. If no fluid flows out of the Open port or line from the blowout preventer, inspect
the following and make necessary repairs (refer to Paragraph 5.4.4 for seal
replacement):
• Bonnet to Cylinder Seal
• Transfer Ring Seals
• MPL Lockout Seal
• Cylinder Head Seals
• Fluid Hinge Sub Seals
• Bonnet Hinge to Bonnet Seal
• Manifold/Hinge or Bonnet Hinge Pipe Plug
• Accumulator System
6. Apply 3000 PSI (207 Bar) opening hydraulic pressure, stop pumping, and allow
the pressure to stabilize.
7. Observe pressure gauge. A drop in pressure indicates leakage.
8. If leakage occurs, reduce pressure to zero and disconnect the closing line.

NOBL-NA-AHC2008A
CHAPTER 5
Compact Ram BOP
9. Reapply 3000 PSI (207 Bar) opening pressure and stop pumping. If fluid flows
out of the closing port or line from the blowout preventer, the leak is at the
piston seals or the bonnet to cylinder port seal.
10. If no fluid flows out of the closing port of the blowout preventer, inspect the
following and make necessary repairs:
• Bonnet to Piston Rod Seal
• Bonnet to Connecting Rod Seal
• Fluid Hinge Sub Seals
• Bonnet to Cylinder Seal
• Bonnet Hinge Seal to Bonnet
• Manifold/Hinge or Bonnet Hinge Pipe Plug
• Accumulator System
Wellbore Test
The wellbore test verifies the sealing integrity of the rams as well as the proper
operation of the MPL locks. Each MPL is equipped with two lockout devices, one on
either side of each MPL cylinder. The lockout devices are manually operated and
require a MPL lockout wrench to operate. Visual indication of lockout device position is
provided. When the lockout stem is retracted all the way (6 to 8 turns clockwise) into
the cylinder, the lockout device is engaged. When the lockout stem extends all the
way out of the cylinder (6 to 8 turns counterclockwise), the lockout device is
disengaged and the MPL is in its normal operating mode. Prior to operating the ram
BOP, inspect each lockout device to be sure that it is disengaged. To verify that the
lockout device is disengaged, turn the lockout gland counterclockwise to see if the
stem is fully extended.
1. Install the ram BOP onto a test stump.
2. Perform testing precautions prior to beginning the test procedure.
3. Open the rams.
4. Install a test mandrel into the bore of the BOP. Do not install mandrel if shear
rams are installed.
5. Fill the bore with clean tap water.
6. Close the rams using 1500 PSI.
7. Vent the operator system to zero.
8. Apply wellbore pressure of 200-300 PSI (14-21 Bar). Isolate (block) test pump
from ram BOP and allow test pressure to stabilize. Hold pressure for three
minutes minimum. Observe for dramatic pressue loss. If no pressure is lost,
the integrity of the ram packers and seals is verified under low pressure and the
proper operation of the MPL locks is confirmed. Continue to the next step. If
pressure is lost, stop the test and vent the pressure from the BOP. Make
necessary repairs. If repairs require disassembly of the BOP, perform the
wellbore test again, beginning with step 2.
9. Increase wellbore pressure to BOP working pressure.
WARNING
THE RATED WORKING PRESSURE OF THE DUAL
COMPACT RAM BOP IS 15,000 PSI (1035 BAR). USE
EXTREME CAUTION WHEN WORKING WITH HIGH
PRESSURE. TAKE EVERY PRECAUTION TO PROTECT

CHAPTER 5
MPL Operators
PERSONNEL FROM COMING IN CONTACT WITH

PRESSURE DURING TESTING OPERATIONS.
Isolate or block the test pump from ram BOP and allow test pressure to stabilize.
Hold pressure for three minutes minimum. Observe for dramatic pressure loss.
If the pressure does not drop more than 100 PSI (7 Bar), the integrity of the
ram packers and seals is verified under working pressure. Continue to the next
step. If more than 100 PSI (7 Bar) pressure is lost, stop the test and vent the
pressure from the BOP. Make necessary repairs. Perform the wellbore test
again after repair, beginning with step 2.
10. Vent the wellbore pressure to zero. Allow a few seconds to allow any residual
pressure to bleed off.
11. Open rams and remove mandrel.
12. Drain water from wellbore.
Seal Replacement
Replace seals as required.
1. Disassemble the ram BOP.
2. Replace the seals and assemble the ram BOP.
MPL Overhauling Nut and Thrust Bearing Replacement

Replace MPL overhauling nut and thrust bearings yearly.
1. Disassemble the MPL cylinder and remove the MPL overhauling nut and thrust
bearings from the ram BOP. "
2. Replace the MPL overhauling nut and thrust bearings and assemble the MPL
cylinder. "
3. Perform the MPL Overhauling Nut Break-In Procedure.
MPL Operators
The following procedures apply to the 151/2"-3,000 PSI and the 19"-5,000 PSI MPL operators.
Disassembly
Refer to the appropriate assembly drawing, except where other assembly drawings are
referenced. Item numbers in procedure correspond to item numbers on assembly drawing.
Refer to the Operator’s Manual for weights.
Tools and Materials Required

Disassembly of the operator can be performed with standard mechanic tools. Refer to
the Operator’s Manual for wrench size requirements.
• Two all-threaded studs, 1/2"-13UNC x 12" long
Fluid Stab Removal

1. Loosen attachment bolts until they are free of the attachment plate.
2. Pull each fluid stab assembly out of the attachment plate.
Fluid Stabs Disassembly

Follow the procedure below for each fluid stab assembly.

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CHAPTER 5
MPL Operators
1. Remove two hex head cap screws holding the retainer plate to the fluid stab
body.
2. Remove the plunger from the fluid stab body.
3. Remove the floating seal.
4. Remove the spring.
5. Remove the O-rings and back-up ring seals from the fluid stab body and floating
seal.
Nose Seal Carrier Removal

Follow the procedure below for each operator.
1. Remove the locking pins, one on each side of the operator.
2. Pull the seal carrier off the load block.
3. Remove the seals from OD of the seal carrier.
4. Remove the piston rod seals from ID of seal plate.
Lock Ring Removal

WARNING
DO NOT MIX THE SEGMENTS FROM ONE OPERATOR
WITH ANOTHER. KEEP THEM SEPARATE AND IN THE
SAME ORDER AS REMOVED.
1. Remove the screws holding curved lock ring segments to the back-up sleeve.
2. Remove the curved segments.
3. Remove the screws holding the straight lock ring segments to the back-up
sleeve.
4. Remove the straight segments.
Cylinder Head Removal

1. Remove the cap screws holding the cylinder head to the operator cylinder.
2. Remove the cylinder head.
3. Remove the O-rings from the cylinder head.
MPL Clutch Assembly Removal

1. Ensure that the piston is in the full open position, making the MPL clutch
assembly accessible.
2. Remove the MPL clutch assembly from the operator cylinder by rotating it
counterclockwise off the piston rod.
MPL Clutch Assembly.

1. Remove the socket head cap screws from the front clutch plate.
2. Remove the front clutch plate from the MPL clutch assembly.

CHAPTER 5
MPL Operators
3. Remove the rear clutch plate and retainer keys from the retainer plate.
4. Remove the clutch springs.
5. Remove the retainer plate and locating pin.
6. Remove the thrust bearing from between the MPL nut and the retainer plate.
Transfer Ring Removal

1. Gather two 1/2"-13UNC x 12" long all-threaded studs.
2. Install studs into threaded holes in transfer ring. Pull transfer ring out of
operator cylinder, taking care not to damage the threads on the piston rod.
3. Remove O-rings and back-up rings from transfer ring.
Cylinder Removal
1. Remove cap screws and handles from cylinder.
2. Remove cylinder from operator.
Piston Removal
1. Pull the piston and piston rod out of the operator.
2. Remove the piston seals and wear rings from the piston.
3. Remove the screws from the retaining ring.
4. Remove the retaining ring from the piston rod.
5. Remove the two halves of the piston retaining ring from the piston rod and
remove the piston from the piston rod.
6. Remove the piston to piston rod seals from the piston.
Lock Pin Removal

1. Remove the cap screws and washers holding the retention plates over each of
the four lock pins. Remove the retention plates.
2. Remove back-up sleeve lock pins.
3. Remove manual backup lock pins.
4. Remove the shoulder screws, back-up clamps, and spacers from the attachment
plate.
Cylinder Seal Plate Seal and Piston Rod Seal Removal

1. Remove the back-up rings and O-ring seal from the cylinder seal plate.
2. Remove the piston rod seals from the cylinder plate inside diameter.
Cylinder Seal Plate Removal

1. Pull the cylinder seal plate off the attachment plate.

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MPL Operators
Remove Attachment Plate Removal

1. Remove the cap screws holding the attachment plate to the load block.
2. Remove the attachment plate from the load block.
3. Remove trash guard mounting bolts and trash guard.
4. Remove piston rod wear rings from load block.
Remove Back-Up Sleeve Assembly Removal

1. Remove retaining screws holding the back-up sleeve assembly to the load block.
2. Remove the back-up sleeve assembly from the load block.
3. Remove O Ring from back-up sleeve.
4. Remove operation gland nuts and operation shafts from back-up sleeve.
Remove Lock Ring Retention Mechanism Removal

1. Unscrew the retaining caps.
2. Remove the springs.
3. Remove the pistons.
MPL Overhauling Nut and Thrust Bearing Replacement and Break-In
Replacement Procedure
1. Replace MPL overhauling nut and thrust bearings on the 151/2" MPL operator
(3,000 PSI) yearly.
2. Disassemble the MPL cylinder head and remove the MPL overhauling nut and
thrust bearings from the ram BOP.
3. Replace the MPL overhauling nut and thrust bearings and assemble the MPL.
4. Perform the MPL Overhauling Nut Break-In Procedure. Refer to Step B below.
Break-In Procedure
CAUTION
Make sure that pipe is in bore when opening and closing fixed
bore pipe rams or variable rams. However, remove pipe when
closing blind/shear rams.
1. Using the minimum pressure, cycle the operator closed and open three times.
Record the minimum pressure required. The operator pressure required will be
typically less than 200 PSI (14 BAR).
2. Cycle the operator fully closed and open five times with 500 PSI (35 BAR)
operator pressure.
operator pressure.
operator pressure.

CHAPTER 5
MPL Operators
5. Cycle the rams fully closed and open one time with minimum operator pressure.
The pressures should be recorded for comparison with later minimum pressure
If the minimum pressure exceeds 200 PSI (14 BAR), the MPL assembly should
be removed and component parts examined for the possible cause of the
increase.
Assembly
Refer to the appropriate assembly drawing except when other assembly drawings are
referenced. Item numbers in procedure correspond to item numbers on assembly drawing.
WARNING
DO NOT OPEN THE OPERATORS OF THE RAM BOP
UNLESS IT IS INSTALLED ON A TEST STUMP OR
SUPPORTED SO THAT IT CANNOT FALL OVER. THE
WEIGHT OF AN OPEN OPERATOR COULD TIP OVER AN
UNSUPPORTED BOP AND CAUSE AN INJURY.
For weight data and wrench sizes, refer to the Operator’s Manual for weights and wrench
sizes and torque.
Tools and Materials Required

Assembly of the operator can be performed with standard mechanic tools. Refer to the
Operator’s Manual for wrench size and requirements.
• Lock ring retention mechanism spanner socket Hydril Part No. 3133560
(Optional)
• Seal kits and spare parts
Cleaning and Inspection

1. Ensure that working surfaces are free of burrs, rough edges, or other defects.
2. Remove minor pits and scores in the field with emery cloth (240 grit or finer).
Coat the repaired surface with light machine oil. Severe pits and scores that
require machining and/or welding must be repaired in a Hydril authorized repair
facility (ARF).
3. Inspect all seals and replace any damaged seals or seals in use over one year,
not to exceed two years.
Lubrication
Lubricate all parts during assembly using the following lubrication guide:
• Castor oil or equivalent for seal installation lubrication.
• Moly Paste 503 thread lubricant or equivalent (0.065 coefficient of friction)
for alloy steel thread applications.
• Never-Seez Pure Nickel Special or equivalent for stainless steel thread
applications.
• Magnalube-G grease or equivalent heavy marine grade grease for
lubrication of load block OD, lock ring retention mechanism, and
overhauling screw.

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CHAPTER 5
MPL Operators
equivalent for lubrication of internal metal surfaces.
• Cortec VCI-369 grease for machined or unpainted exterior surfaces.
Lock Ring Mechanism Installation

1. Install the springs.
2. Install the plungers with the flat side toward the bottom of the hole.
3. Fill each hole full with Magnalube G or equivalent marine grade grease.
4. Install the retaining caps. Refer to the Operator’s Manual for wrench size and
tightening torque.
Back-Up Sleeve Assembly Installation

1. Follow the procedure below for each operator.
2. Install the O-ring onto the back-up sleeve.
3. Install the operation shafts and the operation gland nuts onto the back-up
sleeve with the holes perpendicular to the top edge of the back-up sleeve. Refer
to the Operator’s Manual for tightening torque.
4. Apply a generous coat of Magnalube G or equivalent marine grade grease to the
entire outside surface of the upper load block, shoulder of the lock ring, and
inside surfaces of the back-up sleeve.
5. Install the back-up sleeve over the load block, ensuring that the word "TOP" on
the back-up sleeve and the load block are on the same side.
6. Install the retaining screws into the load block.
CAUTION
Do not install the two pins located at each end of the back-up
sleeve.
Attachment Plate Installation

1. Apply a generous coat of Magalube G or equivalent marine grade grease to the
piston rod wear bands and bore of the load block. Install the wear bands into the
load block.
2. Install trash guard using the mounting screws. Refer to the Operator’s Manual
for wrench size and tightening torque.
3. Install the attachment plate onto the load block, ensuring the load block sockets
into the small recess on the attachment plate. Verify the word "TOP" on the
attachment plate is oriented to the same side as "TOP" is marked on the back-up
plate and load block.
4. Install cap screws to hold the attachment plate to the load block. Refer to the
Operator’s Manual for wrench size and tightening torque.
Cylinder Seal Plate Installation

1. Install the cylinder seal plate onto the attachment plate.

CHAPTER 5
MPL Operators
Cylinder Seal Plate Seal and Piston Rod Seal Installation

1. Lubricate the back-up rings and O-ring seal with castor oil and install them onto
the OD of the cylinder seal plate. Refer to assembly drawing for seal orientation.
2. Lubricate the piston rod seals lightly with castor oil and install them into the
inside diameter of the cylinder seal plate. Refer to assembly drawing for seal
orientation.
Back-Up Sleeve Clamp and Lock Pin Installation

1. Install the back-Up sleeve retaining clamps, spacers, and shoulder screws. Refer
to the Operator’s Manual for wrench size and tightening torque.
2. Lubricate the four lock pins with Magnalube G or equivalent heavy marine
grease and install the shorter pins into the attachment plate) and the longer
pins into the back-up sleeve.
3. Install the lock pin retention plates, cap screws, and washers. Refer to the
4. Pull each pin up until the slot in the pin shaft is aligned with the sides of the U-
shaped retainer plate. Then, turn the pin so that the slot engages the sides of
the clip to hold the pin in the retracted position. Release the pins by turning
them until they drop through the retainer plates into the back-up sleeve and
attachment plate. Ensure that the shoulder of each lock pin is in contact with the
back-up sleeve or attachment plate.
Lock Ring Installation

WARNING
THE LOCK RINGS ARE ISSUED AS A KIT, CONTAINING
ROUND AND STRAIGHT SEGVERIFY THAT THE ROUND
SEGMENTS HAVE THE SAME SERIAL NUMBERS. THE
CURVED SEGMENTS ARE ISSUED AS A MATCHED SET.
THE STRAIGHT SEGMENTS DO NOT HAVE TO MATCH
EACH OTHER OR THE ROUND SEGMENTS. DO NOT
INSTALL USED SEGMENTS MIXED WITH NEW SEGMENTS.
IF ONE SEGMENT NEEDS REPLACEMENT, REPLACE ALL
OF THE SEGMENTS FROM THE SAME KIT. DO NOT USE
SEGMENTS FROM OTHER OPERATORS OR KITS.
1. Lubricate the shoulder of the lock ring or each segment and the surface of the
back-up sleeve where the back of the lock ring segments will contact with
Magnalube G or equivalent heavy marine grease.
2. Position the back-up sleeve against the attachment plate so that the lock ring
can be installed in the lock ring recess.
3. Install the straight segments in the same order as removed and so that the
screws engage the lock ring retention mechanism installed previously. Refer to
the Operator’s Manual for the wrench size and tightening torque.

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CHAPTER 5
MPL Operators
CAUTION
Do not over tighten the screws. Excessive torque will cause the
screws to fail.
4. Install the curved lock ring segments and screws onto the back-up sleeve in the
same order as when removed. Refer to the Operator’s Manual for the wrench
size and tightening torque.
Piston Assembly
1. Lubricate piston to piston rod seals, piston seals, and wear rings with castor oil.
Install the piston to piston rod seals into the ID of the piston. Refer to assembly
drawing for seal orientation.
2. Using the piston seal installation tool, install the piston seal and wear rings onto
the piston, taking care not the damage the seals.
3. Slide the piston over the threaded end of the piston rod until it stops against the
larger diameter. Take care not to damage the piston to piston rod seals in the ID
of the piston as it slides over the threads on the piston rod.
4. Install the two halves of the piston retaining ring around the piston rod and
against the piston.
5. Install the retaining ring over the piston retaining ring and against the piston.
Install the screws. Refer to the Operator’s Manual for wrench size and tightening
torque.
Piston Installation
1. Lubricate the piston rod with castor oil and install it through the cylinder seal
plate, attachment plate, and out the back of the load block.
2. Continue installation until the piston rests against the cylinder seal plate.
Cylinder Installation
1. Align cylinder with piston and attachment plate with word "TOP" on the same
side as the cylinder.
2. Slide the cylinder over the piston, taking care not to damage piston seals.
Position the cylinder against the flange of the cylinder seal plate, taking care not
to damage the cylinder seals.
3. Install bolts to secure the cylinder to the attachment plate. Refer to the
4. Install the operator handles on both sides of the cylinder.
Transfer Ring Installation

1. Lubricate O-rings and back-up rings with castor oil and install them onto the
transfer ring.
2. Install the transfer ring into operator cylinder.

CHAPTER 5
MPL Operators
MPL Clutch Assembly

NOTE
If MPL clutch was not disassembled, continue to next step.
CAUTION
Damage to the clutch during assembly can be avoided by
placing a cardboard mat or using a table with a smooth wooden
surface.
1. Place the rear clutch plate on a smooth table, clutch teeth down. Slip the key
retainer ring through four clutch plate keys, then position the keys and rings in
slots in the clutch plate. Insert springs in the rear clutch plate.
2. Place the retainer plate, locating pin up, over the rear clutch plate. Engage the
keys with the slots in the retainer plate, making certain that the retainer ring is
trapped under lip of retainer plate.
3. Place the overhauling nut large OD end down on the table.
4. Install one of the thrust bearings over the MPL nut. Lubricate the bearing with a
thin film of Magnalube G or equivalent heavy marine grease prior to installation.
5. Holding the rear clutch plate, springs, and the retainer plate together. Turn the
assembly over so that the teeth of the rear clutch plate face up. Install the
assembly over the MPL nut so that it rests on the bearing.
NOTE
Move the assembly to the edge of the table to allow the
locating pin to clear the table so that the retainer plate and
rear clutch plate rest squarely on the MPL nut.
6. Install the front clutch plate onto the MPL nut teeth down.
7. Install the socket head cap screws to hold the front clutch plate onto the MPL
nut. Tighten alternately. Apply Moly Paste 503 to the screw threads prior to
installation. Refer to the Operator’s Manual for wrench size and tightening
torque.
MPL Clutch Installation

CAUTION
Take care not to damage the outside diameter of the lock
nut/clutch assembly during installation.

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CHAPTER 5
MPL Operators
NOTE
If the MPL lock nut has been replaced, perform a MPL Nut
Break-In Procedure after the BOP is assembled.
1. Place the piston in the full Open position.

2. Lubricate the threads of the piston rod and MPL nut with a light coat of
Magnalube-G or equivalent heavy marine grease.
3. Install the MPL clutch assembly onto the piston rod. Turn the clutch assembly
until it shoulders on the cylinder. Mark with a suitable marker (grease pencil),
the top (twelve o'clock position) of the lock nut (
CAUTION
Do not mark on the bearing surface). Turn the clutch assembly
in the other direction until it is located on the end of the piston
rod.
NOTE
A new nut may be placed on a piston rod in any one of the
thread starts. However, after a nut has gone through the
break-in procedure, the nut must always be timed to the same
thread start.
4. Use two C-clamps to depress the rear clutch plate. Turn the retainer plate so
that the mark on the lock nut aligns with locating pin. Release the two C-clamps
and rotate the lock nut/clutch assembly clockwise until it shoulders on the
operating cylinder. The hole in the cylinder head will now align with locating pin.
Cylinder Head Installation

1. Lubricate the O-rings with castor oil and install them onto the cylinder head.
Refer to assembly drawing for seal orientation.
2. Lubricate the remaining MPL bearing with a film of Magnalube G or equivalent
heavy marine grease and install it onto the overhauling nut.
NOTE
Apply lube heavy enough that the bearing will stick securely to
the nut.
3. Install the cylinder head.

4. Install the cap screws holding the cylinder head to the operator cylinder. Refer to
the Operator’s Manual for wrench size and tightening torque.
Fluid Stab Assembly

1. Follow the procedure below for each operator.

CHAPTER 5
Blind Shear Ram
2. Lubricate the O-rings and back-up ring seals with castor oil and install them on
the fluid stab body and floating seal.
3. Install the spring.
4. Install the floating seal.
5. Install the plunger.
6. Install the retainer plate.
7. Install two screws to hold the retainer plate to the fluid plate body. Apply Moly
Paste 503 to threads. Refer to the Operator’s Manual for wrench size and
tightening torque.
Fluid Stab Installation

1. Install each fluid stab assembly into the attachment plate.
2. Install attachment bolts. Lubricate threads of bolts with Moly Paste 503 before
installing. Refer to the Operator’s Manual for wrench size and tightening torque.
Blind Shear Ram

Lower Blade Carrier Disassembly
Top Seal
Refer to Figure 5-36.
• Screw driver
2. Remove the top seal from the ram block by
inserting a screw driver between the top seal
and ram block and prying the top seal out of
its groove.
Pry Here
3. Remove the right anti-extrusion block.
4. Remove the left anti-extrusion block.
5. Using the 3/4" hex key wrench, remove the
socket head cap screws from the lower shear
blade.
6. Remove the lower shear blade from the lower
blade carrier.
Shear Blade
Lower Blade Carrier Assembly Cap Screws
Refer to Figure 5-36. Figure 5-36 Blind/Shear Ram Lower
Blade Carrier Disassembly/Assembly
• Castor oil
• TS Moly Paste 70 thread lubricant (0.069 coefficient of friction)
• Cortec 369 Grease or equivalent
• Torque wrench
2. Clean all parts thoroughly.
3. Insure that the lower blade carrier, lower shear blade, and top seal groove are free of
burrs and any foreign matter.

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CHAPTER 5
Blind Shear Ram
4. Lubricate the carrier and lower shear blade with Cortec 369 grease or equivalent.
5. Using the 3/4" hex key wrench, Install the lower shear blade on the carrier with the
attachment screws hand tight. Insure that the upper surface of the lower shear blade
is flush with the seal surface of the carrier. Torque the socket head cap screws to 800
lb-ft (1085 N•m). Lubricate the threads of the screws with TS Moly Paste 70 lubricant
before installation.
6. Lubricate the top seal groove and the top seal with castor oil.
7. Install the top seal into the groove.
Upper Blade Carrier Disassembly

Top Seal
2. Screw driver
3. Remove the top seal from the ram block by
inserting a screw driver between the top seal
and Lateral T-seal and prying the top seal out
of its groove.
socket head cap screws from the front of the
shear blade. Pry Here
5. Remove the upper shear blade from the upper

blade carrier. Lateral
T-Seal
6. Remove the lateral T-seal from the lateral T-
seal groove.
Upper Blade Carrier Assembly Shear Blade Cap Screws

Refer to Figure 5-37. Figure 5-37 Blind/Shear Ram Upper
1. Gather the following tools and materials: Blade Carrier Disassembly/Assembly
• Castor oil
• TS Moly Paste 70 thread lubricant (0.069 coefficient of friction)
• Cortec 369 grease or equivalent
• Torque wrench
3. Insure that the upper blade carrier, upper shear blade, and seal grooves are free of
burrs and any foreign matter.
4. Lubricate the upper blade carrier and upper shear blade with Cortec 369 grease or
equivalent.
5. Lubricate the top and lateral seal grooves with castor oil.
6. Lubricate the lateral T-seal with castor oil and install it in the lateral T-seal groove.
Insure that the lower T-section of the seal is completely within the groove in the upper
blade carrier.
7. Using the 7/8" hex key wrench, install the upper shear blade on the upper blade
carrier with the screws. Torque the screws to 1600 lb-ft (2169 N•m). When
installing the blade, insure that the T-seal is correctly fitted into the groove on the

CHAPTER 5
Casing Shear Ram
back side of the blade. Lubricate the socket head cap screws with TS Moly Paste 70
lubricant before installation.
8. Lubricate the top seal with castor oil and install it in the top seal groove.
Casing Shear Ram
WARNING
BONNET CAN CAUSE AN UNSUPPORTED BOP TO TIP
OVER.
Lower Blade Carrier Disassembly

1. Gather the Following Tools and Materials:
two shear blade cap screws from the lower
shear blade.
3. Remove the lower shear blade from the lower
blade carrier.
Lower Blade Carrier Assembly Shear Blade

Shear Blade
1. Gather the Following Tools and Materials: Cap Screws
• TS Moly Paste 70 thread lubricant (.065
coefficient of friction)
• Light machine oil, Gulf "Harmony No. 46"
or Exxon "Coray 100" or equivalent
• 7/8" hex key wrench Figure 5-38 Casing Shear Ram - Lower
Blade Carrier Disassembly/Assembly
2. Torque wrench (0 to 2000 lb-ft/2169 N•m)
4. Insure that the lower blade carrier and lower shear blade are free of burrs and any
foreign matter.
5. Lubricate the carrier and lower shear blade with light machine oil.
6. Using the 7/8" hex key wrench, Install the lower shear blade on the carrier with the
shear blade cap screws hand tight. Torque the socket head cap screws to 1600 lb-ft
(2169 N•m). Lubricate the threads of the screws with TS Moly Paste 70 lubricant
before installation.

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CHAPTER 5
Casing Shear Ram
Upper Blade Carrier Disassembly

1. Gather the Following Tools and
Materials:
2. Using the 7/8" hex key wrench, remove
the shear blade screws from the shear
blade.
3. Remove the upper shear blade from
the upper blade carrier.
Shear Blade Shear Blade
Upper Blade Carrier Assembly
Cap Screws
1. Gather the Following Tools and
Materials:
• TS Moly Paste 70 thread lubricant
(.065 coefficient of friction)
• Light machine oil, Gulf "Harmony Figure 5-39 Casing Shear Ram - Upper Blade
No. 46" or Exxon "Coray 100" or Carrier Disassembly/Assembly
equivalent
• Torque wrench
3. Insure that the upper blade carrier and upper shear blade are free of burrs and any
foreign matter.
4. Lubricate the upper blade carrier and upper shear blade with light machine oil.
5. Using the 7/8" hex key wrench, install the upper shear blade on the upper blade carrier
with the shear blade cap screws. Torque the screws to 1600 lb-ft (2169 N•m).
Lubricate the socket head cap screws with TS Moly Paste 70 lubricant before
installation.

CHAPTER 5
Variable Pipe Ram
Variable Pipe Ram

Ram Block
Variable Pipe Ram Disassembly
The following procedure is for
changing the front packer and top seal
(refer to Figure 5-40). This change
may be performed without removing
the ram from the piston rod. Always Ram Packer Cotter Pin
use the front packer size to match the Bolt
ram size.
1. Gather the following tools and
materials:
• Two screw drivers
• 1-Inch hex socket wrench
2. Remove the top seal from the
ram block by inserting a screw
driver between the top seal and
front packer and prying the top
seal out of its groove.
3. Remove two cotter pins that
block entry to the holes where
the ram packer bolts are
installed.
Top Seal
4. Using the 1-inch hex socket
wrench, remove the ram packer
bolts.
5. Remove the front packer by
inserting two screw drivers, one Insert
on either side, behind the front Screwdriver
packer and moving forward until Here
it can be slipped out.
Ram Packer
Variable Pipe Ram Assembly
Refer to Figure 5-40. Figure 5-40 Variable Pipe Ram Disassembly/Assembly
1. Gather the following materials:
• Castor oil
• 1-inch socket wrench
• New front packer and top seal
2. Clean the ram block thoroughly. Lubricate the block with Cortec 369 grease or
equivalent.
3. Lubricate the front packer with castor oil and insert it into the ram until it is seated.
4. Lubricate the top seal with castor oil and fit it into its groove with the pins pointing
down. NOTE: The pins of the top seal fit into holes in the front packer. The pins of the
top seal and holes of the ram packer are designed in such a way that the top seal and
ram packer fit together in only one way.
5. Install the ram packer bolts through the holes in the back of the ram block and into the
ram packer. Tighten the bolts using 50± 20 lb-ft (68 ± 27 N•m) torque.

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CHAPTER 5
Fixed-Bore Pipe Ram
CAUTION
Do not lubricate threads of ram packer bolts.
6. Install cotter pins into the holes provided above the bolt holes. Spread the ends to
block the bolt holes.
7. If the ram has been removed from the piston rod, lift the assembled ram and lower it
onto the piston rod. Remove the lifting eye.
Fixed-Bore Pipe Ram

Ram Block
Fixed-Bore Pipe Ram Dissassembly
The following procedure is for
changing the front packer and top
seal. Refer to Figure 5-41. This
change may be performed without
removing the ram from the piston rod. Ram Packer Cotter Pin
Always use the front packer size to Bolt
match the ram size.
1. Gather the following tools and
materials:
• Two screw drivers
• 1-Inch hex socket wrench
2. Remove the top seal from the
ram block by inserting a screw
driver between the top seal and
front packer and prying the top
seal out of its groove.
3. Remove two cotter pins that
block entry to the holes where
the ram packer bolts are
installed.
4. Using the 1-inch hex socket Top Seal
wrench, remove the ram packer
bolts.
5. Remove the front packer by
inserting two screw drivers, one
Insert
on either side, behind the front Screwdriver
packer and moving forward until Here
it can be slipped out.
Ram Packer
Fixed Bore Pipe Ram Assembly
Refer to Figure 5-41. Figure 5-41 Fixed-Bore Pipe Ram
1. Gather the following materials: Disassembly/Assembly
• Castor oil
• 1-inch socket wrench
• New front packer and top seal

CHAPTER 5
Fixed-Bore Pipe Ram
2. Clean the ram block thoroughly. Lubricate the block with Cortec 369 grease or
equivalent.
3. Lubricate the front packer with castor oil and insert it into the ram until it is seated.
4. Lubricate the top seal with castor oil and fit it into its groove with the pins pointing
down.
NOTE
The pins of the top seal fit into holes in the front packer. The
pins of the top seal and holes of the ram packer are designed
in such a way that the top seal and ram packer fit together in
only one way.
5. Install the ram packer bolts through the holes in the back of the ram block and into the
ram packer. Tighten the bolts using 50± 20 lb-ft (68 ± 27 N•m) torque.
CAUTION
Do not lubricate threads of ram packer bolts.
6. Install cotter pins into the holes provided above the bolt holes. Spread the ends to
block the bolt holes.
7. If the ram has been removed from the piston rod, lift the assembled ram and lower it
onto the piston rod. Remove the lifting eye.

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Chapter 6
Description
The HPTU is used to pressure test the sealing integrity of BOP components. With the HPTU, test
pressures ranging up to 22,500 psi can be produced and maintained throughout extended time
periods.
Objectives
• An understanding of the purpose of the High Pressure Test Unit (HPTU).
• An ability to identify the major components and features of the HPTU.
System Overview
The HPTU is a modular system that provides a controlled, high-pressure fluid source for hydrostatic
testing. The HPTU comprises three freestanding modules as follows:
• Hydraulic Power Module (HPM)
• Pump Control Console (pump control and test valves)
• Remote Console (test valves and remote pump control)
Hydraulic Power Module (HPM)

The HPM is a skid mounted assembly consisting of a 100-horsepower electric motor, triplex
pump, hydraulic pumps and motors, water and hydraulic fluid reservoirs, accumulator, and
accessory components, such as valves, regulators, etc. The HPM supplies pressurized test
fluid to the pump control and remote consoles. The test fluid is used for hydrostatic testing
and pressure rating of equipment.
The HPM pressurizes the fluid using a hydrostatic transmission consisting of an electric drive
motor, two variable displacement pumps, hydraulic motor, and a triplex pump. The pumps
are driven by the electric drive motor and can be operated separately or simultaneously. In
turn, the pumps drive a hydraulic motor that couples to the triplex pump. The triplex pump
ingests water from an external source to produce the high-pressure test fluid.
Figure 6-1 is the hydraulic schematic for the HPM, Figure 6-3 is a side view of the skid.
Figure 6-4and Figure 6-5 show top and end views of the HPM. Refer to drawing AA869 in
section 6, Engineering Drawings, BOM, and Vendor Information, to identify specific HPM
components and their BOM part numbers.

CHAPTER 6
System Overview
Figure 6-1 HPTU Hydraulic Schematic

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CHAPTER 6
System Overview
Figure Dwg Item

Ref. No.* Nomenclature Part Number
EM 2* Electric Drive Motor (100-HP) 51-502968
TP 3* Triplex Pump 37-502189
R1 5* 50-Gallon Water Reservoir 36-501919
R2 6* 30-Gallon Reservoir 36-502966
HE 7* Swirl Cool Heat Exchanger 37-502972
FLTV 9* Tank Mounted Float Valve (1/2-Inch) 37-503110
FLTR2 10* Suction Strainer AB589
ACLTR 11* 1-Gallon Accumulator 37-501946
HM2 14* Hydraulic Drive Motor, Lubrication pump 37-502446
FC1, FC2 16* Tank Mounted Filter/Breather Cap 37-500242
SG 18* Tank Mounted Sight Gauge (10-Inch) 37-503157
L&TG 19* Sight Gauge, Fluid level and temperature 37-503158
RV3 20* Panel Mounted Relief Valve (1/4-Inch) 37-501878
FV 21* Loop Flushing Valve 37-501870
NV2 22* Needle Valve 37-502791
BV7 31* 3-Way Ball Valve (1-Inch) 37-503125
NV1 32* Needle Valve, Bonnet, shutoff 37-503124
CV2 33* Check Valve (9/16-Inch) 37-501916
SV 36* Shuttle Valve, (1/4-Inch) 37-500119
RV1 37* Direct Acting Relief Valve 37-501939
RV2 40* Relief Valve, 20 KSI 37-503037
FLTR1 43* Filter (1-Inch) 37-503165
PG1 45* Pressure Gauge (1/4-Inch) 37-503168
RD1 53* Rupture Disk 20 KSI 37-503773
VDP1, VDP2 Dual Pump (Series-90) 37-502968
HM1 Hydraulic Motor, Triplex pump 37-502973
P1 Gear Pump 37-502975
P2 Lube Pump 37-501879
RD2 Rupture Disk, 18 KSI
RD3 Rupture Disk, 22 KSI
BV1 – BV6 Ball Valve
PG2 Pressure Gauge, 0-35 KSI
Figure 6-2 HPTU Hydraulic Schematic (From Drawing AA782) (Cont.)
*Components without item numbers are on HPTU subassemblies.

CHAPTER 6
System Overview
Figure 6-3 Hydraulic Power Module (HPM), Side View

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CHAPTER 6
System Overview
Figure 6-4 HPM, Top View

CHAPTER 6
System Overview
Figure 6-5 HPM, End View
Pump Control Console (with Eleven-Valve Test Manifold)
The pump control console (PCC) is the primary station used to conduct hydrostatic testing
(Figure 6-6, Figure 1-7, Figure 6-7, Figure 6-8, and Figure 6-9). Designed to be installed
remotely from the HPM, the PCC has all the required power and control interface connections
with the HPM and the remote console. The console is equipped for conducting high and low
pressure testing. Low-pressure test components include a relief valve set at 1,100 PSI and a
rupture disk rated for 1,200 PSI. High-pressure test components include a relief valve set at
20,000 PSI and a rupture disk rated at 25,000 PSI.
Two sections comprise the PCC: test cell and common. The test cell section contains the
same components as are found in the remote console, including manual flow control valves
for test fluid, a dual chart recorder, and high and low pressure monitoring gauges. The
recorder plots high and low test pressure values against time of application.
The common section of the console includes an operator joystick, joystick selector, manually-
adjusted pressure regulator valve, gauges, pushbutton controls, air operated pressure
booster pump, and the storage/knowledge box. The joystick selector inside the section is
used to select either the PCC or remote console for conducting the testing. An emergency
stop pushbutton is mounted on the console control panel to provide operators with quick
HPM shutdown capability. The storage/knowledge box is made available for storing chart
paper and maintenance or repair equipment.

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CHAPTER 6
System Overview
From
From
Pump
Pump
Figure 6-6 Pump Control Console (PCC) Hydraulic Schematic

CHAPTER 6
System Overview
Table 6-1 Pump Control Console (PCC) Hydraulic Schematic (Cont.)

ITEM DESCRIPTION PART NUMBER
21 Relief Valve 37-503038
25 Pressure Gauge (1/4-Inch) 37-503071
27 Pressure Gauge (4 inch) 37-500835
28 Hydraulic Pilot Joystick Valve 37-502974
29 Red Emergency Stop Station 54-502983
30 Remote Start/Stop Station 54-502982
31 Pressure Gauge (4-Inch) 37-503040
33 Explosion Proof Digital Indicator 52-502984
35 Dual Chart Recorder 37-502978
36 Relief Valve (1/2-Inch) 37-503098
37 Stellite Valve W/O Body 07-503118
38 Rupture Disk (1/2-Inch) 37-503772
45 Relief Valve AB185
46 240:1 Pump 37-503036
47 Joy Stick Selector AB438
48 2-Way Ball Valve (1/2-Inch) 37-503031
49 Filter/Regulator (1/2-Inch) 37-503072
50 Filter 37-503735

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CHAPTER 6
System Overview
Digital Indicator
Low Pressure
Gauge Hydraulic Supply
(0-1500 psi) Pressure Gauge
(0-600 psi)
High Pressure
Gauge Station Remote
(0-30,000 psi) STOP/START
Main Pump Test

Pressure Gauge
Dual Chart (0-30,000 psi)
Recorder
Rig Air Supply
Pressure Gauge
Test Cell (0-160 psi)
Valves
Filter Regulator
Auxiliary Pump
ON/OFF Valve
Pump Test
Pressure Gauge
(0-6,000 psi)
Joystick
Emergency
Stop Button
Figure 6-7 PCC (with Callouts)

CHAPTER 6
System Overview
Station Remote Pump Test Pressure Gauge

STOP/START (0-6,000 psi)
Main Pump Test Pressure
Gauge (0-30,000 psi Rig Air Supply
Pressure Gauge
Digital Indicator (0-160 psi)
Filter Regulator
Supply Pressure
Gauge (0-600 psi)
Auxiliary Pump
ON/OFF Valve
Emergency
Stop Button
Joystick
Figure 6-8 PCC Operator Control Paney
Station Remote
STOP/START
Main Pump Test
Digital Indicator Pressure Gauge
(0-30,000 psi)
Oil Pump
Pressure Gauge
(0-6,000 psi)
Hydraulic Supply
Pressure Gauge
Rig Air Supply
(0-600 psi)
Pressure Gauge
(0-160 psi)
Filter Regulator
Joystick
Emergency Stop
Button
Auxiliary Pump
ON/OFF Valve
Figure 6-9 PCC Operator Controls
Remote Console (With Eight-Valve Test Manifold)

The remote console (RC) is a single module with a component arrangement similar to that on
the PCC test cell. The RC has a dual chart recorder, test valves, joystick (for pump control),
and gauges to control and monitor high and low pressure hydrostatic testing. The console is
installed at a different location than the HPM and PCC and, unlike the PCC, has no provisions
for monitoring HPM hydraulic fluid charge pressure, temperature, and supply pressure.
The output from the triplex pump on the HPM applies to the PCC and RC simultaneously,
however, when assigned control by the joystick selector in the PCC, the RC joystick operates
the HPM to set test pressures applied to equipment.

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CHAPTER 6
System Overview
As in the PCC, the remote console has a low-pressure relief valve set at 1,100 and low-
pressure rupture disk rated at 1,200 PSI. The high-pressure relief valve is set at 20,000 PSI
with a rupture disk rated at 25,000 PSI. The chart recorder records the high and low
pressure testing. A test valve manifold has eight manual valves for controlling test fluid flow.
An emergency stop pushbutton is also provided.
Figure 6-10 is the hydraulic schematic for the remote console, and Figure 6-11, and Figure
6-12 show the left, front, and right side views. Refer to drawing AA782, Hydraulic Schematic
High Pressure test Unit, in section 6, Engineering Drawings, BOM, and Vendor Information,
for more information.
To Joystick Selector
(for pump output control)
Figure 6-10 Remote Console (RC) Hydraulic Schematic

Table 6-2 Remote Control Console Hydraulic Schematic Callouts
ITEM DESCRIPTION PART NUMBER
25 Pressure Gauge (1/4-Inch) 37-503071
27 Relief Valve 37-503037
28 Hydraulic Pilot Joystick Valve 37-502974
29 Red Emergency Stop Station 54-502983
35 Dual Chart Recorder 37-502978
36 Relief Valve (1/2-Inch) 37-503098
37 Stellite Valve W/O Body 07-503118

CHAPTER 6
System Overview
Figure 6-11 Remote Console (RC)

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CHAPTER 6
System Overview
High Pressure
Gauge
(0-30,000 psi)
Low Pressure
Gauge
(0-1,500 psi)
Dual Chart
Recorder
Emergency Stop
Test Cell
Valves Joystick
Figure 6-12 RC (with Callouts)
Electrical
Electrical interconnections between the rig motor control center (MCC), HPM, PCC, and RC
are shown in Figure 6-13. The power is single phase 120 VAC supplied from a three-phase
440 VAC bus bar. The step-down transformer is connected across two legs and has fusible
links on both the primary and the secondary sides. An overload contactor and motor relay
are also located in the MCC (off the leg without the fusible link).
The HPM pump skid J-box has a single terminal strip that receives the power from the MCC
step-down transformer. Power applies from the HPM terminal strip to a terminal strip in the
PCC. The only power connection to the RC is for the emergency stop button (momentary
open switch).
There are two contacts and one relay for the stop/start circuit in the HPM pump skid J-box.
The stop circuit has a normally closed relay that opens the latching circuit (to stop the
pump). The starting circuit is a normally open contact that closes to complete circuit and
start the pump (from a momentary closed start switch). The starting circuit energizes a
contactor coil (at the MCC) that closes the motor contactor and starts the pump motor. The
stating circuit also energizes a (K) relay to latch in the starting circuit (normally open
contact). Activating any stop switch (normal or emergency) will o pen the running circuit.
Open the running circuit will interrupt the power that keeps the latching relay energized (and
stop the pump).

CHAPTER 6
Equipment Description
The PCC has pump start (momentary closed to start contact), pump stop (momentary open
to stop contact), and an emergency stop (momentary open to stop contact) switches. All the
switches (and the temperature indicator are fed from the common terminal strip).
The RC also has an emergency stop push button (momentary open to stop contact). This
switch is fed from the PCC terminal strip and is wired in series with the PCC. Both remote
stop switches are wired in series with the PCC pump stop switch.
The power to an instrument (24 VDC) power supply is also fed from the HPM pump skid J-
box. The instrument power supply has a hot and neutral connection (ground and common)
that supply power to the temperature transmitter and indicator. The temperature indicator is
located in the PCC and is wired to the PCC terminal strip. The temperature transmitter is
mounted in an explosion proof housing separate from the other components. The
transmitter and indicators are connected in series (transmitter first). The indication signal is
not routed through the PCC terminal strip.
Figure 6-13 HPTU Wiring Diagram
This section provides detailed descriptions of the High-Pressure Test Unit (HPTU) equipment. The
equipment is distributed among the HPM, PCC and RC.
The HPM, PCC and RC are self-contained units that can be installed in different locations. The PCC
and RC are free standing consoles of stainless steel construction. HPM equipment is mounted on an
oilfield type skid having four-point padeyes for overhead lifting and balanced for handling by
offshore cranes. The skid is fully seam welded sandblasted to white metal and coated with a four-
part marine paint system that includes:

NOBL-NA-AHC2008A
CHAPTER 6
• One layer of dimetcote primer

• One layer of dimetcote intermediate sealer
• One layer of marine epoxy top-coat
• One layer of polyurethane finish-coat
As per API R-2A, a single padeye on the skid can support the full weight of the skid if snatch lifting
is required.
The HPM alone provides pressurized test fluids at pressures up to 15 PSI. Pressures above 15 PSI
can be produced from air operated auxiliary pump in the PCC.
Hydraulic Power Module (HPM)

The HPM contains the components required to supply test fluid at pressures up to 15 PSI.
These components include a 100-horsepower electric drive motor coupled to a hydrostatic
transmission. The transmission drives a hydraulic motor, which, in turn, powers a triplex
water pump. Also included are reservoirs, gauges and pressure relief valves and other
equipment that support HPTU operation and control.
Hydrostatic Transmission
The hydrostatic transmission is a pressure compensated hydraulic system comprising a 100-
cc primary pump and a 42-cc secondary pump. Both pumps are variable displacement types
and driven in tandem by the electric motor. The transmission drives a SMA hydraulic motor
which, in turn, powers a triplex water pump.
A one-gallon accumulator is installed in the discharge line of the variable displacement
pumps to dampen any pressure surges.
Both transmission pumps are axial piston/slipper designs with tilt-table cradle swash plates.
Independently operated joysticks mounted on the PCC and RC control the swash plates.
The transmission design provides dynamic braking for optimum pressure control during high
pressure testing. The transmission pressure compensator can be set to terminate triplex
pump operation when test pressure is reached. With the transmission operating solely with
the primary pump, the triplex pump will produce an output of 7-13-gallon per minute (GPM)
at 15,000 PSI. Adding the flow from the secondary pump increases the triplex pump output
to either 10.22 GPM at 14,250 PSI or 8.68 GPM at 15,000 PSI (when the test unit is
operating at 3,000 PSI).
Controls
The output of each transmission pump is determined by the angle of its swash plate. For
both pumps, the output is at zero when the swash plate is at its neutral position. The pumps
begin turning as the swash plate angles (tilts) away from the neutral position.
The HPTU joysticks are used to tilt the swash plates to and from their neutral positions. The
joysticks control the pilot-operated proportional flow valve that regulates the output of the
hydrostatic transmission. This provides for load-independent, regulated hydraulic fluid flow
at increased pressures. The pilot valve is ported to operate either the primary pump alone or
both pumps together. Pushing either joystick forward engages only the primary pump;
pulling either joystick to the rear engages both pumps.
Swash plate angles increase as the joysticks move away from their neutral (center)
positions. The greater the distance from the center position, the greater the output from the
pumps.
A pressure relief valve on the HPM can be manually adjusted to override the relief valves in
the transmission pumps. The valve can be used to increase the accuracy of control over the
output of the triplex pump.

CHAPTER 6
By controlling transmission output, the HPTU joysticks control the output of the triplex pump,
which is driven by the transmission. Thus, triplex pump output can be varied between zero
to maximum from either the PCC or the RC. The joysticks operate independently and a valve
on the PCC is used to manually switch swash plate control from one joystick to the other.
A hydraulic supply (charge) pump supplies cool fluid to the transmission system and
maintains positive pressure for the main pump circuit. This pump also provides makeup oil
and supplies fluid for the pump control system.
NOTE
For a detailed description of the transmission pumps, refer to
Saur Sundstrand vendor information in Section 6,
"Engineering Drawings, BOM and Vendor Information".
Flow Loop
The variable-displacement pumps are in a closed circuit with fluid flowing in either direction.
Swash plate position determines which of the two main hydraulic lines is under high-
pressure. Fluid from the charge pump is directed to the low-pressure side of the main circuit
by one of two charge check valves. The second charge check valve is held closed by the
high-pressure oil on the other main circuit.
The check valves are part of the multifunction valve assembly (located in the end cap of each
variable-displacement pump). The valve assembly includes the main loop check valve,
pressure-limiter valve, high-pressure relief valve and heat exchanger bypass valve
(replaceable cartridge). Each variable-displacement pump contains two multi-function valve
cartridges.
Two pilot-operated, sequenced, high-pressure relief valves prevent sustained abnormal
pressure surges in the main hydraulic lines. This is done by dumping oil from the high-
pressure lines to the low-pressure lines during rapid acceleration, abrupt braking, or sudden
application of load. The pressure limiter can be preset to stop the triplex pump automatically
when the test pressure is reached.
Swash plate inclination is reduced to zero degrees (to stop the triplex pump) when the main
circuit preset pressure level is reached. The relief valves are sequenced to operate at
pressures above the pressure limiter de-stroke pressure level. The pressure limiter sensing
and relief valves are incorporated into the multifunction valves in the pump end cap.
The hydraulic system includes an externally mounted loop flushing valve that flushes the
main circuit and a shuttle valve. The flushing valve opens to connect the low-pressure side
of the loop and the charge-pressure relief valve in the motor end-cap. The shuttle valve is
spring-centered in the closed position so that no high-pressure fluid is lost during reverse
pressure transition in the circuit. The charge relief valve regulates the charge pressure level
when there is a pressure differential in the main circuit. The valves control the charge
pressure level and remove the excess cooling oil from the charge pump.
System Cooling Circuit

Cooling fluid enters the motor case from the charge pump through the manifold charge
pressure relief valve. The fluid circulates through the motor case and into the case drain
lines for the transmission pumps. Cooling fluid circulates through each of the hydraulic
elements (in series) to remove heat, passes through a heat exchanger for cooling and
returns to the reservoir.
In the heat exchanger, a bypass valve vents fluid directly to the reservoir if backpressure
exceeds a preset limit. High case backpressure can occur if cooling fluid temperature is too
low or if the flow in the cooling circuit is restricted.

NOBL-NA-AHC2008A
CHAPTER 6
Hydraulic Motor
The hydrostatic transmission drives a hydraulic motor that has five piston sleeves radial
mounted in a cylinder block. The cylinder block is mounted on a drive shaft eccentric.
Pressurized hydraulic fluid is sent to the piston sleeves through a timing slot in the eccentric
(from axial galleries in the crankshaft). Flat reaction pads located inside the motor case
support the piston sleeves.
Pressurizing the cylinders produces a resultant turning moment on the eccentric. Each
piston sleeve is supported at the reaction pad end by a hydrostatic bearing. An Oldham
coupling maintains the position of the cylinder block relative to the reaction pads. The
crankshaft is supported on large taper roller bearings that accept both radial and axial
external loads. Fluid enters into and drains from the crankshaft galleries through a rotating
distributor system at the non-drive end of the shaft.
Triplex Pump
The triplex pump is a positive-displacement, triple-plunger type pump that supplies
pressurized test fluid to the PCC and RC. Major components are contained in the power and
fluid ends of the pump.
Power-End Components
The power end comprises the power frame, crankshaft, main roller bearings, rods,
crossheads, wrist pins and plunger adapters and covers. These components are lubricated
with oil splashed from the pump case and supplied from an auxiliary lubrication system.
The auxiliary lubrication system ensures that crankshaft bearings and crossheads receive
adequate lubrication at operating speeds below 200 RPM. The system consists of an
externally mounted pump powered by a hydraulic motor and draws oil from the pump case.
A gear pump drives the motor in the hydrostatic transmission and the pump delivers oil at a
rate of 0.25 GPM.
A relief valve in the system provides overpressure protection.
Fluid-End Components
The fluid end of the pump is machined from a solid block of precipitation-hardened (PH)
stainless steel that is shot-peened for greater fatigue strength. The block encloses three
3/4-inch plungers that produce 5.8 GPM at 15,000 PSI. A relief valve set at 18,000 PSI and
a rupture disc set at 22,000 PSI provide overpressure protection.
The pump plungers are packed with a multiple-element, chevron style packing. The packing
is spring loaded, self-adjusting and replaceable from the rear of the stuffing box. Packing
rings are lubricated and cooled by force-fed water.
All fluid end valves and seats are wing-guided, machined from 17-PH stainless steel and
field-replaceable. The valves are spring-loaded for positive closure and are of straight-
shoulder design with O-ring seals.
Pressure surge protection for the fluid end is provided a high-pressure discharge manifold.
The manifold includes an 18,000 PSI high-pressure relief valve and 20,000 PSI rupture disc.
Reservoirs
The hydraulic power module is equipped with 30-gallon and 50-gallon reservoirs. Both
reservoirs comprise a stainless steel tank with removable cover, externally mounted sight
gauges, internal suction strainer and baffle and filler/breather cap.
The water reservoir inlet has a level actuated shutoff valve to prevent overfilling and a three-
way ball valve for directing incoming water to either the reservoir or the triplex pump. A
connection is provided on the HPM skid for adding glycol from an external source and a

CHAPTER 6
selector valve has been installed for shifting pump suction between the water reservoir and
the glycol supply line.
The water reservoir has two externally mounted sight gauges for tank level monitoring. The
fluid reservoir has one sight gauge that indicates both fluid level and temperature.
Pump Control Console (PCC)

The console comprises right and left side modules with different design configurations. The
left side module is designated Cell 1 and contains the valves used to pass fluids to equipment
subjected to pressure testing. On the right side is the High Pressure Unit Remote Control
(HPURC) module with the components used for operating either the PCC. The PCC is
designed for installation at locations remote from the HPM.
The PCC has an explosion-proof junction box in which the electrical wiring connections with
the HPM are made. Supply lines for the test fluid and externally supplied air connect at the
rear.
HPURC Module
The Remote console components include a joystick (for transmission control), joystick
selector valve, adjustable air pressure regulating valve, gauges, pushbutton controls
and air-operated auxiliary pump and storage box.
Indicators and Switches

Figure 6-14 depicts the layout and nomenclature assigned to indicators and
switches on the Remote console. These items serve the following functions:
• STOP-START: Two press-to-operate pushbuttons that start and stop
the electric drive motor on the HPM. Each button illuminates when
pressed.
•OIL TEMP: A digital
readout gauge that
START STOP monitors hydraulic fluid
temperature in the HPM
hydraulic fluid reservoir.
OIL TEMP MAIN PUMP TEST PRESS. The transmitter for this
gauge is mounted on the
side of the reservoir.
•MAIN PUMP TEST
Aux Pump PRESS: A glycerin filled
Hydraulic Supply Motor Supply Air Supply gauge that indicates the
pressure of test fluid
supplied to the PCC from
the triplex pump.
•Hydraulic Supply: A
High Pressure
Low Volume
Air Regulator
glycerin filled gauge that
Emergency indicates pressure at the
Stop
Charge pump outlet in
Air Pump the HPM hydrostatic
High Volume
ON transmission.
Low Pressure
OFF •Motor Supply: A
Aux Pressure
glycerin filled gauge that
22,500 PSI indicates fluid pressure
at the input to the
Figure 6-14 HPURC Operator Panel

NOBL-NA-AHC2008A
CHAPTER 6
hydraulic motor that couples to the triplex pump.

• Pump Air Supply: A gauge that monitors air pressure at the input to
the air operated pump
• Emergency Stop: A press-to-operate mushroom pushbutton. Like the
STOP button above, the emergency stop button terminates the supply
of electrical power to the drive motor for the hydrostatic transmission.
• High Pressure/Low Volume-High Volume/Low Pressure: Joystick
position indicators.
• Air Regulator: Control knob for setting regulated air pressure at the
inlet to the air-operated auxiliary pump.
• Air Pump ON-OFF: Switch for turning air operated pump on and off.
Air-Operated Auxiliary Pump

The air-operated auxiliary pump is substituted for the triplex pump when test
fluid pressures above 15 PSI are required. The pump has an input-to-output
ratio of .240:1, meaning that, when supplied with air at 100 PSI, the pump can
produce a test fluid pressure of 24 PSI.
The pump operates with air from an external source and a manually adjustable
regulator with filter is installed for setting pressures at the pump inlet. Airflow
to the pump is initiated and terminated with a two-position panel mounted
switch.
Joystick and Joystick Selector Valve

The joystick regulates the output of the triplex pump by controlling the speeds
of the hydrostatic transmission pumps. The joystick is servo-assisted and has a
spring-return to neutral (center) position that enables positioning with minimal
force. Pushing the joystick toward the HIGH PRESSURE/LOW VOLUME position
initiates flow solely from the primary transmission pump. Pulling the joystick to
the LOW PRESSURE/HIGH VOLUME position initiates flow from both transmission
pumps simultaneously.
The joystick selector is a two-position, lever-operated valve mounted inside the
Remote console. The valve is used to manually switch control of the triplex
pump between the joysticks in the PCC and RC.
Storage Box
The HPURC module has a watertight stainless steel box for storing recorder
charts, pens, etc.
Cell 1
The test cell section includes the test valve manifold, dual chart recorder and the high
and low-pressure gauges used to monitor hydrostatic testing.
Test Valve Manifold

The test valve manifold is a weldment that contains eleven hand operated, high-
pressure needle valves. All valves are cartridge-type, rising-vee stem/block
designs with replaceable seats. Seat and stem assemblies can be top-loaded for
easy replacement and the valves have non-rotating stems and PTFE-
encapsulated packing for stem and body sealing. Figure 6-15 illustrates test
valve layout and connections in the weldment. Also shown is the identifying
nomenclature etched in detail panel AB217 that is installed over the weldment.

CHAPTER 6
Only the valve handles are visible above the detail panel. Counterclockwise
handle rotation opens the valves; clockwise rotation closes them.
Isolation Bleed - Off Bleed - Off

The valves can be opened in
(C) (G) (J) several different combinations to
produce a variety of flow paths
through the manifold. Figure 6-16
Low Pressure
Aux High shows the combinations that
Pressure
0 - 1000 PSI 22,500 PSI produce flow paths for low
Bleed - Off
(F) Isolation pressure, high pressure and
(K)
Pump auxiliary pump testing. Low
pressure testing ranges from zero
Test O to 1,000 PSI, high pressure testing
from zero to 15 PSI and the
Isolation
(B) Bleed - Off Main Pump auxiliary pump test range is zero
to 25 PSI. All three paths connect
(E) Isolation
(I)
to a gauge and dual chart recorder

and rupture disks and manually
adjustable relief valves protect
Supply Bleed Off
against overpressures. In each
(A) (D) (H) path, normally closed valves can
be opened for drainage.
Dual Chart Recorder

In
The dual chart recorder is 12
Test Out
Notes: inches in diameter and has two

1. Nomenclature reflects that etched on panel
AB217 installed over test valve manifold. pens and a two-speed clock (2-
2. Letters in parentheses correspond to letter hour/8-hour) for recording high
identifications of valves in functional
illustrations in this section and low pressure testing. For each
Figure 6-15 Cell 1 Test Valve Weldment test, the recorder plots the amount
and duration of applied pressures.
Pressure Gauges
Cell 1 has low and high pressure gauges for registering applied test pressures.
The low-pressure gauge registers from zero to 1500 PSI and the high-pressure
gauge registers from zero to 30,000 PSI. Both gauges are made of stainless
steel and are liquid-filled.

NOBL-NA-AHC2008A
CHAPTER 6
Low High Low High

Pressure Chart Pressure Presure Chart Pressure
Gauge Recorder Gauge Gauge Recorder Gauge
Set at Set at
1100 PSI 1100 PSI
25 KSI 25 KSI
1200 PSI 1200 PSI
J
Set at Set at
25 KSI 25 KSI
C G C G
Auxiliary Pump Auxiliary Pump

Input Input
F K F K
B E I B E I
Set at Set at
20 KSI 20 KSI
A D H A D H
1000 PSI/15 KSI 1000 PSI/15 KSI
Outlet Output
Drain Drain
Triplex Pump In Triplex Pump In
All Manifold Test Valves Closed 1000 PSI Test Flow Path, Valves A, B, C, E,
and H Open
Low High Low High
Pressure Chart Pressure Pressure Chart Pressure
Set at Set at
1100 PSI
1100 PSI
25 KSI 25 KSI
1200 PSI 1200 PSI
J
Set at Set at
25 KSI 25 KSI
C G C G
Auxiliary Pump Auxiliary

F K Input F K Pump Input
B E I B E I
Set at Set at
20 KSI
20 KSI
A D H A D H
1000 PSI/15 KSI 1000 PSI/15 KSI
Output Outlet
Drain Drain
15 KSI Test Flow Path, Valves A, B, E, I, Auxiliary Pump Test Flow Path, Valve K
and H Open Open
Figure 6-16 Fluid Flow Paths Through Eleven-Valve Weldment 07-502993
NOTE
1.Valve layouts above conform to layout etched in valve plate
on test valve detail panel AB217.
NOTE
2.Letters in parentheses correspond to valve identifications in
the three flow path diagrams.
Remote Console (RC)

The RC is designed to be operated at locations that are remote from both the HPM and the
PCC. The RC receives pressurized test fluid from the triplex pump via high-pressure piping.
RC equipment includes a test valve manifold, joystick, high and low test pressure gauges,
dual chart recorder and emergency stop pushbutton. Except for the test valve manifold,

CHAPTER 6
these equipment items function as previously described for the PCC. Figure 6-17 illustrates
equipment layout and identifying nomenclature on the RC control panel.
Test Valve Manifold

The weldment for the RC test valve
(E M E R G E N C Y
manifold contains only eight hand
STOP BUTTO N)
operated, high-pressure needle valves.
IS O L A T IO N B L E E D -O F F
As in the PCC manifold, the valves are
C G cartridge-type, rising-vee stem/block
designs with replaceable seats. Seat
LOW
PRESSURE
(J O Y S T IC K )
and stem assemblies can be top-loaded
for easy replacement and the valves
B L E E D -O F F
have non-rotating stems and PTFE-
F encapsulated packing for stem and
body sealing.
Test valve layout and the top left panel
IS O L A T IO N B L E E D -O F F IS O L A T IO N in Figure 6-18 illustrates connections in
B E H
the weldment. Also shown is the
identifying nomenclature etched in
H IG H detail panel AB162 that is installed over
the weldment. Only the valve handles
PRESSURE
SUPPLY B L E E D -O F F TEST OUT are visible above the detail panel.

A D
Counterclockwise handle rotation opens
the valves; clockwise rotation closes
them.
The valves can be opened in several
Figure 6-17 Detail Panel on RC different combinations to produce a
variety of flow paths through the
manifold. The three remaining panels in Figure 6-18 show the open valve
combinations that produce the flow paths for low and high pressure testing. Low
pressure testing ranges from zero to 1,000 PSI and high pressure testing from zero to
15 PSI. Both paths connect to a gauge and dual chart recorder and rupture disks and
manually adjustable relief valves protect against overpressures. In each path,
normally closed valves can be opened for drainage.

NOBL-NA-AHC2008A
CHAPTER 6
Isolation Bleed - Off Emergency Stop Low High

(c) (G) Pressure Chart Pressure
Gauge Recorder Gauge
Low Volume
High Pressure
Low
Pressure Set at
Bleed - Off 1200 PSI
(F)
20 KSI
1200 PSI
High Volume
Low Pressure
Isolation Bleed - Off Isolation C G

(B) (E) (H)
Set at
18 KSI
F
High
Pressure B E H
Test Out
A D
Supply Bleed - Off 1000 PSI/15 KSI
(A) (D) Outlet
Drain
In Triplex Pump In
RC Test Valve Weldment All Manifold Test Valves Closed
Low High Low High

Set at Set at
1100 PSI 1100 PSI
20 KSI 18 KSI
1200 PSI 1200 PSI
C G C G
Set at Set at
18 KSI 18 KSI
F F
B E H B E H
A D A D
1000 PSI/15 KSI 1000 PSI/15 KSI
Outlet Output
Drain Drain
1000-PSI Test Flow Path, Valves A, B, C, 15-KSI Test Flow Path, Valves A, B, E, and
and H Open H Open
Figure 6-18 Fluid Flow Paths Through Eight-Valve Weldment AC972
NOTE
NOTE
Joystick
As in Cell 1, the RC joystick regulates the output of the triplex pump by controlling the
speed of the hydrostatic transmission. The joystick is servo-assisted and has a spring-
return to neutral (center) for positioning with minimal force.
Pushing the joystick toward the HIGH PRESSURE/LOW VOLUME position initiates flow
solely from the primary transmission pump. Pulling the joystick to the LOW
PRESSURE/HIGH VOLUME position initiates flow from both transmission pumps
simultaneously.

CHAPTER 6
Operation
Operation
This section contains instructions for the initial startup and subsequent operation of the HPTU.
In general, use only approved procedures that conform API RP53, Section 7A. High pressure
testing procedures should be specific regarding test criteria, steps to be taken, pressure ratings
(amount and duration), recorded data, and acceptable results.
General
HPM Fluids
Use premium grade, anti-wear hydraulic fluid, such as Chevron AW-32 or an
equivalent, for the HPM hydrostatic transmission. For the triplex pump crankcase, only
premium grade oil, such as Exxon Spartan EP-150 or equivalent, is recommended.
Pass hydraulic fluid through a 10-micron filter before adding it to the hydrostatic
transmission.
PCC and RC Controls

The triplex pump supplies test fluid simultaneously to both the PCC and RC; therefore,
high and low pressure tests can be conducted independently from either console.
Auxiliary pump testing can only be conducted at the PCC.
Joystick control should be switched to the RC only when it is manned and should be
returned to the PCC when testing is concluded (or when the RC is to be unmanned for
any period of time). This precaution prevents inadvertent pump operation (while the
RC is unmanned).
Chart recorders can be operated at either panel or at both panels simultaneously.
Figure 6-19, and Figure 6-20 identify the valves and diagram. Pre-Start Inspection
Before conducting any test, verify that:
• Test fluid pressures will not exceed equipment pressure ratings.
• Test equipment is in optimum working condition. Replace or repair

equipment that exhibits damage.
• PCC joystick selector valve is set for test control from PCC joystick.
• Flow lines and fittings exhibiting wear or damage are replaced.
• Clamps and connections are tight. Reconnect and retighten as required.
• Correct, new, and clean paper form is in chart recorder.
• Ink flows in chart recorder pen(s). Stoppages can often be cleared by

carefully touching pen tip (recording arm) with clean paper towel or clean
finger.
Operation
Initial Startup
Use the following procedure for the initial HPTU startup (and for startups after
maintenance or extended shutdowns). The procedure assumes that hydrostatic
transmission fluid lines and both HPM skid mounted reservoirs are empty.

NOBL-NA-AHC2008A
CHAPTER 6
Operation
WARNING
THE HPTU DISCHARGES FLUIDS AT PRESSURES THAT
CAN BE INJURIOUS TO PERSONNEL AND DAMAGING TO
EQUIPMENT. PRIOR TO STARTING ANY TEST, REFER TO
SECTION 4.1. CONDUCT ALL HYDROSTATIC TESTING
ACCORDING TO APPROVED PROCEDURES AND
GUIDELINES.
1. Verify test and hydraulic fluid flow line connections are properly made between
the HPM, PCC, and RC.
2. Inspect interiors of hydraulic fluid and water tanks and system valves, fittings,
heat exchanger, and sumps for contaminates. Clean as required.
3. Fill reservoirs to proper levels.
4. Open shutoff valves in flow lines between reservoirs, triplex pump, and
hydrostatic transmission. As appropriate, open shutoff valves in glycol supply
line.
5. Disconnect and fill the flow lines leading from the fluid reservoir to the pumps.
Reconnect the lines and tighten the fittings.
6. Inspect water and hydraulic fluid flow line connection for leaks.
CAUTION
Pump and motor housings must be filled with hydraulic oil
before startup. Failure to observe this precaution can result in
damage to the pump or motor during startup.
7. .Fill the pump and motor housings by pouring filtered hydraulic oil into their
upper case drain ports.
8. Prepare triplex pump for startup by:
a.Inspecting pump sump for dirt and foreign objects. Clean as required.
b.Filling pump housing by pouring filtered gear oil into the upper case drain
port.
c.Verifying the water reservoir is full. As appropriate, add glycol.
d.Opening the shutoff valves in packing coolant and power head water
supply lines.

CHAPTER 6
Operation
WARNING
HIGH-PRESSURE WATER JETS CAN CAUSE SERIOUS
INJURY OR DEATH TO PERSONNEL BY BREAKING SKIN
AND INDUCING AIR INTO THE BLOODSTREAM. IF ANY
(EVEN SLIGHT) INJURY OCCURS FROM A HIGH-
PRESSURE WATER JET, CONTACT A PHYSICIAN
IMMEDIATELY AND INFORM HIM OF THE CAUSE.
9. .Start the electric drive motor and cycle transmission pumps at lowest possible
speed until MOTOR SUPPLY gauge on PCC indicates charge pressure.
10. When charge pressure reaches 320 to 340 PSI, gradually bring pump to normal
operating speed
CAUTION
Charge pressures outside prescribed range can reduce
operator ability to control speed and output of the triplex pump.
NOTE
If charge pressure STABILIZES between 320 and 340 PSI, go
to step 9.
NOTE
If charge pressure DOES NOT STABILIZE between 320 and
340 PSI, shut HPM down and troubleshoot.
11. Slowly cycle the pump from neutral to forward operation for at least five
minutes.
NOTE
If charge pressure REMAINS STABILIZED between 320 and
340 PSI, assume HPM is ready for operation.
NOTE
If charge pressure DOES NOT REMAIN STABILIZED etween
320 and 340 PSI, shut HPM down and troubleshoot.
12. Press the EMERGENCY STOP button on PCC and verify hydrostatic pump shuts
down.
13. Verify proper levels in the fluid reservoir. Replenish as necessary.

NOBL-NA-AHC2008A
CHAPTER 6
Operation
Low High Low High

Pressure Chart Pressure Presure Chart Pressure
Set at Set at
1100 PSI 1100 PSI
25 KSI 25 KSI
1200 PSI 1200 PSI
J
Set at Set at
25 KSI 25 KSI
C G C G
Auxiliary Pump Auxiliary Pump

Input F Input
F K K
I B E I
B E
Set at Set at
20 KSI 20 KSI
A D H A D H
1000 PSI/15 KSI 1000 PSI/15 KSI
Outlet Output
Drain Drain
All Manifold Test Valves Closed 1000 PSI Test Flow Path, Valves A, B, C, E,
and H Open
Low High Low High

Set at Set at
1100 PSI 1100 PSI
25 KSI 25 KSI
1200 PSI 1200 PSI
J
Set at Set at
25 KSI 25 KSI
C G C G
Auxiliary Pump Auxiliary

F K Input F K Pump Input
B E I B E I
Set at Set at
20 KSI
20 KSI
A D H A D H
1000 PSI/15 KSI 1000 PSI/15 KSI
Output Outlet
Drain Drain
15 KSI Test Flow Path, Valves A, B, E, I, Auxiliary Pump Test Flow Path, Valve K
and H Open Open
Figure 6-19 Fluid Flow Paths Through Eleven-Valve Weldment 07-502993
NOTE
NOTE

CHAPTER 6
Operation
Pressure Testing from PCC
WARNING
BEFORE STARTING THE HPM HYDROSTATIC
TRANSMISSION, SET THE PCC JOYSTICK SELECTOR
VALVE FOR TEST CONTROL AT THE PCC. FAILURE TO
OBSERVE THIS PRECAUTION CAN RESULT IN
UNEXPECTED WATER JETTING THAT CAN INJURE
PERSONNEL AND DAMAGE EQUIPMENT.
Refer to Figure 6-19 and conduct pressure testing from the PCC according to Table 6-
11, Table 6-12, Table 6-13, and Table 6-14.
Table 6-3
Table 4-1.Preparation
Preparation for
for All PressureTests
All Pressure Tests
Step Operator Action Result Remarks
1 At PCC and RC, close all Drain paths closed for all test
manifold test valves. ranges.
2 At PCC, set joystick PCC alone controls triplex
selector valve for PCC. pump output.
3 At HPM, open appropriate Ensures flow of water and
shutoff valves in water and hydraulic fluid to and from
hydraulic fluid lines. triplex pump and hydrostatic
transmission.
4 As appropriate, open As determined by diverter
shutoff and diverter valves valve, glycol flows to water
in glycol supply lines. reservoir or to triplex pump.
5 At PCC, press ON 1. HPM drive motor starts.
pushbutton and observe
MOTOR SUPPLY and 2. Triplex pump rotates.
MAIN PUMP TEST
PRESS. gauges. 3. Hydraulic fluid pressure on
MOTOR SUPPLY gauge
If gauge pressure RISES to rises to 300 psi.
or near 300 psi, go to step
4. 4. Water pressure rises on
MAIN PUMP TEST
If gauge pressure DOES PRESS. Gauge.
NOT rise to or near 300 psi,
press the STOP button and
troubleshoot.

NOBL-NA-AHC2008A
CHAPTER 6
Operation
Table 6-4
Table Conducting
4-2. Conducting1000-PSI Pressure
1000-PSI Pressure Tests
Tests at PCC
at PCC
1 Perform startup in Table 4- HPM supplies test fluid to
1. console inlet.
2 At Cell 1, successively 1. Flow path opened to low As necessary, relieve
open test valves A, B, and pressure rupture disk, overpressures in the
C. relief valve, gauge, and test valve manifold by
dual chart recorder. opening valve G and
cracking valve F.
2. Cell 1 low pressure gauge
and chart recorder indicate
test fluid pressure.
3 Successively open Cell 1 Pressurized test fluid emits
test valves E and H. from 1000 psi/15 KSI output at
rear of PCC.
4 Observe console low In response to joystick
pressure gauge and movement, indicated pressure
operate PCC joystick to rises and falls on:
establish desired test
pressure. ? Cell 1 Low pressure gauge.
? PCC HYDRAULIC SUPPLY
gauge.
? PCC MAIN PUMP TEST
PRESS. gauge
5 When indicated pressure is Pressurized test fluid locked Closing valves E and H
as desired, shut PCC into flow lines from 11-valve gives double valve
valves E and H. PCC to equipment under test. sealing for test fluid
flow path.
6 Release joystick and For entire observation period,
observe Cell 1 low pressure indicated pressure should
gauge for a suitable time remain stable without
period. noticeable decrease.
If gauge pressure does

remain stable, go to step 7.
If gauge pressure does not

remain stable, open valves
E and H and repeat steps 4
and 5 to confirm leakage.

CHAPTER 6
Operation
Table 6-5 Conducting 1000-PSI Tests at PCC (Cont.)

Table 4-2. Conducting 1000-PSI Pressure Tests at PCC (Cont.)
7 Start chart recorder and 1. Chart recorder plots
press PCC STOP pressure versus time.
pushbutton.
2. Hydrostatic transmission
shuts down.
3. Pressure falls to zero on

MOTOR SUPPLY and
HYDRAULIC SUPPLY
gauges on PCC.
8 At end of time period:
1. Stop chart recorder.
2. Remove chart paper.

9 At Cell 1, open valves D, E, Test fluid drains from:
F, G, and H.
? Cell 1 test valve manifold.
? Lines between triplex pump,
PCC, and equipment under
test.
? Cell 1 low pressure gauge
indication drops to zero.
Table 6-64-3.
Table Conducting 15KSI
Conducting 15 PSIPressure
Pressure Tests
Tests at PCC
at PCC
1 Perform startup in Table 4- HPM supplies test fluid to
1. console inlet.
2 Successively open Cell 1 1. Flow path opened to high- As necessary, relieve
valves A, B, E and I. pressure rupture disk, overpressures in the
relief valve, gauge, and test valve manifold by
dual chart recorder. cracking valve D.
2. Cell 1 high pressure gauge


NOBL-NA-AHC2008A
CHAPTER 6
Operation
Table 6-7 Conducting 15-PSI Pressure Texts at PCC (Cont.)

Table 4-3. Conducting 15-KSI Pressure Tests at PCC (Cont.)
3 Open manifold test valve H. Pressurized test fluid emits
from 1000 psi/15 KSI output at
rear of PCC.
4 Observe Cell 1 high In response to joystick
pressure gauge and movement, indicated pressure
operate PCC joystick to rises and falls on:
achieve desired test
pressure. ? Cell 1 high pressure gauge
? PCC HYDRAULIC SUPPLY
gauge.
? PCC MAIN PUMP TEST
PRESS. gauge
5 When Cell 1 gauge Pressurized test fluid locked Closing valves E and H
pressure is as desired, into flow lines between Cell 1 gives double valve
close valves E and H on and equipment under test. sealing for test fluid
Cell 1. flow path.
observe Cell 1 high indicated pressure should
pressure gauge for a remain stable without
suitable time period. noticeable decrease.


remain stable, open valves
E and H and repeat steps 4
and 5 to confirm leakage.
press STOP pushbutton on pressure versus time.
PCC.
shuts down.
3. Pressure falls to zero on

MOTOR SUPPLY and
HYDRAULIC SUPPLY
gauges on PCC.

CHAPTER 6
Operation
Table 6-8
Table Conducting 15-PSI
4-3. Conducting 15-KSI Pressure Tests
Pressure Tests at PCC
at PCC (Cont.)
(Cont.)
8 At end of time period, stop
chart recorder and remove
chart paper.
If leakage is evident,
troubleshoot and repeat
test.
If leakage not evident, go
to next step.
9 At Cell 1, open valves D, E, a. Test fluid drains from:
and H.
? Console test valve
manifold.
? Lines between triplex
pump, console, and test
vessel.
b. High pressure gauge

indication falls to zero.
Table 6-9 Conducting

Table Auxilliary
4-4. Conducting AuxiliaryPump Pressure
Pump Pressure Tests
Tests at PCC
at PCC
1 Perform startup in Table 4- HPM supplies test fluid to PCC
1. inlet.
2 Verify air supplied to PCC
at required pressure.
3 On Cell 1, open valve K. Opens flow path to Cell 1 high
pressure gauge, dual chart
recorder, and 25-KSI rupture
disk.
4 Rotate ON-OFF switch for 1. Air operated pump To reduce pressure in
air operated auxiliary pump operates. test valve manifold,
to ON. crack valve J as
2. Cell 1 high pressure gauge needed.
hydrostatic pressure.
5 Observe Cell 1 high Pressure gauge indication
pressure gauge and varies according to regulator
operate AIR REGULATOR setting.
control to set desired
pressure.

NOBL-NA-AHC2008A
CHAPTER 6
Operation
Table 6-10abConducting
e Co duct Auxilliary
g u a y Pump
u p Pressure
essu e estsTests
at CCat(Co
PCC
t ) (Cont.)
6 When Cell 1 high pressure 1. Air operated pump
gauge indicates desired operation terminates.
pressure:
1. Close valve K on Cell 1. 2. Pressurized test fluid
locked into flow lines
2. Set ON-OFF switch to between PCC and
OFF. equipment under test.
7 Observe Cell 1 high For entire observation period,
pressure gauge for a indicated pressure should
suitable time period. remain stable without
noticeable decrease.

remain stable, open valve K
and repeat steps 4, 5, and
6 to confirm leakage.
8 Start chart recorder. Chart recorder plots pressure
versus time.

10 At Cell 1, open valves J, K, Test fluid drains from:
I, E and D.
? Cell 1 test valve manifold.
? Lines between PCC, and
equipment under test.
? Pressure on Cell 1 high
pressure gauge drops to
zero.

CHAPTER 6
Operation
Isolation Bleed - Off Emergency Stop Low High

(c) (G) Pressure Chart Pressure
Gauge Recorder Gauge
Low Volume
High Pressure
Low
Pressure Set at
Bleed - Off 1200 PSI
(F)
20 KSI
1200 PSI
High Volume
Low Pressure
Isolation Bleed - Off Isolation C G

(B) (E) (H)
Set at
18 KSI
F
High
Pressure B E H
Test Out
A D
Supply Bleed - Off 1000 PSI/15 KSI
(A) (D) Outlet
Drain
In Triplex Pump In
RC Test Valve Weldment All Manifold Test Valves Closed
Low High Low High

Set at Set at
1100 PSI 1100 PSI
20 KSI 18 KSI
1200 PSI 1200 PSI
C G C G
Set at Set at
18 KSI 18 KSI
F F
B E H B E H
A D A D
1000 PSI/15 KSI 1000 PSI/15 KSI
Outlet Output
Drain Drain
1000-PSI Test Flow Path, Valves A, B, C, 15-KSI Test Flow Path, Valves , B, E, and H
and H Open Open
Figure 6-20 Fluid Flow Paths Through Eight-Valve Weldment AC972
NOTE

NOBL-NA-AHC2008A
CHAPTER 6
Operation
NOTE
Pressure Testing from RC
WARNING
BEFORE STARTING THE HPM HYDROSTATIC
TRANSMISSION, SET THE PCC JOYSTICK SELECTOR
VALVE FOR TEST CONTROL AT THE PCC. FAILURE TO
OBSERVE THIS PRECAUTION CAN RESULT IN
UNEXPECTED WATER JETTING THAT CAN INJURE
PERSONNEL AND DAMAGE EQUIPMENT.
Refer to Figure 6-20 and conduct pressure testing from the RC according to Table 6-
11, Table 6-12, Table 6-13, and Table 6-14.
Table 6-11
Table Conducting
4-5. Conducting1000-PSI Pressure
1000-PSI Pressure TestsTests
at RC at RC
1 Perform startup in Table 4- Pressurized test fluid supplied
1. to RC inlet.
2 At PCC, set joystick Transfers control of HPM
selector valve for RC. output to RC joystick.
3 Successively open test 1. Flow path opened to low As necessary, relieve
valves A, B, and C. pressure rupture disk, overpressures in the test
relief valve, gauge, and valve manifold by
dual chart recorder. opening valve G and
cracking valve F.
2. Cell 1 low pressure gauge
4 Successively open test Pressurized test fluid emits
valves E and H. from 1000 psi/15 KSI output at
rear of RC.
5 Observe low pressure In response to joystick
gauge and operate joystick movement, indicated
to establish desired test pressures rises and falls on
pressure. low pressure gauge.
6 When indicated pressure Pressurized test fluid locked Closing valves E and H
is as desired, shut valves into flow lines from RC to gives double valve
E and H. equipment under test. sealing for test fluid flow
path.

CHAPTER 6
Operation
Table 6-12
TableConducting 1000-PSI
4-5. Conducting Pressure
1000-PSI Pressure Tests
Tests at RCat(Cont.)
RC (Cont.)
observe low pressure indicated pressure should

remain stable, go to step
7.

not remain stable, open
valves E and H and repeat
steps 4 and 5 to confirm
leakage.
Table
Table6-13 Conducting15-KSI
4-6. Conducting 15-PSI Pressure
Pressure Tests
Tests at RC
at RC
1 Perform startup in Table 4- Pressurized test fluid supplied
1. to RC inlet.
2 At PCC, set joystick Transfers control of HPM
selector valve for RC. output to RC joystick.
3 Successively open valves 1. Flow path opened to high- As necessary, relieve
A, B, and E. pressure rupture disk, overpressures in the test
relief valve, gauge, and valve manifold by
dual chart recorder. cracking valve D.
2. High pressure gauge and

chart recorder indicate test
fluid pressure.
4 Open manifold test valve Pressurized test fluid emits
H. from 1000 psi/15 KSI output at
rear of RC.
5 Observe high pressure In response to joystick
gauge and operate RC movement, indicated pressure
joystick to achieve desired rises and falls on high
test pressure. pressure gauge.
6 When gauge pressure is Pressurized test fluid locked Closing valves E and H
as desired, close valves E into flow lines between RC and gives double valve
and H. equipment under test. sealing for test fluid flow
path.

NOBL-NA-AHC2008A
CHAPTER 6
Maintenance
Table Table
6-14 4-6.
Conducting
Conducting 15-PSI Pressure
15-KSI Pressure Tests
Tests at RCat RC (Cont.)
(Cont.)
observe high pressure indicated pressure should

remain stable, go to step
7.

not remain stable, open
valves E and H and repeat
steps 4 and 5 to confirm
leakage.
press EMERGENCY pressure versus time.
STOP pushbutton.
shuts down.
3. Triplex pump output

terminates.

10 Open valves D, E, and H. Test fluid drains from:
? Test valve manifold.

? Lines between triplex pump,
RC, and equipment under
test.
? Pressure on RC high
pressure gauge drops to
zero.
Maintenance
General
This section contains HPTU troubleshooting and maintenance information.
Table 6-15 below lists preventive maintenance requirements and scheduling for major HPTU
equipment. Included in the table are the hydrostatic transmission pumps, reservoirs, triplex
pump, hydraulic drive motor, and accessories, such as hoses, fittings, and connectors.
Table 6-16, Table 6-17, Table 6-18, and Table cover troubleshooting for major HPTU
equipment, and Table 6-19 lists vendor supplied HPTU equipment by source and part
number. Maintenance procedures for serviceable Hydril equipment appear at the end of this
section. The procedures contain disassembly/assembly instructions, parts listing,
repair/seals kit data, and ordering information.

CHAPTER 6
Maintenance
Table 6-15 HPTU Equipment Maintenance Schedules

Equipment Maintenance Interval
After First 100 250 / 500
Daily Service Hours Service As Required
Hours
Hydraulic Fluid Inspect for; Drain and Replenish fluid
Reservoir ? Proper fluid level (add refill with new level as
as needed) filtered oil. required.
? Water in fluid (milky oil Replace
or water present) reservoir
? Heat damaged fluid filter.
(strong rancid odor)
Note: If milky or rancid fluid
is detected, drain and clean
reservoir and replace fluid
and filter.
Water Inspect for; Add one gallon
Reservoir ? Proper water level (float of Erifon-856 (or
valve is working) equivalent) and
? Contaminates in water pump through
Note: If contaminants are circuit before
found, drain and clean storage or
reservoir. extended
shutdown.
Table 6-16 HPTU Equipment Maintenance Schedules (Cont.)

Hours
Hydrostatic Check for general condition Inspect / tighten Drain power end
Transmission and leaks. mounting bolts; fluid. Replace
motor assembly with new
screws; drive (filtered) fluid as
couplings; pipes, per fluid
hoses, and supplier
connections. schedule.
Inspect filters;
replace as
required.
Lines, Pipes, Check for tightness,
Fittings, and damage, and contaminants.
Connectors Tighten, clean or replace as
required.
Triplex Pump Close water coolant line to Drain power end 250 Hrs: If hoses pulsate,
packing (while pump is oil and replace Replace replace valves,
running). with new filtered packing and seats, and
oil. packing rings. springs.
Inspect and clean suction Inspect and clean 500 Hrs: Drain and flush
plumbing, Y-strainer, and power end parts. replace power after each use.
micron filters. Tighten loose end oil with
items. new filtered
oil.
Replace worn packing if Inspect, Inspect cylinder
water is venting. clean, and inner surfaces
tighten power for scratches
end
components
Check power end oil level; Replace power
add oil as required. end oil per oil
supplier
schedule.

NOBL-NA-AHC2008A
CHAPTER 6
Maintenance
Table 6-17 HPTU Equipment Maintenance Schedules (Cont.)

Hours
Hydraulic Check for general Verify mounting Replace power Replace
Motor condition and leaks. bolts and socket end lubricant. hydraulic fluid
head screws are per oil supplier
fully torqued. schedule.
Clean or replace
filters as
required.
Inspect drive
couplings and
pipe fittings.
Pressure Relief Inspect
Valves condition and
adjustment.
Pump Lever Inspect
Control condition and
Linkage adjustment..
Flow Control Inspect
Valve (lube condition and
circuit) adjustment.
Lubricating Inspect
Pump Relief condition and
Valves adjustment..
TROUBLESHOOTING INFORMATION
Table 6-16, Table 6-17, Table 6-18, and Table present troubleshooting information for major
HPTU equipment, such as the hydrostatic transmission, hydraulic drive motor, etc. and their
associated subsystems.
Before placing a service call, verify all connections and fittings are tight and that tubing and
hoses are connected and not leaking.
Hydrostatic Transmission
Table 6-16 contains troubleshooting information for the primary and secondary
variable-displacement pumps in the hydrostatic transmission.

CHAPTER 6
Maintenance
Table 6-18 Troubleshooting Hydrostatic Transmission

Problem Possible Cause Remedy
Neutral is difficult or 1. Loose control linkage. Adjust linkage tension or replace the control
impossible to find. linkage.
2. Faulty control valve. Inspect; replace if necessary.

Pumps run hot. 1. Clogged inlet filter. Inspect filter elements. Clean daily and
replace as required.
2. Reservoir fluid level too Replenish with filtered fluid as required.

low.
3. Faulty heat exchanger. Inspect heat exchanger; replace as required.
4. Faulty pump bypass Inspect valve; replace as required.

valve.
Pump responds 1. Low charge pressure. If charge pressure low when pump is in
Sluggishly neutral, inspect charge pressure relief valve
at the pump. If charge pressure low when
pump is engaged, inspect charge pressure
relief valve at the motor. Repair or replace
valve (s) as required.
2. Clogged inlet filter Inspect inlet filter. Clean or replace as

required.
3. Control valve not
functioning properly. Inspect valve; repair or replace as required.
Pumps run hot. 1. Clogged inlet filter. Inspect filter elements. Clean daily and
replace as required.
2. Reservoir fluid level too Replenish with filtered oil as required.

low.
3. Faulty heat exchanger. Replace as required.
4. Faulty pump bypass Inspect valve; replace as required.

valve.

NOBL-NA-AHC2008A
CHAPTER 6
Maintenance
Triplex Pump
Table 6-17 contains troubleshooting information for the triplex water pump on the HPM
skid. Troubleshooting Triplex Pump
Pump pressure Pump is cavitating. Shut pump down and inspect feed-water
fluctuates rapidly as supply on suction side.
pump operates.
Pump power-end Worn wrists pins, worn Shut pump down and inspect components.
makes abnormal bearings, or loose plunger Replace wrist pins or bearings as required. If
noises. adapter. plunger adapter is loose:
? Remove adapter from crosshead.
? Apply Loc-tite 242 or equivalent to
threads.
? Re-torque adapter to crosshead.
Water supply to pump not Refer to "Pump is cavitating" above.

adequate.
Pump discharge 1. Pump plunger packing Tighten or replace as required.
pressure too low. worn or leaking.
2. Pump valves or seats Replace the affected components and check

pitted or eroded. water supply filters. Replace filters if
necessary.
3. Pump plungers are
scored. Replace the pump plunger.
4. Discharge nozzle worn or Check nozzle condition. Replace if

not correct size. necessary.
Air-Operated Auxiliary Pump

Table 6-18 contains troubleshooting information for the air-operated auxiliary pump in
the PCC.
Table 6-19 Troubleshooting Air Operated Auxiliary Pump
Pump operates Air in hydraulic system. 1. Inspect suction line and pipe joints for
irregularly or does not leaks. Retighten connections and
produce required replace leaking items as required.
pressure. 2. Check sealing between air and high-
. pressure sections of booster pump.
Replace seal as required.
Booster pump check valves Inspect check valves for foreign material.
not operating properly. Clean as required.
Suction filter blocked. Clean or replace filter element.
High-pressure seal worn. Replace seal.
Fluid escapes via pump High-pressure seal worn. Replace seal.
exhaust.

CHAPTER 6
Maintenance
Table 6-20 Troubleshooting Air Operated Auxiliary Pump (Cont.)

Pump not operating at O-rings causing excessive Inspect gate valve O-ring for wear.
low air pressure. friction on control gate valve. Lubricate or replace as required.
Pump operates at high Air escaping from piston guide Replace O-ring on high-pressure piston
air pressure only in top cap. extension.
Pump operates slowly or Exhaust or control gate valve Shut pump down for short while. As
not at all. is “icy “. required, remove water from compressed
air supply.
Pump not operating, air Pilot valve tappet in top cap is Inspect tappet for wear; clean and grease
escaping from exhaust fouling. before reassembling or replace if
port (or small bores in required.
bottom cap).
Pump not operating, air Control gate valve is fouling. 1. Inspect valve for wear; replace as
escaping from small required. If replacement not required,
bores on control gate clean valve and valve sleeve.
valve case.
2. Inspect O-rings and sleeve; replace
as required.
Pump only operates at Pilot valve defective. Replace valve.
high frequency and short
strokes.
Motor Supply Pump

Table 6-19 contains troubleshooting information for the motor supply lubrication
pump, which supplies supplementary lubrication for the triplex pump.
Table 6-21 Troubleshooting Motor Supply Pump

Pump not delivering oil Suction line or port Inspect suction line for leaks by
to triplex pump housing. passages leak. submerging pressure line from pump
discharge side in a container of oil.
? Replace line if leaking or bubbles are
seen.
? Inspect pump port passages if suction line
intact.
Pump strainer clogged. Clean strainer.
Pump shaft not rotating. Inspect pump coupling. Tongue and groove
or gear not engaged.
Pump operates Suction lines leak. Inspect suction lines; replace as required.
irregularly.
Pump shaft coupling Tighten pump coupling.
slipping.
Table 6-22
Problem Troubleshooting
Possible Cause Motor Supply Pump
Remedy(Cont.)
Pump is noisy. Air leaking into suction side 1. Inspect suction side components.
of pump. 2. Inspect suction lines for leakage; replace
as required.
Pump leaks. Loose cover bolts or Inspect the cover bolts and gasket. Tighten
defective cover gasket. cover bolts if needed or replace the gasket if
defective.
Pressure Gauge
Pressure gauges are prone to shock failure. A gauge may have suffered shock failure
if it fails to return to zero after pressurization or shows a slow response to pressure
changes. Damaged gauges are not field repairable and should be replaced.

NOBL-NA-AHC2008A
CHAPTER 6
Maintenance
Dual Chart Recorder

HPTU chart recorders are not field repairable and should be replaced if damaged or
rendered unreliable.
Chart recorders are also prone to shock failure. A recorder may have suffered shock
failure if it does not return to zero (i.e., stops at a higher pressure or drops below zero)
after pressure is removed. Shock failure can also cause pressure readings to be lower
or greatly reduced.
If a recorder remains unused for extended time periods, ink in the recording arm may
dry out and cause paper to stick. Carefully move the paper or clean the tip to start ink
flowing again. Often, touching the tip with a clean finger will cause the ink to flow.
Replace the ink supply if required.
Install new chart papers prior to pressurizing the HPTU system. Re-using previously
used paper can cause confusion in reading test results. Use only properly sized paper
with printed scale lines that correspond to recorder requirements.
Unit Storage Or Extended Shutdown

Should the HPTU be scheduled for storage or nonuse over extended time periods, such
as between drilling operations, perform the following tasks prior to its shutdown:
1. Perform all periodic maintenance in Table 5-1.
2. Check all components for wear or damage. Make repairs before placing the
HPTU in storage.
3. Add one gallon of Erifon-856 (or equivalent) to the HPM water reservoir. Pump
the mixture through the HPM, PCC, and RC.
Maintenance Procedures
The following maintenance procedures are for major HPTU components.
HPTU Vendor Equipment

Table 6-20 lists vendor supplied HPTU components. Items identified with the term
VENDOR are field repairable. Those identified with the term NONE, such as a safety
relief valve, are remove-and-replace items that must be returned to the vendor.

CHAPTER 6
Maintenance
Table 6-23 Maintenance Summary of Vendor Supplied HPTU Components

Repair/ Vendor Hydril Part Number Vendor Component
Transmission & Pump Assemblies
None 51-502967 Marathon Electric Motor
Both 37-502189 Butterworth Triplex Pump
Vendor 37-502968 Sauer/Sundstrand Variable Displacement Pump
Vendor 37-502975 Bosch Gear Pump
Vendor 37-502973 Rotary Power LSHT Hydraulic Motor
Vendor 37-502446 Danfoss Hydraulic Motor
Vendor 37-501879 Tuthill Lubrication Pump
Vendor 37-501946 Bosch Accumulator
None 37-503165 JB Services Filter housing (Filter 37-
503166)
Ball Valves
Repair 37-503125 Apollo 3-way (ball valve)
Repair 37-502191 Apollo Ball Valve (1-Inch cone
check)
Repair 37-503154 Apollo Ball Valve (1-Inch FNPT)
Needle Valves
None 37-503124 AEI Needle Valve (1/4-Inch 20k
psi)
Vendor 37-502791 Whitey Needle Valve (integral)
Relief Valves
None 37-501939 Fluid Controls Relief Valve (direct acting)
None 37-503037 AEI Relief Valve (18k set point)
None 37-501899 AEI Safety Head
None 37-501878 Racine Relief Valve (Panel Mounted)
Other Valves
None 37-501916 AEI Check Valve
None 37-500119 Kepner Shuttle Valve
37-501870 Sauer/Sunstrand Valve (loop flushing)

NOBL-NA-AHC2008A
CHAPTER 6
Maintenance
Stellite Body Valve Cartridges

The following procedure covers maintenance of the stellite body valves used in the test
valve manifolds of the PCC and RC.
Notes and Specifications

Design: seat seals
Connection: 1-inch
Valve Components: Stainless Steel, Alloy Steel, Celcon (seat
Seal), Polymyte (Stem seal)
Elastomers: Nitrile
Temperature Range: -50? F to +200? F (-45? C to +93? C)
Hydraulic Service: Water-based Fluids
Pressure Rating: 5000 psi
WARNING
DO NOT ATTEMPT TO SERVICE VALVE WHILE THE
SYSTEM IS PRESSURIZED. THIS VALVE CAN HAVE
PRESSURE AGAINST THE VALVE UP TO 25,000 PSI.
HYDRAULIC FLUID EJECTED FROM A VALVE AT
OPERATING PRESSURE CAN CAUSE SERIOUS INJURY
TO PERSONNEL AND DAMAGE TO EQUIPMENT.

CHAPTER 6
Maintenance
Disassembly Procedure
Parts List - Stellite Body Valve Flange (Model AF124)
3
2
1. Depressurize the system. Verify by opening valve and venting any pressure.
OPEN the valve part way to verify there is no pressure on one side of the valve.
OPEN all vent valves in system.
2. Loosen and remove the four Allen screws (Item 5). Remove Cartridge Valve
(Item 1) from cartridge body. Use two of the Allen screws (Item 5) as jacking
screws if needed to remove cartridge (Item 1) and assembly.
3. Use a sturdy pick to pry the valve seat (Item 2) and O-Ring (Item 3) from the
cartridge body.
NOTE
The valve seat is reversible. Removing and installing (flipped
over) the same valve seat (Item 2) with a new O-Ring (Item 3)
can often cure a slight leak.
4. Inspect all components for damage or wear. Inspect O-ring grooves for pitting.
Remove minor surface damage by polishing with a fine emery cloth if necessary.
5. Loosen and remove the stem housing and stem assembly (Item 6) from
Cartridge Valve Assembly (Item 1).

NOBL-NA-AHC2008A
CHAPTER 6
Maintenance
NOTE
Replace components that are worn or damaged and cannot
be repaired by polishing.
Assembly Procedure
1. Lightly lubricate the threads with anti-seize and install the stem housing (Item
5) and stem assembly in the cartridge (Item 1).
2. Lightly lubricate the 2-016 O-rings (Item 7) with petroleum jelly and install 2-
016 O-ring and back up ring (Item 3 and 4) in the O-ring groove.
3. Lightly lubricate the 2-016 O-ring (Item 3) with petroleum jelly and install in
the valve seat (Item 2) O-ring groove.
4. Install in the valve seat (Item 2) and O-ring (Item 7) in the cartridge body.
5. Install the valve assembly in the cartridge body. Verify the valve seat is
correctly positioned in the cartridge body.
6. Install the four Allen screws (Item 5). Tighten enough to seat the valve
assembly and valve seat in the cartridge body.
7. The stellite valve is now ready for operation. Remember to slowly pressurize the
valve during initial operation to check for leaks.

CHAPTER 6
Maintenance

NOBL-NA-AHC2008A
Appendix A
Glossary of Terms
10/100Base-T
10 Mbps to 100 Mbps standards for Ethernet over twisted pair or copper-based computer networking
physical connectivity
100Base-SX
10 Mbps to 100 Mbps standards for Ethernet over fiber optic computer networking physical connectivity
accumulator
a metal cannister or bottle which contains a nitrogen-filled rubber bladder and is designed to maintain
the constancy of hydraulic fluid pressure in the MUX control system
annular blowout preventer (ABOP)

blowout preventer that uses a shaped elastomeric sealing element to seal the space between the
tubular and the wellbore or an open hole.
automatic station keeping (ASK)

a software application which communicates data to the drilling vessel’s navigational computer to assist
in maintaining the vessel’s proper position relative to the BOP stack
battery
an array of electrochemical cells used to store electricity (see also: battery, uninterruptible power
supply)
battery cabinet
a sub-component of the uninterruptiple power supply which provides a power source to the MUX control
system when rig power is not available
blowout preventer (BOP)

equipment (or valve) installed at the wellhead to contain wellbore pressure either in the annular space
between the casing and the tubulards or in an open hole during drilling, completion, testing, or
workover operations.
breaker
see circuit breaker
cable reel
a skid mounted, motorized drum used to store, deploy and retrieve cable from the rig floor (see: MUX
cable)
cable sheave
a wheel or pulley with a groove for holding a cable and reducing the magnitude of the force on the cable
as it is deployed and retrieved
circuit breaker
an automatically-operated electrical switch designed to protect an electrical circuit from damage caused
by overload or short circuit.
control pod
an assembly installed on the LMRP and composed of an electro-hydraulic section and a lower valve
control unit which together serve as the hub or terminal for all hydraulic and electronic communications
between the BOP stack and the surface
Advanced Hydraulics Course A-1

APPENDIX A
Glossary of Terms
data logger
a cabinet mounted processor capable of monitoring and printing alarms, errors, and other events
generated by the MUX control system software
direct hydraulic control

a blowout preventer control system primarily used in land applications which employs hydraulic valves
and lines connected directly to the actuators on the blowout preventers to perform the stack functions
diverter
a hydraulically operated component of the BOP stack used to eliminate gas from the wellbore in the
event of a kick during drilling operations
electro-hydraulic (EH) section

the section of the control pod responsible for processing surface commands, distributing electric power,
and communicating with the surface controls
electronic riser angle (ERA)

a system which measures the position of three sensors along the path of the riser and the stack and
calculates the angle of the riser in relation to the stack and the drilling vessel
Ethernet
a family of multi-speed computer networking technologies which facilitate physical connections in local
area networks (LANs)
fiber optics
a glass or plastic fiber designed to guide light along its length, which permits communications over
longer distances and at higher data rates than other forms of wired and wireless communications
flowmeter
an electrical device which measures the velocity of a medium (liquid or gas)
fluid reservoir/mixing unit (FRU)

a surface component of the hydraulic subsystem which combines glycol, water, and hydraulic fluid
concentrate to create hydraulic fluid used in the MUX control system
gas handler
a hydraulically operated component installed below the drilling vessel and used to eliminate gas from
the wellbore in the event of a kick during drilling operations (see also: diverter)
high pressure high temperature probe (HPHT)

a combination of a pressure transducer and resistance temperature detector located in the LMRP and
used to sense the temperature and pressure in the wellbore
hose reel
a skid mounted, motorized drum used to store, deploy, and retrieve hydraulic hose from the rig floor
(see: hotline hose)
hose sheave
a wheel or pulley with a groove for holding a hose and reducing the magnitude of the force on the hose
as it it deployed and retrieved (see also: hotline hose)
hotline hose
a hydraulic hose which delivers hydraulic fluid to the subsea control pods from the surface hydraulic
system
A-2 Noble Roger Eason / Muravlenko

NOBL-NA-AHC2008A
APPENDIX A
Glossary of Terms
hydraulic control
the process of delivering stored energy in the form of hydraulic fluid under pressure to open or close
(actuate) a valve or blowout preventer stack component
hydraulic fluid
a mixture of water (77.5%), glycol (20%), and concentrate (2.5%)
hydraulic pumping unit (HPU)

a skid mounted assembly which uses air motorized pumps, regulators, and valves to pressurize and to
deliver hydraulic fluid to the surface and subsea accumulators, the BOP stack components, and the
subsea control pod
inverter
an electrical component of the uninterruptible power supply which converts direct current (DC) voltage
into alternating current (AC) voltage voltage
junction box
an electrical box which provides termination points for copper and fiber optic wiring.
kick
a sudden and typically unanticipated rise in wellbore pressure created by the penetration of a gas
pocket during drilling operations
logic drawer
a sub-component of the central control unit which routes and manages the flow of electricity to the
control pod subsea electronic modules (SEMs) using a group of switches and buttons
lower valve control unit

the section of the control pod responsible for regulating and directing the flow of hydraulic fluid to to
operate the stack equipment
manifold pressure transducer

on the hydraulic pumping unit, an inline pressure transducer which monitors the fluid pressure brefore
it is dispersed to the various hydraulic equipment
multiplex (MUX)
a process where multiple analog message signals or digital data streams are combined
multiplex (MUX) hydraulic control

a blowout preventer control system used in deep water drilling applications which employs an electro-
hydraulic pod which processes electrical signals passed from the surface and distributes hydraulic fluid
to the stack functions (see also: direct hydraulic control, piloted hydraulic control)
multiplex (MUX) cable

a cable composed of multiple copper and fiber optic wires used to transmit power and communications
signals between the subsea and surface equipment
piloted hydraulic control

a blowout preventer control system used primarily in shallow water drilling applications which employs
a hydraulic pod which processes hydraulic signals passed from the surface and distributes hydraulic
fluid to perform the stack functions (see also: direct hydraulic control, multiplex hydraulic control)
pod
see control pod

APPENDIX A
Glossary of Terms
power distribution panel (PDP)

a component of the MUX control system which routes electrical power to the surface equipment and
manages the flow of electricity using a series of circuit breakers
pulsation dampener (PD)

a metal cannister or bottle containing a rubber bladder which is installed on a hydraulic line
downstream from the discharge port of a hydraulic pump and is designed to reduce fluctuations in fluid
pressure caused by pump activity
pressure transducer
an electrical component that converts pressure into an analog electrical signal
ram blowout preventer (RBOP)

blowout preventer that uses metal blocks with integral elastomer seals to seal off pressure on a
wellbore with or without tubulars in the bore
regulator
a valve which has the function of maintaining a designated hydraulic or pneumatic pressure
remote terminal unit (RTU)

a subsea instrument package
reel console
a stand-alone system of pneumatic valves and regulators which condition, regulate, and direct the air
which controls the direction and speed of the the cable and hose reel pneumatic motors
rig power
the electrical power source which comes from the drilling vessel (see also: ship’s power)
rigid conduit
a steel, two inch diameter tube attached to the riser for the purpose of delivering hydraulic fluid to the
control pod during normal operation.
rigid conduit manifold

the point where the rigid conduit connects to the LMRP, and where surface-generated hydraulic fluid is
distributed to the contol pod and the stack mounted BOP accumulator
rotary junction box
shear seal valve

a hydraulic valve actuated manually or by a solenoid (see also: solenoid valve)
ship’s power
the electrical power source which comes from the drilling vessel (see also: rig power)
skid
a metal frame on which heavy equipment is mounted for storage, transport, and operation
solenoid
an electromagnetically inductive coil, wound around a movable iron armature which provides force to
actuate a hydraulic or pneumatic valve
solenoid valve
an electro-mechanical assembly containing a solenoid which actuates a hydraulic or pneumatic valve
(see also: shear seal valve)

NOBL-NA-AHC2008A
APPENDIX A
subsea electronics module (SEM)

the primary signal processing assembly located on the electro-hydraulic section of the control pod
step down transformer

a transformer in which the primary winding contains more turns than the secondary, which decreases
the transformer’s output voltage
step up transformer
a transformer in which the primary winding contains fewer turns than the secondary, which increases
the transformer’s output voltage
sub-plate mounted (SPM) valve

a valve that routes hydraulic fluid to a BOP stack function
transformer
a device that transfers energy from one electrical circuit to another by magnetic coupling without
requiring relative motion between primary and secondary windings, which determine the ratio of the
input and output voltages, i.e., stepping it up or down (see also: step up transformer, step down
transformer)
ultrasonic flowmeter
an electrical device which measures the velocity of a medium (liquid or gas) by employing acoustic
signals
uninterruptible power supply (UPS)

a device which maintains a continuous supply of electric power to connected equipment by supplying
power from a separate source when utility power is not available

APPENDIX A

NOBL-NA-AHC2008A
Appendix B
°C degrees Celsius
°F degrees Farenheit
AC alternating current
API American Petroleum Institute
ASK automatic station keeping
ASME American Society of Mechanical Engineers
BOP blowout preventer
CAT5 category-5
CCU central control unit
CCR central control room
CFM cubic feet per minute
DC direct current
ECM electronic control module
EH electro-hydraulic
ERA electronic riser angle
FRU fluid reservoir unit
GPS global positioning satellite
HPHT high pressure high temperature
HPTU high pressure test unit
HPU hydraulic pumping unit
Hz hertz
KVM keyboard video mouse
LCD liquid crystal display
LED light emitting diode
LMRP lower marine riser package
LVCU lower valve control unit
MΩ meg-ohms
mA milli-amperes
MCC master control console
MMI man-machine interface
MUX multiplex
NACE National Association of Corrosion Engineers
NAS National Aerospace Standard
PCB printed circuit board
PDP power distribution panel
PSI pounds per square inch
PSIA pounds per square inch absolute
Advanced Hydraulics Course B-1

APPENDIX B
PSIG pounds per square inch gauge

RSN remote services network
RTU remote terminal unit
SEM subsea electronics module
SCFM standard cubic feet per minute
SPM sub-plate mounted
TFT thin film transistor
UPS uninterruptible power supply
UPQ uninterruptible power quality
VAC volts alternating current
VDC volts direct current
VGA video graphics array
B-2 Noble Roger Eason / Muravlenko

NOBL-NA-AHC2008A

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Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Advanced Hydraulics 1-1

1-2 Noble Roger Eason / Muravlenko

Advanced Hydraulics 1-3

Cylinder Seal Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

1-4 Noble Roger Eason / Muravlenko

Advanced Hydraulics 1-5

1-6 Noble Roger Eason / Muravlenko

Advanced Hydraulics Course 1-1

How to Use This Manual

1-2 Noble Roger Eason / Muravlenko

Advanced Hydraulics Course 1-1

Figure 1-1 Direct, Piloted, and Multiplexed Control Systems

1-2 Noble Roger Eason / Muravlenko

System Operational Summary

Advanced Hydraulics Course 1-3

Figure 1-3 Fluid Reservoir Hydraulic Schematic

1-4 Noble Roger Eason / Muravlenko

Figure 1-5 Hydraulic Pumping Unit Hydraulic Schematic

Advanced Hydraulics Course 1-5

Fluid is stored on the surface in Accumulator Racks. Each Hydril

1-6 Noble Roger Eason / Muravlenko

Figure 1-8 MUX BOP Control System

Advanced Hydraulics Course 1-7

1-8 Noble Roger Eason / Muravlenko

Advanced Hydraulics Course 2-1

Rigid Conduits and the Rigid Conduit Manifold

TO YELLOW Blue Accumulator TO RIGID

Figure 2-1 Rigid Conduit Manifold Schematic

2-2 Noble Roger Eason / Muravlenko

Advanced Hydraulics Course 2-3

Two pods identified as Blue and Yellow are

Electro-Hydraulic (EH) Section

2-4 Noble Roger Eason / Muravlenko

Solenoid VCC-29 Connector

Shear Seal Solenoid

One Atmosphere Solenoid Housing

Shear Seal Valve

Lower Hydraulic Seal Sub Stab Stainless

Figure 2-5 Typical Solenoid Valve Circuit

Advanced Hydraulics Course 2-5

2-6 Noble Roger Eason / Muravlenko

Electronic Control Module

Advanced Hydraulics Course 2-7

Figure 2-8 Solenoid Housing

Figure 2-10 Assembled Solenoid

2-8 Noble Roger Eason / Muravlenko

Shear Seal Valves

Figure 2-11 Shear Seal Valve Assembly

Advanced Hydraulics Course 2-9

Figure 2-12 Solenoid Diagnostic Screen

While the Solenoid

Figure 2-13 Fluid and Power Control Screen

2 - 10 Noble Roger Eason / Muravlenko

Flow Meter Port

Figure 2-14 Flow Meter (Right) Connectors

Figure 2-15 Pressure Transducer