Hydril Deepwater Drilling System

Deepwater Drilling SystemReliable to the Extremes


Runs for an entire year with zero downtimeA Hydril stack has stayed on the seabed for 364 days, with the stack pulled just once to escape a hurricane. While such performance is exceptional, it’s hardly unique for Hydril. Our standard design can provide one year of operation with zero downtime: • All subsea components certifi ed for an operational depth of 12,500 ft. • Mechanical and electrical components designed for 20-year design life.• Designed and manufactured in accordance with API 16A, D, E, NFPA 70 (NEC), NFPA 496, ISO and more.

Time saving modular designFrom factory acceptance testing (FAT) to installation and commissioning, Hydril’s true modular design optimizes time upfront and minimizes downtime throughout the life of the system. Additional benefi ts include:• Greater commonality between systems.• Easier troubleshooting: Quickly narrow down failure to a single module.• More effi cient maintenance, part replacement, manufacturing and delivery.

Hydril Deepwater Drilling SystemReliable to the Extremes

Hydril: A Deep Commitment to Blowout Prevention

The annular blowout preventer. The fi rst hydraulically operated blowout preventer (BOP), and a history of record-

setting and market-changing technologies that reaches back to 1933. At Hydril, we work to increase the world’s

energy potential, and we do so by designing, manufacturing and marketing the tools and technologies that

protect both the environment and oilfi eld personnel.

Wherever drilling meets high pressure, high temperature (HPHT) extremes, the biggest names in the business rely

on Hydril Pressure Control. Our shallow-to-medium depth, piloted subsea systems and high-quality surface BOP

control units make easy work of demanding applications in extreme environments. And in the critical deepwater

environment, the Hydril Deepwater Multiplex (MUX) BOP Control System repeatedly sets benchmarks for reliability

and time spent on bottom.

Count on Hydril to continuously redefi ne reliability, with best-performing, world-class, industry-leading systems.

Pushing the Limits

Reliable BOP technology combined with advanced hydraulic circuit design, state of the art hardware and software

design, robust materials and complete lifecycle support ranks Hydril systems among the most technically superior

deepwater drilling systems in the world. Our current system can be confi gured to reach 12,500 ft below sea level,

but we won’t stop there. Look to future Hydril technologies to push both HPHT and water depth capabilities.

A never-satisfi ed position on technological advances combined with a commitment to quality, performance and

excellence has made Hydril synonymous with world class blowout prevention.

Works easily with a broad range of equipment Hydril systems are as fl exible as they are durable. Our commitment to open architecture means we can adapt the Hydril MUX BOP control system to manage multiple stack confi gurations and interface with other shipboard computer systems, including DP systems, installation and workover interfaces, tree-handling systems and more.

Battle-tested and universally certifi ed softwareMore than 50 man-years have gone into developing the full life cycle of our software. Hydril meets the certifi cation and compliance guidelines for every applicable international standard.

Full lifecycle reliability studies and testingExtensive system tests subject all components to real-world work environments—those environmental extremes encountered by our customers—including:• Subsea Electronic Module (SEM) Electronics: Vibration and shock subsea and extreme temperature testing on the deck.• All electronics assemblies and major components are extreme temperature rated.• Pod SPM valves, shear seal pilot valves and regulators: Life cycle testing performed.• All pod components: Tested at 5,600-psi external pressure at ambient and low temperatures.

Integrated testing of the complete control system before shipmentWe can conduct complete end-to-end testing of the stack, pods and MUX control system in our deepwater assembly building. In our control system test lab we can load any system’s software and troubleshoot issues that are occurring in the fi eld, shortening downtime and providing as close to a real world working environment as possible.

Real time diagnostic and monitoring capabilitiesVital information is at your fi ngertips with these system displays:• Event Screen: View a sequence of events without ever having to access a database or archival system. All digital events including commands, solenoid states and pressure switches are displayed in real time on the event screen.• Active Alarms Screen: Continuously maintain observance of any system issues. The active alarms screen displays all active alarms in real time. • Alarm Log Screen: View in real time the conditions that caused an alarm to become active or inactive without accessing a database or archival system.• Network Topology Screen: View in real time a status display of processor, disk and memory utilization for all system nodes—those separate processors that exist on a network—and the network interface status for each network on all nodes. Examples of nodes include six (6) in the CCU (two (2) system controller, two (2) communication controller, and two (2) utility processors), two (2) in the driller’s panel, two (2) in the tool pusher’s panel, the HPU and the diverter.• System Confi guration Screen: View the online/offl ine status of all system nodes and all Hydril applications, as well as whether the applications are operating in primary, secondary or backup role. Also view the communication, master/slave and online/offl ine status of all SEMS.

Unparalleled safety features While each control system includes many features designed to maximize uptime, two independent options can also be added to increase operations safety under specifi c emergency conditions: Hydril AutoshearThe Hydril autoshear option adds valves to the MUX control pod and BOP stack, creating a hydraulic circuit that, once activated, performs automatic well shut-in under emergency conditions. In the armed state, the autoshear feature initiates when pilot pressure is removed from the hydraulic autoshear valve on the stack, as in the unplanned disconnect of the Lower Marine Riser Package (LMRP) from the BOP stack. Hydraulic fl uid from the stack mounted accumulators passes through the open valve to the close ports on the BOP, activating the blind shear rams to protect the well bore.

The Hydril Autoshear option satisfi es the requirements of the “Deadman” as defi ned in American Petroleum Institute publication 16D, Specifi cation for Control Systems for Drilling Well Control Equipment and Control Systems for Diverter Equipment. This occurs when the control pod suffers a catastrophic loss of both electrical power and hydraulicfl uid pressure, as in the case of the riser parting. Electrohydraulic (E/H) Backup SystemIn the rare event that the subsea BOP Control System is inaccessible or nonfunctional, an optional independent control system known as the E/H backup system can be used to initiate emergency disconnect operations.

The E/H backup system includes a small control panel powered by its own uninterruptible power supply (UPS) and dedicated conductors located in the MUX control cable that connect directly to specifi c circuits in the MUX control POD. The circuits in the control POD are dedicated to perform the minimum operations to allow the LMRP to disconnect from the BOP stack during these emergency situations. Users control the EH backup system with an E/H backup panel or through the E/H backup panel control screen on the toolpusher’s or driller’s panels. This option is often used as an alternative to an acoustic back-up system.

Hydril Service OrganizationTechnical solutions are a call, chat or handshake away through Hydril’s global network of certifi ed personnel: • 24/7/365 Service & Support Call (281) 449-2000 to request service—any day, any time. • Live! Chat Support In non-critical situations, log on to www.hydril.com for live customer support. • Field Service Whether it is a rig down, routine maintenance, new rig commissioning or anything in between, our service team is certifi ed to work wherever you may need them and available to you any hour of the day or night. • Remote Service Network (RSN) By joining the remote service network and purchasing the required hardware, customers gain access to remote diagnostic services by factory-trained Hydril technicians. To learn more about RSN, see Accessories. • Service Center Located within the Hydril Technology Center, the Service Center was designed specifi cally for the service and repair of control systems. A team dedicated to the management of purchased BOP maintenance

programs is also housed within the Service Center to assist customers with service and warranty work.• Training Hydril faculty combine comprehensive product knowledge, an understanding of our customers’ needs and the support of our engineering team into the hands-on and computer-based training available in our Technology Center. An experienced staff of instructors provides instructor- led, hands-on and computer-based training in our state-of-the-art facilities. From rig-specifi c to custom designed courses, our faculty can keep your personnel certifi ed in the use of all Hydril products and systems.

Visit www.hydril.com for access to additional support information.

MUXLIFE: Upgradeable System ComponentsExtend the life of your control system with a Hydril MUXLIFE upgrade. Hydril’s team of engineers and technical experts will personally assess your system, recommend appropriate surface electronics maintenance and/or upgrades and calculate the time required to implement the upgrades and optimize your system performance. All upgrades are performed on the rig with no docking required. Whether you need a new driller’s panel, pod electronics, UPS, or fi ber optic communications, Hydril can upgrade your electronics to maximize the life of your system.

Energy, Safety, ProtectionAt Hydril we have built our reputation on a commitment to increase the world’s energy potential through technologies that protect both natural resources and oilfi eld personnel. Our deepwater multiplex BOP drilling systems represent the very best of successive generations of innovation and experience. We continue to write the book on blowout prevention, and our story is one of reliability, quality and consistency.

Hydril System Features and Benefi tsHydril pressure control equipment typically stays on the job for decades. Why? Read on.

Hydril Pressure Control3300 N. Sam Houston Pkwy. E.Houston, Texas 77032-3411

PHONE: 281.449.2000FAX: 281.985.3480www.hydril.com

® 2008 Hydril Pressure Control

















Pushing the Limits








































Pushing the Limits








































Pushing the Limits








































Pushing the Limits
























SURFACE COMPONENTS:1) Automatic Hydraulic Power UnitsRapidly charge the accumulator banks with the electric motor-driven positive displacement hydraulic pumps in Hydril’s pumping units. Designed to meet customer specifi cations and applicable regulations, each power unit offers ease of use, long service life and the functions and refi nements born of many years’ experience. Features include:• Three (3) electric motor-driven pumps per standard pump unit.• Identifi ed connections for rapid installation and easy inspection.

2) Fluid Reservoir Unit (FRU)/Mixing SystemHydril’s FRU/Mixing System pumps the proper mixture of hydraulic fl uid concentrate, water and antifreeze from storage reservoirs into the mixed control fl uid reservoir, providing the necessary lubricity and freeze protection to maintain reliable BOP stack operations and long service life. Electrically driven metering pumps are mounted with the reservoir assembly.

3) Accumulator BanksThe Hydril nitrogen-oil separator type accumulator is ideal for furnishing the hydraulic power to operate blowout preventers, valves and connectors from surface and subsea accumulator banks. When stripping drill pipe through closed annular blowout preventers or dampening quick acting control circuits, it also functions as a surge absorber.

4) Driller’s Control PanelAchieve full system control at the driller’s control panel. As the primary control station it provides for full control of the BOP stack and selected auxiliary functions. The panel design permits well control operations as required, even in adverse conditions. Units can be provided to meet requirements for hazardous area operation and all specifi cations and regulations.

5) Toolpusher’s PanelDesigned for operation in safe (non-hazardous) areas, the toolpusher’s panel provides the same functionality as the driller’s control panel, and serves as a secondary control station.

6) Central Control Unit (CCU)The CCU provides a common communications interface point for all surface panels and the subsea MUX pods. The CCU is designed to operate in safe (non-hazardous) areas. It contains control computers and network equipment and serves as a third control station.

7) Uninterruptible Power System (UPS)Should a power failure occur on the rig, the UPS provides a 2 hour minimum emergency power reserve for remote control panel operation and instrumentation. The system includes heavy-duty batteries, a rack and a battery charging control unit. It provides electricity to all electrically powered components with the exception of the electric motors.

8) Power Distribution Panels (PDP) Control the fl ow of power to and from each component of the MUX control system with the PDP. Our unique system architecture provides maximum reliability of quality power, ensuring that a power surge or loss of a major power bus will not affect operation.

9) Hose/Cable ReelsHose and cable reels provide live function and assured control of the hose or electric cable during running and retrieving operations. Reels are also available with constant torque winches for constant tension on cables and hoses.

10) Hydril FS™ 21-500 Marine Riser DiverterHydril diverters are known for signifi cantly enhancing safety and rig protection. The FS 21-500, in particular, is fundamentally simplistic, designed to avoid the functional complexities that increase the chance for human error and equipment breakdown. With models available for use with 49-1/2” and 60-1/2” rotary tables, the FS 21-500 is readily adapted to fi t virtually any rig confi guration. Moreover:• It closes on the open hole, eliminating a serious safety gap caused by cartridge inserts. • It is used in conjunction with the Seal-All™ Diverter Insert to enhance safety further. • The patented integral valve design eliminates sequencing of diverter valves and simplifi es the control system’s need to operate the diverter system. • There is no stagnant vent line space, caking of solids or ice formation that could obstruct or shut off the fl ow. • Both models are rated for 2 million lbs up or down loading.

SUBSEA COMPONENTS11) Hydril Blowout Preventer StackHydril invented the annular BOP and the hydraulically operated BOP. Since 1933 Hydril has been redefi ning reliability and pushing the limits of BOP technology. The deepwater BOP stack can be confi gured with a variety of Hydril’s proven BOPs.

12) Multiplex Control PodThe unique wedge-shaped Hydril subsea control pod assembly includes a male pod and female receiver and houses the subsea valve control manifold. The compact design features subplate-mounted control valves and pressure regulators for all subsea hydraulically controlled functions—96 in all. Two control pods on each stack provide system duplicity, and one receiver attaches to the Lower Marine Riser Package (LMRP).

13) Shuttle ValvesLong life, dependable Hydril shuttle valves compatible with the control system are available in 1 1/2”, 1” and 1/2” sizes.

14) Subsea Accumulator Racks Stack-mounted accumulator banks are equipped with a common header—these subsea racks are hinge-mounted to the BOP Stack frame and swing clear of BOP components for ease of inspection and maintenance. If required, an option using large volume bottles (80, 160 gallon) eliminates the need for swing frame racks.

15) Subsea Electronics Module (SEM)The two SEM units located on each control pod provide a fully redundant system for control of all subsea valve operations and all communications with the central control unit (CCU).

16) Gas Handler™ Hydril diverter systems are designed for strength and simplicity to provide safe venting of shallow gas fl ows. Located below the telescopic joint, the Gas Handler (GH) adds capabilities to standard diverter systems. The GH is a specialized annular closing device installed as part of the riser string for deepwater drilling. It allows the operator to circulate out gas entrapped in the riser string without the requirement to vent mud and/or gas overboard. This product has quick response time, a low risk of malfunction and several other

unique features and benefi ts that include:• A 21” bore for easy passage of casing and well bore tools. • Available in both single and dual confi gurations. • Economical, easy installation, recovery and maintenance; the GH installs as a standard riser joint. • Adaptable for any rig or riser system. • Enhances safety for personnel and the rig.

17) Riser Fill-Up Valve The Hydril Riser Fill-Up Valve prevents collapse of the subsea riser wall due to a sudden evacuation of drilling fl uids from the riser. Sudden evacuations can occur during unplanned events such as a disconnect of the LMRP or a failure in the lower riser section. The Hydril Riser Fill-Up Valve backfi lls the drilling riser with seawater as heavier drilling fl uid evacuates the riser from the bottom. This prevents creation of a vacuum inside the riser that would collapse it. The Fill-Up Valve can be set to open automatically due to a sudden pressure differential inside and outside the riser, or it may be operated manually.

ACCESSORIES18) Acoustic Control System (Emergency)Similar to the E/H backup system, the acoustic control system has a separate stack-mounted acoustic pod for performing emergency disconnect operations. The system uses an acoustic link from the surface rather than the dedicated electrical circuits used by the E/H backup.

19) Cable/Hose Reel Control ConsoleEach of the two (2) Multiplex Cable Reels and one (1) Hot Line Reel are controlled from the freestanding control console. Manufactured from mild stainless steel, the console provides for the mounting of the control valves, gauges and indicators.

20) Cable/Hose SheavesThe half-moon MUX cable sheaves are appropriately sized to the outside diameter and minimum bend radius of the cables/hoses.

21) Diverter Control PanelThe diverter control panel is a skid-mounted unit that actuates solenoids for the pilot-operated control of diverter valves. The unit contains a processor with network connection to the CCU for remote control, as well as full local control via valves and gauges.

22) Electro-Hydraulic (E/H) Backup PanelThe E/H backup panel enables emergency disconnection should the surface BOP control system become non-functional. The system employs hardwired circuits to the MUX control pods for initiating disconnecting functions.

High Pressure High Temperature (HPHT) Probe (not pictured)The system uses an HPHT Probe to monitor well bore pressure and temperature. It will be mounted on an unused outlet of the lower Pipe Ram of the BOP stack. All components that come in contact with the well bore fl uid meet NACE MR01-75 requirements.

High Pressure High Temperature (HPHT) Probe Assembly (not pictured)The pressure/temperature probe is a 4-20mA device that interfaces to the blue and yellow pod electronics through the Remote Terminal Unit (RTU) (see below). Design specifi cations follow:• Environmental media: Seawater and well bore fl uid.• Hyperbaric (external) pressure rating: 5,700 psi.• Operating temperature: 0-150 degrees C (process media).• Pressure sensor range: 0-25,000 psia operating.• Pressure reference: Absolute.

23) Remote Service Network (RSN)The remote service network (RSN) and hardware allow Hydril technicians anywhere in the world to login to a customer’s system through the Internet for diagnostic purposes. The network is a link between the Hydril control system network and the rig’s satellite communications network system.

How does it work? A Hydril technician can log onto the Hydril control system network on a rig anywhere in the world by connecting through the ISPs to the land-based satellite uplink location nearest the rig. The satellite link then completes the path from shore to the rig satellite communications network and to the control system network. RSN features and benefi ts include:• Remote diagnostics of the control system.• Reduces or eliminates automatic need for service trip.• Download of software upgrades via link.• Faster service response to system problems.• End of well fi le maintenance and system check up.• Save or eliminate downtime days.

Remote Terminal Unit (RTU) (not pictured)The RTU is the serial communications module for reading the 4-20mA signals from the HPHT probe and converting them to signals that are communicated to the MUX pod. The housing is constructed of stainless steel and can withstand 15,000 psi external pressures while maintaining a one-atmosphere internal environment. The electrical connectors are two (2) 4-pin and one (1) 8-pin FCR type with face and radial o-ring seals.

Subsea Accumulator Pressure Transducer (not pictured)The pressure transducers are absolute pressure strain gauge type, temperature compensated, and packaged in a three (3)-section stainless steel housing with redundant seals at each housing section. Each pressure transducer is calibrated to determine the necessary offset for both the lower and upper roll off. Specifi cations follow:• Range: 0 - 10,000 psi.• Temperature Limits Operating: - 30 to + 180 deg F.• Compensated Range: 0 to + 160 deg F.• Overpressure Limits Proof: 150% or 20,000 psi. Burst: 200% or 25,000 psi.

24) Surface/Subsea Electronic Riser Angle System (ERA)The Surface and Subsea ERA provides real time monitoring of the riser angle using angular deviation sensors. The control pods contain gyroscopes for measuring stack rotation, and information from the two systems is displayed in graphical plots on surface workstations.

Deepwater Drilling System ComponentsThe Hydril subsea MUX control system supplies and controls the fl ow of hydraulic fl uid for actuation of the subsea BOP stack functions. The system includes surface components, the connecting control MUX cable/hose components and subsea components.

Annular Blowout Preventers:25) GX® Annular BOPExpect more closures, stripping and uptime. Drilling contractors have called the Hydril GX® “the best annular in the business” for one reason: exceptional uptime. Its single packing unit has provided continuous service for as long as a year, and it has continued to hold pressure after exposure to extreme temperatures and extensive stripping. In the fi eld and in laboratory tests, GX units have:• Passed an ABS-witnessed, 10,000-psi API pressure test at 270° F. • Stripped more than 30,000 ft of 6-5/8” drill pipe with 8-1/4” tool joints. • Stripped 300,000 ft of 5” drill pipe with 6-3/8” tool joints. • Held pressure in the fi eld after 328 closing cycles plus stripping.

Annu-Flex™ (not pictured)A variation of our GX annular BOP, Hydril’s Annu-Flex combines either a single or dual subsea annular blowout preventer with a maintenance-free, fl exible underwater riser joint. Together, the BOP head/fl ex joint combination reduces overall stack height and requires fewer stack connections. Additionally, the Annu-Flex offers rapid and economical maintenance, simple and reliable operations, and long service life.

Ram Blowout Preventers:Quik-Loq™ BOP (not pictured)Change rams and resume drilling fast. Well suited for surface and subsea operations, the Boltless™ Hydril blowout preventer, the Quik-Loq, radically reduces downtime while enhancing safety and environmental protection. It accomplishes these goals in part by:• Minimizing personnel exposure to safety hazards that are inherent to BOP maintenance on the rig by eliminating the need for tools and rigging. • Allowing changeout of rams and/or operator assemblies in a matter of minutes rather than hours. • Using Boltless bonnets, redundant operator seals, and redundant rod seals.

26) Compact™ Ram BOPHold pressure at 15,000 psi from 30° F to 500° F. The 18-3/4”, 15,000-psi Hydril Compact Ram BOP delivers proven reliability for safe operation in the harshest environments. Rated for water depths to 12,500 ft, the Compact Ram has worked on the seabed continuously for one year during drilling of a 34,000-ft well. It also can add hundreds of hours of drilling time annually when confi gured to seal upside-down as a Subsea Stack Test Valve (SSTV) so that required pressure tests can be completed with the drill pipe in place. In the lab, this BOP has:

• Held full rated working pressure at 300° F for 8 hours using blind/shear rams. The tested unit then completed 3 additional closing cycles at low and high pressure. • Passed API temperature testing to 350° F using blind/shear rams. • Passed API temperature tests to 500° F using 5” fi xed-bore rams. All fi xed-bore ram sizes on the 18-15 Compact Ram are rated for this temperature. • Passed API pressure tests at temperatures as low as 30° F for 5-1/2”-7-5/8” and 4-1/2”-7” variable rams. • Sheared large-diameter pipe (16”, 109 lb-per-ft, P-110) using optional, high pressure, 4,000 psi, 22” operators.

Conventional Ram BOP (not pictured)The 18-3/4”, 15,000-psi Hydril Conventional Ram BOP delivers the same proven reliability as the Compact Ram for safe operation in the harshest environments. It is also rated for water depths to 12,500 ft.

123

21

HPTU Skid

HPTU Controller & VFD Subsea Workstation

Diverter Storage Base

Datalogger23

GPS Unit

6

5Power Isolation J-Box

4

1822

Blue Subsea XFMR

Blue J-Box MUX Umbilical

Surface ERA J-Box

19

9

20Diverter Fill-Up Valve

Diverter Flowline Valve

10Diverter Vent Line Valve

Flow Selector

20

Goosenecks

Yellow J-Box MUX Umbilical

Yellow Subsea XFMR

High Pressure Test Unit (HPTU) System

9

16

17

2411

25

26

13

14

15

12

18

18

77 8

















Pushing the Limits
























Documents

Hydril Deepwater Drilling System