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BOP and Its parts
The BOP or Blow Out Preventer although ran as an assembly is actually made up of
two packages. The Main Package is the lower section and working from the bottom
up it has;
1- Wellhead Connector
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1- Wellhead Connector
2- Lower Pipe Rams
3- Middle Pipe Rams
4- Upper Pipe Rams
5- Shear Rams,
6- Lower Annular
7- Connector Mandrel.
The Upper section or Lower Marine Riser Package LMRP has;
Connector
Upper Annular
Flex Joint.
To understand the size and the equipment. It is 13.5 metres high and weighs 230
tonne. The inside bore is 18 or 476.25mm and the maximum working pressure is
15000psi/1020bar. The pipe rams can be changed for different pipe sizes and they
are capable of supporting upto 600000lb/272 tonne.
There are different pipe ram rubbers also, there are fixed which means they can only
close and seal around a specific pipe size and Variable pipe rams which are capable
of closing around a range of pipe sizes, the most common ones being 3 to 5 and 3
to 7 5/8 the pressure ranges can reduce when the rams are working at the smaller
sizes.
The other type of Preventer on the BOP is called the Annular and is capable of
closing around most equipment used to drill a well. It is also capable of closing and
sealing open hole or when there are no tubulars across the BOP, the maximum
working pressure for this type of Preventer is 10000psi/680bar.
The final type of ram is called the Blind/Shear ram and comprises of two cutting
blades and a face seal, the shear ram is capable of cutting the rig drill pipe and
certain other tubulars.
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certain other tubulars.
The Pipe Rams are in two pieces and positioned opposite to each other in the Ram
Cavities. Pistons are attached to the back of the rams and hydraulic fluid is forced
under controlled pressure and the rams are closed around the pipe. Seals which are
installed to the top and sides of the rams close off the well to the riser.
The control system for the BOP on the Eirik Raude is a Cameron MultiPlex System
the signals are electrical which are then converted into hydraulic functions. The
Electronic sections have 100% redundancy in each pod and there are two hydraulic
pods. Only one pod is on line at a time. To differentiate they are called Blue & Yellow
Pods. Control panels are located on the Drill floor in the Dog house / the
Toolpushers office and the Pilot House. The hydraulic fluid is supplied at
5000psi/345bar down Conduit lines installed down the outside of the riser. The fluid
pressure is regulated down to 3000psi/205bar before entering the control pods. They
can then be remotely regulated to there normal operating pressure of
1500psi/102bar for the functions. There are several special features and
requirements for the BOP, the rig being DP positioned and not anchored needs the
requirements for the BOP to be programmed to complete certain functions rapidly. If
problems were to occur with the rig power system or thrusters and the rig could not
maintain position then severe damage to the BOP / Riser system could result. When
the DP operators advise of a Yellow caution or straight into a Red alarm the well must
be made safe, the Driller has certain one button functions which when operated will
Close the Pipe Rams / Close the Shear Rams Shear the pipe / Lock the rams in the
closed position / Unlatch the LMRP connector which will then lift off and away from the
BOP main package. This operation or EDS1 will be completed in 37 seconds. EDS 2
is where the Driller has time to space out and land the drill pipe and shear the pipe.
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Information between the Driller and the DP Operator must be direct and not via other
personnel and the reason why we have a direct communication Squawk Box.
The BOP is connected to the rig via the Marine Riser, this can be described as a pipe
with a pin & box connector and several service lines attached to the outside. The
riser joint has been engineered to be capable of taking 3 million pound tension. The
risers are connected together by 6 locking dogs which are engaged from the outside.
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The Riser may have buoyancy modules attached or be SLICK which means that there
are no buoyancy modules installed. There are several different types of buoyancy
available giving various buoyancy factors from 64% to 102% buoyancy, the riser
joints are 75/22.86ft/metres long and vary in weight from 16 Tonne for a SLICK joint
to 25 Tonne for a buoyed joint. A selection of PUP Joints allow the riser to be spaced
out to place the Slip Joint in the mid-position.
The Slip Joint is run at the top of the riser and comprises of two tubes one inside of
the other. The bottom of the Outer Barrel section attaches to the riser and at the top
of the Outer Barrel the Marine Riser Tensioners are attached. The Outer Barrel also
has the SIX service lines with female receptacles for the Gooseneck / Coflexip hose
attachment. The top of the Inner Barrel is attached to the Diverter which is located
beneath the rotary table; the bottom of the Inner Barrel has a stop ring or shoe
installed. Packing elements are used between the Inner and Outer Barrels to retain
the mud. Why do we require a Slip Joint? Due to the rig floating and also being
attached to the wellhead via the BOP/Riser system there must be a method of
allowing for vertical and side movement (the 6 movements of a vessel) we also have
to be able to maintain a fluid circulation system so that the drilling mud can be recirculated. To allow for Heave or up and down motion the Slip Joint Inner and Outer
barrels compensate, for side movement Pitch/Roll and the rig surface location to
wellhead location on the seabed there are two Flex Joints installed, one at the top of
the BOP and one on the bottom of the Diverter located below the rotary table.
The Slip Joint has a 65/19.8ft/metre stroke to allow for vertical movement and the
Flex Joints each allow +/- 10 degree movement Pitch-Roll and the rig being off
location.
The SIX service lines are;
2 Conduit lines for BOP control fluid with a working pressure of 5000/345 psi/bar
working pressure
1 Glycol line
1 Choke line
1 Kill Line, these three lines have a working pressure of 15000/1020psi/bar
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1 Booster line with a working pressure of 7500/510psi/bar
As mentioned earlier the Conduit lines are used to supply BOP control fluid at
5000/345psi/bar.
The Glycol Line is used to inject chemicals at the bottom of the BOP to reduce the
possibility Hydrates forming if gas were encountered.
Choke and Kill Lines are used during the well kill operations and are used to take the
returning fluids from the well bore back to the rig at pressures far greater than the
riser could take. Also to retain back pressure from the well kill operations.
Booster Line is used to increase the mud flow rate up the riser, this would also assist
to boost the drilled cuttings back to the rig.
The riser can not be free standing or it would buckle, to maintain tension on the
Marine Riser there are 16 Marine Riser Tensioners each rated to pull a maximum of
200000/91lbs/tonne each. They have 2 diameter wires and capable of
50/15.25ft/metre line movement. They are arranged with 8 on the Forward and 8 on
the Aft sides of the rig floor. The piston has a stroke of 12.5/3.82ft/metre and by
using double sheaves at both ends of the tensioner the 50/15.25 line movement can
be achieved. The tensioners are energised with High Pressure Air which can be
regulated or set to give specific tensions. The tensioners are attached to the rig and
the end of the wire is attached to a special ring which in turn is locked onto the Slip
Joint Outer Barrel this is how the riser is kept in tension when the rig is moving.
The BOP / Riser systems have several functions but the two main ones are to
provided a circulation route for drilling fluids and to be able to isolate and control hole
problems at high pressures.
The DIVERTER is installed beneath the rotary table and uses rubber inflatable seals
to finalise the sealed circulating system. It also has a packer which can be closed to
seal around the tubulars through the rotary table and down through the riser, this
would be closed in the event of gas entering the well bore and being allowed to flow
up into the riser. To give an idea of gas entering the well bore at 3000 metres and
allowed to expand then the volume could be upto 300 times the original volume.
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To give a general idea of the time involved to running the BOP and to continue to drill
ahead typically 3 days would be required to rig up run pressure test rig down
for 1500 metres water depth. It is a very labour intensive operation which requires
personnel for operations on the riser deck / moonpool and drill floor. Failure of this
equipment would also require that it be retrieved / repaired / re-run which could would
result in downtime and lost revenue for both Ocean Rig and the Client.
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