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GL ABOP Training
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1
®
GL 18-3/4” 5,000 psiGL 18-3/4” 5,000 psiAnnular Blowout PreventerAnnular Blowout Preventer
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Blowout Preventer (BOP)The equipment (or valve) installed at the wellhead to contain wellbore pressure either in the annular space between the casing and the tubulars or in an open hole during drilling, completion, testing,or workover operations.
Annular BOPA BOP that uses a shaped elastomeric sealing element to seal the space between the tubular and the wellbore or an open hole.
DefinitionsDefinitions
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Hydril GL ABOPHydril GL ABOP
Latched head design for easy access
Only two moving parts for simplicity
Piston design to prevent piston binding
Field replaceable wear plate
Opening and closing chamber tested to BOP operating pressure - secondary chamber to twice BOP operating pressure
API 16A monogram
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Large lip-type seals for improved reliability
All packing units are factory acceptance tested
BOP acoustic emission monitored during shell test
Materials are resistant to sulfide stress cracking - meet the requirements of NACE
3 models
Hydril GL ABOPHydril GL ABOP
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Piston OperationPiston Operation
Piston raised by applying closing pressure
Packing unit squeezed inward to sealing engagement with pipe in the hole or with itself on open hole
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Full bore opening to pass large diameter tools and allow maximum annulus flow
Returns to full bore because of normal packing unit resiliency
Retention of opening pressure reduces piston wear caused by vibration
Packing Unit - Fully OpenPacking Unit - Fully Open
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Packing Unit - Closed on PipePacking Unit - Closed on Pipe
Closed on drill pipe
Seals on tool joints, pipe, casing, tubing or wire line to rated working pressure
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Packing Unit - Closed on KellyPacking Unit - Closed on Kelly
Closes and seals on square or hex Kellys to rated working pressure
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Packing UnitPacking UnitClosed on Open HoleClosed on Open Hole
Complete shutoff sealing up to rated working pressure
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OperationOperationStandard Surface HookupStandard Surface Hookup
Connects the secondary chamber to the opening chamber
Hookup requires least amount of control fluid for fastest closing time
Control pressure to closing chamber raises piston closing the packing unit to create seal-off
Return flow from opening chamber splits to fill secondary chamber and balance flows to control system reservoir
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Operating CurvesOperating CurvesStandard Surface HookupStandard Surface Hookup
GL 18-3/4 - 5000 MD Packing Unit Closing Pressure -Standard Hookup
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OperationOperationOptional Surface HookupOptional Surface Hookup
Connects the secondary chamber to the closing chamber
Hookup requires least amount of closing pressure for optimum closing force.
Control pressure to closing chamber and secondary chamber raises piston, closing the packing unit to create seal off.
Return flow from opening chamber flows to control system reservoir.
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Operating CurvesOperating CurvesOptional Surface HookupOptional Surface Hookup
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Stripping OperationStripping OperationStandard Surface HookupStandard Surface Hookup
Full seal-off while rotating or stripping of drill pipe and tool joints
Slight leakage prolongs packing unit life by providing lubrication
Slow tool joint stripping speeds reduce surge pressures
Installation of surge absorber accumulator for faster closing pressure response
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Stripping OperationStripping OperationOptional Surface HookupOptional Surface Hookup
Full seal-off while rotating or stripping of drill pipe and tool joints
Slight leakage prolongs packing unit life by providing lubrication
Slow tool joint stripping speeds reduce surge pressures
Installation of surge absorber accumulator for faster closing pressure response
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Subsea OperationSubsea Operation
Hydrostatic Pressure of Drilling fluid column exerts opening force on BOP piston because of unbalanced areas
Hydrostatic pressure of control fluid column has no effect on opening and closing chambers because they are of equal area
Two hookup techniques provide means of compensating for the effects of the drilling fluid on the BOP piston
Standard HookupSecondary chamber connected to the opening chamber
Optional HookupSecondary chamber connected to the closing chamber
Standard Hookup
Optional Hookup
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Subsea Closing PressureSubsea Closing PressureComparison ChartComparison Chart
0 640 440500 730 530
1000 815 6151500 905 7002000 990 7902500 1075 8753000 1165 9653500 1250 10504000 1340 11404500 1425 12255000 1515 1310
* All pressures have been rounded up to the nearest 5 psi.
MD Packing Unit
Depth Ft.Water
GL 18-3/4" 5,000 psi: 5" drill pipe; 5,000 psi well pressure; 16 lb/gal drilling fluid
*Closing Pressure psiStandard Hook-up
*Closing Pressure psiOptional Hook-up
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Standard Subsea HookupStandard Subsea Hookup
Considered standard hookup for water depths to 800-1000’
Hookup requires least amount of control fluid thus gives the fastest closing time.
This hookup requires an adjustment pressure P to be added to the surface closing pressure
Closing pressure = PSC + PWhere:PSC = surface closing pressure P = adjustment pressure
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Standard Subsea HookupStandard Subsea Hookup(continued)(continued)
Adjustment Pressure Calculation
Adjustment Pressure P = (0.052 x Wm x Dw) - (0.45 x Dw)
Where:Wm = drilling fluid density in lb/galDw = water depth in ft0.052 - conversion factor = 2.19 = the ratio of closing chamber area
to the secondary chamber area0.45 psi/ft = pressure gradient of sea water,
using a specific gravity of sea water = 1.040.433 psi/ft = pressure gradient of fresh water
2 methods to arrive at closing pressure1. Calculation
Add surface closing pressure from chart to calculated adjustment pressure2. Using charts
Add surface closing pressure from chart to adjustment pressure from chart
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Standard Subsea HookupStandard Subsea Hookup(continued)(continued)
Example Method 1
Drill pipe = 5”Well pressure = 3500 psiDrilling fluid = 16 lb/galWater depth = 500 ft.
Closing pressure = Psc + P
Where: Psc = Surface closing pressure Psc = 560 psi from surface closing pressure
chart for standard hookup
Adjustment pressure P = (0.052 x 16 lb/gal x 500 ft) - (0.45 psi/ft x 500 ft)
2.19
P = 87 psiPsc + P = Pc
560 + 87 = 647 say 650 psi560 + 87 = 647 say 650 psi
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Standard Subsea HookupStandard Subsea Hookup(continued)(continued)
Method 2
From surface closing pressure = 560 psi
From adjustment pressure P chart = 87 psi
Closing Pressure PC = 647 psi
Adjustment Pressure P Standard Hookup
GL 18-3/4 5000 MD Packing Unit Closing PressureStandard Hookup
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Optional Subsea HookupOptional Subsea Hookup
Recommended hookup for water depths below 3000’
Hookup requires from14% to 28% less closing pressure
This hookup also requires an adjustment pressure (P) to be added to surface closing pressure to compensate for hydrostatic pressure of drilling fluid column
Closing pressure = surface closing pressure + adjustment pressure
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Optional Subsea HookupOptional Subsea Hookup(continued)(continued)
Adjustment Pressure CalculationAdjustment Pressure (P) = [(0.052 X Wm X Dw) - (0.45 X Dw)]
Where:
Wm = drilling fluid density in lb/galDw = water depth in ft0.052 = conversion factor = 2.19 = the ratio of closing chamber area
to the secondary chamber area0.45 psi/ft = pressure gradient of sea water,
using a specific gravity of sea water = 1.040.433 psi/ft = pressure gradient of fresh water = 1.0
= __AC _ = Closing chamber area _ (AC + AS) Closing chamber area + Secondary chamber area
Two methods to arrive at closing pressure1. Calculation - Add surface closing pressure from chart to calculated adjustment
pressure2. Using charts - Add surface closing pressure from chart to adjustment pressure
from chart
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Optional Subsea HookOptional Subsea Hook(continued)(continued)
Example Method IDrill Pipe = 5”Well pressure = 3500 psiDrilling fluid = 16 lb/galWater depth = 2000 ft
Closing pressure = Psc + PWhere: Psc = Surface closing pressure Psc = 384 psi from surface closing pressure chart for optional hookup
Adjustment pressure P = 0.69[(0.052 x 16 lb/gal x 2000 ft) - (0.45 psi/ft x 2000 ft)]
2.19
P = 240 psiPsc + P = PC
384 + 240 = 624 say 625 psi384 + 240 = 624 say 625 psi
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Optional Subsea HookupOptional Subsea Hookup(continued)(continued)
From surface closing pressure chart = 385 psi
From adjustment pressure P chart = 240 psi
Closing pressure PC = 625 psi
Adjustment Pressure P Optional Hookup
Example Method 2
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Stripping Operation Subsea Stripping Operation Subsea Standard HookupStandard Hookup
Full seal-off while rotating or stripping of drill pipe and tool joints
Slight leakage prolongs packing unit life by providing lubrication
Slow tool joint stripping speeds reduce surge pressures
Installation of surge absorber accumulator for faster closing pressure response
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Standard Subsea HookupStandard Subsea HookupClosing Chamber Surge Absorber PrechargeClosing Chamber Surge Absorber Precharge
Calculation:Pipe = 5”Water Depth = 500 ftPrecharge PPC = 0.80 [surface closing pressure + (0.41 X Dw)]
Where:Dw = water depth in ft0.41 psi ft = Control fluid pressure gradient
PSC = 400 psi = From closing pressure chart - surface standard hookup
PPC = .80[400 + (0.41 X 500)]
PPC = .80(400 + 205)
PPC = .80 X 605 psi
PPC = 485 psi
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Stripping Operation Subsea Stripping Operation Subsea Optional HookupOptional Hookup
Full seal-off while rotating or stripping of drill pipe and tool joints
Slight leakage prolongs packing unit life by providing lubrication
Slow tool joint stripping speeds reduce surge pressures
Installation of surge absorber accumulator for faster closing pressure response
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Calculation:Pipe = 5”Water Depth = 2000 ftPrecharge PPC = 0.80 [surface closing pressure + (0.41 X Dw)]
Where: Dw = Water depth in ft0.41 psi ft = Control fluid pressure gradient
PSC = 260 psi = From closing pressure chart - surface optional hookup
PPC = .80[260 + (0.41 X 2000)]
PPC = .80(260 + 820)
PPC = .80 X 1080
PPC = 865 psi
Optional Subsea HookupOptional Subsea HookupClosing Chamber Surge Absorber Precharge
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Physical DataPhysical Data
Engineering Data
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Physical Data Physical Data (continued)(continued)
Bolt & Wrench DataBolt & Wrench Data
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Packing UnitsPacking Units
Manufactured by Hydril
High quality rubber compounds bonded to flanged steel segments
Flanged steel segments anchor the packing unit and control rubber extrusion and flow during sealing
Original Packing Unit LL Long Life Packing Unit
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Packing Units Packing Units (continued)(continued)
Newest packing unit design for use in GL-18-3/4 5000 annular BOPs
Better fatigue life
Better stripping life
2 Compounds:Natural rubberNitrile rubber
MD Packing Unit
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Packing Unit ReplacementPacking Unit Replacement
Pull Down Bolt Assembly
Jaw Operating Screw
Pipe Plug
Sleeve Screw
Jaw
Head
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Packing Unit Replacement Packing Unit Replacement (continued)(continued)
Retract Jaw Operating Screws (4 turns counter clockwise)
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Packing Unit Replacement Packing Unit Replacement (continued)(continued)
Retract jaw operating screws 4 turns. This releases the jaws
from the head.
Remove 4 pull-down bolt assemblies from the top of the
head.Lift off preventer head.
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Packing Unit ReplacementPacking Unit Replacement (continued)(continued)
Lift out Packing Unit and Lubricate Piston Bowl
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Packing Unit ReplacementPacking Unit Replacement (continued)(continued)
Install new Packing Unit
Replace head
Install pull-down bolt assemblies and pull head fully into place
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Packing Unit ReplacementPacking Unit Replacement (continued)(continued)
Tighten jaw operating screws 4 turns and torque to 300-400 ft-lbs
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SealsSeals
Dynamic Seals - Hydril molded lip-type pressure energized design
Static seals - O-ring or square design
Seals molded from special synthetic rubber
Dynamic Seals Static Seals
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MaintenanceMaintenance
1. Inspect upper and lower connections
2. Check body
3. Inspect vertical bore
4. Check inner and outer body sleeve for wear
5. Check piston for wear or damage
6. Check wear plate
7. Inspect packing unit
8. Inspect seals
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Seal TestingSeal TestingHydril recommends all seals be replaced if a seal leak is suspected.1. Test seals 18, 16, 23, & 14
a. Pressure closing chamber to 1000 psi(Packing unit closed on test pipe)
b. Open opening chamber to atmospherec. Open secondary chamber to atmosphered. Pressurize well bore to 1000 psiIF: Well bore fluid (clean water or dyed water
is seen at secondary chamber1)Seal 18 is leaking, OR2) Seal 23 is leaking, OR3) Seal 18 and 23 are leaking
IF: Closing fluid (milky colored water andsoluble oil) is seen at secondarychamber--Seal 16 is leaking.
IF: Closing fluid is seen at openingchamber--seal 14 is leaking.
NOTE: Seals 14, 16 and 18 are 2-way seals and get tested in both directions.
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Seal Testing Seal Testing (continued)(continued)
2. Test seals 18, 16, 23a. Open closing chamber to atmosphereb. Open opening chamber to atmospherec. Pressurize secondary chamber to
1500 psi (packing unit closed on test pipe)d. Well bore full of water at 0 pressureIF: Secondary chamber pressure gauge is
dropping and well bore pressure gauge(below packing unit) is rising.1) Seal 18 is leaking, OR2) Seal 23 is leaking, OR3) Seal 18 and 23 are leaking
IF: Secondary chamber fluid is seenin closing chamber, seal 16 is leaking.
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Seal Testing Seal Testing (continued)(continued)
3. Test Seals 14, 27 (lower) and 29a. Open closing chamber to atmosphereb. Pressurize opening chamber to 1000 psic. Secondary chamber is at 0 pressure and
plugged (after application of openingchamber pressure)
d. Well bore is emptyIF: Opening fluid is seen at closing
chamber, seal 14 is leaking.IF: Opening fluid is seen in well bore or
coming from the relief valve.1. Seal 27 (lower) is leaking, OR2. Seal 29 is leaking, OR3. Seal 27 (lower) and 29 are leaking.
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Seal Testing Seal Testing (continued)(continued)
4. Test seal 27 (upper)a. Plug closing chamberb. Open opening chamber to
atmospherec. Plug secondary chamberd. Pressurize well bore to 1000 psi
(requires blind flange on top, aspacking unit is open)
IF: Well bore fluid is seen at openingchamber, seal 27 (upper) is
leaking.5. Seals 2 and 3 are used primarily to
exclude external matter and are notfeasibly testable.
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Packing Unit TestingPacking Unit Testing
Reliable packing unit testing achieved by measuring piston stroke.
Maintain closing pressure during all seal-off operations
Begin test with recommended closing pressure
Measure piston stroke through opening in thehead - Use 5/16 rod
Maximum & minimum distance from top of headto top of piston stamped in the head
Record piston stroke
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DisassemblyDisassembly
Vent all pressures
Remove head (1) Release jaws (10) by rotating jaw
operating screw (4) counter clockwise4 turns
Remove pull-down bolt assemblies (32) Install three (2”- 4-1/2” NC) eyebolts Lift off head (1) Remove wear plate by removing 12 cap
screws (35 & 36)
Remove packing unit (11) Install two (5/8” 11 NC) eyebolts Lift out packing unit (11)
Remove opening chamber head (24) Install three (7/8” 9 UNC) eyebolts Install triple-line sling Lift out head (24)
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Disassembly Disassembly (continued)(continued)
Remove piston (12)
Install two piston lifting devices
Install two-line sling
Lift piston (12)Do not use air or gasLow pressure hydraulic pressure(50 psi) may be used
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Disassembly Disassembly (continued)(continued)
Remove slotted body sleeve (20)
Remove 14 cap screws (19)
Lift out slotted body sleeve (20)
Remove outer body sleeve (21)
Install two (3/4”-10 NC) eye bolts
Lift out sleeve (21)
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Disassembly Disassembly (continued)(continued) Disassemble jaw operating screw assembly
Remove pipe plug (7) Remove sleeve screw and spacer sleeve (5 & 6) Remove jaw operating screw (4) Remove jaw from inside the body (10)
Assembly is the reverse
Pull Down Bolt Assembly
Jaw Operating Screw
Pipe Plug
Sleeve Screw
Jaw
Head
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AssemblyAssembly
Clean & inspect all parts
Install slotted body sleeve and outer body sleeve (20 & 21) Install O-ring in seal groove (18) at
bottom of outer body sleeve Lubricate O-ring thoroughly Install inner double U-seal (23) and
inner non-extrusion rings (22) Install outer body sleeve (21) Install slotted body sleeve (2) Install 14 cap screws (19) Remove eyebolts from outer body
sleeve
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Assembly Assembly (continued)(continued)
Install piston (12) Install lower double
U-seal (16) and lower non-extrusion rings (15)Lubricate seals before installation
Install middle doubleU-seal (14) and middle non-extrusion rings (13)Lubricate seals before installation
Lubricate internal mating body surfaces
Carefully lower piston into body Remove piston eyebolt
assemblies
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Assembly Assembly (continued)(continued)
Install opening chamber head (24) Install square head gasket (29) Install U-seal (27) Install three (7/8” - 9 NC) eye bolts Install three-line sling Install opening chamber head
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Assembly Assembly (continued)(continued)
Install packing unit (11) Lubricate piston bowl Install two (5/8” - 11 NC) eyebolts Lift in packing unit
Install BOP head (1) Install wear plate (35) with 12 cap screws
(36) torque 20 ft-lbs Install O-ring (2) Install U-seal (27) Install three (2” - 4-1/2 NC) eyebolts Lift head in place Install pull-down bolt assemblies
Ensure head & body clearance 0.5” (32) Rotate jaw operating screws (4) 4 turns
clockwise 300-400 ft-lbs torque
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Position of PartsPosition of Parts
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Position of PartsPosition of Parts
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Parts IdentificationParts Identification