CONTROL SYSTEM

FOR
SURFACE MOUNTED BOP STACKS

OPERATION MANUAL

Shanghai Shen Kai Petroleum & Chemical Equipment Co., Ltd.

 Table of contents

1.0 General
2.0 Model designation
3.0 Technical parameters
4.0 Construction & features
4.1 Remote control panel
4.2 Driller’s panel
4.3 Air interconnect cable
4.4 Hydraulic control line
5.0 Operation principle and description
5.1 Controlling for the “start” or “stop” of electric oil pump
5.2 The control principle of hydraulic control system
5.3 Controlling for pneumatic oil pump
5.4 Hydraulic principle of FKQ640-6 control system for surface mounted BOP stacks
6.0 Installation and Pilot run
6.1 Installation
6.2 Pilot run
6.3
7.0 Operations, Maintenance and Lubrication
7.1 Operation instruction
7.2 Maintenance
7.3 Lubrication Instruction
8.0 Troubleshooting
9.0 Order instruction

Appendix A: Conversion table

Appendix B: Recommended hydraulic fluid for BOP stacks
1.0 General
Control system for surface mounted BOP stacks (hereafter called hydraulic control
system) is very important equipment which controls BOP stacks and gate valves
controlled by hydraulic pressure especially in drilling and repairing well operations. It is
necessary to accurately operate and maintain hydraulic control system.
The hydraulic control system is divided into two types. One is the type liquid controlled
by air with a driller’s panel to remotely open or close BOP equipment. The type is often
used for drilling operation. The other type is directly operated by hand and often used
for drilling or workover operation.

2.0 Model designation

FK Q 640 6

Number of objects controlled: (6)

Total capacity of accumulator (640L)

Remote control type (“Q” means liquid controlled by air)

Product code of control system of surface mounted BOP

3.0 Technical parameters

Working pressure: 21MPa 3000Psi
Adjusting pressure range: 0-14MPa 0-2000Psi
Nitrogen pressure of accumulator: 7+0.7MPa 1000+100Psi
Pressure control units range: 18.9-21MPa 2700-3000Psi
Hydraulic/pneumatic switch range: 18.9-21MPa 2700-3000Psi
Air supply pressure: 0.65-0.8MPa 93-115Psi
Power supply: 380±19V/50Hz

3.1 Main technical parameter of control system for surface-mounted BOP stacks

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 Mode Numbers of controlled object Accumulator Effective
Annular Ram Choke Backup Total Useful Installation Volume
Volume liquid (L) of oil
(L) tank (L)
FKQ 1208- 1 3 2 2 80×16 640 Side 1800
8
FKQ 800-7 1 3 2 1 40×20 400 1800
FKQ 800-6 1 3 2 40×20 400 1600
Side/Back
FKQ 640-6 1 3 2 40×16 320 1600
FKQ 640-5 1 3 1 1 40×16 320 1400
FKQ 480-5 1 3 1 1 40×12 240 1400
FKQ 480-4 1 3 1 40×12 240 1200
FK200-4 3 1 40×5 100 Side 700
FK 160-3 3 40×4 80 550

Mode Motor Flow-rate of pumps Rated Maximnm

power (KW) Triplex Pneumatics working working

(ml/r) (ml/stroke) pressure pressure

(MPa) (MPa)
FKQ 1208-8 18.5×2 80×2 60×2 21 31.5
FKQ 800-7 18.5 80 60×2 21 31.5
FKQ 800-6 18.5 80 60×2 21 31.5
FKQ 640-6 18.5 80 60×2 21 31.5
FKQ 640-5 18.5 80 60×2 21 31.5
FKQ 480-5 15 60 60×2 21 31.5
FKQ 480-4 15 60 60×1 21 31.5
FK200-4 15 60 21 31.5
FK 160-3 15 60 21 31.5

3.2 The model and arrangement of the control system for surface-mounted BOP stacks
Mode Electric Pneumatics Manual Alarm Nitrogen Protect Insulated Driller’s Auxiliary Pipe
pump oil punp system Backup house House panel Control Racks
system & panel &
air-condition hose
FKQ 1208-8 ● ● ○ ○ ○ ● ○ ● ○ ○
FKQ 800-7 ● ● ○ ○ ○ ● ○ ● ○ ○
FKQ 800-6 ● ● ○ ○ ○ ● ○ ● ○ ○
FKQ 640-6 ● ● ○ ○ ○ ● ○ ● ○ ○
FKQ 640-5 ● ● ○ ○ ○ ● ○ ● ○ ○
FKQ 480-5 ● ● ○ ○ ○ ● ○ ● ○ ○
FKQ 480-4 ● ● ○ ○ ○ ● ○ ● ○ ○
FK200-4 ● ● ○ ● ○
FK 160-3 ● ● ○ ● ○

Note：1. All above are all model of our coMPany. “●”is basal arrangement, “○”is optional arrangement.

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 2. The arrangement above not mean each model can be choose. It must confirm by negotiate when sign the
contract.
3. All above arrangement or function can design and manufacture according to the request of custom.

Accumulators
4.0 Construction and features
Air junction box
FKQ series control systems for surface mounted BOP stacks consist of the followings:
1. Remote control panel (normally equipping with protecting house)
Remote control
interconnect cable
2. Driller’s panel
3. Air interconnect cable
4. Hydraulic control lines including hose bundle Pipeor pipe racks
Racks
Auxiliary electric pump
Drill’s panel interconnect cable
Auxiliary air pump

Driller’s panel

Air junction box

Master hydraulic control manifold

Auxiliary remote control panel

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Air junction box and Figure 1 Connecting of control system for surface mounted BOP stacks
shuttle valve
assembly

4.1 Remote control panel

Remote control panel consists of reservoir, pump units, accumulator units, manifold
various valves & gauges and electric boxes. The primary function of the remote control
panel is to receive high-pressure fluid from the pump unit and to store the fluid in
accumulator bank. The high-pressure fluid flowed though 3-positon and 4-way
hydraulic valve controls the “OPEN” or “CLOSE” of BOP.
The remote control panel has the following features:
(1) FKQ series equipping with two separate motive power supply systems, electric
pump and pneumatic pump, can ensure the operation of system even if electric power
supply is shut-off.
(2) Accumulator unit should be provided with sufficient high-pressure fluid to open or
close BOP stacks. Accumulator system is divided into four groups, the loss of capacity
is less than twenty-five percent of the total accumulator system capacity when an
individual accumulator or one group loses effectiveness, and pressure isolation valves
and bleed valves shall be provided on each group accumulator line and bleed valves can
drain the pressure out from the accumulators to the control fluid reservoir.
(3) Electric oil pump and pneumatic oil pump can be automatically started up or shut
down. Relief valve can immediately overflow even if the automatic control unit fails to
start or stop during work.
(4) Each BOP is controlled by a relevant 3-position and 4-way hydraulic valve to open
or close. FKQ series hydraulic control systems can be changed direction by either hand
or pneumatic remote control equipment.

4.2 Driller’s panel

FKQ series hydraulic control system equip with driller’s panel placed on drill platform,
so that it is convenient for driller to remotely control BOP stacks.
The features of driller’s panel are as follows:
(1) Working media is compressed air to safely operate.
(2) “Y” type valve bushing of air-operated valve can automatically come back to
normal place so that the remote operation can’t be influenced in any case.
(3) Memory function. Every 3-position and 4-way air-operated valve is individually
connected with a cylinder. When the air-operated valve is placed on “open” or “close”,
the show window appears “o” or “c”. The show isn’t changed after the handle of air-
operated valve comes back so that operator can understand the last state.
(4) Two steps operation is used in valves of driller’s panel to ensure correct operation
of BOP stacks. The first step is to turn air supply valve to open air supply switch,
then turn air control valve at the same time so as to control related objects.

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4.3 Air interconnect cable
Air interconnect cable is connected remote control panel to driller’s panel. The air
interconnect cable consists of protector and multicore with flanges on its both ends
sealed rubber rings connecting remote control panel and driller’s panel.

4.4 Hydraulic control line

In general, the remote control panel is 40 meters away from BOP stacks. They are
connected with hydraulic control lines, hose and pipe.
The pipes include pipe rack and flexible pipeline. To connection with pipe is reliable
and safe for operation, but inconvenient for installation. To connection with hose is
simple and convenient, but not safe enough. You can use hose and pipe together
according to actual site situation.

5.0 Operation principle and description

5.1 Controlling the “start” or “stop” of electric oil pump
When turning the main switch of electric box (figure 2) on remote control panel to
“automatic” position, the system is in automatic state. In this time, pressure controller
will automatically start the electric oil pump, if the pressure of system is blow
18.9MPa(2700Psi). The pressured oil is flowed from check valve to accumulator bank
after the isolate valve of accumulator bank is opened. When the system of pressure is up
to 21MPa(3000Psi), the pressure controller automatically shut up power to stop oil
supply.
When the system is in “automatic” state, the pressure controller makes the pressure of
accumulator bank 18.9-21MPa(2700-3000Psi) in order to open or close BOP in any
time.
When turning the main switch to “manual” position, the electric oil pump will
immediately work no mater what the system pressure is. Operator must turn the main
switch to “stop” position, when the system pressure id up to 21MPa(3000Psi).

Note: the electric oil pump cannot be stopped, when the main switch is in
“manual” position. Operator shall watch the system pressure and turn the main
switch to “stop” position to stop electric oil pump.

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 Connection power ： 380 V / 50 HZ ：

Air switch

--------------------
Manual
Stop

Contactor Automatism
--------------------
Main switch

Heated electric

Connection Connection light Connection

Motor pressure valve

Figure 2: Electric principle of control system for surface mounted BOP stacks

5.2 The control principle of hydraulic control system

The pressured oil stored in accumulator bank flow from isolate valve (high-pressure ball
valve), filer, and relief valve into control manifold, then to 3-position and 4-way valve,
final to inlet. In the same time, the pressured oil from accumulator bank to filer, then to
the relief bleed valve of annual BOP. The relief pressure oil is only used by annual BOP.
Operator just easily pushes the handle of 3-position and 4-way valve to “open” or
“close” BOP.
Operator can remotely control the turning of 3-position and 4-way valve in driller’s
panel. Firstly, turning 2-position and 2-way air-supply valve of driller’s panel to “open”,
and turning the other 3-position and 4-way air-operated valve at the same time. The
compressed air flows from air connection cable to remote control panel in order to
control relevant cylinder to turn changing way handle, then to turn 3-position and 4-way

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valve in remote control panel. In the turning air-operated valve of driller’s panel, the
compressed air makes the piston of cylinder move. Operator of driller’s panel can watch
the window show “o” or “c” on every air-operated valve to judge BOP “open” or
“close”.

Note: Turning valve must be two steps operation. In other words, when turning
valves of each controlled objector, operator must turn air supply valve at the same
time. Turning valves must maintain 3 seconds to make the valves of remote control
panel in proper position.
The outlet pressure range of relief bleed valve on controlling manifold is 0-
14MPa(2000Psi). In generally, operator adjusts pressure 10.5MPa(1500Psi). The
pressure of controlling manifold will be the same as the pressure of the system, when
turning pass-by valve from “close” to “open”. At this time, the relief bleed valve does
not work.
The relief bleed valve of controlling annual BOP is selected as “manual” or
“pneumatic/manual” valve. When the system is installed with “pneumatic/manual”
valve, operator can pneumatically adjust the outlet pressure of the “pneumatic/manual”
valve on remote control panel or driller’s panel. The position of pneumatic pressure is
selected by distribution valve on remote control valve. The distribution valve is placed
in remote control panel or in driller’s panel.
In manual operation, turning the handle of relief bleed valve can adjust the outlet
pressure to the pressure what operator need. Turning down is to up the outlet pressure.
Turning up is to down the outlet pressure.
Pneumatic/manual adjusting operation description is followed:
(1) When the air pressure is zero, manually adjusting the pressure 10.5MPa or the
pressure what the operator need, then locking adjusting rod.
(2) Turning the handle of distribution valve to the position of “driller’s panel”,
operator can adjust the controlling pressure of annual BOP in driller’s panel by remotely
control Pneumatic/manual relief bleed valve. The Pneumatic handle of remote control
panel does not work in this time.
(3) Turning the handle of distribution valve to the position of “remote control panel”,
operator can adjust the controlling pressure of annual BOP in remote control panel by
remotely control Pneumatic/manual relief bleed valve. The Pneumatic handle of driller’s
panel does not work in this time.

Note 1: In Pneumatic adjusting operation, the air pressure must be zero. Turning
the handle of relief bleed valve down, setting the annual BOP pressure what the
manufacture recommend such as 10.5MPa(1500Psi). then locking the adjusting rod
to adjust pressure.
Note 2: When the pneumatic adjusting operation does not work, the controlling
pressure of annual BOP will automatically come back to the setting pressure such
as 10.5MPa(1500Psi) to safeguard the system.
Note 3: In Pneumatic adjusting operation, the outlet pressure of relief bleed valve
cannot be changed immediately because of longer air control line. Operator shall

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carefully watch and slowly operate.

The “O” type 3-positong and 4-way valve can be used in remote control panel. When
the handle is in middle place, the room of valve is not connected. While the handle is in
“open” or “close” position, the compressed oil flows into the side of oil tank of BOP,
the other sides of oil flow into reservoir by 3-position and 4-way valve.
The “Y” type 3-position and 4-way valve can be used in driller’s panel.

5.3 Controlling pneumatic oil pump

Control units are equipped with a pneumatic oil pump. The system pressure can be
adjusted with pneumatic oil pump in no power or stopping using power.
To open air supply switch, then to close pass-by valve, the compressed air flow from
pneumatic cells into air/liquid switch in system with pneumatic oil pump. When the
manifold pressure is blow 18.9MPa(2700Psi), the air/liquid switch will automatically
open. The compressed air flows into pneumatic oil pump to drive it start. The relief oil
flow into manifold by check valve. When the system pressure is up to 21MPa(3000Psi),
the air/liquid switch will automatically shut-off. Then the power is shut-off. The
pneumatic oil pump is stopped.
In special, when the pressure what the system need is over 21MPa(3000Psi), operator
only use the system with pneumatic oil pump. Firstly, shutting down isolate valve of
accumulator bank to prevent compressed oil into accumulator bank. Turning pass-by
valve of relief bleed valve to “open” at the same time. Opening the pass-by valve of
air/liquid switch so that the air/liquid switch does not work. The compressed air can
directly flow into pneumatic oil pump.

Note 1: Operator must make sure the relief bleeds valve work normally, when
using pneumatic oil pump. In necessarily, operator shall test complete relief in
34.5MPa(5000Psi).
Note 2: When the manifold pressure is up to 21MPa(3000Psi), the isolate valve of
accumulator bank (ball valve) must be closed to make equipment normal and
make persons safe.

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5.4 Hydraulic principle of FKQ640-6 control system for surface mounted BOP stacks
Item Product name Qty. Drawing No. Type Notes
1 Gate valve 7 1”
2 Pneumatic cells 1 set AF5000, AR500, AL5000

3 Gate valve 1 2”
4 Air/liquid switch 1 Y10-00 QKY21-25
5 Check valve 2 DIF-L10H2 31.5 40l/min
6 Pneumatic oil pump 2 Y04-00A QYB40-60L
7 Oil filter 2 1”
8 Oil filter 1 2”
9 Flame-proof electric 1 YB180M-4 18.5KW

Motor
10 Electricity box 1 BQC83-40
11 Check valve 1 DIF-L20H1 31.5 100l/min
12 Plunger pump 1 Y15-00 QB21-80
13 Relief valve 1 Y08-00 Y25-20
14 Pressure controller 1 YTK-02
15 Isolation valve 1 Q11NS-31.5-1” 1”
(ball valve)
16 Relief valve 1 Y09-00 Y40-20
17 Cylinder 7 K4-01-51-00
18 3-position and 4-way 6 Y01-00 34ZS21-25
valve
19 2-position and 3-way 1 Y01-00A 23ZS21-25
valve
20 Quake-proof 2 YN100BF 0-40MPa
pressure gauge
21 Filter 3 Y14-00
22 Manually adjusting 1 Y02-00 JYS21-25
valve
23 High pressure ball 4 YQ2-32H-Z1” 1”
valve
24 Accumulator 8 NXQ1-L80/31.5/H
25 Pneumatic pressure 3 YPQ400B 0-40MPa
transmitter
26 Air filter relief valve 1 QFH-261 0-0.6MPa
27 Quake proof pressure 1 YN100BF 0-25MPa

9
 gauge
28 Pneumatic/manual 1 Y16-00 JYSQ21-25
adjusting pressure
valve
29 Distribution valve 1 Remade by Q34SR2-
8
30 Unloading valve 1 Y06-00 φ10
31 Pneumatic cells 1 AW4000,AL4000
32 Pneumatic adjusting 2 QTY-8 0.05-0.63MPa
valve
33 Pressure gauge 3 Remade by Y-100ZT 0-0.2MPa
34 Pressure gauge 1 Y-100ZT 0-2.5MPa
35 3-position and 2-way 1 Remade by 34XR6Y-
valve L8-F
36 3-position and 4-way 7 Remade by 34XR6Y-
valve L8-F
37 Cylinder 7
6.0 Installation and Pilot run
6.1 Installation
(1) Smoothly safely install remote control panel.
(2) The remote control panel is located a place away from wellhead over 30m
according to standard and requirements. The driller’s panel is located in a convenient
place for driller on drill floor.
(3) Connecting oil pipe
Connecting oil pipe from BOP it is good for arranging oil pipe and changing oil pipe. It
is important to clean every oil pipe with compressed air before the oil pipes are
connected. Every oil pipe is welded on “o” or “c” mark over channel steel on the base of
remote control panel. “o” means open, “c” means close. When the oil pipes are
connected, operators watch not only the mark “blind ram”, “pipe ram” and “annular”
the same with the show of valve on remote control panel, but also the mark “o” or “c”
corresponding the open or close of BOP.
Note 1: carefully check about control object and switch direction before connecting
pipe.
Note 2: checking pipe without stuff or leakage before connecting pipe.
(4) Connecting air pipe
The air supply pipes and air connect cables are connected to the FKQ hydraulic control
system. Be careful flanges direction, flanges seal, and tight bolts& nuts when
connecting pipes.
ID 25mm hose is used in air supply of remote control panel. ID 13mm hose is used in
air supply of driller’s panel. Be good tight between hoses and connections to prevent
loosing. The hoses are no default especially no rifts and no ageing to prevent from
explosion in use.
Note 1: There no dead angle when connecting pipe to prevent from broken pipe.

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Note 2: when connecting air connection cables flanges, the air will go though
everywhere in cables if the seal rings do not work.
(5) Connecting power lines
The power shall be 440V, 60Hz alternating current. Connecting power line according to
relevant regulations.
The main switch of electric power control box on remote control panel shall be turned
on the stop to prevent from electric accident before connecting power line.
Note: Be sure about the main switch is turned on the stop to prevent from accident
before connecting.
Carefully checking all connection of pipes, flexible joints and connections without
loosing and defaults after the equipment is completely installed.
6.2 Pilot run
The preparation of pilot run according to the following procedures:
(1) Precharging Nitrogen or checking pressure of accumulators. The pressure is
7+0.7MPa (1000+100Psi). Refilled again if the Nitrogen is not enough.
(2) Adding oil into reservoir
The oil is added from inlet on the top of reservoir or sucking oil with sucking pump.
The oil volume shall be controlled on the level of oil mark.
Using YA-N32 hydraulic pressure oil or other proper oil under circumstances
temperature over 0oC.
Using YC-N32 low temperature hydraulic pressured oil or other proper oil under
circumstance temperature below 0 oC.
(3) Lubrication motion parts according to lubrication requirements.
(4) Open isolates valves on pipe and accumulators.
Open bleed down valves on control manifold.
Turn the handle of 3-position and 4-way hydraulic valve and by-pass valve on the
middle place.
(5) Turn main switch to “manual ” then turn main switch to “stop” after starting motor.
Be careful if the direction of motor and chain protector is the same, otherwise changing
the electric phase.
The procedures of pilot run are followed:
(1) Testing start-up or shut-off of electric oil pump.
Turning main switch to “automatic” position, making the motor oil pump run without
load 10 minutes, then closing bleed down valve on control manifold to make
accumulator pressure up to 21 MPa (3000Psi), result in the pump automatically stopped.
Turning main switch to “ stop” if the pumps is fail to automatically stop.
Gradually open bleed down valve to slowly down pressure to 18.9 MPa (2700Psi),
result in electric oil pump automatically stopped.
In operation, checking and adjusting pressure controller to automatically stop or start.
Watching about the each joint on remote control panel in the pressure rising up.
(2) Testing start-up or shut-off pneumatic oil pump.
When using pneumatic oil pump, closing by-pass valve of fluid / air switch and opening
air supply valve acting on pneumatic oil pump to make accumulator’s pressure up to
21MPa(3000Psi). Then watching about if the air supply is automatically shut-off to stop

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pneumatic pump.
Gradually open bleed down valve to slowly down pressure to 18.9MPa(2700Psi), result
in the pneumatic oil pump automatically stopped.
(3) Adjusting relief valves
Watching about if the outlet pressure of manifold or annular is 10.5 MPa (1500Psi),
otherwise adjusting to 10.5 MPa (1500Psi).
(4) Direction changed test
When the accumulator pressure is up to 21MPa(3000Psi) and the by-pass valve of
control manifold is in middle place, changing handle direction of 3-positin and 4-way
hydraulic valves, then watching about if “open” or “close” of BOP is the same with “
open” or “close of 3-position and 4-way hydraulic valve, otherwise checking pipe
connecting.
(5) Relief valve test
To close the isolate valves of accumulator bank on pipes and, turn 3-position and 4-way
hydraulic valve in a middle place, then turn main switch of electric box to “manual”,
finally start electric motor to make the pressure of accumulator up to 23MPa (3300Psi),
and watch about if the relief bleed valve on the outlet of motor oil pump fully kick off.
If fully kick, to turn main switch to the “stop” position and stop motor oil pump. The
relief valve completely is closed with the pressure not less than 18.9 MPa.
To close isolate valve of accumulator on pipes, then turn by-pass valve of control
manifold on open. To open air supply switch valve and by-pass of fluid and air switch,
then to start pneumatic oil pump to make the manifold pressure up to 345MPa(4900Psi)
and watch about if the relief valve is fully kick off. After fully kick, to close air supply
and stop pneumatic oil pump. The relief valves shall be fully closed with pressure not
less than 29MPa(4200Psi).
Note: when testing and adjusting relief valves, the isolate valve of accumulators on
pipes must be closed to prevent from pressure rising accident.
(6) Pneumatically adjusting testing in annual BOP.
Turning the handle of manual adjusting valve on annual BOP down. Setting the outlet pressure of the
valve in 10.5MPa.
Turning the handle of distribution valve on remote control panel in “driller’s panel’ position. Then
adjusting pneumatic handle in driller’ panel, and watch about the reader of pressure gauge on
driller’s panel is the same with the reader of pressure gauge on remote control panel.
Turning the handle of distribution valve in “remote control panel” position, then
adjusting pneumatic handle in remote control panel and watch the reader of pressure
gauge on annual BOP.
(7) Testing reservoir height
Adding oil into reservoir if there leakage oil too much in above mentioned procedure.

7.0 Operations, Maintenance and Lubrication

Because the hydraulic control system is more important equipment in well control
system, relevant person must be technically trained, managers and operators shall
understand the principle, installation, operation and maintenance.
7.1 Operation instruction

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1) In normal drilling operation, BOPS are open, blowout valves are closed, and
by-pass valves are in middle place.
2) Two-steps operation is used in turning valve of driller’s panel.
3) Don’t go through transport vehicles on hydraulic or pneumatic line between control
units and BOP stacks to prevent from damaged.
4) Operator must check control system at least once week. Check control system every
shift work once when drilling approach to oil or gas. The following contents should be
inspected:
- The height of reservoir is in normal
- Electric cells and wire are safe
- No leakage on oil or gas line
- The control units are reliable and accurate
- The range of pressure gauges are in normal
- Testing “open” or “close” of BOP according to safe requirements.
5). Suggesting customers to establish operation and maintenance records. Write down
the work of operations, shutdowns and maintenance at any time.

7.2 Maintenance
1) Monthly carefully checking strainers of reservoir or the other parts.
2) For diverter strainer of air supply elements: Everyday discharging water in cup.
Every one-week cleaning strainer cup and disposed water cup with gasoline then to dry
cup.
3) Oil part of pneumatic cells: everyday checking the water lever, and adding
lubrication oil such as N32 gasoline in time. Cleaning it with stuffed.
4) Periodically check precharging Nitrogen pressure. At the beginning, weekly
check Nitrogen pressure once. Monthly check it once in normal operation.
Checking the Nitrogen pressure under only the accumulator bank completely relief
pressure.
5) When transportation hydraulic controls equipment in long distance, the Nitrogen
pressure of accumulator shall be in 1MPa(140Psi).
6) Checking the oil lever of reservoir and cleaning the bottom of reservoir covered
sands and mud in any time.
7) Periodically check the pack-off of and pneumatic oil pump.
8) Keep the “o” seal rings well in unloading pipe lines.
9) Often cleaning the surface of remote control panel and driller’s panel.
10) Correcting the pressure gauge after completion a well.
7.3 Lubrication Instruction
1) Adding grease or machine oil weekly to two nozzles of air cylinder with grease
gun.
2) Monthly checks the grease oil of crankshaft box. Add N32 machinery oil under
insufficient oil circumstance.
3) Monthly checks the grease lever in motor oil pump. Add N32 machinery oil under
insufficient oil circumstance.
4) Monthly take off chain protector to check grease. Add N32 machinery oil under

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insufficient oil circumstance.
8.0 Troubleshooting
1 Running noise from control units.
Cause: mixed gas in oil.
Remedy: Running equipment with unload to circulate gas out. Checking the
bladder of accumulator to ensure it is good otherwise changing it.

2 Electric motor can not be started.

Cause (1): The power parameter is closed in bad.
Remedy (1): Checking and repairing power circuit.
Cause (2): Electric elements in electric control box are broken down or the
fuse is blown.
Remedy (2): Inspecting and repairing electric control box or changing the
fuse.

3 The pressure rises slowly or stop and the noise of pump are in abnormal.
Cause (1): The oil of reservoir is below normal level to make pump suck
nothing.
Remedy (1): Adding oil into reservoir
Cause (2): The gate valve of sucking oil is closed or the sucking mouth of the
oil strainer is blocked.
Remedy (2): Checking pipe, then opening gate valve and cleaning the strainer.
Cause (3): The bleed valve of control manifold does not close.
Remedy (3): Closing bleed down valve
Cause (4): The electric oil pump broken down.
Remedy (4): Checking the electric oil pump.

4 The electric oil pump can not automatically stopped

Cause (1): Oil pipe or connection of pressure controller is blocked or leakage.
Remedy (1): Checking the pipe lines of pressure controller.
Cause (2): The pressure controller does not work.
Remedy (2): Adjusting or changing pressure controller.

5 The outlet pressure of relief valve is too high

Cause (1): Dirt on the surface of seal ring.
Remedy (1): Revolving the adjusting pressure handle to make sealing box up
and down several times to push dirt out.

6 Driller’s panel can not close or open BOP or the action of “close” or “open” is
inconsistent.
Cause (1): The cable core is wrongly connected, or broken or blocked. The
rubble ring of flange is not sealed.
Remedy (1): Checking air interconnect cable or changing seal parts.
9.0 Order instruction

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Control systems for surface BOP stacks have various structural models. Please provide
the technical parameters and requirements required, including:
1 Number of objects controlled and model
Manufacturer:

The type of BOP stacks:

Liters required Liters required
-Annular __________ Open ____________ (L) Close ____________ (L)
-Blind ram _____ __ Open ____________ (L) Close ____________ (L)

-Pipe ram ____ _ Open ____________ (L) Close ____________ (L)

-Pipe ram __________ Open ____________ (L) Close ____________ (L)

-Preventer __________ Open ____________ (L) Close ____________ (L)

-Preventer __________ Open ____________ (L) Close ____________ (L)

-Spare parts

2 Order scope
Please choose the following parts what you need, and write down details about your
chose parts.
- Driller’s panel
- Air interconnect cable
- Hydraulic control lines (pipe rack, flexible lines and hose bundle)
- Others

3 Special requirements
Please describe the special requirements of products or parts when ordering:
-Protect house pattern
-Painting
-Connecting
-Others
Our factory manufactures the hydraulic control system according to national standard,
industrial standard.

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 APPENDIX A
CONVERSION TABLE

1. Mass
1kg=2.2lbs
1lbs=0.45kg

2. Volume
1L=0.264 US. Gal=61 cu.in
1 US. Gal=3.785L=231 cu.in

3. Pressure
1MPa=145 Psi
1Psi=0.0069 MPa

4. Length
1m=3.28ft=39.37 in
1ft=0.305 m

5. Temperature
1OC=5/9 (OF-32)
1 OF=1.8X OC+32

6. Power
1kw=1.34 hp
1hp=0.746kw

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 APPENDIX B
RECOMMENED HYDRAULIC FLUID FOR BOP STACKS

ISO Brand: HM32 (used for plunger pump system with low or no Zn)

Mobil Brand: D.T.E24 (used for plunger pump system with low or no Zn)

Shell Brand: Tellus32 (used for plunger pump system with low or no Zn)

Note: The moving viscosity of hydraulic fluid oil is 17-33mm2/s when the
temperature is at 50oC.

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