DRILLING BOP CONTROL SYSTEMS

Windlass BOP Control Systems meet or exceed the most stringent quality standards including American Petroleum Institute specifications API 16D, RP16E & RP53 to assure safe and reliable operation under critical conditions. We provide BOP Control Systems for both onshore and offshore applications worldwide as well as ATEX marked systems.

Our BOP Control Systems are custom designed and manufactured to meet customers’ requirements and certifications.

Our Design department is well equipped with the best tools and software for designing these units and each unit undergoes extensive tests and checks before dispatch to ensure trouble free operation to minimize rig shutdown time and ensure greater safety for the drilling crew.

We can also upgrade and refurbish an obsolete unit as per API 16D or any other similarly recognized standard. All of which are supported by the Windlass field service network of engineers and technicians with extensive knowledge of electrical, hydraulic and pneumatic systems.

Windlass BOP Control Systems are highly customizable. The following sections describe some of the options available on each subassembly. You can always contact us with your requirements and we can design the entire system for you.

ACCUMULATOR MODULES

The Accumulator Module consists of a welded structural steel skid assembly with a fluid reservoir, provisions for mounting the electric pump, air pump system, hydraulic control manifold, interface module and the type and quantity of accumulators.

M – Series

The M-Series Accumulator Module has standard features and is a quality economical choice

T – Series

The T-Series Accumulator Module has advanced safety features and is additionally equipped with a reservoir level sight gauge and 14 inch x 14 inch clean-out man-way for reservoir maintenance

ELECTRIC MOTOR DRIVEN PUMP MODULES

The Electric Motor Driven Pump Module is the primary source for generating hydraulic energy which is stored in the accumulators to operate the BOP stack. These pumps are offered in a variety of options and operating voltages to meet customer requirements.

Standard Electric Pump Module is designed for operation in hazardous locations where the presence of explosive gases is anticipated and includes automatic electric explosion-proof starters, motors and pressure switches. Electrical components that meet NEMA, NEC and UL specifications are standard in these modules

The Electric Pump Module is set to automatically stop when system reaches working pressure and restart when system pressure drops to 10% below working pressure

Each Electric Pump Module is sized to meet the greater of the following two conditions:

Close the specific annular preventer in use and open the hydraulic-actuated choke valve within two minutes (with the accumulators blocked)

Charge the accumulators from zero to working pressure in less than fifteen minutes

Type of Modules

T-SERIES

The T-Series Electric Driven Pump has a triplex plunger

The electric motor is horizontally mounted but can be vertically mounted over the pump in order to meet the length restrictions

The motor is mechanically coupled to the pump drive by a rugged chain and sprocket drive assembly specifically designed for the working horsepower of the assembly

The drive assembly is encased in an oil bath protective guard to ensure years of hassle-free operation

M-SERIES

This pump module has the same features as the T-Series but is limited to 20 Horsepower by plunger load design specifications

S-SERIES

This pump module has the same features as T-Series but comes with a special drive

AIR OPERATED PUMP MODULES

Air Operated Pump Module is the Secondary source used to provide high pressure fluid energy to charge the accumulator and operate the BOP stack functions.

Air Pump Module is supplied in many options to meet the specifications and economic requirements of the customer

The design performance ratios offered ensure that the rig air supply system is not overburdened while at the same time the system can still develop the hydraulic system operating pressure even in the event of low rig air pressure flow

Air Pump Module has a hydro pneumatic pressure valve which is set to stop the pumps at slightly below operating pressure and restart automatically when system pressure falls to approximately 400 PSI

Types of Modules

T-SERIES

This series features a Super Sixty (60:1) pump ratio with self adjusting packing and tungsten carbide valve seats driven by an 8-1/2" air motor producing the highest flow rate

M-SERIES

This series features the same fluid end design as the T-Series but with pumps available in 7-3/8" air motor

E-SERIES

This economy series maintains the ability to reach system opening pressure even if the rig air supply pressure is low. This module is available with a 6 inch air motor

UNIT MOUNTED HYDRAULIC CONTROL MANIFOLD

Types of Modules

T-SERIES

The T-series Hydraulic Control Manifold provides safe, dependable operation for control of the BOP stack utilizing and having the following features:

⦿ Sub-plate mounted control valves
⦿ Separate circuits provide independent pressure regulation and control for the annular preventer, ram and HCR valve
⦿ 1 inch full flow controlling annular preventer for up to 36 gallons closing capacity and 1-1/2 inch for over 36 gallons
⦿ The manifold functions are supplied through the 3 inch machined manifold rated for 3,000 PSI or 5,000 PSI working pressure
⦿ The internal override feature of the regulator permits immediate working accumulator pressure to the manifold, doubling the closing force on the rams in an emergency
⦿ The manifold directional control valves and outlet piping to the preventers are rated for 3,000 PSI or 5,000 PSI working pressure
⦿ These manifolds are available with glycerin-filled, panel-mounted, direct reading gauges indicating manifold regulated, annular regulated and accumulator pressures
⦿ When hydro-pneumatic valve by-passes are selected in the air pump assemblies, this series manifold can be used for testing up to 5,000 PSI and extreme well control problems

M-SERIES

The M-Series Hydraulic Control Manifold differs from the T-Series Manifolds only in that the control valves are directly plumbed into the circuits instead of being sub-plate mounted. This makes the unit easier to service and repair

These four way selector valves and manifolds are also rated for 3,000 PSI or 5,000 PSI working pressure

E-SERIES

The E-Series Hydraulic Control Manifolds are rated for 3,000 PSI. Outlet pipes to the BOP stack are rated for 3,000 PSI working pressure

REMOTE CONTROL PANELS

Located at a safe distance from the rig floor to ease space restrictions and increase safety, Remote Control Panels give the driller complete control of the BOP stack and provide intuitive operation of the BOP Control System with its hydraulic control manifold.

Types of Modules

DRILLER REMOTE PANEL

Easily accessible to the driller

This panel is located at the driller station and is capable of operating every BOP stack function, controlling regulated pressure to the annular preventer for stripping operation and is capable of immediately switching from regulated pressure to the full accumulator pressure to the RAM preventer. It can also provide additional closing force that may be required during extreme well control conditions

This panel includes gauges or meters for remote indication of the various operating pressures and open-close status of the manifold control valves position

AUXILIARY REMOTE PANEL

A second Remote Panel is recommended near the emergency exit or in a safe location from where the BOP stack can be controlled. Should the drilling crew have to evacuate the drill floor, they will still be able to operate all the BOP functions

At least one Remote Control Panel is required in order to comply with AP116 D, RP53, API- RP-16E.

Remote Panels used for offshore installations must have meters to indicate pressure, alarm indicators and position status indication at the driller’s position.

Types of Remote Control Panels

AIR REMOTE PANEL

Easily accessible to the driller

This panel includes gauges or meters for remote indication of the various operating pressures and open-close status of the manifold control valves position

ELECTRIC REMOTE PANEL

Electric Remote Panels provide remote control signals to the electro-pneumatic or electro-hydraulic interface module on the accumulator unit which in turn control the hydraulic control manifold functions

Electric Remote Control Panel ensures fast, dependable operations and minimizes installation requirements

Each electric panel includes an indicator light to indicate the function status of the hydraulic control manifold valves

Electric Remote Panels are available in weather proof, explosion-proof, air purge or intrinsic safe models

PLC REMOTE PANEL

PLC based Remote Control Panels have a programmable logic controller (PLC) which receives input signals from the BOP Control Unit, processes this information in real time using the structure and rules entered into the program and then issues control commands that operate the BOP Control Units. These PLC panels are designed to meet the recommendations of API RP/4F

Suitable for use in hazardous locations with option of pressurized enclosure or cast aluminum enclosure

All panel control functions are two handed to avoid accidental operation

Electrical components, panel etc. used in and exposed to hazardous atmospheres are designed as per API RP 500 and IEC529 and certified as suitable for use in hazardous locations

Panel display is physically arranged as a graphical representation of the BOP stack

Push buttons for open-close function with indicator lights for all BOP functions

Transparent safety cover which does not obstruct visibility of function is provided to avoid uninterrupted operation of critical functions

Audible and visual alarms indicate:

• Low accumulator pressure
• Low rig air pressure
• Low hydraulic fluid reservoir level
• Panel on standby power

Equipped with displays for the following:

• Accumulator pressure
• Manifold regulated pressure
• Annular BOP regulated pressure
• Rig air pressure

INTERCONNECT CABLE ASSEMBLIES

Air interconnect bundle assemblies are used to carry signals from the air operated remote control panels to the air interface assemblies on the accumulator unit

It includes a customer specified length of flame resistant multi-tube air bundle

The junction boxes consist of a hose half of an air junction box on each end which connects to the fixed plate halves mounted on the air panels and on the air interface assemblies

Electric Interconnect Cable Assemblies are used to carry signals from the electric control interface panels to the electric remote interface assemblies on the accumulator unit which includes customer specified length of electric cable terminated to cable connector plugs

Control Systems & Panels

Piping and Flow Control

Test Equipment

Seals, Rings, and Gaskets

Unions and Connectors

Hydraulic Systems

Valves and Manifolds