4 OPERATING INSTRUCTIONS
4.12 ESD SYSTEM CHECK
4.1 RIG-UP INSTRUCTIONS
Place the skid with reels facing the wellhead. Do not connect to the wellhead control valves or to the air supply.
Units in ATEX classified hazardous areas shall be earthed.
A valve, located at the right-hand side of the control panel allows fluid to be dumped externally, or back to the fluid tank. Set to DRAIN TO TANK position.
Ensure that air supply to the pumps is OFF by turning regulators on control panel fully anti-clockwise.
Connect unit to the air supply - min 90 psi/ max 120 psi. Check air pressure on the AIR SUPPLY gauge.
Check operation of the unit. See function test procedures (Sections 4.12-4.15)
Set all control panel valves to the OFF/CLOSED position.
Ensure that air supply to the pumps is OFF by turning regulators on control panel fully anti-clockwise.
Connect hydraulic hoses onto the relevant couplings on the wellhead control valves.
4.2 RIG-DOWN INSTRUCTIONS
Turn OFF the rig air supply and vent the supply line.
Turn OFF and vent the unit air supply by turning OFF the Off/Vent valve located at the main air filter.
Set the LOW PRESSURE WARNING SYSTEM valve to OFF.
Turn the hydraulic pump air regulators fully anti-clockwise.
Set ACCUMULATOR valve to the ON position.
Turn the BOP dump valve to the DUMP position.
All pressure must be removed from the BOP hoses before reeling up by moving the BOP controls from open to close twice.
Open the DUMP valve and two crossover valves for the MV, DHSV and Test Line.
Set the MV, DHSV and Test Line OPEN/CLOSE valves to CLOSE twice.
This will release fluid pressure in the MV, DHSV and Test Line hoses and reels, and from the unit itself.
Check hydraulic pressure gauges to ensure that all pressure has been released.
Disconnect the air and hydraulic lines.
Rewind hoses onto reels. Reels must not be rotated with pressure in the hoses. This will reduce '0' ring seal life.
NOTE!
If unit is to be transported reference should be made to Section 3.1 Handling Instructions. This covers the full requirements for shipping preparation.
4.3 GENERAL CHECK BEFORE OPERATION
Airline Filter: Drain water from bowl. (If autodrain, check that it functions).
Tank Fluid Levels: Tanks should be kept filled. High and Low levels are indicated by the high and low marks on the sight glasses.
CAUTION!
Always check hydraulic oil levels with accumulators discharged otherwise over-filling will result.
Refer to Section8 for correct hydraulic fluid.
Tank Return Filters: A visual indicator on each filter shows the condition of the filters. Replace elements as necessary.
Tubing: Check all tubing, fittings etc. for signs of damage. Replace as necessary.
Hoses: Check all hoses, fittings etc. for signs of damage. Replace as necessary.
Control Panel: Ensure that all valves are OFF/CLOSED and all air regulators are turned OFF (anti-clockwise).
4.4 EMERGENCY SHUTDOWN SYSTEM
Operate the unit until the desired operating pressures on each circuit are reached.
To shutdown the MV and DHSV, lift the flap and turn the EMERGENCY SHUT DOWN valve anti-clockwise to the vertical position. The hydraulic pressure in each control line will dump immediately.
CAUTION!
Operation of the ESD system will close MV and DHSV without accumulator pressure.
4.5 LOW PRESSURE WARNING SYSTEM
To prevent the warning horn sounding whilst hydraulic pressures are building up, set the LOW PRESSURE WARNING ALARM valve to OFF.
Select ON after desired pressures have been reached. Valves for each individual function should be set to the ON position. If the Warning Horn sounds, turn each individual warning system valve OFF/ON to detect the function causing the alarm.
NOTE!
See the hydraulic schematic drawing (Section 9) for the recommended alarm settings.
4.6 MV DHSV AND TESTLINE HYDRAULIC SYSTEM MV SYSTEM MAX. WORKING PRESSURE 10,000 PSI SSSV SYSTEM MAX. WORKING PRESSURE 10,000 PSI AV SYSTEM MAX. WORKING PRESSURE 10,000 PSI
Ensure MV, DHSV and TEST LINE OPEN/CLOSE valves are in the OFF position.
Ensure both crossover valves are in the horizontal OFF position.
Ensure that the Dump Valve is in the horizontal OFF position.
Ensure that the Emergency Shutdown valve is re-set.
To open the MV, DHSV or TEST LINE, turn the appropriate valve to. the OPEN position.
Adjust pressures by slowly turning the. air regulators, located at the bottom right of. the control panel, clockwise until the desired pressures are obtained on the gauges above.
To CLOSE the MV or DHSV, turn the appropriate valve to the close position. This will dump the hydraulic pressure in the relevant circuit.
To dump TEST LINE pressure, turn the DUMP valve to the vertical DUMP position.
NOTE!
In the event of a pump failure, one of the other pumps can be utilised.
Turn the MV, DHSV and TEST LINE valves to the OFF position.
CAUTION!
Do not CLOSE.
Turn the air regulators for MV and DHSV fully anti-clockwise (OFF).
Turn the relevant crossover valve(s) to the vertical position (ON).
For the function to be operated, turn the appropriate OPEN/CLOSE valve to the OPEN position.
For the pump to be operated, adjust pressure by slowly turning the air regulator clockwise until the desired working pressure is obtained on the gauge for the function being operated.
NOTE!
In the event of an air supply failure, the hand pumps can be utilised.
Turn the MV, and DHSV valves to the OFF position.
CAUTION!
Do not CLOSE.
Turn the air regulators for MV and DHSV fully anti-clockwise (OFF).
For TEST LINE, turn the relevant crossover valve to the. vertical position (ON).
Operate hand pump until correct pressure is obtained on the gauge for the function being operated. (Hand pump handle is stored at left hand side of control panel).
4.7 BOP HYDRAULIC SYSTEM
BOP SYSTEM MAX. WORKING PRESSURE 3,000 PSI
Ensure the BOP OPEN/CLOSE valves (located in centre of panel) are in OFF positions.
Ensure the; BOP air regulator, located at bottom of panel, is OFF (fully anti-clockwise).
Ensure that the DUMP valve is in the vertical (OFF) position.
To charge the accumulators:-
Set the accumulator valve to the ON position.
Turn the BOP air regulator slowly anti-clockwise so that pump charges the accumulators.
When the accumulator charge pressure has been reached, turn the accumulator valve to the OFF position.
Turn the BOP air regulator OFF (fully anti-clockwise).
Turn the BOP dump valve to the DUMP position.
To operate the BOP normally (i.e not in an emergency):-
Ensure the BOP OPEN/CLOSE valve(s) are in OFF position.
Ensure the BOP air regulator, located at bottom of panel, is OFF (fully anti-clockwise).
Ensure that the BOP dump valve is in the vertical (OFF) position.
Set the accumulator valve to the OFF position.
Turn the BOP air regulator slowly clockwise until the BOP Pressure gauge reaches the BOP operating pressure.
The BOPs may now be operated by moving the BOP OPEN/CLOSE valves to either the OPEN or CLOSE position.
In. the. event of an air supply failure; the hand pump.can.be utilised.
Turn the air regulator fully anti-clockwise (OFF)
Ensure that the DUMP valve is in the vertical (OFF) position.
Ensure that the ACCUMULATOR valve is set to the OFF position.
Set the BOP OPEN/CLOSE valve(s) to either the OPEN or CLOSE position(s) as required.
Set the hand pump change valve to BOP function.
Operate hand pump and maintain operating pressure on the BOP Pressure gauge.
To operate the BOP in an emergency:-
Ensure the BOP OPEN/CLOSE valve(s) are in OFF position.
Ensure the BOP air regulator, located at bottom of panel, is OFF (fully anti-clockwise).
Ensure that the BOP dump valve is in the vertical (OFF) position.
Ensure the SB/BOP valve is set to STUFFING BOX.
Set the accumulator valve to the ON position. Check for operating pressure on the BOP PRESSURE gauge.
The BOP's may now be operated by moving the BOP OPEN/CLOSE valves to either the OPEN or CLOSE position.
4.8 EMERGENCY STOP
To STOP the unit in an emergency, turn the main air supply valve to the OFF (vertical) position. This will stop all pumps from operating normally.
However, hydraulic pressure is stored in accumulators to maintain control of the well.
CAUTION!
Do not confuse the Emergency Stop function with the Emergency Shutdown (ESD) system.
Operation of the ESD system by turning the Emergency Shutdown Valve on the control panel will close the well in an emergency and cut the wireline.
4.9 PRESSURE/FUNCTION TEST FOR DHSV/MV/TEST SYSTEM DANGER!
The following pressure tests are only carried out at up to maximum working pressure (MWP) of the systems in order to check for leaks and correct operation. Any testing above MWP should be carried out in a recognised pressure test bay.
Reference should be made to the preceding operating instructions.
Fully un-spool all hoses. Check the condition of all hose ends, hoses and quick couplings. These should all be in good condition.
Turn OFF all air regulators by turning fully anti-clockwise.
Close the DHSV/MV/TEST dump valve (horizontal position).
Set the crossover valves to OFF.
Set all Low Pressure Warning Alarm valves to OFF.
Set the MV OPEN/CLOSE valve to CLOSE position.
Slowly turn air regulator for MV clockwise.
Pump will stall. No pressure should register on the MV gauge.
Set the MV OPEN/CLOSE valve to OFF position.
Pump will stall. No pressure should register on the MV gauge.
Turn air regulator for MV OFF (fully anti-clockwise).
Set the Low Pressure Warning Alarm valve to ON.
Set the MV Low Pressure Warning Alarm valve to ON. Alarm should sound.
Set the MV OPEN/CLOSE valve to OPEN position.
Slowly turn air regulator for MV clockwise until MV gauge exceeds the alarm pressure. Alarm should stop.
Use the MV hand pump to increase the MV pressure to pressure/function test pressure.
Check for leaks behind control panel, hoses and hose ends.
Set the MV OPEN/CLOSE valve to CLOSE. (Test Line valve should be set to OPEN) Gauge pressure should dump and Alarm should sound.
Open dump valve. Set the Low Pressure Warning Alarm to OFF.
Repeat the above procedure for the DHSV system.
Repeat the above procedure for the Test Line system, omitting alarm tests.
SYSTEM PRESSURES MV
Alarm Pressure 2,500psi
Max Working Pressure 10,000psi SSSV
Alarm Pressure 2,500psi
Max Working Pressure 10,000psi Test
Max Working Pressure 10,000psi
4.10 PRESSURE/FUNCTION TEST FOR DHSV/MV/TEST SYSTEM DANGER!
The following pressure tests are only carried out at up to maximum working pressure (MWP) of the systems in order to check for leaks and correct operation. Any testing above MWP should be carried out in a recognised pressure test bay.
Reference should be made to the preceding operating instructions.
Fully un-spool all hoses. Check the condition of all hose ends, hoses and quick couplings. These should all be in good condition.
Follow all start-up procedures and ensure all valves, regulators etc are OFF.
Set all Low Pressure Warning Alarm valves to OFF.
Turn air regulator for BOP OFF (fully anti-clockwise).
Close the hydraulic dump valve (vertical position).
Turn the accumulator valve to OFF position.
Set BOP controls to off position.
Slowly turn air regulator for BOP clockwise until the max. required pressure is reached.
Check for leaks behind the panel, at hose reel centres and at hose ends.
Set the BOP controls to CLOSE. Check gauge for pressure. Check for leaks.
Set the BOP controls to OPEN. Check gauge for pressure. Check for leaks.
Set the BOP controls to OFF.
Turn the accumulator valve to OFF position.
Slowly turn air regulator for BOP clockwise until the accumulator charge pressure is reached. Check for leaks.
Turn the accumulator valve to the OFF position.
Turn air regulator for BOP OFF (fully anti-clockwise).
Open the dump valve. Accumulator should remain at full charge pressure.
Open the accumulator valve. Accumulator pressure should drop.
SYSTEM PRESSURES
L-690267-V01 690267-V02 690101507 Accumulator
Max Working
Pressure 3000psi 3,000psi 3,000psi
Gas Precharge
Pressure 900psi 1,500psi 900psi
BOP
Max Working
Pressure 3000psi 3,000psi 3,000psi
4.11 BOP HAND PUMP CHECK
Close the hydraulic dump valve (vertical position).
Turn the accumulator valve to OFF position.
Set BOP controls to OFF position.
Set Hand Pump selection valve to Function BOP's (Handle points down).
Insert the pump handle into the BOP hand pump and pressure up to 3000 psi. Check pressure on BOP pressure gauge.
Open the hydraulic dump valve (horizontal position) to release pressure.
4.12 ESD SYSTEM CHECK
DANGER!
The ESD system check should not be carried out while the unit is connected to the Wellhead Control Valves. Operation of the ESD system could result in the accidental open/close of the DHSV and MV.
Set ESD valve to the horizontal position.
Pressure up the MV and DHSV circuits
Lift flap, and turn ESD valve to the vertical, ESD position.
Pressures in the DHSV and MV circuits should drop immediately.