DRAWNBY DATE: John T. Mangan Nov. 12, 2001 X-208744-01 APPROVED BY DATE: PAGE | OF 7 CAMERON | MF. Whitby Nov. 12. 2001 (File: X-208744-01.doc / Disk# 4) FUNCTION PROCEDURE FOR “TL” BLOWOUT PREVENTER (BOP) BONNET ASSEMBLIES WITH RAMLOCKS (or RamLocks with Sequence Valves) RamLocks were designed and developed in the late nineties in order to supplement the ST-Lock with a simpler, lighter, reliable locking device with a greater locking range for the Cameron TL BOP. After early teething problems, the RamLock has proven to fulfill its design criteria, though the teething problems have taught that some critical routines must be followed in this operation. (1) Therams should never be opened or closed unless the secondary (RamLock) chamber is completely filled with fluid (ie. Locking one set of 10M RamLocks takes 7.63 gallons and to Unlock takes 8.13 gallons). The flow meter should be monitored during operation to ensure that volumes are correctly recorded before attempting to proceed with operating the rams. (2) After any maintenance work has been carried out on a bonnet, the RamLock chamber must be thoroughly purged of air (following the multiple pressure procedure). (3) Some systems make use of sequence valves. These valves must be fitted with the latest metal-to- ‘metal poppets and should be regularly inspected. If these valves leak, then the RamLock may attempt to lock prematurely. (4) Each system is different, so the times that are written in the software to interlock the functions may vary with each installation. ‘These times must be checked by experimentation . (These interlocks are to protect the system in the event that Step 1. was not carried out correctly.) ‘The purpose of this procedure is to provide step-by-step instructions on purging air from the ram Jock bonnet operating system and to test the bonnet before installing on the BOP. The hydraulic operating fluid for the function test shall be a hydraulic equipment preservation fluid able to withstand —40 degrees Fahrenheit without freezing. A. FUNCTIONING OF THE RAM LOCK BONNET ASSEMBLIES (NO SEQUENCE VALVE) (1) Bonnet assemblies should be in the open position prior to testing. Ifnot, apply pressure (a minimum of 1500 psi) to the unlock/lock port. Apply pressure (200 psi) to the open side in order to open the bonnet. (2) Apply a minimum of 1500 psi to the unlock/lock port with close port vented. (3). Apply 400 psi to the close port. Allow connecting rod and ram change pistons to fully extend, Keep pressure on close port. (4) Vent the unlock/lock port. The close pressure will drop momentarily. Allow it to CAM.356DRAWN BY DATE: John T. Mangan Nov. 12, 2001 X-208744-01 [APPROVED BY DATE. PAGE 20F 7 CAMERON | MF. Whitby Nov. 12, 2001 retum to 400 psi. The bonnet assembly is now locked. (5) Vent the close port. (6) Apply a minimum of 1500 psi to the unlock/lock port. NOTE Allow the unlock/lock chamber to fully pressurize each time pressure is applied to the unlockock port. The pressure should be steady as flow occurs, then rise to the applied pressure. If pressure spikes very rapidly without a momentary drop, the lock is not functioning properly. (7) Apply 400 psi to the open port with close port vented. (8) Repeat steps 3 through 7 for a total of 3 cycles. (9) Apply a minimum of 1500 psi to the unlock/lock port with close port vented. (10) Apply 800 psi to the open port with close port vented. Allow connecting rod and ram change pistons to fully retract. (11) Apply 800 psi to the close port with open port vented. Allow connecting rod and ram change cylinders to fully extend. Keep pressure on close port. (12) Vent the unlock/lock port, The close pressure will drop momentarily. Allow it to return to 800 psi. The bonnet assembly is now locked. (13) Vent the close port. (14) Repeat steps 9 through 13 for a total of 2 cycles. (15) Apply a minimum of 1500 psi to the unlock/lock port with close port vented. (16) Apply 1200 psi to the open port with close port vented, Allow connecting rod and ram change pistons to fully retract. (17) Apply 1200 psi to the close port with open port vented. Allow connecting rod and ram change pistons to fully extend. Keep pressure on close port. (18) Vent the unlock/lock port. The close pressure will drop momentarily. Allow it to return to 1200 psi. The bonnet assembly is now locked. (19) Vent the close port. (20) Apply 1500 psi to the unlock/lock port. (21) Apply 1500 psi to the open port with close port vented, Allow connecting rod and (CAM-356DRAWNBY DATE John T. Mangan Nov. 12, 2001 ‘X-208744-01 APPROVED BY DATE: PAGE 3 OF 7 CAMERON | MF. Whitby Nov. 12, 2001 ram change pistons to fully retract. (22) Apply 1500 psi to the close port with open port vented. Allow connecting rod and ram change pistons to fully extend. Keep pressure on close port. (23) Vent the unlock/lock port. ‘The close pressure will drop momentarily. Allow ito retum to 1500 psi. The bonnet assembly is now locked. (24) Vent the close port. (25) Apply 1500 psi to the unlock port with the close port vented. Allow it to fully unlock. B. _ FUNCTIONING OF THE RAM LOCK BONNET ASSEMBLIES TO ENSURE PROPER OPERATION PRIOR TO INSTALLATION ON BOP. NOTE — At each stage the unlock pressure should be equal to or greater than the open or close pressure. (1) Bonnet assemblies should be in the open position prior to testing. Ifnot, apply pressure (a minimum of 1500 psi) to the unlock/lock port. Apply pressure (200 psi) to the open side in order to open the bonnet. @ Apply minimum of 1500 psi to the unlock/lock port with close port vented, (3) Apply 1500 psi to the close port. Allow connecting rod and ram change cylinders to fully extend. Keep pressure on close port. (4) Vent the unlock/lock port. The close pressure will drop momentarily. Allow it to return to 1500 psi. The bonnet assembly is now locked. Wait approximately 20-30 seconds after flow has stopped. (5) Vent the close port. NOTE — Allow the unlock/lock chamber to fully pressurize each time pressure is applied to the unlock/lock port. The pressure should be steady as flow occurs, then rise to the applied pressure. If pressure spikes very rapidly without a momentary drop, the lock is not functioning properly. (6) Apply a minimum of 1100 psi to the unlock/lock port. If it unlocks, raise the pressure to 1500 psi in preparation to open the bonnet. If 1100 psi is not sufficient, apply 1500 psi to the unlock port and wait until fully unlocked. (7) Apply 1500 psi to the open port with close port vented. (8) Apply a minimum of 2000 psi to unlock/lock port with close port vented. CAM-356DRAWNBY DATE John T. Mangan, ‘Nov. 12, 2001 APPROVED BY DATE: CAMERON | MF. Whitby: Nov. 12, 2001 TREVSION X-208744-01 2 PAGE 4 OF 7 (©) Apply 2000 psi to the close port with open port vented. Allow connecting rod and ram change cylinders to fully extend. Keep pressure on close port. (10) Vent the unlock/lock port. The close pressure will drop momentarily. Allow it to retum to 2000 psi. The bonnet assembly is now locked. Wait approximately 20-30 seconds after flow has stopped. (11) Vent the close port. (12) Apply a minimum of 1500 psi to the unlock/lock port with close port vented. Ifthe lock unlocks, wait until it is fully unlocked and raise pressure to 2500 psi. (13) Ifthe lock does not unlock, raise pressure to 2000 psi to unlock, then wait until fully unlocked. (14) Apply 1500 psi to the open port with close port vented. Allow connecting rod and ram change cylinders to fully retract. (15) Apply 2500 psi to the close port with open port vented. Allow connecting rod and ram change cylinders to fully extend. Keep pressure on close port. (16) Vent the unlock/lock port. The close pressure will drop momentarily. Allow it to return to 2500 psi, The bonnet assembly is now locked. Wait approximately 20-30 seconds after flow stopped. (17) Vent the close port. (18) Apply 1500 psi to the unlock/lock port and wait until fully unlocked and flow has stopped. (19) Ifthe lock does not unlock, raise the pressure to 2500 psi and unlock. (20) Apply 1500 psi to the open port with close port vented, Allow connecting rod and ram change cylinders to fully retract. (21) Apply 3000 psi to the unlock chamber, (22) Apply 3000 psito the close port with open port vented. Allow connecting rod and ram change cylinders to fully extend, Keep pressure on close port.DRAWNBY DATE: John T. Mangan Nov. 12, 2001 X-208744-01 APPROVED BY DATE: PAGE 5 OF 7 CAMERON | MF. Whitby Nov. 12. 2001 (23) Vent the unlock/lock port. ‘The close pressure will drop momentarily, Allow it to return to 3000 psi. The bonnet assembly is now locked. Wait approximately 20-30 seconds after flow has stopped. (24) Vent the close port. (25) Apply1500 psi to the unlock port with the close port vented. If'the lock unlocks, wait until it is fully unlocked and raise the pressure to 2000 psi. (26) If it does not unlock, then raise the pressure to 3000 psi and apply to unlock port. C. OPERATING INSTRUCTIONS FOR BOPs EQUIPPED WITH RAMLOCKS (1) Functional Overview ‘The Cameron RamLock is a mechanical locking device integral to the BOP operating system. ‘The operator or bonnet has three pressure chambers: (a) Open chamber (b) Unlock chamber (©) Closing chamber In normal operation, the Unlock chamber is kept pressurized in order to prevent accidental or unnecessary locking of the operator. In order to Lock the BOP, the Unlock chamber is vented to allow closing pressure to effect a Lock. (2) Initial Start-Up ‘Cameron BOPs equipped with RamLaocks should be completely purged of air before commencing any regular operation. ‘This may be accomplished by Low pressure (500 psi) cycling, Close, Lock, Unlock, Open and ramping up in 500 psi increments to normal operating pressure (1500 psi). CAUTION ~ Failure to adequately purge air from the operating system may result in erratic performance of the RamLock mechanism. (3) Hotline Operation For ram block and or cavity maintenance, the BOP can be operated using hotlines from a local hydraulic source. It is recommended that the Unlock supply be fitted with a needle valve that, after supplying unlock pressure (equal to or greater than the closing pressure), can be closed and the Unlock pressure locked in, The BOP can now be functioned Close and Open in order to open and close the bonnets of the BOP hydraulically, CAM.356DRAWNEY DATE: PROPERTY OF John T. Mangan Nov. 12, 2001 X-208744-01 APPROVED BY DATE: PAGE 6 OF 7 CAMERON | MF. Whitby Nov. 12. 2001 (4) To Close the BOP Dependant on the type and arrangement of the control system the close operation of the BOP can be controlled in a number of different ways, however the sequence of the operation SHALL follow these parameters. (a) Prior to initiating the close function, the Unlock supply should first be initiated. (b) Following initialization of the Unlock supply, the Close function can be initiated. CAUTION — Closing the BOP without pressure equal to or greater than the Close function may cause damage to the BOP operating system and or locking mechanism (5) To Open the BOP Assure that the BOP has NOT been locked, while Unlocked the Open function may be initiated at any time after a Closure. In the Unlocked state the BOP may be Closed and Opened at will. (6) To Close and Lock the BOP Following the normal procedure to Close the BOP stated in paragraph 4.0 above, the BOP can be locked if desired. This is accomplished by the removal or venting of the pressure in the Unlock chamber. The initiation of this Lock function will allow Closing pressure to Lock the BOP in the Closed position. CAUTION — Attempting to Lock the BOP prior to the Close function being completed (premature locking), may cause damage to the operating system and or locking mechanism. After closing and locking the BOP, it is recommended that the Close function be vented or removed PRIOR to the application of wellbore test pressure, CAUTION — Failure to vent closing pressure prior to application of wellbore test pressure may result in a higher than normal Unlock pressure being required to Unlock the BOP. (7) ToUnlock and Open the BOP Prior to opening the BOP after being locked, the RamLock MUST first be Unlocked. This is accomplished by supplying pressure to the Unlock chamber. Confirmation of the Unlock can be accomplished by careful monitoring of the flow meter. CAUTION —~ Attempting to open a BOP before Unlocking will result in the rams not functioning. No damage should occur, however a higher than normal Unlock pressure may result. After the RamLock is fuully unlocked, the open function may be either manually or automatically CAM.356DATE fer ot X-208744-01 PAGE 7 0F 7 DATE: CAMERON | MF. Whitby Ceca, CAUTION ~ Premature initiation of the Open function before the RamLock is fully Unlocked may result in damage to the operating system and or locking mechanism. D. OPERATING INSTRUCTIONS FOR RAMLOCK BOPs FITTED WITH SEQUENCE VALVES (1) Funetional Overview BOPs equipped with RamLocks fitted with sequence valves can, if necessary, be closed and locked simultaneously. The sequence valve negates the requirement to have Unlock pressure present when closing the BOP as the sequence valve will check fluid and or pressure in the Unlock chamber until such time as the BOP is closed. The sequence valve is then mechanically activated (by the operating piston) allowing the closing pressure to Lock the BOP in the closed position. This operation is especially usefill when operating the BOP with a ROV or acoustic package and can simplify EQD or EDS operation of any operator fitted with a sequence valve. 2) To Close and Lock the BOP ‘The Close function of the BOP can be accomplished as in Paragraph 4.0 above or if necessary be functioned in the following manner. (a) Vent Unlock supply pressure. (b) Initiate the Close funtion. NOTE — When sequence valves are present it is NOT necessary to supply Unlock pressure before initiating the Close function. (2.1) To Close the BOP using a ROV or Acoustic package. Follow the instructions as outlined in 2 above. (2.2) To Close the BOP as a function of an EQD or EDS. Follow the instructions as outlined in 2 above. 3) ToUnlock and Open the BOP