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The hose reel manifold is designed to give control to the pods so that a few primary functions can be operated while the BOP is being run or pulled. The system should be used during these times and not during normal operations.

The hose reel manifold receives its primary fluid pressure from the 1″-3000 psi feed into the reel via the swivel connection. A 3/16” I.D. jumper hose tee off from the 1"

line feeds the main shut off valve for the hot line system (manifold supply shut off).

The manifold supply shut off feeds a common manifold from which the following 4 way valves are fed fluid pressure:

• Riser Connector - primary latch and unlatch SPM's.

• Riser Connector - secondary unlatch SPM.

• Wellhead Connector primary latch and unlatch SPM's.

• A Shear or Pipe Ram open and closed SPM's (pending hook up).

• A regulator for ball joint pressure. (This is no longer required but some older rig systems may still have the regulator not hooked up).

• A regulator for the manifold pressure command pilot signal to the live pod.

Selecting one of the above pod hose 4 way valves; Riser Connector Secondary Wellhead Connector, Shear or Rams, and placing it in the desired mode of operation sends a pilot signal to the pod to lift that particular SPM. With the manifold regulator adjusted to 1500 psi and with the manifold regulator shut off valve open a pilot signal is sent to the manifold regulator at the pad. With this signal the regulator will then regulate the 3000-psi feed to the desired pressure (1500-psi). Now with the SPM lifted off of its seat, manifold pressure can now flow to the desired function and operate the function. With the 4 way valve kept in the desired mode (say riser connect lock) and with the pod reel regulator adjusted to 1500 psi, the regulator will reduce the 3000 psi feed to 1500 psi, and keep 1500 psi on the riser connector lock while the BOP is being run or pulled. Obviously this is of primary concern whilst running or retrieving a BOP stack - maintaining hydraulic closing pressure on the L.M.R.P. connector.

An important consideration to keep in mind while working and the way valve is that they are of the “selector type” . If a “manipulator type” body is installed once the reel hot line system is shut down and the junction box is mated together any pilot signal using the above 4 way valves can be bled off because a manipulator valve bleeds of pressure from its functions while in block, where as the selector valve will hold pressure in the block position. Therefore Pod hose valves should always be selector type which will not bleed off pressure when thrown into a block position.

a) The procedure for activating the reel hot line system for running or pulling the BOP is as follows:

• Place the pod selector to either blue or yellow pod (use the same pod that was previously used).

• Go to the hose reel and check to see if all 4 way valves are in block, if not put them in the block position.

• Open the manifold supply shut off valve.

• Open the manifold regulator shut off valve.

• Adjust both regulators to the desired operating pressures (manifold 1500 psi).

• If BOP is to be run, place riser connector to lock position wellhead connector to open (unlatch) position. REMOVE THE HANDLE TO THE RISER CONNECTOR VALVE WHILE RUNNING OR PULLING THE B.O.P. AS A SAFETY PRECAUTION.

• If BOP is to be retrieved put the riser connector to lock, and wellhead connector to the latch position. Then put manifold pressure at pod reel to minimum 1500 psi.

• Go to Koomey Unit, place all four way valves into the block position, bleed off regulators, place regulator selectors to block position.

• Remove junction boxes from hose reels and activate hose reel functions.

• You are ready to go about with your BOP stack operation.

b) To deactivate the hot line system if the BOP is down:

• Mate on junction box, make sure air to motor and lock pin on reel is engaged.

• Go to unit, place all 4 way valves into the drilling mode (rams open, annular open, failsafes closed and (Connectors locked).

• Select mode of operation for the regulators (electric or manual). Set regulators to drilling pressures.

• Go to the reel and secure the manifold regulator shut off valves.

• Bleed down regulators.

• Place 4 way valves into the block position.

• Secure manifold supply shut off valve.

c) To secure the reel hot line system if BOP is on deck:

• Secure ball joint and manifold regulator shut off valves.

• Bleed down regulators.

• Place 4 way valves into block position.

• Secure manifold supply shut off valve.

d) A few comments about the Pod Reel hot line system:

• To avoid any confusion at the pods, always use the reel hot line system on the pod that is on line.

• The hot line system is not to be used when the reels junction boxes are mated.

• The 4 way valves are of the selector type.

Troubleshooting: SPM Failure

1) 42 Line Pod

Scenario: B.O.P. on beams ready to be run or at the wellhead and a function fails to operate. What should be done?

a) If no fluid flow is indicated by the flowmeter check the following:

• The Pod selector valve is selected to proper pod.

• The Regulator pressures: manifold and annular regulator selectors are in proper mode and both regulators have the right amount of pressure on them -Check read back gauges to verify.

• Pod reel junction box is on and secured.

• Pod reel hot line system is secured. To do this check:

a) 4 Way valves are in block position.

b) The Pod reel shut off valves (manifold supply, manifold regulator and the prehistoric ball joint regulator if still in use) are closed.

c) The Regulators are bled off.

b) Switch pods, try same function again (same panel):

• If function works this tells you that your problem is between the RBQ’s (for that pad that did not work) at Koomey Unit to the shuttle value going to that function.

• If function still does not work check out:

a) Air pressure at Koomey Unit.

b) Electricity to unit (proper current, voltage).

c) Obstructions that may stop the 4 way valves from working.

c) Try function again from another source and if the function works then check out:

• Panel which would not operate: The easy way to check out the solenoid is to disconnect the air fitting to air piston. `Try functioning again and you should get a shot of air. If you don't check out the electrics for that function and solenoids. (Electrical box right hand side of main control panel).

• If function still doesn't work review steps 1 a

• If the function did work on the other pod, switch back to the pod which is malfunctioning.

d) Try functioning it again, if it still doesn't work:

• Go to pod reel, find proper pilot line and disconnect it on the inside of the reel so that you can see if the signal is getting through the junction box check valves. Be sure pod hose reels are locked out and can not be rotated.

• If you are getting a good pilot signal through, then the signal you are getting should be a good one at the pod. Obviously a leaking pilot line in the hose bundle can prevent the signal lifting the SPM.

• If you don't get a signal here, reconnect pilot line and disconnect it on the outside of the pod reel before the check valves, if you get a signal here then either the male or female check valve is damaged -change out the check valve.

• If you don't get a signal, go to Koomey unit and inspect the check valves on the RBQ and also check to see if the correct pilot line is hooked up between the unit and pod reel.

e) If you are getting a good pilot signal to the pod:

• Try another function that will use the same regulator on the pod to determine if the regulator is shot.

• If the other function works you can be fairly sure that:

a) The SPM is not working.

b) The shuttle valve is jammed and not allowing the fluid flow to the function.

c) Or the component functioned is inoperable.

f) If at anytime that you operate the function and the fluid flow doesn't stop and the function works on the other pod then you have a broken hose or connection on the pod side to that particular function.

Once you have the problem isolated to an SPM, then the only operation to pull the pod (see section on PULLING A POD).

• After pulling the pod, repairing the SPM, function testing it on surface, rerun the pod. Use a T.V. camera, don't stab it blind.

• Function test pod.

• If the function still doesn’t work from any source, the shuttle valve must be jammed. Depending on the particular function, wellhead connector, shear or pipe rams, failsafes, or lower annular then both halves of the BOP will have to be pulled. If the riser connector, upper annular, or choke and kill connector SPM1S fail then your only need to pull the L.M.R.P. section to surface.

g) Basically a function needs only 4 requirements to be fulfilled and they are:

• The regulators need a continuous feed of high pressure fluid (3000 psi).

• A Pilot signal to the regulator telling it what pressure to reduce the 3000 psi

• A pilot signal (3000 psi) to the SPM, to lift it off its seat.to.

• An uninterrupted means of letting regulated fluid to the function (hose, shuttle, valve).

• If you can be sure these requirements are met then it can only be 2 things:

the SPM or the function (ram operator, annular assembly, failsafe or connector pistons).

Final Note:

Remember that the manner and way you troubleshoot your control system problem is vital to the rigs safety. How you derive the problem will determine whether you require to make a surface repair, pull a pod, pull the L.M.R.P. or pull the complete BOP stack. Therefore know your system well.

Troubleshooting: Leaks and Malfunctions