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Schematics Interpretation and Subsea BOP Controls Fundamentals


Detailed Daily Course Outline
Note: The actual outline of the course may vary depending on instructors and new material. Manuals provided during the course are the following: Classroom presentation slides and BOP schematics During the course, there are many references made to various standards and regulations, including: Primary: API RP (Recommended Practice) 53 3rd Edition, Recommended Practices for Blowout Prevention Equipment Systems for Drilling Wells (American Petroleum Institute) API RP 16Q 1st Edition, Recommended Practice for Design, Selection, Operation and Maintenance of Marine Drilling Riser Systems. API Spec 16A 3rd Edition, Specification for Drill Through Equipment API Spec 16D 2nd Edition, Specification for Control Systems for Drilling Well Control Equipment and Control Systems for Diverter Equipment Secondary: API Spec 16F 1st Edition, Specification for Marine Drilling Riser Equipment API Spec 16R 1st Edition, Specification for Marine Drilling Riser Couplings API Spec 17D 1st Edition, Specification for Subsea Wellhead and Christmas Tree Equipment

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WEST Schematics Interpretation and Subsea BOP Controls Fundamentals Course

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INTRODUCTION
A. B. C. D. Facility safety policy Smoking policy Meals and breaks Class schedule and instructional approach

Section I SCHEMATIC DRAWING INTERPRETATION


Students will be introduced to the fluid and pneumatic symbology used in both fluid control and fluid power schematics. Students will use actual BOP control system component and subsystem schematics of both pilotcontrolled systems and MUX-controlled systems to become familiar with command paths and actuation characteristics. The overall system command and response characteristics will be described in terms of the component symbols used. Typical MUX and pilot control system schematic drawings will be used to understand the basic differences in design and operational philosophy between the two types of control systems. As a final exercise, students will develop a schematic drawing of a single BOP control system command loop using actual system schematics and use it to trace control functions through actual hardware.

Module 1 - Fluid Control System Symbols A discussion of the process used to develop pneumatic or hydraulic control systems from the block diagram phase, through simple schematics, engineering flow diagrams, piping and instrumentation drawings (P&ID), and fabrication and construction drawings. Symbols used in fluid control schematics and P&ID drawings will be explained in detail. Lab From a block diagram, develop a fluid control schematic of a simple fluid control process.

Module 2 - Fluid Power System Symbols Detailed instruction will be given on the ANSI and ISO symbols used in fluid power control process schematics. Differences between fluid power and fluid control processes will be discussed. The types of fluid power cylinders will be described. Fluid power valve schematics will be explained, and each type of valve configuration and control function will be reviewed.

2011 WEST Engineering Services

WEST Schematics Interpretation and Subsea BOP Controls Fundamentals Course Lab Develop simple schematic drawing of a single BOP fluid power control circuit. Module 3 - Fluid Power System Schematics Using their knowledge of fluid power system symbols, students will be introduced to the various fluid power subsystems used in a subsea BOP control system. Both pilotcontrolled and MUX-controlled subsystems will be evaluated. Each subsystem will be explained in detail and actual animated functional schematics will be used to show the functional inter-relationships between each control in a subsystem circuit. Lab Using the system schematic developed in class, trace a subsystem control circuit from the drillers panel to the subsea pod.

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Module 4 - Electrical Control Circuits The typical electrical symbols used in the BOP control system will be described. Typical electrical components, used in BOP piloted control systems will be discussed. The interrelationships between the electrical commands and signals and the BOP hydraulic control system functions will be described. The complete BOP control system electrical schematic, including the drillers panel and the Hydraulic Pressurization Unit (HPU), will be evaluated to discuss the troubleshooting and problem assessment process.

Module 5 - BOP Control System Schematics Both the BOP control system hydraulic and electrical schematics will be discussed in detail to evaluate the inter-relationships between them. Troubleshooting and problem analysis techniques for end-to-end problem analysis of the control system will be discussed in detail.

Section II FUNDAMENTALS OF BOP CONTROL


Instruction will include the fundamentals of control for each subsystem of the accumulator unit, the drillers panel, and the subsea pod. Students will be introduced to the control characteristics of both pilot-controlled and the MUX-controlled systems. A comparison of the differences and similarities in the two control systems will be studied. Component and subsystem

2011 WEST Engineering Services

WEST Schematics Interpretation and Subsea BOP Controls Fundamentals Course

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schematics will be used to show command paths and actuation characteristics. Fluid mixing systems will be discussed. The following sub-systems will be individually discussed: Hydraulic Pressurization Unit (HPU) fluid power main hydraulic system supply and distribution Fluid mixing system HPU pilot pressure supply and control system MUX command system Master control panel controls Electrical system Hose reels and hoses Subsea pods Emergency systems

Module 1 - Fluid Mixing System A discussion of the operation and maintenance of the fluid mixing system will be carried out. BOP fluid mixing and fluid contamination problems will be discussed and assessment techniques will be evaluated.

Module 2 HPU - Main Fluid Power Supply and Distribution System The Triplex pump hydraulic power supply and distribution system will be discussed in detail. The discussions will include the Triplex pumps, accumulators, pump pressure shut-off switches, relief valves, filters, and isolation valves.

Module 3 - HPU Pilot Pressure and MUX Control System The pilot pressure generation and control system operation and maintenance will be discussed in detail. Components to be discussed include: Air-operated hydraulic pumps Hydro/Pneumatic pressure switch Solenoid valves Pressure switches Pressure regulators Hydraulic control manifold Pneumatic cylinders RBQ plates

The MUX control system (a 5th generation system) will be discussed in detail: Pressure generation system similarities and differences with pilot system Hydraulic conduit

2011 WEST Engineering Services

WEST Schematics Interpretation and Subsea BOP Controls Fundamentals Course Module 4 - Master Panel Controls and Electrical System

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The drillers control panel operation and maintenance will be discussed in detail. Use of control panel schematics will be described and importance of keeping schematics up-to-date will be demonstrated. The need for enclosing all electrical functions in explosion-proof enclosures will be discussed. Electrical subsystems to be discussed include: Pilot control Pressure gauges (HPU versus drillers panel differences) Flow meters Drillers panel switches Push-to-Operate switch BOP, system locking mechanisms, pod latch, and valve position indicator lights Pressure switch continuity tests of normally open and normally closed circuits MUX control Drillers panel Computer control units Multiplexing/De-multiplexing system Data systems

Module 5 - Hose Reels and Hoses The operation and maintenance of the hose reel control panel will be described. This will include a description of the problems that an improperly configured control panel can cause. The operational characteristics of umbilical hoses and their effects on BOP opening and closing times will be discussed in detail.

Module 6 - Subsea Control Pods The operation and maintenance of pilot-controlled subsea control pods will be described. The effects of blue or yellow pod selection will be discussed regarding the common and unique command functions that result from pod selection. The control characteristics of Subsea Plate Mounted (SPM) valves will be evaluated. Pod seating on female receptacles of the LMRP will also be discussed. Discussion will include: Kidney plates Regulators SPM valves Pressure data Pod latching mechanisms Pod packer seal maintenance and inspection

2011 WEST Engineering Services

WEST Schematics Interpretation and Subsea BOP Controls Fundamentals Course

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The operations and maintenance of MUX-controlled subsea pods will be described. The subsea electronics units, compensation chamber-mounted solenoid valves, and SPM valves will be discussed in detail. Similarities and differences between pilot-controlled and MUXcontrolled system components will be analyzed. Specific discussion points include: Pod general layout Compensation chamber design characteristics Subsea electronics unit design characteristics SPM valves Data systems Temperature and inclinometer sensors Pressure data instrumentation locations

Module 7 - Combined Control System This module will describe the complete BOP control system using system schematics and command logic diagrams for both the pilot control system and the MUX control system. Descriptions of command sequencing, command/response indicators, problem indicators, and troubleshooting techniques will be included. The importance of keeping system schematics up-to-date will be discussed and demonstrated.

Module 8 Emergency Control Systems The various emergency control systems design and control requirements will be described in detail. The sensing and operational characteristics of each type of emergency system will be evaluated. Animated system schematics will be used to demonstrate the operation of each of the following systems: Emergency disconnect systems Auto-disconnects Auto-shear systems Dead man systems

2011 WEST Engineering Services

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