Odebrecht 1

(Norbe VIII)
Multiplex BOP Control System

Operation and Maintenance Manual

TC8225, Volume 7

Cameron International Corporation (“Cameron”)

P.O. Box 1212, Houston, TX 77251-1212, 713-939-2211, http://www.c-a-m.com
 All the information contained in this manual is the exclusive property
of Cameron International Corporation (“Cameron”). Any reproduction
or use of the calculations, drawings, photographs, procedures or
instructions, either expressed or implied, is forbidden without the
expressed written permission of Cameron or its authorized agent.

Initial Release 01
August 2010

Copyright © 2010 all rights reserved

by
Cameron International Corporation (“Cameron”)

TC8225, Volume 7 ii
PREFACE

The procedures included in this book are to be performed in conjunction with the
requirements and recommendations outlined in API Specifications. Any repairs to
the equipment covered by this book should be done by an authorized Cameron
service representative. Cameron will not be responsible for loss or expense resulting
from any failure of equipment or any damage to any property or death or injury
to any person resulting in whole or in part from repairs performed by other than
authorized Cameron personnel. Such unauthorized repairs shall also serve to
terminate any contractual or other warranty, if any, on the equipment and may
also result in equipment no longer meeting applicable requirements.

File copies of this manual are maintained. Revisions and/or additions will be made
as deemed necessary by Cameron. The drawings in this book are not drawn to
scale, but the dimensions shown are accurate.

This book covers Cameron products, which are products of Cameron International
Corporation (“Cameron”).

Cameron International Corporation (“Cameron”)

P.O. Box 1212
Houston, Texas 77251-1212
713-939-2211
http://www.c-a-m.com

TC8225, Volume 7 iii

Author´s Notes

This System Manual contains descriptions of the various control systems

equipment supplied by Cameron Drilling for the Drilling Rig Odebrecht 1
(Norbe VIII).

This system is an integrated system which is separated into Surface Equipment

that resides full time on board the ship, and SubSea Equipment that is
mounted on the Lower Marine Riser Package and the BOP Stack.

Bill of Material Structure

Cameron Drilling Bills of Materials (BOM) are constructed in a multitier format

to provide a listing of all components in a system. All BOM are organized
with assemblies and discrete components listed first followed by reference
documents, specifications, procedures, etc. The base number, 2020700, is
assigned to the top level or project BOM with a two digit dash number to
designate a particular project. The Odebrecht 1 (Norbe VIII) project being
2020700-65. Each deliverable item is listed on this BOM. If an item is an
assembly or requires additional documentation or components, this listing will
consist of a BOM containing the components listed in the next tier down in
the structure. In this manner all components in a system may be identified as
each tier is examined.

TC8225, Volume 7 iv
Volume Table of Contents
Multiplex Drilling Controls
Installation, Operation and Maintenance Manual

Section 1 - Volume 1 - System Introduction and Overview

Section 2 - Volume 1 - System Bills of Material, Drawings, and Documents

Section 3 - Volumes 2, 3, 4 & 5 - Assembly Descriptions, Bills of Material,

Drawings, and Procedures

Section 4 - Volume 6 - Cameron and Vendor Component Bills of Material,

Drawings and Documentation

Section 5 - Volume 7 - Procedures

Section 6 - Volume 7 - Glossary of Acronyms and Definitions

TC8225, Volume 7 v
TC8225, Volume 7 vi
Section 5 - Procedures
Procedure Number: AP-000001-04 Revision: 01
Description: 1", 3000/5000 psi WP, 3-Position, Dual Pilot Operated, Supply/
Spring Centered, Open Center, Drg. Valve Assembly Procedure

Procedure Number: AP-000002-02 Revision: 01

Description: 1-1/2", Stab Mounted, with Dual Supply, Premium Deepwater
Hydraulic Regulator Assembly Procedure

Procedure Number: AP-000003-01 Revision: A08

Description: 3/4 - Inch, 4-Way, 3-Position Valve, 5 ksi WP, Stab Mounted,
w/Dual 3 ksi Pilots, Supply/Spring Assist Centered, Open Center Directional
Control Valve Assembly Procedure
3/4 - Inch, 4-Way, 3-Position Valve, 5 ksi WP, NPT Mounted, w/Dual 3 ksi Pilots,
Supply/Spring Assist Centered, Open Center Directional Control Valve
Assembly Procedure
3/4 - Inch, 4-Way, 3-Position Valve, 5 ksi WP, SAE Mounted, W/Dual 3 ksi
Pilots, Supply/Spring Assist Centered, Open Center Directional Control Valve
Assembly Procedure

Procedure Number: AP-000004-02 Revision: 01

Description: Valve Check, 1-1/2", 5 ksi WP, Pilot Operated, Dual Stab
Mounted X .25" NPT Pilot Assembly Procedure

Procedure Number: AP-000005-23 Revision: 01

Description: Drilling Valve, 1/4", 5 ksi WP, 3 Way 2 Pos, Subplate Mounted,
Single 3 ksi Pilot, Spring Return Assembly Procedure

Procedure Number: AP-000005-28 Revision: 01

Description: Drilling Valve, 1/4", 5 ksi WP, 4-Way, 3-Position, Subplate
Mounted, Dual 3 ksi Pilot, Supply/Spring

Procedure Number: AP-000005-29 Revision: 01

Description: Drilling Valve, 1/4", 5 ksi WP, 4-Way, 2-Pos, Subplate Mounted,
Single 3 ksi Pilot, Supply/Spring Return Assembly Procedure

Procedure Number: AP-000011-01 Revision: A01

Description: 3/4-Inch, 4-Way, 2-Position Valve, 5 ksi WP, Stab Mounted, w/
Dual 3 ksi Pilots, Spring Detented Assembly Procedure

TC8225, Volume 7, Section 5 1

 Procedure Number: AP-000012-01 Revision: 01
Description: 3/4", Hydraulic Regulator, Stab Mounted, with Single Supply,
Premium Deepwater Assembly Procedure

Procedure Number: AP-000013-01 Revision: 05

Description: 1/8” Solenoid Valve, Pressure Compensated, Manifold Mounted,
with Single Coil, Premium Deepwater Assembly Procedure

Procedure Number: AP-000014-01 Revision: 01

Description: Drilling Valve, 1/2”, 5 ksi WP, 4-Way 3-Position, Subplate Mount-
ed, Dual 3 ksi Pilot, Supply/Spring Centered Assembly Procedure

Procedure Number: AP-000014-02 Revision: 01

Description: Drilling Valve, 1/2”, 5 ksi WP, 4-Way 2-Position, Subplate Mount-
ed, Single 3 ksi Pilot, Spring Return Assembly Procedure

Procedure Number: AP-000014-03 Revision: 01

Description: Drilling Valve, 1/2”, 5 ksi WP, 4-Way 2-Position, Subplate Mount-
ed, Dual 3 ksi Pilot, Spring Detented Assembly Procedure

Procedure Number: X-093325-01 Revision: 05

Description: DSDM Canbus Node I.D. Configuration and Can Bus Fault-Toler-
ance Verification Procedure, for Multiplex Section, Control Pod (Mark III)

Procedure Number: X-145945-01 Revision: 02

Description: Procedure to Establish Ethernet Network Functionality

Procedure Number: X-200111-65 Revision: 02

Description: Procedure for BOP Control Pod Hardware Installation

Procedure Number: X-200136-02 Revision: 02

Description: Assembly Procedure for MSSL Hydraulic Hose Assemblies

Procedure Number: X-200136-03 Revision: 01

Description: Re-Rill Procedure for P.B.O.F. Assemblies

Procedure Number: X-200136-05 Revision: 01

Description: Test Procedure for Verifying Seal Integrity Between Mated PBOF
Cable and Mating Connector

Procedure Number: X-200917-65 Revision: 04

Description: Commissioning Procedure

TC8225, Volume 7, Section 5 2

 Procedure Number: X-200934-01 Revision: 04
Description: Procedure for Nitrogen Purged Subsea Equipment

Procedure Number: X-200934-02 Revision: 07

Description: Seal Test Procedure for Subsea Equipment

Procedure Number: X-260421-65 Revision: 01

Description: Lubrication Point List

Procedure Number: X-261720-65 Revision: 05

Description: Software Logic (Interlocks and Sequences)

Procedure Number: X-262167-01 Revision: 01

Description: Dielectric Fluid Filling Procedure for Acoustic Electronic Module

Procedure Number: X-262167-02 Revision: 05

Description: Dielectric Fluid Filling Procedure for Mux Section of the Subsea
Control Pod

TC8225, Volume 7, Section 5 3

TC8225, Volume 7, Section 5 4
PROPERTY OF REVISED BY REVISION
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ASSEMBLY PROCEDURE

1”, 3000/5000 PSI WP, 4-WAY, 3-POSITION, DUAL PILOT

OPERATED, SUPPLY / SPRING CENTERED,
OPEN CENTER, DRG VALVE

CAMERON PART NO. 2185014-04 - 3000 PSI WP

CAMERON PART NO. 2185611-01 - 5000 PSI WP

DRAWING NO. SK-122777-04

Originator: R. Lancaster Date: 25-Feb-00

Checked: D. Breazeale Date: 25-Feb-00
Approved: K. Keene Date: 25-Feb-00

CAMERON CONTROLS
6650 BINGLE ROAD
HOUSTON, TX 77092
PROPERTY OF REVISED BY REVISION
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TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

LIST OF FIGURES

Figure 1 – DRG Valve Assembly (1) .................................................................... 5

Figure 2 – Back-up Ring Scarf Cut Edge Alignment............................................. 5
Figure 3 – DRG Valve Assembly (2) .................................................................... 6
Figure 4 – Retaining Ring Edge ........................................................................... 7
Figure 5 – DRG Valve Assembly (3) .................................................................... 8
Figure 6 – DRG Valve Assembly (4) .................................................................... 9
Figure 7 – DRG Valve Assembly (5) .................................................................. 10
Figure 8 – DRG Valve assembly (6) ................................................................... 11
Figure 9 – Back-up Ring Scarf Cut Edge Alignment........................................... 11
Figure 10 – DRG Valve Assembly (7) ................................................................ 12
Figure 11 – DRG Valve Assembly (8) ................................................................ 13
Figure 12 – DRG Valve Assembly (9) ................................................................ 14
Figure 13 – DRG Valve Assembly (10) .............................................................. 15
Figure 14 – DRG Valve Assembly (11) .............................................................. 16
Figure 15 – DRG Valve Assembly (12) .............................................................. 17
PROPERTY OF REVISED BY REVISION
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1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly of

the 1”, 3000/5000 PSI WP, 4-Way, 3-Position, Dual Pilot Operated, Supply
/ Spring Centered, Open Center, DRG Valve.

2.0 Documents / Materials Required

• Cameron Assembly Drawing No. SK-122777-04, (latest revision)

• Bill of Materials (BOM): 2185014-04/2185611-01 (latest revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• Internal (90° angle tip) retainer ring pliers
• Calibrated Torque Wrench Capable of 50 ft-lbs. of torque
• Thread sealing compound
• Light oil
• Light spray lubricant

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt and
other foreign material. It is important to eliminate any external influences
that could cause a regulator functional failure during bench testing or
shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF REVISED BY REVISION
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5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• INDIVIDUAL FIGURE NUMBERS SHOWING THE VALVE ASSEMBLY HAVE BEEN
INCLUDED IN THE ILLUSTRATIONS OF THIS PROCEDURE FOR CONVENIENCE
“ONLY”. IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SK-
122777-04 SHALL TAKE PRECEDENCE.

• Refer to assembly drawing SK-122777-04 for orientation of components and item number
references. Refer to BOM 2185014-04/2185611-01 to cross-reference item numbers with their
respective part numbers and descriptions.
PROPERTY OF REVISED BY REVISION
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5.1 Lubricate two o-rings (Item 21) with light oil and install o-ring into
the OD groove of each end cap (Item 2) in Figure 1.

22

21

32
Figure 1 - DRG Valve Assembly (1)

5.2 Lubricate two back-up rings (Item 32) and o-ring (Item 22) with light
oil and install into the bore groove of each end cap. Inspect the
installed back-up ring after assembly to ensure that the angled
edges of the scarf cut (Figure 2) are aligned and in contact. Install
o-ring into the same groove between the two back-up rings. See
assembly drawing SK-122777-04 for correct orientation of the o-
ring and back-up rings.

Figure 2 - Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF REVISED BY REVISION
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5.3 Build both double spring stacks (Figure 3) by inserting the .590 OD
spring (Item 35) into the .850 OD spring (Item 28).

5.4 Lubricate back-up ring (Item 31) and o-ring (Item 23) and install
back-up ring into the OD groove on each centering piston (Item 10).
Install o-ring into the same groove toward the counterbored end of
each centering piston. Refer to assembly drawing SK-122777-04
to confirm proper orientation of o-rings and back-up rings. Inspect
the installed back up rings after assembly to ensure that the angled
edges of the scarf cut are aligned and in contact.

5.5 Carefully place and properly support the main piston (Item 9) on its
end on a flat, clean table. Insert one of the double spring stacks,
assembled in step 5.3, into the bore of the piston, and ensure that
the springs fit into the smaller counter-bore.

5.6 Apply light oil to the o-ring and back-up ring of one centering piston
and to the entrance bevel in the end of the main piston. Fit the
centering piston over the springs in the main piston and align it with
the bore in the main piston.

28 35

10

31
23

9
Figure 3 - DRG Valve Assembly (2)
PROPERTY OF REVISED BY REVISION
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NOTE
• The retaining ring (Figure 4) has a slightly rounded side and a sharp side. The retaining ring
should be installed such that the rounded side is facing the piston retainer, and the sharp edged
side is facing out of the bore. This will ensure that the sharp edge is loaded against the groove
wall.

• If a clamping method is used to compress the springs, it is critical that all valve component
surfaces be protected from damage, such as scratches or impressions. Use an appropriate soft
material, such as rubber or plastic, between any clamping device and the parts it contacts.

Figure 4 - Retaining Ring Edge

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5.7 Place a piston retainer (Item 15) in Figure 5, over the end of the
centering piston (raised center portion facing outboard).

5.8 Compress the springs and install retaining ring (Item 14) in the
groove behind the piston retainer, in accordance with the
instructions in the note for Figure 4.

14

15

Figure 5 - DRG Valve Assembly (3)

5.9 Place and properly support, the piston on a table on it’s opposite
end from step 5.5. Repeat steps 5.6 through 5.8 to complete the
assembly of the 2nd centering piston.

5.10 Stand the body (Item 1) on end, on a table. Position the body so
that the single side hole surrounded by four bolt holes is facing you
(this is the vent port of the valve).
PROPERTY OF REVISED BY REVISION
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5.11 Lubricate the entrance bevel on the end bore of the body (Item 1) in
Figure 6, with light oil. Apply light oil to the OD of the end cap (Item
2), on the surface where the OD o-ring is located. Apply light oil to
the ID o-ring and back-up ring of the end cap.

5.12 Position end cap so that the face with both the 1/8” NPT port and
stab port is facing you (the NPT port should be oriented with the
body vent port). Carefully press the end cap into the body.

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with an anti-
galling/low friction coating.

5.13 Install four of the socket head cap screws (Item 17) through the
holes in the end cap, and hand tighten (Do not torque).

17

Figure 6 - DRG Valve Assembly (4)

NOTE
The two holes for the seal rings must be perpendicular to the side of the body, which contains the
vent port.

5.14 Turn the body (Item 1) over on the table (Figure 7) so that it is
resting on the 4 socket head cap screws that were just installed.
PROPERTY OF REVISED BY REVISION
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Apply light oil to the entrance bevel on one end of the main piston
(Item 9), and insert it carefully into the body. Carefully press it
through the o-ring seal (Item 22) of the end cap (Item 2).

5.15 Position the body again so that the body vent port is facing you.
Lubricate the ID bore of the end cap, the OD of the end cap, the
end of the main piston and the entrance bore of the body with light
oil. Position the main piston so that the two large through bores of
the main piston are aligned with, and parallel to, the two
corresponding large holes in each side of the body.

5.16 Position the end cap so that the face with both the 1/8” NPT port
and the stab port is facing you. Carefully align it with the main
piston and body and press it into place.

NOTE
The NPT ports of both end caps should now be oriented on the same side as the body vent port.

5.17 Install the four remaining socket head cap screws (Item 17) through
the holes in the end cap, and hand tighten (Do not torque).

17

22

Figure 7 - DRG Valve Assembly (5)

5.18 Lay the body (Item 1) down onto its long side (Figure 8), with the
vent port facing you and with the outlet face (the face with the
PROPERTY OF REVISED BY REVISION
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larger bolt hole pattern) facing up. Lubricate the four seal rings
(Item 11), four o-rings (Item 33) and four back-up rings (Item 30)
with light oil.

30
33

11
Figure 8 - DRG Valve assembly (6)

CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, valve function and
operation.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.

5.19 Install back-up ring (Item 30) onto each of the seal rings (Item 11).
For each seal ring, slide the back-up ring towards the lapped side
of the seal ring, and install o-rings in the groove. See assembly
drawing SK-122777-04 for orientation of the o-ring and back-up
ring. Inspect the installed back-up ring after assembly to ensure
that the angled edges of the scarf cut are aligned and in contact.

Figure 9 – Back-up Ring Scarf Cut Edge Alignment

CAUTION
PROPERTY OF REVISED BY REVISION
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Extreme care must be taken to avoid any contact with the lapped surface of each seal plate. Small
dings or raised edges will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring. It is only necessary to install the seal ring
assembly so that the o-ring and back-up ring are fully within the bore of the main piston. Leave
approximately 1/16” to 5/32” of the seal ring extending beyond the flat surface of the main piston.

5.20 Lubricate the OD of two seal rings (Item 11) in Figure 10 and the
entrance bores of the main piston (Item 9), that accept the seal
rings, with light oil. Carefully press a seal ring into each bore,
making sure that the seal ring’s lapped surface is facing outward.

5.21 Lubricate the outlet and inlet seal plates (Items 6 and 7) with light
oil and install o-ring (Item 24) into the OD groove on each seal
plate. Note that one surface of each seal plate is lapped. Carefully
set seal plates aside until needed.

24

7
9 11
Figure 10 – DRG Valve Assembly (7)

5.22 Position outlet flange (Item 5) in Figure 11, on the table with the
four ports facing up. Press four of the dowel pins (Item 37) into
their respective holes in outlet flange. Lubricate four of the o-rings
PROPERTY OF REVISED BY REVISION
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(Item 25) with light oil and install into each of the four outlet flange
face seal grooves.

5.23 Verify that the bolt hole pattern in the outlet flange matches the
threaded holes (facing upward) in the body (Item 1).

CAUTION
Use extreme care not to drop the seal plates on top of the body or one of the seal rings. These
parts become very slippery when lubricated.

5.24 Re-check the alignment of the main piston (Item 9) with respect to
the large port holes (sized to fit the seal plates) in the body. The
previously installed seal rings (Item 11) should be facing up, with
the center of each seal ring aligned to the large port holes in the
body. Position each outlet seal plate (Item 6) so that the dowel pin
holes align with the outlet flange dowel pin locations. Note that the
outlet seal plates have two through ports (as opposed to the inlet
seal plates (Item 7), which have only one center through port).
Lubricate the body entrance bevels and bores, and the OD and
seals of each outlet seal plate with light spray lubricant. Carefully
press both outlet seal plates into their respective bores until each
lands on its respective shoulder in the body.

5 25
37
6

7
9 11
Figure 11 – DRG Valve Assembly (8)

5.25 Lubricate the exposed face of each outlet seal plate (Item 6) in
Figure 12 and the inboard side of the outlet flange (Item 5) with light
PROPERTY OF REVISED BY REVISION
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spray lubricant. Place the outlet flange onto the body (Item 1) and
over the outlet seal plates.

NOTE
The outlet flange may be used to slightly rotate each outlet seal plate. The centerline formed
between the two dowel pins in each seal plate should be perpendicular to the length of the body.

5.26 Align the dowel pins (Item 37) with the holes in the seal plates and
land the flange onto the body.

NOTE
• If the inboard face of the outlet flange is raised more than .010” off the body, an o-ring has fallen
out of its groove. If this is not the case, continue.

• The larger stab counterbores in the outlet flange should be 180˚ opposite from the NPT port in
each end cap and the body vent port.

5.27 Install eight of the socket head cap screws (Item 16) through the
holes in the outlet flange, and hand tighten (Do not torque).
16
5 37
6

Figure 12 – DRG Valve Assembly (9)

5.28 Rotate the body 180 degrees, so that the body is resting on the 8
socket head cap screws of the outlet flange, and the vent hole is
facing away from you.
PROPERTY OF REVISED BY REVISION
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5.29 Insert a spring (Item 12) into each main piston bore in Figure 13,
making sure it lands in the counter bore of the previously installed
seal ring (Item 11). With light oil, lubricate the OD surfaces and
sealing elements of the remaining two seal rings and the entrance
bores of the main piston (Item 9) that accepts the seal. Carefully
place each opposing seal ring over the spring and into the piston
bore, with the lapped surface facing up.

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate. Small
dings or raised edges will cause the valve to leak.

5.30 Lubricate inlet flange (Item 4) and remaining two o-rings (Item 25)
with light oil. Position inlet flange on the table with inboard side
facing upwards. Press the four remaining dowel pins (Item 37) into
their respective bores in the inboard face of the inlet flange. Install
o-rings into each of the two face seal grooves.

12

37 11
4 9
25
Figure 13 – DRG Valve Assembly (10)
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5.31 Position each inlet seal plate (Item 7) in Figure 14, so that a line
through the dowel pin holes is perpendicular to the length of the
body. Note that the inlet seal plate has just one central through
port (as opposed to the outlet seal plate (Item 6), which has two
through ports). Lubricate the body entrance bevels and bores, and
to the OD of each inlet seal plate with light spray lubricant.
Carefully press inlet seal plate into each bore until it lands on its
respective face in the body (Item 1).

5.32 Lubricate the exposed face of each inlet seal plate and the inboard
face of the inlet flange (Item 4). Place the inlet flange onto the body
and over the seal plates. Align the dowel pins (Item 37) with the
holes in the seal plates and land the flange onto the body. Refer to
the NOTE after step 5.25.

5.33 Install the remaining eight socket head cap screws (Item 16)
through the holes in the inlet flange, and hand tighten (Do not
torque).

5.34 Begin to torque the socket head cap screws using a calibrated
torque wrench. Torque all flange cap screws first. Apply final
torque to the four inboard flange caps screws prior to applying final
torque to the four flange cap screws at the outboard corners.
Torque all end cap screws last. Torque socket head cap screws to
50 ft-lb. +/- 2-ft lb. Always use a criss-cross pattern when
tightening the screws. Do not apply all of the necessary torque on
the first pass.

6 1

37
4 16

Figure 14 – DRG Valve Assembly (11)

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5.35 Lightly coat the threads of the 3/4” NPT pipe plugs (Item 19) in
Figure 15 with an appropriate sub-sea thread sealant and install
one into each of the three ports, two in the outlet flange and one in
the inlet flange.

5.36 Lightly coat the NPT threads of the manual relief valves (Item 18)
with an appropriate sub-sea thread sealant. Install the two manual
relief valves into their NPT ports on both end caps.

5.37 Place the component tag (Item 26) onto the DRG Valve body (Item
1) in the location shown in the assembly drawing and secure it in
place with two drive screws (Item 27). Stamp the tag per Part
Identification Spec D-000100-09-04, document: X-043764-01,
(latest revision).

5.38 Cover and protect the body vent port.

18
26
27 1
19
Figure 15 – DRG Valve Assembly (12)

5.39 The DRG Valve Assembly is now ready for bench testing using FAT
X-201943-04.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 1 of 17

ASSEMBLY PROCEDURE

1-1/2”, STAB MOUNTED, WITH DUAL

SUPPLY, PREMIUM DEEPWATER
HYDRAULIC REGULATOR

CAMERON PART NO. 2185621-01

DRAWING NO. SK-122778-01

Originator: S. Ward Date: May-15-2002

Checked: D. Breazeale Date: July-9-2002
Approved: T. Bell Date: July-10-2002

CAMERON CONTROLS
6650 BINGLE ROAD
HOUSTON, TX 77092
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 2 of 17

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 MATERIALS REQUIRED...................................................................................3

3.0 HYDRAULIC REGULATOR PREPARATION PRIOR TO ASSEMBLY ...........................3

4.0 HYDRAULIC REGULATOR INSPECTION PROCEDURE ..........................................3

5.0 HYDRAULIC REGULATOR ASSEMBLY ...............................................................4

List of Figures

Figure 1 – Hydraulic Regulator Assembly.............................................................. 4

Figure 2 – Hydraulic Regulator Assembly.............................................................. 5
Figure 3 - Back-up Ring Scarf Cut Edge Alignment ............................................... 5
Figure 4 - Back-up Ring Scarf Cut Edge Alignment ............................................... 6
Figure 5 – Hydraulic Regulator Assembly.............................................................. 7
Figure 6 – Hydraulic Regulator Assembly.............................................................. 9
Figure 7 – Hydraulic Regulator Assembly............................................................ 10
Figure 8 – Hydraulic Regulator Assembly............................................................ 13
Figure 9 – Hydraulic Regulator Assembly............................................................ 16
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 3 of 17

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for assembly of the

1.5-Inch Premium Deepwater Hydraulic Regulators.

2.0 Documents/Materials Required

• Cameron Assembly Drawing No. SK-122778-01, Regulator, 1.5”,

Hydraulic, Stab Mounted, W / Dual Sub Supply (latest revision).
• Bill of Materials (BOM): 2185621-01 (latest revision).
• Lint-free rags or cleaning tissues.
• Internal (90° angle tip) retainer ring pliers.
• Calibrated Torque Wrench Capable of 130 ft-lbs. of torque.
• Thread sealing compound or Teflon tape.
• Light oil.
• Light spray lubricant.
• 3/8” Dia. X 6”-12” round nosed wooden dowel

3.0 Hydraulic Regulator Preparation Prior to Assembly

All components of the hydraulic regulator must be cleaned thoroughly prior

to assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths must not be used.

The Hydraulic Regulator should be assembled in a clean area, free from

all dirt and other foreign material. It is important to eliminate any external
influences that could cause a regulator functional failure during bench
testing or shorten the expected life of the regulator in field operation.

Personnel working on the hydraulic regulator shall wear clean clothing,

safety shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the hydraulic regulator
assembly area.

4.0 Hydraulic Regulator Component Inspection

Follow the inspection requirements specified in QP-000160-21.

NOTE
Refer to assembly drawing SK-122778-01 for orientation of components and item number
references. Refer to BOM 2185621-01 to cross-reference item numbers with their
respective part numbers and descriptions.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 4 of 17

5.0 Hydraulic Regulator Assembly

Figure 1 – Hydraulic Regulator Assembly

5.1 Position regulator body (Item 1), Figure 2, in assembly area so that
the three-porthole side is facing up and the two-porthole side is
facing down.

5.2 Insert internal guide bushing (Item 13) into regulator body (Item 1).
See assembly drawing for correct orientation.

5.3 Using retaining ring pliers, install retaining ring (Item 12) into the
groove inside the regulator body to secure internal guide bushing
(Item 13).

5.4 Stand regulator body (Item 1) up on end so that the vent piston
(exhaust) side is up.

5.5 Insert vent piston (Item 21) into the vent piston bore of the regulator
body until it rests in the internal guide bushing (Item 13). Orient seal
ring bores in vent piston with vent seal plate bores in body.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 5 of 17

5.6 Install the vent piston return spring (Item 29) into the bore of vent
piston.

Figure 2 – Body with Vent Piston and End Cap

CAUTION
Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function and
operation.

5.7 Lubricate with light oil and install o-ring (Item 16) into the OD
groove on the pilot relief end cap (Item 3).

5.8 Lubricate with light oil and install one of the two back-up rings (Item
42) into the bore groove of pilot relief end cap. Inspect the installed
back-up rings (Figure 3) after assembly to ensure that the edges of
the scarf cut are aligned and in contact with each other.

Figure 3 - Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 6 of 17

5.9 Lubricate with light oil and install o-ring (Item 35) into the same
groove next to the first back-up ring (Item 42). Install second back-
up ring on pilot relief end cap. See assembly drawing for correct
orientation of o-ring and back-up rings.

5.10 Lubricate the vent piston OD (Item 21) and pilot relief end cap inner
bore with light oil. Position the pilot relief end cap over the exhaust
spring (Item 29) and the vent piston OD and press into place until
the exhaust spring is properly seated in the pilot relief end cap
counterbore.

5.11 Position the pilot relief end cap (Item 3) as shown in Figure 1. This
will place the 1/8” NPT bore, that is 90 degrees to the stab bore, on
the same side as the three hole side of the regulator body (Item 1).

5.12 Install four socket head cap screws (Item 8) in relief pilot end cap
(Item 3) and regulator body (Item 1) and tighten hand tight only (Do
Not Torque).

5.13 Stand regulator body (Item 1) up on pilot relief end cap. Lubricate
with light oil and install o-ring (Item 6) into the ID groove on the
(Figure 5) supply piston end cap side of the regulator body (Item 1).

5.14 Lubricate with light oil and install both back-up rings (Item 40) into
the OD groove of the supply piston (item 2). Inspect the installed
back-up rings after assembly to ensure that the edges of the scarf
cut are aligned and in contact with each other (Figure 4).

Figure 4 - Back-up Ring Scarf Cut Edge Alignment

5.15 Lubricate with light oil and install o-ring (Item 5) into the same
groove between the back-up rings (Item 40) in supply piston. See
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 7 of 17

the assembly drawing for correct orientation of the o-ring and back-
up rings.

Figure 5 – Body with Main Piston and End Cap

5.16 Install the supply piston spring (Item 28) over the vent piston end
sticking through the internal guide bushing in the regulator body.

5.17 Lubricate both ends of the supply piston (Item 2) with light oil and
install into the regulator body (Item 1). Orient seal ring bores in
supply piston with seal plate bores in body.

5.18 Lubricate the supply piston end cap inner bore and outer surface
with light oil and position the supply piston end cap over supply
piston and press into place.

5.19 Position the supply piston end cap (Item 4) as shown in Figure 5.
This will place the 1/8” NPT bore, that is 90 degrees to the stab
bore, on the same side as the three hole side of the regulator body.

5.20 Install four (Item 8) socket head cap screws in supply piston end
cap and regulator body and hand tighten only (Do Not Torque).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 8 of 17

5.21 Position regulator body (Item 1) so that the regulated pressure,

supply and exhaust port hole side is facing up, the two port hole
side is facing down.

CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function
and operation.
• Extreme care must be taken to avoid any contact with the lapped surface of each vent
seal ring (Item 34). Any damage to these surfaces will cause the regulator to leak.

5.22 Lubricate the OD of the vent seal rings (Item 34), o-rings (Item 33),
back-up rings (Item 43) and both vent piston bores (Item 21) with
light oil and install back-up ring and o-ring on vent seal ring. See
the assembly drawing for correct orientation of the o-ring and back-
up ring.

5.23 Install one of the vent seal ring springs (Item 32) into the vent
piston bore (Figure 6).

5.24 Carefully press one vent seal ring assembly (Item 34) into the vent
piston bore (Item 21), through the relief seal flange bore (Figure 6).
Make sure that the seal ring’s lapped surface is facing outboard
from the regulator body (Item 1).

NOTE
The vent seal ring spring will hold the back-up and o-ring outside the vent piston bore. Use
your thumb to press against the bevelled ID surface of the seal ring. (Do not press directly
on the lapped surface of the seal ring) It is only necessary to press down on the seal ring
assembly so that the o-ring and back-up ring slide fully within the bore of the vent piston
once. This is to ensure the smooth insertion during final assembly.

5.25 Lubricate the OD of the exhaust seal plate (Item 20) and o-ring
(Item 17) with light oil and install the o-ring in exhaust seal plate
groove.

5.26 Press dowel pin (Item 10) fully into the exhaust seal flange (Item
22) (Figure 7).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 9 of 17

Figure 6 – Seal Plates with Seal Rings

5.27 Install o-ring (Item 18) into its respective groove in the exhaust seal
flange (Item 22). A small amount of light oil or grease will help
keep the o-ring in position during assembly.

5.28 Lubricate the lapped face of the exhaust seal plate (Item 20),
exhaust seal plate bore and seal plate face relief in the regulator
body (Item 1) with light lubricant.

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each exhaust
seal plate. Any damage to these surfaces will cause the Regulator to leak.

5.29 Hold the exhaust seal plate above the body. Position it with the
lapped surface facing inboard towards the installed seal ring (Item
34) and the Exhaust port and the dowel pin hole inline with the axis
of the regulator body (figure 6).

5.30 While holding the exhaust seal plate insert rounded end of the
wooden dowel through the outlet hole in the exhaust seal plate.
Place the dowel against the bevelled ID surface of the seal ring.
(Do not press directly on the lapped surface of the seal ring)
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 10 of 17

Figure 7 – Hydraulic Regulator Assembly

5.31 Using the wooden dowel carefully push the vent seal ring (Item 34)
into the vent piston (Item 21) until both the back-up and o-ring are
fully seated.

5.32 Lower exhaust seal plate in to the body ‘s exhaust seal plate bore
until it is fully seated (Figure 7). Lubricate the outboard side of the
exhaust seal plate (Item 20) with light oil.

5.33 Without removing pressure on the wooden dowel, install the

exhaust seal flange (Item 22) down over the wooden dowel through
the exhaust port. Confirm the o-ring and dowel pin are still in their
appropriate positions (Figure 7). Place flange into final position
against surface of body.

5.34 Install four (Item 15) socket head cap screws in the exhaust seal
flange and hand tighten only (Do Not Torque). Remove wooden
dowel.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 11 of 17

CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function
and operation.

• Extreme care must be taken to avoid any contact with the lapped surface of each supply
seal ring (Item 19). Any damage to these surfaces will cause the regulator to leak.

5.35 Lubricate the OD of the supply seal ring (Item 19), o-rings (Item
23), back-up ring (Item 41) and the supply piston bore (Item 2) with
light oil and install the back-up ring and o-ring on the supply seal
ring. See the assembly drawing for correct orientation of the o-ring
and back-up ring.

5.36 Carefully press one supply seal ring assembly (Item 19) into the
supply piston bore (Item 2), through the inlet/outlet flange bore (see
assembly drawing), making sure that the supply seal ring’s lapped
surface is facing outboard from the regulator body (Item 1).

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both
thumbs to press against the bevelled ID surface of the seal ring. It is only necessary to
install the seal ring assembly so that the o-ring and back-up ring are fully within the bore of
the supply piston. Leave approximately 1/16” to 5/32” of the seal ring extending beyond the
flat surface of the supply piston.

5.37 Lubricate the OD of the supply seal plate (Item 25) and o-ring (Item
39) with light oil and install the o-ring on supply seal plate.

5.38 Press dowel pin (Item 10) fully into the supply/outlet flange (Item
11).

5.39 Install o-rings (Items 9 & 30) into their respective grooves in the
supply/outlet flange. A small amount of light oil or grease will help
keep the o-rings in position during assembly.

5.40 Lubricate the lapped face of the supply seal plate (Item 25), supply
seal ring lapped face (Item 19) and supply seal plate bore in the
regulator body (Item 1) with light lubricant.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 12 of 17

CAUTION
Extreme care must be taken to avoid any contact with a foreign object against the lapped
surface of the supply seal plate. Any damage to these surfaces will cause the regulator to
leak.

5.41 Position supply seal plate with lapped surface facing inboard
towards the installed supply seal ring (Item 19) and ports in line
with the axis of the regulator body. See the assembly drawing for
correct orientation. Push the supply seal plate completely into the
regulator body bore.

5.42 Lubricate the outboard side of the supply seal plate (Item 25) and
the bottom of supply/outlet flange assembly (Item 11) with light oil.
Place supply/outlet flange assembly over the supply seal plate.
Align dowel pin in inlet/outlet flange with hole in the supply seal
plate and press into place.

5.43 Verify that the supply/outlet flange is fully mated with the regulator
body (Item 1). Install four socket head cap screws (Item 27) and
two socket head cap screws (Item 24) in supply/outlet flange and
regulator body and tighten hand tight only (Do Not Torque).

5.44 Rotate hydraulic regulator assembly 180° degrees so the

supply/outlet flange is now facing down. Use light oil to lubricate the
accessible portions of the internal bore of the supply piston.

5.45 Insert supply seal ring spring (Item 31) into the bore in the piston
against the installed supply seal ring (Item 19).

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, regulator function
and operation.
• Extreme care must be taken to avoid any contact with the lapped surface of each supply
seal ring (Item 19). Any damage to these surfaces will cause the regulator to leak.

5.46 Lubricate the OD of the second supply seal ring (Item 19), o-rings
(Item 23), back-up ring (Item 41) and the supply piston bore with
light oil and install back-up ring and o-ring on supply seal ring.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 13 of 17

5.47 Carefully press second supply seal ring assembly (Item 19) into the
supply piston bore (Item 2), through the inlet flange bore (see
assembly drawing), making sure that the supply seal ring’s lapped
surface is facing outboard from the regulator body (Item 1).

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both
thumbs to press against the bevelled ID surface of the seal ring. It is only necessary to
install the seal ring assembly so that the o-ring and back-up ring are fully within the bore of
the supply piston once before removing pressure. Like the vent seal ring the supply seal
ring’s back-up and o-ring may extend beyond it’s seating area in the supply piston. Due to
the larger diameter on the supply ring can be safely seated in supply piston, with out the
use of a wooden dowel, in the following steps.

Figure 8 – Hydraulic Regulator Assembly

5.48 Lubricate the OD of the supply seal plate (Item 25) and o-ring (Item
39) with light oil and install the o-ring in supply seal plate groove.

5.49 Press dowel pin (Item 10) fully into the supply flange (Item 14).
 PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 14 of 17

5.50 Install o-ring (Item 30) into its respective groove in the inlet flange.
A small amount of light oil or grease will help keep the o-ring in
position during assembly.

5.51 Lubricate the OD, lapped face, o-ring around the supply seal plate
(Item 39), and supply seal plate bore in the regulator body (Item 1)
with light lubricant.

CAUTION
Extreme care must be taken to avoid any contact with a foreign object against the lapped
surface of the supply seal plate. Any damage to these surfaces will cause the regulator to
leak.

5.52 Hold the supply seal plate above the body. Position it with the
lapped surface facing inboard towards the installed seal ring (Item
25) and the supply port and dowel pin hole inline with the axis of the
regulator body (figure 8).

5.53 Lubricate the outboard side of the supply seal plate (Item 25) with
light oil. Place inlet flange assembly (Item 14) over the supply seal
plate. Align dowel pin (Item 10) in supply flange with respective
hole in the supply seal plate and carefully press into place (Figure
8).

CAUTION
Extreme care must be taken to avoid any lateral movement when the lapped surface of the
supply seal plate comes in contact with the lapped surface of the supply seal ring. Any
damage to these surfaces will cause the regulator to leak.

5.54 Verify that the inlet flange is fully mated with the regulator body
(Item 1). Install four socket head cap screws (Item 27) in supply
flange and regulator body and tighten hand tight only (Do Not
Torque).

I
CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function
and operation.
• Extreme care must be taken to avoid any contact with the lapped surface of each vent
seal ring (Item 34). Any damage to these surfaces will cause the regulator to leak.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 15 of 17

5.55 Lubricate the OD of the vent seal ring (Item 34), o-ring (Item 33)
and back-up ring (Item 43) with light oil and install back-up ring and
o-ring on relief seal ring. See the assembly drawing for correct
orientation of the o-ring and back-up ring.

5.56 Install the remaining vent seal ring spring (item 32) into the vent
piston bore (Figure 8).

5.57 Carefully press the remaining vent seal ring assembly (Item 34) into
the vent piston bore (Item 21), through the relief seal flange bore
(Figure 8). Make sure that the seal ring’s lapped surface is facing
outboard from the regulator body (Item 1).

NOTE
The vent seal ring spring will hold the back-up and o-ring outside the vent piston bore. Use
your thumb to press against the bevelled ID surface of the seal ring. (Do not press directly
on the lapped surface of the seal ring) It is only necessary to press down on the seal ring
assembly so that the o-ring and back-up ring slide fully within the bore of the vent piston
once. This is to ensure the smooth insertion during final assemble.

5.58 Lubricate the OD of the exhaust seal plate (Item 20) and o-ring
(Item 17) with light oil and install the o-ring in exhaust seal plate
groove.

5.59 Press a dowel pin (Item 10) fully into the exhaust seal flange (Item
22) (Figure 8).

5.60 Install o-ring (Item 18) into its respective groove in the exhaust seal
flange (item 22). A small amount of light oil or grease will help keep
the o-ring in position during assembly.

5.61 Lubricate lapped face of the exhaust seal plate (Item 20), exhaust
seal plate bore and seal plate face relief in the regulator body.

CAUTION
Extreme care must be taken to avoid any contact with a foreign object against the lapped
surface of the exhaust seal plate. Any damage to these surfaces will cause the regulator to
leak.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 16 of 17

5.62 Hold the exhaust seal plate above the body. Position it with the
lapped surface facing inboard towards the installed seal ring (Item
34) and the Exhaust port and the dowel pin hole inline with the axis
of the regulator body (Figure 9).

5.63 While holding the exhaust seal plate, insert rounded end of the
wooden dowel through the outlet hole in the exhaust seal plate.
Place the dowel against the bevelled ID surface of the seal ring.
(Do not press directly on the lapped surface of the seal ring)

Figure 9 – Hydraulic Regulator Assembly

5.64 Using the wooden dowel carefully push the vent seal ring (item 34)
into the vent piston (item 21) until both the back-up and o-ring are
fully seated.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000002-02
15-May-02 17 of 17

5.65 Lower exhaust seal plate in to the body ‘s exhaust seal plate bore
until it is fully seated (Figure 9). Lubricate the outboard side of the
exhaust seal plate (Item 20) with light oil.

5.66 Without removing pressure on the wooden dowel, install the

exhaust seal flange (Item 22) down over the wooden dowel through
the exhaust port. Confirm the o-ring and dowel pin are still in their
appropriate positions (Figure 9) when fully seated.

5.67 Install four socket head cap screws (Item 15) in the exhaust seal
flange and hand tighten only (Do Not Torque). Remove wooden
dowel.

5.68 Begin to torque socket head cap screws using a calibrated torque
wrench at this time. Torque all Flange screws first. Torque all End
Cap screws last. Torque socket head cap screws in accordance
with recommended torque in chart below. Always use a crossing
pattern when tightening the screws. Do not apply all of the
necessary torque on the first pass.

Recommended Comments
Makeup Torque
Inlet Flange 130 ft-lb. 5/8” Socket Head Screw – 8X
Inlet/Outlet Flange
Inlet/Outlet Flange 70 ft-lb. 1/2” Socket Head Screw – 2X
Supply Piston Cap 130 ft-lb. 5/8” Socket Head Screw – 8X
Pilot Relief Cap
Exhaust Seal Flange, 70 ft-lb. 1/2” Socket Head Screw – 8X
2X

5.69 Prepare the (2) 1/8”M NPT bleed valves (Item 38) with an
appropriate sub-sea thread sealant or tape. Install the two 1/8”M
NPT bleed valves in their respective NPT ports in the End Caps.
See the assembly drawing for correct orientation.

5.70 Place the component tag (Item 36) onto the regulator body (Item 1)
in the location shown in the assembly drawing and secure it in
place with two drive screws (Item 37). Stamp the tag per Marking
and Stamping Spec D-000100-09-04.

5.71 The Hydraulic Regulator Assembly is now ready for “FAT” testing
per the “BOM”.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 1 of 9

ASSEMBLY PROCEDURE

DRILLING VALVE, 1/4”, 5 KSI WP, 3 WAY 2-POS,

SUBPLATE MOUNTED, SINGLE 3 KSI PILOT,
SPRING RETURN

CAMERON PART NOS.

2185188-23
2185188-26
DRAWING NOS.
SK-122800-05
SK-122800-06

VALVE NO. 2185188-23

Originator: S. Ward Date: May 13, 2004

Checked: T. Bell Date: March 2, 2005
Approved: D. Breazeale Date: March 2, 2005
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 2 of 9

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 3 of 9

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly

of two 1/4”, 5 KSI WP, 2-Position, Non interflow, Subplate Mounted,
Single 3 KSI Pilot, Drilling (DRG) Valves.

2.0 Documents / Materials Required

• Correct Cameron Assembly Drawing; example No. SK-122800-05,

(latest revision)
• Correct Bill of Materials (BOM); example 2185188-23, (latest
revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• Calibrated torque wrench capable of 0-50 ft-lbs. of torque
• Adapter, appropriate torque wrench drive x 0.250” male hex
• 1/4” hex (Allen) wrenches
• Small open end adjustable wrench or 0.50” & 0.625” open end
wrench
• Thread sealing compound or PTFE tape
• Light grease

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt
and other foreign material. It is important to eliminate any external
influences that could cause a valve functional failure during bench
testing or shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

• Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 4 of 9

5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SHALL TAKE
PRECEDENCE.

• Refer to assembly drawing for orientation of components and item number references. Refer to
“BOM” to cross-reference item numbers with their respective part numbers and descriptions.

• Not all items listed in this assembly procedure are present in each Drilling Valve version
covered. Disregard any item number call out in this procedure that is not on the ” BOM”.

5.1 Lubricate back-up ring (Item 16 ) and o-ring (Item15) with light
grease. Install back-up ring (Item 16) into the OD groove of the
piston (Item 4). Inspect the installed back-up rings to ensure that
the angled edges of the scarf cut (Figure 1) are aligned and in
contact. Install o-ring (Item 15) into the same groove adjacent to
the back-up ring on the piston. Refer to the assembly drawing
for the correct orientation of the o-ring and back-up ring.

Figure 1 – Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 5 of 9

5.2 Lubricate back-up ring (Item 19) and o-ring (Item 18) with light
grease and install a back-up ring onto each of the two seal rings
(Item 7) in the assembly drawing. For each seal ring, slide the
back-up ring towards the lapped face of the seal ring. Inspect
the installed back-up ring (Figure 1) to ensure that the angled
edges of the scarf cut are aligned and in contact. Install o-ring
into the same groove adjacent to the back-up ring. See the
assembly drawing for orientation of the o-ring and back-up ring.
Place the seal ring subassemblies carefully aside until needed.

5.3 Apply light grease to all three o-rings (Item 14) and adjacent
body (Item 1) internal bore surfaces. Install o-rings into their
proper seal grooves in the end caps (item 2 and 3). See the
assembly drawing for correct orientation of the o-rings.

5.4 Apply light grease to the outer o-ring diameter, internal starting
bevel and ID piston bore of the pilot end cap (Item 2). Install the
pilot end cap into the manual relief valve (item 13) end of the
body (Item 1), until it is fully seated, see assembly drawing.
Make sure mounting holes in the end cap align with the tapped
holes in body.

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with an anti-
galling/low friction coating.

5.5 Install four socket head cap screws (Item 9), through the holes in
the pilot end cap (Item 2), and hand tighten (Do not torque).

5.6 Lay the body (Item 1) subassembly on a flat surface. Position

the body so that the large seal plate opening in the side is facing
upwards.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 6 of 9

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate. Small
dings or raised edges will cause the valve to leak.

5.7 Position the blind seal plate (Item 5), over the side opening in the
body (Item 1) with its lapped surface facing upwards. Place
fingers through the open end of the body to support and lower
the seal plate into its recess in the body, being careful not to
scratch or otherwise damage the lapped sealing surface. Apply
light grease to the exposed lapped surface of the blind seal
plate.

5.8 Apply light grease to the outside of the retainer sleeve (item 12)
and slide inside spring return guide (item 20). Install return spring
(item 8) over the non o-ring side of the piston (item 4). Slide the
assembly bolt (item 27) through the guide/retainer assembly and
thread it into the piston. Make sure the small diameter of the
spring return guide (item 20) is positioned inside the return
spring (item 8) then tighten till the retainer sleeve (item 12) is
tight against the piston. Torque the assembly bolt (item 27) to 10
ft-lbs. (120 in-lbs.). See the assembly drawing for correct
orientation.

5.9 Apply a light coating of grease of the outer diameters of the pilot
end of the piston (Item 4). Insert the pilot end of the piston
through the body until it is fully seated in the pilot end cap. The
transverse bore through the piston should be perpendicular to
the blind seal plate. See the assembly drawing for correct
orientation.

5.10 Apply light grease to the outer o-ring diameter, return spring
guide diameter and starting bevel of the spring end cap (Item 3).
Install spring end cap (item 3) until the return spring guide is fully
seated and the bolt holes are aligned with the body. Install the
four socket head cap screws (item 26). Slowly tighten screws in
a criss-cross pattern until the end cap is flush with the body.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 7 of 9

5.11 Torque socket head cap screws in the spring end cap (item 3)
and pilot end cap (Item 2) to 12.5 ft-lbs. (150 in-lbs.) using a
criss-cross pattern.

WARNING
USE CAUTION WHEN INSTALLING SEAL RINGS, THE INNER AND OUTER EDGES OF THE
LAPPED END OF EACH SEAL RING IS VERY SHARP. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY TO PERSONNEL.

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of
the valve.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring

5.12 To install the first seal ring subassembly (Items 7, 18 and 19)
with its o-ring and back-up ring in place, apply light oil to the
entire bore of the piston (Item 4). Position the seal ring over the
bore in the piston, lapped end facing downwards, and press it
into the piston bore using thumb pressure. If insertion is difficult,
be sure that the piston bore is not pinching the back-up ring
(Item 19) or o-ring (Item 18). Push the seal ring downwards until
it contacts the blind seal plate (Item 5).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 8 of 9

5.13 Place the seal ring spring (Item 10) on top of the seal ring (Item
7) just inserted. Again apply light oil to the bore of the piston
(previously wiped off by the seal ring that was installed first).

5.14 Carefully install the remaining seal ring subassembly (Item 7, 18

and 19) with its o-ring and back-up ring already installed.
Position the seal ring over the bore in the piston, lapped end
facing out, and press it into the piston bore. If insertion is
difficult, be sure that the piston bore is not pinching the back-up
ring or o-ring. Push the seal ring downwards until it contacts the
seal ring spring (Item 10).

5.15 Lightly grease o-ring (Item 11) and its respective groove in the
body (Item 1) as shown in the assembly drawing.

5.16 Apply light grease to the lapped surface of the outlet seal plate
(Item 6) as well as to the outer diameter, which contacts the o-
ring (item 11). Install o-ring into body seal groove as shown in
the assembly drawing. Carefully position the outlet seal plate
over the opening in the side of the body, with the ports aligned
with the axis of the body as shown. Lapped surface should be
facing inwards and the dowel pin hole aligned per the assembly
drawing. Carefully press it into place until the outlet seal plate is
fully seated flush with the body.

5.17 Install the two dowel pins (Item 21), into their respective holes,
one in the outlet seal plate (upper hole in section B-B on the
assembly drawing) and one in the body (Item 1).

5.18 Position dust cover (Item 24), over the outlet seal plate (Item 6)
and attach it to the body (Item 1) using four socket head cap
screws (Item 17) and hex nuts (Item 25). The hex nuts only
need to be tightened sufficiently so that the dust cover is held flat
and snug against the side of the body. A piece of tape should be
placed over both dowel pin holes to prevent them from falling
out.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-23
May 13, 2004 9 of 9

5.19 Apply sealing compound or several wraps of PTFE tape to the

tapered threads on the manual relief valve (Item 13). Using the
1/2” wrench, tighten the manual relief valve properly into its
respective hole in the body (Item 1) adjacent to the pilot end cap
(Item 2).

5.20 Place component tag (Item 23) onto the valve body in the
location shown on the assembly drawing and secure it in place
with two drive screws (Item 22). Stamp the tag per Part
Identification Spec D-000100-09-04, per document: X-043764-
01, (latest revision).

5.21 The DRG Valve Assembly is now ready for “FAT” testing. See
“BOM” for proper “FAT” document number.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 1 of 9

ASSEMBLY PROCEDURE

DRILLING VALVE, 1/4”, 5 KSI WP,

4-WAY 3-POSITION, SUBPLATE MOUNTED,
DUAL 3 KSI PILOT, SUPPLY/SPRING RETURN

CAMERON PART NO.

2185188-28
DRAWING NO.
SK-122800-02

VALVE NO. 2185188-28

Originator: S. Ward Date: May 13, 2004

Checked: T. Bell Date: March 2, 2005
Approved: D. Breazeale Date: March 2, 2005
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 2 of 9

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 3 of 9

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly

of a 1/4”, 5 KSI WP, 4-Way 3-Position, Subplate Mounted, Dual 3 KSI
Pilot, Drilling (DRG) Valve.

2.0 Documents / Materials Required

• Cameron Assembly Drawing; No. SK-122800-02, (latest revision)

• Bill of Materials (BOM); 2185188-28, (latest revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• C-clamp (or similar device) with a minimum 7” jaw opening
• Calibrated torque wrench capable of 0-50 ft-lbs. of torque
• Adapter, appropriate torque wrench drive x 0.250” male hex
• 1/4” hex (Allen) wrenches
• Small open end adjustable wrench or 0.50” & 0.625” open end
wrench
• 90 deg. Retainer Ring pliers
• Thread sealing compound or PTFE tape
• Light grease

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt
and other foreign material. It is important to eliminate any external
influences that could cause a valve functional failure during bench
testing or shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

• Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 4 of 9

5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SHALL TAKE
PRECEDENCE.

• Refer to assembly drawing for orientation of components and item number references. Refer to
“BOM” to cross-reference item numbers with their respective part numbers and descriptions.

5.1 Lubricate back-up rings (Item 16 and 27) and o-rings (Item15
and 26) with light oil. Install back-up rings (Item 27) into the OD
groove of both centering piston (Item 28) and a back-up ring
(Item 16) into the OD groove on each end of the piston (Item 4).
Inspect the installed back-up rings to ensure that the angled
edges of the scarf cut (Figure 1) are aligned and in contact.
Install an o-ring (Item 26) into the same groove adjacent to the
back-up ring on the secondary pistons and install o-rings (Item
15) into the same grooves adjacent to the back-up ring on the
piston. Refer to the assembly drawing for the correct orientation
of the o-ring and back-up ring.

Figure 1 – Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 5 of 9

5.2 Carefully place (and support) the main piston (Item 4) on its end
on a flat, clean table. Insert one spring (item 8) into the upright
bore of the piston,

5.3 Apply light oil to the o-ring and back-up ring and outer surfaces
of one centering piston (Item 28), and to the entrance bevel in
the end of the main piston (Item 4). Insert the centering piston
(small end last) over the springs in the main piston, align it with
the bore, and push it into the main piston. Do not release.

CAUTION
• The retaining ring (item 12) has a slightly rounded side and a sharp side. The retaining
ring should be installed so that the rounded side is facing the centering piston retainer
(item 20), and the sharp edged side is facing out of the bore. This will ensure that the
sharp edge is mated with the outboard load bearing wall of the groove.

• If a clamping method is used to compress the springs, it is critical that any valve
component surface be protected from damage, such as scratches dings, or impressions.
Use an appropriate soft material, such as rubber or plastic, between any clamping
device and the part(s) it contacts.

CORRECT INCORRECT

Figure 2 – Retaining Ring Orientation

5.4 Place piston retainer (Item 20) and retaining ring (item 12) over
the end of the centering piston (Item 28). The sharp lip of the
piston retainer ring should be facing outboard as shown in Figure
2.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 6 of 9

5.5 Compress the springs by pushing on the small end of the

centering piston (item 28). A small c-clamp may help. Seat piston
retainer (Item 20) and install retaining ring (Item 12) into its
groove in the main piston.

5.6 Place and properly support the main piston (Item 4) on a flat
surface on its opposite end from step 5.2. Repeat steps 5.3
through 5.5 to complete the assembly of the second centering
piston

5.7 Lubricate back-up ring (Item 19) and o-ring (Item 18) with light
grease and install a back-up ring onto each of the two seal rings
(Item 7) in the assembly drawing. For each seal ring, slide the
back-up ring towards the lapped face of the seal ring. Inspect
the installed back-up ring (Figure 1) to ensure that the angled
edges of the scarf cut are aligned and in contact. Install o-ring
into the same groove adjacent to the back-up ring. See the
assembly drawing for orientation of the o-ring and back-up ring.
Place the seal ring subassemblies carefully aside until needed.

5.8 Apply light grease to all four o-rings (Item 14) and adjacent body
(Item 1) internal bore surfaces. Install o-rings into their proper
seal grooves in the end caps (item 2). See the assembly drawing
for correct orientation of the o-rings.

5.9 Apply light grease to the outer o-ring diameter, internal starting
bevel and ID piston bore of both end caps (Item 2). Install one
end cap into the dowel pin (item 21) end of the body (Item 1),
until it is fully seated, see assembly drawing. Make sure
mounting holes in the end cap align with the tapped holes in
body.

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with
an anti-galling/low friction coating.

5.10 Install four socket head cap screws (Item 9), through the holes in
the end cap (Item 2), and hand tighten (Do not torque).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 7 of 9

5.11 Lay the body (Item 1) subassembly on a flat surface. Position

the body so that the large seal plate opening in the side is facing
upwards.

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate.
Small dings or raised edges will cause the valve to leak.

5.12 Position the blind seal plate (Item 5), over the side opening in the
body (Item 1) with its lapped surface facing upwards. Place
fingers through the open end of the body to support and lower
the seal plate into its recess in the body, being careful not to
scratch or otherwise damage the lapped sealing surface. Apply
light grease to the exposed lapped surface of the blind seal
plate.

5.13 Apply a light coating of grease of the outer diameters of piston

(Item 4) around the o-rings on both sides. Insert the one end of
the piston through the body until it is fully seated in the end cap.
The transverse bore through the piston should be perpendicular
to the blind seal plate. See the assembly drawing for correct
orientation.

5.14 Installing the second end cap (Item 2) over the piston into the
body. Align mounting hole with tapped holes in body but do not
install any socket head cap screws. This step is only performed
to provide support for the piston (Item 4) during installation of the
sealing surfaces.

WARNING
USE CAUTION WHEN INSTALLING SEAL RINGS, THE INNER AND OUTER EDGES OF THE
LAPPED END OF EACH SEAL RING IS VERY SHARP. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY TO PERSONNEL.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 8 of 9

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of
the valve.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring

5.15 To install the first seal ring subassembly (Items 7, 18 and 19)
with its o-ring and back-up ring in place, apply light grease to the
entire transverse bore of the piston (Item 4). Position the seal
ring over the bore in the piston, lapped end facing downwards,
and press it into the piston bore using thumb pressure. If
insertion is difficult, be sure that the piston bore is not pinching
the back-up ring (Item 19) or o-ring (Item 18). Push the seal ring
downwards until it contacts the blind seal plate (Item 5).

5.16 Place the seal ring spring (Item 10) on top of the seal ring (Item
7) just inserted. Again apply light oil to the bore of the piston
(previously wiped off by the seal ring that was installed first).

5.17 Carefully install the remaining seal ring subassembly (Item 7, 18

and 19) with its o-ring and back-up ring already installed.
Position the seal ring over the bore in the piston, lapped end
facing out, and press it into the piston bore. If insertion is
difficult, be sure that the piston bore is not pinching the back-up
ring or o-ring. Push the seal ring downwards until it contacts the
seal ring spring (Item 10).

5.18 Lightly grease o-ring (Item 11) and its respective groove in the
body (Item 1) as shown in the assembly drawing.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-28
May 13, 2004 9 of 9

5.19 Apply light grease to the lapped surface of the outlet seal plate
(Item 6) as well as to the outer diameter, which contacts the o-
ring (item 11). Install o-ring into body seal groove as shown in
the assembly drawing. Carefully position the outlet seal plate
over the opening in the side of the body, with the three ports
aligned with the axis of the body as shown. Lapped surface
should be facing inwards and the dowel pin hole aligned per the
assembly drawing. Carefully press it into place until the outlet
seal plate is fully seated flush with the body.

5.20 Install the two dowel pins (Item 21), into their respective holes,
one in the outlet seal plate (upper hole in section B-B on the
assembly drawing) and one in the body (Item 1).

5.21 Position dust cover (Item 24), over the outlet seal plate (Item 6)
and attach it to the body (Item 1) using four socket head cap
screws (Item 17) and hex nuts (Item 25). The hex nuts only
need to be tightened sufficiently so that the dust cover is held flat
and snug against the side of the body. A piece of tape should be
placed over both dowel pin holes to prevent them from falling
out.

5.22 Reposition valve with the unbolted end cap (Item 3) facing up
and Install socket head cap screws (Item 9) into their respective
holes.

5.23 Torque socket head cap screws both end caps to 12.5 ft-lbs.
(150 in-lbs.) using a criss-cross pattern.

5.24 Apply sealing compound or several wraps of PTFE tape to the

tapered threads on the manual relief valves (Item 13). Using the
1/2” wrench, tighten both manual relief valves properly into the
body.

5.25 Place component tag (Item 23) onto the valve body in the
location shown on the assembly drawing and secure it in place
with two drive screws (Item 22). Stamp the tag per Part
Identification Spec D-000100-09-04, per document: X-043764-
01, (latest revision).

5.26 The DRG Valve Assembly is now ready for “FAT” testing. See
“BOM” for proper “FAT” document number.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 1 of 9

ASSEMBLY PROCEDURE

DRILLING VALVE, 1/4”, 5 KSI WP, 4-WAY 2-POS,

SUBPLATE MOUNTED, SINGLE 3 KSI PILOT,
SUPPLY/SPRING RETURN

CAMERON PART NO.

2185188-29
DRAWING NO.
SK-122800-03

VALVE NO. 2185188-29

Originator: S. Ward Date: May 13, 2004

Checked: T. Bell Date: March 2, 2005
Approved: D. Breazeale Date: March 2, 2005
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 2 of 9

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 3 of 9

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly

of a 1/4”, 5 KSI WP, 2-Position, Subplate Mounted, Single 3 KSI Pilot,
Drilling (DRG) Valve.

2.0 Documents / Materials Required

• Correct Cameron Assembly Drawing; No. SK-122800-03, (latest

revision)
• Correct Bill of Materials (BOM); 2185188-29, (latest revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• C-clamp (or similar device) with a minimum 7” jaw opening
• Calibrated torque wrench capable of 0-50 ft-lbs. of torque
• Adapter, appropriate torque wrench drive x 0.250” male hex
• 1/4” hex (Allen) wrenches
• Small open end adjustable wrench or 0.50” & 0.625” open end
wrench
• Thread sealing compound or PTFE tape
• Light grease

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt
and other foreign material. It is important to eliminate any external
influences that could cause a valve functional failure during bench
testing or shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

• Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 4 of 9

5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SHALL TAKE
PRECEDENCE.

• Refer to assembly drawing for orientation of components and item number references. Refer to
“BOM” to cross-reference item numbers with their respective part numbers and descriptions.

• Not all items listed in this assembly procedure are present in each Drilling Valve version
covered. Disregard any item number call out in this procedure that is not on the ” BOM”.

5.1 Lubricate back-up rings (Item 16 and 27) and o-rings (Item15
and 26) with light grease. Install back-up ring (Item 27) into the
OD groove of the spring end cap (Item 3) and back-up ring (Item
16) into the OD groove of the piston (Item 4). Inspect the
installed back-up rings to ensure that the angled edges of the
scarf cut (Figure 1) are aligned and in contact. Install o-ring
(Item 26) into the same groove adjacent to the back-up ring on
the spring end cap and install o-ring (Item 15) into the same
groove adjacent to the back-up ring on the piston. Refer to the
assembly drawing for the correct orientation of the o-ring and
back-up ring.

Figure 1 – Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 5 of 9

5.2 Lubricate back-up ring (Item 19) and o-ring (Item 18) with light
grease and install a back-up ring onto each of the two seal rings
(Item 7) in the assembly drawing. For each seal ring, slide the
back-up ring towards the lapped face of the seal ring. Inspect
the installed back-up ring (Figure 1) to ensure that the angled
edges of the scarf cut are aligned and in contact. Install o-ring
into the same groove adjacent to the back-up ring. See the
assembly drawing for orientation of the o-ring and back-up ring.
Place the seal ring subassemblies carefully aside until needed.

5.3 Apply light grease to all three o-rings (Item 14) and adjacent
body (Item 1) internal bore surfaces. Install o-rings into their
proper seal grooves in the end caps (item 2 and 3). See the
assembly drawing for correct orientation of the o-rings.

5.4 Apply light grease to the outer o-ring diameter, internal starting
bevel and ID piston bore of the pilot end cap (Item 2). Apply light
grease to the outer o-ring diameter, piston o-ring diameter and
piston starting bevel of the spring end cap (Item 3). Install the
pilot end cap into the manual relief valve (item 13) end of the
body (Item 1), until it is fully seated, see assembly drawing.
Make sure mounting holes in the end cap align with the tapped
holes in body.

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with an anti-
galling/low friction coating.

5.5 Install four socket head cap screws (Item 9), through the holes in
the pilot end cap (Item 2), and hand tighten (Do not torque).

5.6 Lay the body (Item 1) subassembly on a flat surface. Position

the body so that the large seal plate opening in the side is facing
upwards.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 6 of 9

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate. Small
dings or raised edges will cause the valve to leak.

5.7 Position the blind seal plate (Item 5), over the side opening in the
body (Item 1) with its lapped surface facing upwards. Place
fingers through the open end of the body to support and lower
the seal plate into its recess in the body, being careful not to
scratch or otherwise damage the lapped sealing surface. Apply
light grease to the exposed lapped surface of the blind seal
plate.

5.8 Apply a light coating of grease of the outer diameters of the pilot
end and both inner and outer diameters on the spring end of the
piston (Item 4). Insert the pilot end of the piston through the body
until it is fully seated in the pilot end cap.. The transverse bore
through the piston should be perpendicular to the blind seal
plate. See the assembly drawing for correct orientation.

5.9 Without installing spring (item 8) fully seat the spring end cap
(Item 3) into both the piston and body. Do not install any socket
head cap screws. This step is only performed to provide support
for the piston (Item 4) during installation of the sealing surfaces.

WARNING
USE CAUTION WHEN INSTALLING SEAL RINGS, THE INNER AND OUTER EDGES OF THE
LAPPED END OF EACH SEAL RING IS VERY SHARP. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY TO PERSONNEL.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 7 of 9

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of
the valve.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring

5.10 To install the first seal ring subassembly (Items 7, 18 and 19)
with its o-ring and back-up ring in place, apply light oil to the
entire bore of the piston (Item 4). Position the seal ring over the
bore in the piston, lapped end facing downwards, and press it
into the piston bore using thumb pressure. If insertion is difficult,
be sure that the piston bore is not pinching the back-up ring
(Item 19) or o-ring (Item 18). Push the seal ring downwards until
it contacts the blind seal plate (Item 5).

5.11 Place the seal ring spring (Item 10) on top of the seal ring (Item
7) just inserted. Again apply light oil to the bore of the piston
(previously wiped off by the seal ring that was installed first).

5.12 Carefully install the remaining seal ring subassembly (Item 7, 18

and 19) with its o-ring and back-up ring already installed.
Position the seal ring over the bore in the piston, lapped end
facing out, and press it into the piston bore. If insertion is
difficult, be sure that the piston bore is not pinching the back-up
ring or o-ring. Push the seal ring downwards until it contacts the
seal ring spring (Item 10).

5.13 Lightly grease o-ring (Item 11) and its respective groove in the
body (Item 1) as shown in the assembly drawing.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 8 of 9

5.14 Apply light grease to the lapped surface of the outlet seal plate
(Item 6) as well as to the outer diameter, which contacts the o-
ring (item 11). Install o-ring into body seal groove as shown in
the assembly drawing. Carefully position the outlet seal plate
over the opening in the side of the body, with the ports aligned
with the axis of the body as shown. Lapped surface should be
facing inwards and the dowel pin hole aligned per the assembly
drawing. Carefully press it into place until the outlet seal plate is
fully seated flush with the body.

5.15 Install the two dowel pins (Item 21), into their respective holes,
one in the outlet seal plate (upper hole in section B-B on the
assembly drawing) and one in the body (Item 1).

5.16 Position dust cover (Item 24), over the outlet seal plate (Item 6)
and attach it to the body (Item 1) using four socket head cap
screws (Item 17) and hex nuts (Item 25). The hex nuts only
need to be tightened sufficiently so that the dust cover is held flat
and snug against the side of the body. A piece of tape should be
placed over both dowel pin holes to prevent them from falling
out.

5.17 Reposition valve with the spring end cap (Item 3) facing up.
Carefully remove the spring end cap from the body. Reapply
light grease to the o-rings and sealing areas. Lay the body back
on its side on a flat surface with the dust cover facing upwards.

5.18 Place the spring (Item 8) over the end of the piston (Item 4).
Install spring end cap so that the spring is aligned with its seat
and the end cap is aligned with the piston bore.

WARNING
THE SPRING (ITEM 8) UNDER THE SPRING END CAP (ITEM 2) WILL BE EXERTING FORCE
ON THE END CAP WHEN THE END CAP FLANGE FACE IS MATED AGAINST THE VALVE
BODY (ITEM 1). EXTREME CARE MUST BE TAKEN WHEN INSTALLING SPRING END CAP.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY TO PERSONNEL.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000005-29
May 13, 2004 9 of 9

5.19 Position a C-clamp (or similar device) with a minimum 7” jaw

opening over the entire assembly so that the grips of the clamp
are centered on each end cap. Rotate the spring end cap (Item
3) so that its four countersunk holes are aligned with the tapped
holes in the end of the body (Item 1). Tighten the clamp until the
spring end cap is mated properly against the end of the body as
shown in the assembly drawing.

5.20 Install socket head cap screws (Item 9) into their respective
holes in the spring end cap (Item 2). Tighten socket head cap
screws at least hand tight before removing the C-clamp from the
body (Item 1).

5.21 Torque socket head cap screws in the spring end cap and pilot
end cap (Item3) to 12.5 ft-lbs. (150 in-lbs.) using a criss-cross
pattern.

5.22 Apply sealing compound or several wraps of PTFE tape to the

tapered threads on the manual relief valve (Item 13). Using the
1/2” wrench, tighten the manual relief valve properly into its
respective hole in the body (Item 1) adjacent to the pilot end cap
(Item 2).

5.23 Place component tag (Item 23) onto the valve body in the
location shown on the assembly drawing and secure it in place
with two drive screws (Item 22). Stamp the tag per Part
Identification Spec D-000100-09-04, per document: X-043764-
01, (latest revision).

5.24 The DRG Valve Assembly is now ready for “FAT” testing. See
“BOM” for proper “FAT” document number.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 1 of 14

ASSEMBLY PROCEDURE

3/4-INCH, 4-WAY, 2-POSITION VALVE, 5KSI WP,

STAB MOUNTED, W / DUAL 3 KSI PILOTS,
SPRING DETENTED

CAMERON PART NO. 2185606-01

AND DWG. NO. SK-123199-01

Originated: S. Ward _______________________________ Date: Dec. 28, 2001

Checked: T. Bell ________________________________ Date: Jan. 04, 2002

Approved: D. Breazeale ___________________________ Date: Jan. 04, 2002

CAMERON CONTROLS
6650 BINGLE ROAD
HOUSTON, TX 77092
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 2 of 14

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 MATERIALS REQUIRED...................................................................................3

3.0 VALVE PREPARATION PRIOR TO ASSEMBLY .....................................................3

4.0 DISASSEMBLED VALVE COMPONENT INSPECTION .............................................3

5.0 VALVE ASSEMBLY .........................................................................................4

ILLUSTRATIONS

Figure 1 - Valve Assembly .................................................................................... 4

Figure 2 - Piston with O-Rings and Back-up Rings ............................................... 5
Figure 3 - Back-up Ring Scarf Cut Edge Alignment .............................................. 5
Figure 4A - Body ................................................................................................... 6
Figure 4B - Body with End Cap............................................................................. 6
Figure 5 - Main Piston Orientation ........................................................................ 7
Figure 6 - Body with both End Caps ..................................................................... 8
Figure 7 - Body with Outlet Seal Set ..................................................................... 8
Figure 8 - Back-up Ring Scarf Cut Edge Alignment .............................................. 9
Figure 9- Valve Assembly ................................................................................... 11
Figure 10 - Detent Housing Detail....................................................................... 13
Figure 11 - Valve Assembly ................................................................................ 14
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 3 of 14

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly of

a 3/4-Inch, 4-Way, 2-Position, 5 ksi wp, spring detented, stab mounted,
directional control valve.

2.0 Documents/Materials Required

• Cameron Assembly Drawing No. SK-123199-01, (latest revision)

• Bill of Materials (BOM): 2185606-01, (latest revision)
• Clean lint-free rags or cleaning tissues
• Calibrated Torque Wrench Capable of 0 to 150 ft-lbs. of
torque
• Adapter, applicable torque wrench drive to 1/2” male hex
• Adapter, applicable torque wrench drive to 3/8” male hex
• Adapter, applicable torque wrench drive to 1/4” male hex
• Small open end adjustable wrench or 1/2” open end
wrench
• Thread sealing compound or Teflon® tape
• Light oil or grease
• Light spray lubricant

3.0 Valve Preparation Prior to Assembly

All components of the valve must be cleaned thoroughly prior to assembly.

The use of an ultrasonic cleaner is highly recommended. Caustic baths
must not be used.

The valve should be assembled in a clean area, free from dirt and other
foreign material. It is important to eliminate any external influences that
could cause a functional failure during bench testing or shorten the
expected life of the valve in field operation.

Personnel working on the valve shall wear clean clothing, safety shoes,
and safety glasses. This shall also apply to all personnel participating or
operating within the locality of the valve assembly area.

4.0 Disassembled Valve Component Inspection

Inspect all parts after cleaning for burrs, dings or any trash that was
missed during cleaning process. Re-clean parts if still dirty. Contact
Quality or Engineering on any visible burrs or dings.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 4 of 14

5.0 Valve Assembly

CAUTION
Orientation of O-rings and Back-up Rings is critical for proper sealing, valve function and
operation.

NOTE
Refer to assembly drawing SK-123199-01 for orientation of components and item number
references. Refer to BOM 2185606-01 to cross-reference item numbers with their
respective part numbers and descriptions.

5.1 Lubricate o-rings (Item 18) and install o-ring into the OD groove of each
end cap (Items 2 & 3) in Figure 1.

Figure 1 – Valve Assembly

PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 5 of 14

Figure 2 – Piston with O-Rings and Back-up Rings

5.2 Lubricate back-up rings (Item 16) and o-rings (Item 15). First install a
back-up ring into the OD groove on each side of the piston (Item 8).
Install an o-ring into the same groove toward the outside end of the piston
(see Figure 2). Refer to assembly drawing SK-123199-01 to confirm
proper orientation of the o-ring and back-up ring. Inspect the installed
back up ring after assembly to ensure that the angled edges of the scarf
cut are aligned and in contact (see Figure 3).

Figure 3 - Back-up Ring Scarf Cut Edge Alignment

5.3 Stand the body (Item 1) on end on a flat surface. Position the body
(Figure 4A) so that the vent hole (opposite side of the stepped detent
housing hole) is facing towards you and the two tag mounting holes are to
the bottom.

5.4 Lubricate the entrance bevel on the end seal bore of the body with light oil.
Apply light oil to the OD of the end cap (Item 3), on the surface where the
OD o-ring is located. Apply light oil to the ID of the end cap.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 6 of 14

5.5 Position end cap into the end of the body, as referenced by SK-123199-
01. Align the counter-bored side of the stab hole to the same side of the
body as the stepped detent housing hole. Press the nose of the end cap
fully into the body.

NOTE
The through hole or stab hole in the end cap has a front and backside. The backside of the
through hole has a counter-bored section and is the entry point for the mounting stab. The
front side has a smooth bore from the outside to the center chamber.

5.6 Install the four socket head cap screws (Item 14) through the holes in the
end cap and hand tighten (Do not torque).

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with
an anti-galling/low friction coating.

Figure 4A –Body Figure 4B –Body with End Cap

5.7 Turn the body (Item 1) over on the table so that it is resting on the (4)
socket head cap screws that were just installed. Apply light oil to the
entrance bevel on one end of the piston (Item 8), and insert it carefully into
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 7 of 14

the body and end cap. Align the milled flat containing both detent holes
with the detent housing hole in the body (Item 1). See Figure5.

Figure 5 – Main Piston Orientation

5.8 Position the body again so that the vent hole is facing towards you. With
light oil, lubricate the ID bore of the second end cap, the outer surfaces of
the end of the piston, and the seal bore of the body.

5.9 Position the second end cap so that the face with the counter-bored stab
hole is aligned with the same side of the body as the stepped detent
housing hole. The NPT tapped ports should be a mirror image of each
other (see Figure 6). Carefully align the end cap with the piston and press
it into place (also see SK-123199-01 for orientation).

5.10 Install the four socket head cap screws (Item 14) through the holes in the
second end cap and hand tighten (do not torque).

5.11 Using the seal ring bore in the piston move the piston back and forth to
check for binding in the end caps. When finished align the center of one
of the detent holes in the piston with the center of the stepped detent
housing hole in the body. This will assist in installing the detent ball and
housing later.

NOTE
If binding is detected and piston does not have full travel, disassemble and have
parts checked for tolerance compliance.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 8 of 14

Figure 6 – Body with both End Caps

5.12 Lay the body subassembly down on its long side, with the vent port facing
you and with both 1/8” NPT pilot ports are facing down (see Figure 6).
This orientation will leave the face with the outlet seal plate opening facing
upwards. If one port faces up, while the other faces down, one end cap
needs to be rotated 180 degrees.

5.13 Lubricate the two seal rings (Item 9), two o-rings (Item 22) and two back-
up rings (Item 23) with light oil.

Figure 7 – Body with Outlet Seal Set

PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 9 of 14

CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, valve function and
operation.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal
ring. Any damage to these surfaces will cause the valve to leak.

5.14 Install a lubricated back-up ring (Item 23) in Figure 7, on each of the seal
rings (Item 9). Next install a lubricated o-ring (item 22) in the groove
adjacent to the back-up ring. See assembly drawing SK-123199-01for
orientation of the o-ring and back-up ring. Inspect the installed back-up
ring after assembly to ensure that the angled edges of the scarf cut are
aligned and in contact (Figure 8).

Figure 8 – Back-up Ring Scarf Cut Edge Alignment

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate.
Small dings or raised edges will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both
thumbs to press against the bevelled ID surface of the seal ring. It is only necessary to
install the seal ring assembly so that the o-ring and back-up ring are fully within the bore of
the main piston. Leave approximately 1/16” to 5/32” of the seal ring extending beyond the
flat surface of the main piston.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 10 of 14

5.15 Lubricate the OD of the two seal rings (Item 9) and the entrance bores of
the main piston (Item 8) that accept the seal rings with light oil. Carefully
press one seal ring into the bore, making sure that the seal ring’s lapped
surface is facing outboard. The back-up ring will slide in last.

5.16 Lubricate the outlet and inlet seal plates (Items 6 and 7 respectively) with
light oil and install an o-ring (Item 17) into the OD groove on each seal
plate. Note that one surface of each seal plate is lapped. Handle with
care.

5.17 Position the outlet flange (Item 5) on the table with the two angled ports
facing up. Press in the dowel pin (Item 26) into it’s hole in the outlet
flange. Install both o-rings (Item 20) into the face seal grooves. A coating
of light grease on the o-rings should hold them in their groove when the
flange is installed onto the body.

5.18 Position outlet flange next to the body so that the stab bores without the
counter bore are oriented with the vent port of the body. Verify that the
stab counter-bores are aligned with the counter-bores in the end cap pilot
stab holes.

5.19 With the lapped face of the previously installed seal ring (Item 9) facing
upwards, position the outlet seal plate (Item 6) so that the dowel pin hole
is aligned with dowel pin in the Outlet Flange (item 5). Lubricate the body
entrance bevel, bore and the OD of outlet seal plate with a light lubricant.
Carefully press the outlet seal plate (lapped face first) into its bore until it
lands on its respective ledge in the body.

5.20 Lubricate the exposed face of outlet seal plate (Item 6) in Figure 7 with a
light coating of lubricant. Place the outlet flange above the body (Item 1)
and over the outlet seal plate. Align the dowel pin (Item 26) with the hole
in the seal plate and land the flange onto the body. Again check that all
stab counter-bored holes are positioned on the detent side. Rotate the
flange slightly to align its edges with the body if needed. Verify that face
seal o-rings (Item 20) are not pinched.

5.21 Install the four socket head cap screws (Item 13) through the holes in the
outlet flange, and hand tighten (Do not torque).
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 11 of 14

Figure 9 – Valve Assembly

5.22 Flip the body 180 degrees, so that it is resting on the four socket head cap
screws of the outlet flange, and the vent hole is still facing towards you.

5.23 Make sure that the first seal ring is pressed fully against the outlet seal
plate. Insert the spring (Item 10) into the bore (Figure 9), making sure it
lands in the counter-bore of the first installed seal ring (Item 9). Lubricate
the OD of the remaining seal ring and the entrance bore of the main piston
(Item 8) that accepts the seal ring with light oil. Carefully install the
second seal ring into the piston bore, with the lapped surface facing up.
Carefully release the seal ring as the spring may cause it to eject!
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 12 of 14

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate.
Small dings or raised edges will cause the valve to leak.

5.24 Lubricate inlet flange (Item 4) and o-ring (Item 19) with a light grease and
position inlet flange on the table with the face seal groove facing upwards.
Press dowel pin (Item 26) into it’s bores. Install the o-ring (Item 19) into its
face seal groove in the inlet flange.

5.25 Position inlet flange next to the body so that the stab bores without the
counter bore are oriented with the vent port of the body. Verify that the
stab counter-bores are aligned with the counter-bores in the end cap pilot
stab holes and outlet flange.

5.26 Position the inlet seal plate (Item 7) in Figure 9, so that a line through the
tapped holes is perpendicular with the length of the body and the dowel
hole is aligned with the Inlet Flange (item 4). Lubricate the body entrance
bevel, bore and the OD of inlet seal plate with light lubricant. Carefully
press the inlet seal plate into its body bore until it lands on the seal ring.
Carefully release the seal plate as the spring may cause it to eject!

5.27 Lubricate the exposed face of seal plate with light lubricant. Place the
inlet flange over the body and against the inlet seal plate. Align the dowel
pins (Item 26) with the holes in the seal plate and land the flange on the
seal plate. Verify that the face seal o-ring (item 19) has fully remained in
its groove and is not pinched.

NOTE
There will be approximately ½” gap between the body and the inlet flange. This is
due to the free length of the seal ring spring. When both flanges are tight against
the body the seal rings will be preloaded against the seal plates for low-pressure
sealing. If a gap is not present at this stage remove the inlet flange and check the
seal rings and seal ring spring for tolerance compliance.

5.28 Install the four socket head cap screws (Item 13) through the holes in the
inlet flange. Using a cross pattern, slowly and evenly hand tighten the four
socket head cap screws to seat the seal ring, seal plate and inlet flange
(Do not torque).

5.29 Position valve so the back of the valve with the stepped detent housing
hole is facing up.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 13 of 14

5.30 Lubricate outside o-ring surface on detent housing (item 11) and o-ring
(item 21). Install o-ring over detent housing until it is sitting against the
housing step (see Figure 10).

5.31 Lubricate detent ball track on piston and ID of detent housing hole in body.

5.32 Place detent ball (item 28) into the piston detent hole that was previously
centered in the body detent housing hole. Place detent spring (item 12)
inside the detent housing spring bore. With the detent housing now
holding the detent spring, lower it over the detent ball and press the nose
of the housing fully into the body (see Figure 10).

5.33 Install the four socket head cap screws (Item 27) through the holes in the
detent housing, and hand tighten (Do not torque).

Figure10 – Detent housing Detail

5.34 Begin to torque socket head cap screws using a calibrated torque wrench.
Torque all Flange screws first. Torque all End Cap screws last. Torque all
socket head cap screws per Assembly Drawing. Always use a crossing
pattern when tightening the screws. Do not apply all of the necessary
torque on the first pass.

NOTE
This valve is designed with two manual relief valve locations for each end cap pilot circuit.
This was done so the manual relief valves could always be above the pilot stab centerline
for proper circuit bleeding. Refer to Figure 11 for proper placement based on the test stand
mounting for FAT Testing.
PROPERTY OF ORIGINATOR REVISION
S. Ward A01
DATE SHEET AP-000011-01
28 December, 2001 14 of 14

5.35 Lightly coat the NPT threads of the manual relief valves (item 25), with an
appropriate sub-sea thread sealant or Teflon® tape. Install one plug per
end cap in the pilot bleed circuit port above the pilot stab centerline.

5.36 Lightly coat the 1/8” NPT pipe plugs (Item 24), with an appropriate sub-
sea thread sealant or Teflon® tape and install in remaining ports.

Figure 11 – Valve Assembly

5.37 Place the component tag (Item 29) onto the DRG Valve body (Item 1) in
the location shown in the assembly drawing and secure it in place with two
drive screws (Item 30). Stamp the tag per Marking and Stamping
Specification called for in the bill of material and/or quality plan.

5.38 The Valve Assembly is now ready for bench testing in accordance with
FAT X-234365-01. Keep all openings in the valve protected and free of
debris at all times.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 1 of 18

ASSEMBLY PROCEDURE

3/4” HYDRAULIC REGULATOR,

STAB MOUNTED, WITH SINGLE
SUPPLY, PREMIUM DEEPWATER

CAMERON PART NO. 2185583-01

DRAWING NO. SK-154195-01

Originator: S. Ward Date: June-3-2003

Checked: D. Breazeale Date: June-9-2003
Approved: T. Bell Date: June-10-2003

CAMERON CONTROLS R & D

6650 BINGLE ROAD
HOUSTON, TX 77092
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 2 of 18

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 MATERIALS REQUIRED...................................................................................3

3.0 HYDRAULIC REGULATOR PREPARATION PRIOR TO ASSEMBLY ...........................3

4.0 HYDRAULIC REGULATOR INSPECTION PROCEDURE ..........................................3

5.0 HYDRAULIC REGULATOR ASSEMBLY ...............................................................4

List of Figures

Figure 1 – Hydraulic Regulator Assembly ................................................................ 4

Figure 2 – Back-up Ring Scarf Cut Edge Alignment................................................. 5
Figure 3 – Main Piston Install ................................................................................... 5
Figure 4 – Seal Sub Install ....................................................................................... 6
Figure 5 – Vent Piston install .................................................................................... 7
Figure 6 – Body with Main Piston and End Cap ....................................................... 9
Figure 7 – Seal Plates with Seal Rings .................................................................. 10
Figure 8 – Regulated Side Seal Plate Install .......................................................... 11
Figure 9 – Supply Side Seal Plate Install ............................................................... 14
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 3 of 18

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for assembly of the

.75-Inch Premium Deepwater Hydraulic Regulators.

2.0 Documents/Materials Required

• Cameron Assembly Drawing No. SK-154195-01, Regulator, 3/4”,

Hydraulic, Stab Mounted, W / Single Supply (latest revision).
• Bill of Materials (BOM): 2185583-01 (latest revision).
• Lint-free rags or cleaning tissues.
• Calibrated Torque Wrench Capable of 130 ft-lbs. of torque.
• Thread sealing compound or Teflon tape.
• Light oil.
• Light spray lubricant.

3.0 Hydraulic Regulator Preparation Prior to Assembly

All components of the hydraulic regulator must be cleaned thoroughly prior

to assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths must not be used.

The Hydraulic Regulator should be assembled in a clean area, free from

all dirt and other foreign material. It is important to eliminate any external
influences that could cause a regulator functional failure during bench
testing or shorten the expected life of the regulator in field operation.

Personnel working on the hydraulic regulator shall wear clean clothing,

safety shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the hydraulic regulator
assembly area.

4.0 Hydraulic Regulator Component Inspection

Follow the inspection requirements specified in QP-000160-21.

NOTE
Refer to assembly drawing SK-154195-01 for orientation of components and item number
references. Refer to BOM 2185583-01 to cross-reference item numbers with their
respective part numbers and descriptions.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 4 of 18

5.0 Hydraulic Regulator Assembly

Figure 1 – Hydraulic Regulator Assembly

5.1 Stand regulator body (Item 1) up on end so that the vent piston
(exhaust) side is down.

5.2 Install main piston return spring (Item 20) into the spring pocket
surrounding the internal guide bore.

5.3 Lubricate with light oil and install both back-up rings (Item 10) into
the OD groove of the supply piston (Item 3). Inspect the installed
back-up rings after assembly to ensure that the edges of the scarf
cut are aligned and in contact with each other (Figure 2).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 5 of 18

Figure 2 - Back-up Ring Scarf Cut Edge Alignment

Figure 3 – Main Piston Install

CAUTION
Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function and
operation.

5.4 Lubricate with light oil and install o-ring (Item 36) into the same
groove between the back-up rings (Item 10) in supply piston. See
the assembly drawing for correct orientation of the o-ring and back-
up rings.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 6 of 18

5.5 Lubricate both ends of the supply piston (Item 3) with light oil and
install into the regulator body (Item 1), through the return spring
(item 20), until it rests in the internal guide bore. Orient seal ring
bores in supply piston with seal plate bores in body (Figure 3).

5.6 Lubricate the OD of the supply piston end cap (Item 12) and o-ring
(Item 33) with light oil and install the o-ring in end cap OD seal
groove.

5.7 Lubricate the OD of both seal subs (Item 42) and seal sub o-rings
(Item 43) with light oil and install an o-ring in each seal groove.

5.8 Carefully install one seal sub into the small transfer port in the end
of the regulator body (Item1). This will be for the supply piston side
of the body which should be facing up (Figure 4).

Figure 4 – Seal Sub Install

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 7 of 18

5.9 Lubricate the supply piston end cap inner bore and outer surface
with light oil and position the supply piston end cap over supply
piston and press into place. Make sure the small transfer port, in
the end cap, is aligned with the seal sub (Item 42) sticking up out of
the regulator body.

5.10 Install four (Item 37) socket head cap screws in supply piston end
cap and regulator body and hand tighten only (Do Not Torque).

5.11 Stand regulator body (Item 1) up on its other end so that the vent
piston (exhaust) side is up (Figure 5).

Figure 5 – Vent Piston install

5.12 Lubricate with light oil and install both back-up rings (Item 9) into
the OD groove of the vent piston (Item 6). Inspect the installed
back-up rings after assembly to ensure that the edges of the scarf
cut are aligned and in contact with each other (Figure 2).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 8 of 18

CAUTION
Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function and
operation.

5.13 Lubricate with light oil and install o-ring (Item 35) into the same
groove between the back-up rings (Item 9) in vent piston. See the
assembly drawing for correct orientation of the o-ring and back-up
rings.

5.14 Insert vent piston (Item 6) into the vent piston bore of the regulator
body until it slides inside the main piston guide bore (Item 3). Orient
seal ring bores in vent piston with vent seal plate bores in body
(Figure 5).

5.15 Install the vent piston return spring (Item 20) over the vent piston.

5.16 Lubricate with light oil and install o-ring (Item 34) into the OD
groove on the pilot relief end cap (Item 2).

5.17 Carefully install the other seal sub (Item 42) into the small transfer
port in the end of the regulator body (Item1). This will be for the
vent piston side of the body which should now be facing up.

5.18 Lubricate the vent piston OD (Item 6) and pilot relief end cap inner
bore with light oil. Position the pilot relief end cap over the exhaust
spring (Item 20) and the vent piston OD. Make sure the small
transfer port, in the end cap, is aligned with the seal sub (Item 42)
sticking up out of the regulator body. Press into place until the
exhaust spring is properly seated in the pilot relief end cap counter
bore.

5.19 Install four socket head cap screws (Item 40) in relief pilot end cap
(Item 2) and regulator body (Item 1) and tighten hand tight only (Do
Not Torque).
PROPERTY OF ORIGINATOR REVISION
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DATE SHEET AP-000012-01
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Figure 6 – Body with Pistons and End Caps

5.20 Position regulator body (Item 1) so that the regulated pressure,

blank seal plate and exhaust port hole side is facing up, the two
port hole side is facing down (Figure 6).

CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function
and operation.
• Extreme care must be taken to avoid any contact with the lapped surface of each vent
seal ring (Item 17). Any damage to these surfaces will cause the regulator to leak.

5.21 Lubricate the OD of both vent seal rings (Item 17), o-rings (Item
30), back-up rings (Item 7) and both vent piston bores (Item 6) with
light oil and install back-up ring and o-ring on vent seal ring. See
the assembly drawing for correct orientation of the o-ring and back-
up ring.

5.22 Install one of the vent seal ring springs (Item 21) into the upper vent
piston bore (Figure 7).

5.23 Carefully press one vent seal ring assembly (Item 17) into the vent
piston bore (Item 6), through the relief seal flange bore (Figure 7).
Make sure that the seal ring’s lapped surface is facing outboard
from the regulator body (Item 1).
PROPERTY OF ORIGINATOR REVISION
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DATE SHEET AP-000012-01
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NOTE
The vent seal ring spring will hold the back-up and o-ring outside the vent piston bore. Use
your thumb to press against the bevelled ID surface of the seal ring. (Do not press directly
on the lapped surface of the seal ring) It is only necessary to press down on the seal ring
assembly so that the o-ring and back-up ring slide fully within the bore of the vent piston
once. This is to ensure the smooth insertion during final assembly.

5.24 Lubricate the OD of the exhaust seal plate (Item 5) and o-ring (Item
29) with light oil and install the o-ring in exhaust seal plate groove
(Figure 7).

5.25 Press dowel pin (Item 26) fully into the exhaust seal flange (Item
16) (Figure 8).

Figure 7 – Seal Plates with Seal Rings

5.26 Install o-ring (Item 28) into its respective groove in the exhaust seal
flange (Item 16). A small amount of light grease will help keep the
o-ring in position during assembly.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 11 of 18

5.27 Lubricate both faces plus the OD o-ring of the exhaust seal plate
(Item 5) and the exhaust seal plate bore in the regulator body (Item
1) with light lubricant.

CAUTION
Extreme care must be taken to avoid any damage to the lapped surface of each exhaust
seal plate. Any damage to these surfaces will cause the Regulator to leak.

5.28 Hold the exhaust seal plate above the body. Position it with the
lapped surface facing inboard towards the installed seal ring (Item
17) and the Exhaust port and the dowel pin hole inline with the axis
of the regulator body (Figure 8).

5.29 Carefully place the exhaust seal plate into the regulator body until it
is resting on the seal ring.

Figure 8 – Regulated Side Seal Plate Install

5.30 Place exhaust seal flange (Item 16) over the exhaust seal plate
(Item 5). Align the exhaust seal flange so that the bolt holes are in
alignment with the regulator body mounting holes and that the
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 12 of 18

dowel pin (Item 26) is aligned with the dowel hole in the exhaust
seal plate. Confirm the o-ring (Item 28) and dowel pin are still in
their appropriate positions (Figure 8). Slowly press the flange into
final position against surface of body. Care must be taken as this
action will press and seat the seal ring into the vent piston.

5.31 While holding the exhaust seal flange against the regulator body
install the four (Item 39) socket head cap screws. Hand tighten only
(Do Not Torque).

CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function
and operation.

• Extreme care must be taken to avoid any contact with the lapped surface of each supply
seal ring (Item 15). Any damage to these surfaces will cause the regulator to leak.

5.32 Lubricate the OD of the supply seal rings (Item 15), o-rings (Item
27), back-up rings (Item 8) and the supply piston bore (Item 3) with
light oil and install the back-up rings and o-rings on the supply seal
rings. See the assembly drawing for correct orientation of the o-ring
and back-up rings.

5.33 Carefully press one supply seal ring assembly (Item 15) into the
supply piston bore (Item 3), through the outlet flange bore (Figure
8), making sure that the supply seal ring’s lapped surface is facing
outboard from the regulator body (Item 1).

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both
thumbs to press against the bevelled ID surface of the seal ring. It is only necessary to
install the seal ring assembly so that the o-ring and back-up ring are fully within the bore of
the supply piston. Leave approximately 1/16” to 5/32” of the seal ring extending beyond the
flat surface of the supply piston.

5.34 Lubricate the OD of the blind seal plate (Item 11) and o-ring (Item
31) with light oil and install the o-ring on blind seal plate.
PROPERTY OF ORIGINATOR REVISION
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DATE SHEET AP-000012-01
3-JUNE-03 13 of 18

5.35 Press dowel pin (Item 26) fully into the outlet flange (Item 4).

5.36 Install o-ring (Items 27) into its respective groove in the outlet
flange. A small amount of grease will help keep the o-rings in
position during assembly.

5.37 Lubricate both faces plus the OD o-ring of the blind seal plate (Item
11), supply seal ring lapped face (Item 15) and blind seal plate bore
in the regulator body (Item 1) with light lubricant.

CAUTION
Extreme care must be taken to avoid any contact with a foreign object against the lapped
surface of the blind seal plate. Any damage to these surfaces will cause the regulator to
leak.

5.38 Position blind seal plate (Item 11) with lapped surface facing
inboard towards the installed supply seal ring (Item 15) and ports in
line with the axis of the regulator body. See the assembly drawing
for correct orientation. Push the blind seal plate completely into the
regulator body bore.

5.39 Place outlet flange (Item 4) assembly over the blind seal plate.
Align dowel pin in outlet flange with hole in the blind seal plate and
press into place.

5.40 Verify that the outlet flange is fully mated with the regulator body
(Item 1). Confirm the o-ring (Item 27) is still in its appropriate
position (Figure 8). Install four socket head cap screws (Item 38)
through the outlet flange into the regulator body and tighten hand
tight only (Do Not Torque).

5.41 Rotate hydraulic regulator assembly 180° degrees so the outlet

flange is now facing down. Use light oil to lubricate the accessible
portions of the internal bore of the supply piston (Item 3).

5.42 Insert supply seal ring spring (Item 18) into the bore in the piston
against the installed supply seal ring (Item 15).
PROPERTY OF ORIGINATOR REVISION
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DATE SHEET AP-000012-01
3-JUNE-03 14 of 18

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, regulator function
and operation.
• Extreme care must be taken to avoid any contact with the lapped surface of each supply
seal ring (Item 15). Any damage to these surfaces will cause the regulator to leak.

5.43 Lubricate the OD of the second supply seal ring assembly (Item 15)
and carefully press it into the supply piston bore (Item 3), through
the inlet flange bore (Figure 9), making sure that the supply seal
ring’s lapped surface is facing outboard from the regulator body
(Item 1).

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both
thumbs to press against the bevelled ID surface of the seal ring. It is only necessary to
install the seal ring assembly so that the o-ring and back-up ring are fully within the bore of
the supply piston once before removing pressure. Like the vent seal ring the supply seal
ring’s back-up and o-ring may extend beyond it’s seating area in the supply piston.

Figure 9 – Supply Side Seal Plate Install

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 15 of 18

5.44 Lubricate the OD of the supply seal plate (Item 14) and o-ring (Item
31) with light oil and install the o-ring in supply seal plate groove.

5.45 Press dowel pin (Item 26) fully into the supply flange (Item 13).

5.46 Install o-ring (Item 27) into its respective groove in the supply
flange. A small amount of grease will help keep the o-ring in
position during assembly.

5.47 Lubricate both faces plus the OD o-ring of the supply seal plate
(Item 14), supply seal ring lapped face (Item 15) and supply seal
plate bore in the regulator body (Item 1) with light lubricant.

CAUTION
Extreme care must be taken to avoid any contact with a foreign object against the lapped
surface of the supply seal plate. Any damage to these surfaces will cause the regulator to
leak.

5.48 Hold the supply seal plate above the body. Position it with the
lapped surface facing inboard towards the installed seal ring (Item
15) and the supply port and dowel pin hole inline with the axis of the
regulator body (Figure 9). Push the supply seal plate fully into its
final position in the regulator body.

5.49 Lubricate the outboard side of the supply seal plate (Item 14) with
light oil. Place supply flange assembly (Item 13) over the supply
seal plate. Align dowel pin (Item 26) in supply flange with
respective hole in the supply seal plate and carefully press into
place (Figure 9).

CAUTION
Extreme care must be taken to avoid any lateral movement when the lapped surface of the
supply seal plate comes in contact with the lapped surface of the supply seal ring. Any
damage to these surfaces will cause the regulator to leak.

5.50 Verify that the supply flange is fully mated with the regulator body
(Item 1). Install four socket head cap screws (Item 38) in supply
flange and regulator body and tighten hand tight only (Do Not
Torque).
 PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 16 of 18

I
CAUTION
• Orientation of O-rings and Back-up Rings is critical for proper sealing, regulator function
and operation.
• Extreme care must be taken to avoid any contact with the lapped surface of each vent
seal ring (Item 17). Any damage to these surfaces will cause the regulator to leak.

5.51 Lubricate the OD of the remaining vent seal ring assembly (Item
17) with light oil.

5.52 Install the remaining vent seal ring spring (Item 21) into the vent
piston bore (Figure 9).

5.53 Carefully press the remaining vent seal ring assembly (Item 17) into
the vent piston bore (Item 6), through the relief seal flange bore
(Figure 9). Make sure that the seal ring’s lapped surface is facing
outboard from the regulator body (Item 1).

NOTE
The vent seal ring spring will hold the back-up and o-ring outside the vent piston bore.
Use your thumb to press against the bevelled ID surface of the seal ring. (Do not press
directly on the lapped surface of the seal ring) It is only necessary to press down on
the seal ring assembly so that the o-ring and back-up ring slide fully within the bore of
the vent piston once. This is to ensure the smooth insertion during final assembly.

5.54 Lubricate the OD of the exhaust seal plate (Item 5) and o-ring (Item
29) with light oil and install the o-ring in exhaust seal plate groove
(Figure 9).

5.55 Press a dowel pin (Item 26) fully into the exhaust seal flange (Item
16) (Figure 9).

5.56 Install o-ring (Item 28) into its respective groove in the exhaust seal
flange (Item 16). A small amount of light grease will help keep the
o-ring in position during assembly.

5.57 Lubricate both faces plus the OD o-ring of the exhaust seal plate
(Item 5) and the exhaust seal plate bore in the regulator body (Item
1) with light lubricant.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 17 of 18

CAUTION
Extreme care must be taken to avoid any contact with a foreign object against the lapped
surface of the exhaust seal plate. Any damage to these surfaces will cause the regulator to
leak.

5.58 Hold the exhaust seal plate above the body. Position it with the
lapped surface facing inboard towards the installed seal ring (Item
17) and the Exhaust port and the dowel pin hole inline with the axis
of the regulator body (Figure 9).

5.59 Carefully place the exhaust seal plate into the regulator body until it
is resting on the seal ring.

5.60 Place exhaust seal flange (Item 16) over the exhaust seal plate
(Item 5). Align the exhaust seal flange so that the bolt holes are in
alignment with the regulator body mounting holes and that the
dowel pin (Item 26) is aligned with the dowel hole in the exhaust
seal plate. Confirm the o-ring (Item 28) and dowel pin are still in
their appropriate positions (Figure 8). Slowly press the flange into
final position against surface of body. Care must be taken as this
action will press and seat the seal ring into the vent piston.

5.61 While holding the exhaust seal flange against the regulator body
install the four (Item 39) socket head cap screws. Hand tighten only
(Do Not Torque).

5.62 Begin to torque socket head cap screws using a calibrated torque
wrench at this time. Torque all Flange screws first. Torque all End
Cap screws last. Torque socket head cap screws in accordance
with recommended torque in chart below. Always use a crossing
pattern when tightening the screws. Do not apply all of the
necessary torque on the first pass.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000012-01
3-JUNE-03 18 of 18

Recommended Comments
Makeup Torque
Inlet Flange 130 ft-lb. 5/8” Socket Head Screw – 8X
Outlet Flange
Supply Piston Cap 130 ft-lb. 5/8” Socket Head Screw – 8X
Pilot Relief Cap
Exhaust Seal Flange, 70 ft-lb. 1/2” Socket Head Screw – 8X
2X

5.63 Prepare the (2) 1/8”M NPT bleed valves (Item 25) with an
appropriate sub-sea thread sealant or tape. Install the two 1/8”M
NPT bleed valves in their respective NPT ports in the End Caps.
Install 1/8” NPT pipe plug (Item 41). See the assembly drawing for
correct orientation.

5.64 Place the component tag (Item 22) onto the regulator body (Item 1)
in the location shown in the assembly drawing and secure it in
place with two drive screws (Item 24). Stamp the tag per Marking
and Stamping Spec D-000100-09-04.

5.65 The Hydraulic Regulator Assembly is now ready for “FAT” testing
per the “BOM”.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 1 of 10

ASSEMBLY PROCEDURE

DRILLING VALVE, 1/2”, 5 KSI WP,

4-WAY 3-POSITION, SUBPLATE MOUNTED,
DUAL 3 KSI PILOT, SUPPLY/SPRING CENTERED

CAMERON PART NO.

2232114-01
DRAWING NO.
SK-154396-01

Originator: S. Ward Date: May 17, 2004

Checked: T. Bell Date: March 22, 2005
Approved: J. Wilkirson Date: March 23, 2005
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 2 of 10

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 3 of 10

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly

of a 1/2”, 5 KSI WP, 4-Way 3-Position, Subplate Mounted, Dual 3 KSI
Pilot, Drilling (DRG) Valve.

2.0 Documents / Materials Required

• Cameron Assembly Drawing; No. SK-154396-01, (latest revision)

• Bill of Materials (BOM); 2232114-01, (latest revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• C-clamp (or similar device) with a minimum 7.5” jaw opening
• Calibrated torque wrench capable of 0-50 ft-lbs. of torque
• Adapter, appropriate torque wrench drive x 0.313” male hex
• 5/16” hex (Allen) wrenches
• Small open end adjustable wrench or 0.50” & 0.625” open end
wrench
• 90 deg. Retainer Ring pliers
• Thread sealing compound or PTFE tape
• Light grease

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt
and other foreign material. It is important to eliminate any external
influences that could cause a valve functional failure during bench
testing or shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

• Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 4 of 10

5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SHALL TAKE
PRECEDENCE..

• Refer to assembly drawing for orientation of components and item number references. Refer to
“BOM” to cross-reference item numbers with their respective part numbers and descriptions.

5.1 Lubricate back-up rings (Item 35 and 37) and o-rings (Item16
and 20) with light grease. Install back-up rings (Item 37) into the
ID groove in each end of the piston end bores (Item 2) and a
back-up ring (Item 35) into the OD groove on each end of the
piston. Inspect the installed back-up rings to ensure that the
angled edges of the scarf cut (Figure 1) are aligned and in
contact. Install an o-ring (Item 20) into the same groove
adjacent to the back-up ring in the ID bore and install o-rings
(Item 16) into the same grooves adjacent to the back-up ring on
the pistons OD. Refer to the assembly drawing for the correct
orientation of the o-ring and back-up ring.

Figure 1 – Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 5 of 10

5.2 Carefully place (and support) the main piston (Item 2) on its end
on a flat, clean table. Insert one spring (item 12) into the upright
bore of the piston until seated into the spring pocket.

5.3 Apply light grease to the outer surfaces of one centering piston
(Item 9), and to the o-ring and back-up ring in the end of the
main piston (Item 2). Insert the centering piston (small end last)
over the springs in the main piston, align it with the bore, and
push it into the main piston.

CAUTION
• The retaining ring (item 27) has a slightly rounded side and a sharp side. The retaining
ring should be installed so that the rounded side is facing the centering piston retainer
(item 10), and the sharp edged side is facing out of the bore. This will ensure that the
sharp edge is mated with the outboard load bearing wall of the groove.

• If a clamping method is used to compress the springs, it is critical that any valve
component surface be protected from damage, such as scratches dings, or impressions.
Use an appropriate soft material, such as rubber or plastic, between any clamping
device and the part(s) it contacts.

CORRECT INCORRECT

Figure 2 – Retaining Ring Orientation

5.4 Place piston retainer (Item 10) and retaining ring (item 27) over
the end of the centering piston (Item 9). The sharp lip of the
piston retainer ring should be facing outboard as shown in Figure
2.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 6 of 10

5.5 Compress the springs by pushing on the small end of the

centering piston (item 9). A small c-clamp may help. Seat piston
retainer (Item 10) and install retaining ring (Item 27) into its
groove in the main piston.

5.6 Place and properly support the main piston (Item 2) on a flat
surface on its opposite end from step 5.2. Repeat steps 5.3
through 5.5 to complete the assembly of the second centering
piston

5.7 Lubricate back-up rings (Item 36) and o-rings (Item 19) with light
grease and install a back-up ring onto each of the two seal rings
(Item 8) in the assembly drawing. For each seal ring, slide the
back-up ring towards the lapped face of the seal ring. Inspect
the installed back-up ring (Figure 1) to ensure that the angled
edges of the scarf cut are aligned and in contact. Install o-ring
into the same groove adjacent to the back-up ring. See the
assembly drawing for orientation of the o-ring and back-up ring.
Place the seal ring subassemblies carefully aside until needed.

5.8 Place body (item 1) on a clean flat surface with the top (side with
the four counter bores for the thru holes and name tag mounting
holes) up.

5.9 Apply light grease to all four o-rings (Item 17) and adjacent body
(Item 1) internal bore surfaces. Install o-rings into their proper
OD seal grooves in the end caps (item 3). See the assembly
drawing for correct orientation of the o-rings.

5.10 Apply light grease to the outer o-ring diameter, internal starting
bevel and ID piston bore of both end caps (Item 3). Install one
end cap into the body (Item 1), until it is fully seated, see
assembly drawing. Make sure mounting holes in the end cap
align with the tapped holes in body and the manual relief valves
(Item 26) hole is positioned at the top of the body. See the
assembly drawing for correct orientation.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 7 of 10

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with
an anti-galling/low friction coating.

5.11 Install four socket head cap screws (Item 23), through the holes
in the end cap (Item 3), and hand tighten (Do not torque).

5.12 Apply a light coating of grease of the outer diameters of piston

(Item 2) around the o-rings on both sides. Insert the piston
through the body until it is fully seated in the end cap. The
transverse bore through the piston should be perpendicular to
the seal plate holes. See the assembly drawing for correct
orientation.

5.13 Install the second end cap (Item 3) over the piston into the body,
until it is fully seated. Make sure mounting holes in the end cap
align with the tapped holes in body and the manual relief valves
(Item 26) hole is positioned at the top of the body.

5.14 Install four socket head cap screws (Item 23), through the holes
in the end cap (Item 3), and hand tighten (Do not torque).

WARNING
USE CAUTION WHEN INSTALLING SEAL RINGS, THE INNER AND OUTER EDGES OF THE
LAPPED END OF EACH SEAL RING IS VERY SHARP. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY TO PERSONNEL.

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of
the valve.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 8 of 10

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring

5.15 To install the first seal ring subassembly (Items 8, 19 and 36)
with its o-ring and back-up ring in place, apply light grease to the
entire transverse bore of the piston (Item 2). Position the seal
ring over the piston in the top bore of the body (item 1), lapped
end facing outwards, and press it into the piston bore using
thumb pressure. If insertion is difficult, be sure that the piston
bore is not pinching the o-ring (Item 19) or back-up ring (Item
36). Push the seal ring downwards until its flush with the piston
bore.

5.16 Install one dowel pin (item 28) into the dowel pin hole located at
the bottom of the blind seal plate bore in the top of the body.

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate.
Small dings or raised edges will cause the valve to leak.

5.17 Lightly grease o-ring (Item 18) and its respective groove in the
blind seal plate (item 6). Install o-ring into the o-ring groove.
Apply light grease to the lapped surface of the blind seal plate.

5.18 Position the blind seal plate (Item 6), over the top opening in the
body (Item 1) with its lapped surface facing inwards. Align the
dowel pin hole, in the lapped surface, of the blind seal plate with
the dowel pin in the body. Lower the seal plate into its bore in the
body, being careful not to scratch or otherwise damage the
lapped sealing surface, until fully seated.

5.19 Install the blind seal plate flange (item 5) with its four mounting
bolts (item 24), and hand tighten (Do not torque). See the
assembly drawing for correct orientation.
PROPERTY OF ORIGINATOR REVISION
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DATE SHEET AP-000014-01
May 17, 2004 9 of 10

5.20 Place body (item 1) on a clean flat surface with the blind seal
plate flange (item 5) facing down.

5.21 Place the seal ring spring (Item 13) on top of the seal ring (Item
8) just inserted. Push the seal ring downwards until it contacts
the blind seal plate (Item 6).

5.22 Carefully install the remaining seal ring subassembly (Item 8, 19

and 36) with its o-ring and back-up ring already installed.
Position the seal ring over the bore in the piston, lapped end
facing out, and press it into the piston bore. If insertion is
difficult, be sure that the piston bore is not pinching the o-ring or
back-up ring. Push the seal ring downwards until it contacts the
seal ring spring (Item 13).

5.23 Install the other dowel pin (item 28) into the dowel pin hole
located at the bottom of the outlet seal plate bore in the bottom
of the body.

5.24 Lightly grease o-ring (Item 18) and its respective groove in the
outlet seal plate (item 7). Install o-ring into the o-ring groove.
Apply light grease to the lapped surface of the outlet seal plate.

5.25 Position the outlet seal plate (Item 7), over the bottom opening in
the body (Item 1) with its lapped surface facing inwards. Align
the dowel pin hole, in the lapped surface, of the outlet seal plate
with the dowel pin (item 28) in the body. Lower the seal plate into
its bore in the body, being careful not to scratch or otherwise
damage the lapped sealing surface, until fully seated.

5.26 Install dowel pins (Item 32), into its respective hole in the body
(Item 1). See the assembly drawing for correct orientation.

5.27 Position dust cover (Item 31), over the outlet seal plate (Item 7)
and attach it to the body (Item 1) using four socket head cap
screws (Item 22) and hex nuts (Item 25). The hex nuts only
need to be tightened sufficiently so that the dust cover is held flat
and snug against the side of the body. A piece of tape should be
placed over the dowel pin hole to prevent it from falling out.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-01
May 17, 2004 10 of 10

5.28 Torque socket head cap screws for both end caps and the blind
seal plate flange to 25 ft-lbs. (300 in-lbs.) using a criss-cross
pattern.

5.29 Apply sealing compound or several wraps of PTFE tape to the

tapered threads on the manual relief valves (Item 26). Using the
1/2” wrench, tighten both manual relief valves properly into the
end caps.

5.30 Place component tag (Item 29) onto the valve body in the
location shown on the assembly drawing and secure it in place
with two drive screws (Item 30). Stamp the tag per Part
Identification Spec D-000100-09-04, per document: X-043764-
01, (latest revision).

5.31 The DRG Valve Assembly is now ready for “FAT” testing. See
“BOM” for proper “FAT” document number.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 1 of 9

ASSEMBLY PROCEDURE

DRILLING VALVE, 1/2”, 5 KSI WP,

4-WAY 2-POSITION, SUBPLATE MOUNTED,
SINGLE 3 KSI PILOT, SPRING RETURN

CAMERON PART NO.

2232114-02
DRAWING NO.
SK-154396-02

Originator: S. Ward Date: May 17, 2004

Checked: T. Bell Date: March 22, 2005
Approved: J. Wilkirson Date: March 23, 2005
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 2 of 9

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 3 of 9

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly

of a 1/2”, 5 KSI WP, 4 Way 2-Position, Subplate Mounted, Spring
Return, Single 3 KSI Pilot, Drilling (DRG) Valve.

2.0 Documents / Materials Required

• Cameron Assembly Drawing; No. SK-154396-02, (latest revision)

• Bill of Materials (BOM); 2232114-02, (latest revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• Calibrated torque wrench capable of 0-50 ft-lbs. of torque
• Adapter, appropriate torque wrench drive x 5/16” male hex
• 5/16” hex (Allen) wrenches
• Small open end adjustable wrench or 0.50” & 0.625” open end
wrench
• Thread sealing compound or PTFE tape
• Light grease

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt
and other foreign material. It is important to eliminate any external
influences that could cause a valve functional failure during bench
testing or shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

• Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 4 of 9

5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SHALL TAKE
PRECEDENCE.

• Refer to assembly drawing for orientation of components and item number references. Refer to
“BOM” to cross-reference item numbers with their respective part numbers and descriptions.

5.1 Lubricate back-up ring (Item 35) and o-ring (Item16) with light
grease. Install back-up ring (Item 35) into the OD groove on the
piston (Item 2). Inspect the installed back-up ring to ensure that
the angled edges of the scarf cut (Figure 1) are aligned and in
contact. Install an o-ring (Item 16) into the same groove
adjacent to the back-up ring in the bore on the pistons OD.
Refer to the assembly drawing for the correct orientation of the
o-ring and back-up ring.

Figure 1 – Back-up Ring Scarf Cut Edge Alignment

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 5 of 9

5.2 Lubricate back-up rings (Item 36) and o-rings (Item 19) with light
grease and install a back-up ring onto each of the two seal rings
(Item 8) in the assembly drawing. For each seal ring, slide the
back-up ring towards the lapped face of the seal ring. Inspect
the installed back-up ring (Figure 1) to ensure that the angled
edges of the scarf cut are aligned and in contact. Install o-ring
into the same groove adjacent to the back-up ring. See the
assembly drawing for orientation of the o-ring and back-up ring.
Place the seal ring subassemblies carefully aside until needed.

5.3 Place body (item 1) on a clean flat surface on it’s end so that the
side with the name tag mounting holes is facing up. Apply light
grease to the internal bore surfaces.

5.4 Apply light grease to two o-rings (Item 17) and Install o-rings into
their proper OD seal grooves in the pilot end cap (item 3). See
the assembly drawing for correct orientation of the o-rings.

5.5 Apply light grease to the outer o-ring diameter, internal starting
bevel and ID piston bore of the end cap (Item 3) and Install into
the body (Item 1), just until the four socket head cap screws
(Item 23) can be started by hand. Make sure mounting holes in
the end cap align with the tapped holes in body and the manual
relief valves (Item 26) hole is positioned at the top of the body.
See the assembly drawing for correct orientation.

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with
an anti-galling/low friction coating.

5.6 Install four socket head cap screws (Item 23), through the holes
in the end cap (Item 3), engage only two to three threads per
screw.

5.7 Turn body (item 1) over so that it is sitting on the installed end
cap.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 6 of 9

5.8 Apply light grease to two o-rings (Item 17) and Install o-rings into
their proper outer OD seal grooves in the spring end cap (item
4). Lubricate back-up ring (Item 37) and o-ring (Item 15) with
light grease and install the back-up ring onto the inner OD seal
groove. Inspect the installed back-up ring to ensure that the
angled edges of the scarf cut (Figure 1) are aligned and in
contact. Install an o-ring (Item 15) into the same groove
adjacent to the back-up ring in the bore on the pistons inner OD.
Refer to the assembly drawing for the correct orientation of the
o-ring and back-up ring.

5.9 Apply a light coating of grease to both outer diameters of piston

(Item 2) and the internal starting bevel and ID piston bore on the
spring side of the piston. Insert the large end of the piston
through the body until it is fully seated in the end cap. The
transverse bore through the piston should be perpendicular to
the seal plate holes. See the assembly drawing for correct
orientation.

WARNING
THE SPRING (ITEM 12) UNDER THE SPRING END CAP (ITEM 4) WILL BE EXERTING FORCE
ON THE END CAP WHEN THE END CAP FLANGE FACE IS MATED AGAINST THE VALVE
BODY (ITEM 1). EXTREME CARE MUST BE TAKEN WHEN INSTALLING SPRING END CAP.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY TO PERSONNEL.

5.10 Install spring (item 12) over the piston (item 2) then install the
spring end cap (Item 4) into both the piston and body. Make sure
mounting holes in the end cap align with the tapped holes in
body.

5.11 Install socket head cap screws (Item 23) into their respective
holes in the spring end cap (Item 4). Tighten end cap bolts in a
criss-cross pattern (Do not torque). Turn over the body (item 1)
and tighten the other end cap bolts in a criss-cross pattern (Do
not torque).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 7 of 9

5.12 Place body (item 1) with the top (side with the four counter bores
for the thru holes and name tag mounting holes) up.

WARNING
USE CAUTION WHEN INSTALLING SEAL RINGS, THE INNER AND OUTER EDGES OF THE
LAPPED END OF EACH SEAL RING IS VERY SHARP. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY TO PERSONNEL.

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of
the valve.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring

5.13 To install the first seal ring subassembly (Items 8, 19 and 36)
with its o-ring and back-up ring in place, apply light grease to the
entire transverse bore of the piston (Item 2). Position the seal
ring over the piston in the top bore of the body (item 1), lapped
end facing outwards, and press it into the piston bore using
thumb pressure. If insertion is difficult, be sure that the piston
bore is not pinching the o-ring (Item 19) or back-up ring (Item
36). Push the seal ring downwards until its flush with the piston
bore.

5.14 Install one dowel pin (item 28) into the dowel pin hole located at
the bottom of the blind seal plate bore in the top of the body.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 8 of 9

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate.
Small dings or raised edges will cause the valve to leak.

5.15 Lightly grease o-ring (Item 18) and its respective groove in the
blind seal plate (item 6). Install o-ring into the o-ring groove.
Apply light grease to the lapped surface of the blind seal plate.

5.16 Position the blind seal plate (Item 6), over the top opening in the
body (Item 1) with its lapped surface facing inwards. Align the
dowel pin hole, in the lapped surface, of the blind seal plate with
the dowel pin in the body. Lower the seal plate into its bore in the
body until fully seated, being careful not to scratch or otherwise
damage the lapped sealing surface, until fully seated.

5.17 Install the blind seal plate flange (item 5) with its four mounting
bolts (item 24), and hand tighten (Do not torque).

5.18 Place body (item 1) with the blind seal plate flange (item 5)
facing down.

5.19 Place the seal ring spring (Item 13) on top of the seal ring (Item
8) just inserted. Push the seal ring downwards until it contacts
the blind seal plate (Item 6).

5.20 Carefully install the remaining seal ring subassembly (Item 8, 19

and 36) with its o-ring and back-up ring already installed.
Position the seal ring over the bore in the piston, lapped end
facing out, and press it into the piston bore. If insertion is
difficult, be sure that the piston bore is not pinching the o-ring or
back-up ring. Push the seal ring downwards until it contacts the
seal ring spring (Item 13).

5.21 Install the other dowel pin (item 28) into the dowel pin hole
located at the bottom of the outlet seal plate bore in the bottom
of the body.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-02
May 17, 2004 9 of 9

5.22 Lightly grease o-ring (Item 18) and its respective groove in the
outlet seal plate (item 7). Install o-ring into the o-ring groove.
Apply light grease to the lapped surface of the outlet seal plate.

5.23 Position the outlet seal plate (Item 7), over the bottom opening in
the body (Item 1) with its lapped surface facing inwards. Align
the dowel pin hole, in the lapped surface, of the outlet seal plate
with the dowel pin (item 28) in the body. Lower the seal plate into
its bore in the body until fully seated, being careful not to scratch
or otherwise damage the lapped sealing surface.

5.24 Install dowel pin (Item 32), into its respective hole in the body
(Item 1). See the assembly drawing for correct orientation.

5.25 Position dust cover (Item 31), over the outlet seal plate (Item 7)
and attach it to the body (Item 1) using four socket head cap
screws (Item 22) and hex nuts (Item 25). The hex nuts only
need to be tightened sufficiently so that the dust cover is held flat
and snug against the side of the body. A piece of tape should be
placed over the dowel pin hole to prevent it from falling out.

5.26 Torque socket head cap screws for both end caps and the blind
seal plate flange to 25 ft-lbs. (300 in-lbs.) using a criss-cross
pattern.

5.27 Apply sealing compound or several wraps of PTFE tape to the

tapered threads on the manual relief valve (Item 26). Using the
1/2” wrench, tighten the manual relief valve properly into the end
cap.

5.28 Place component tag (Item 29) onto the valve body in the
location shown on the assembly drawing and secure it in place
with two drive screws (Item 30). Stamp the tag per Part
Identification Spec D-000100-09-04, per document: X-043764-
01, (latest revision).

5.29 The DRG Valve Assembly is now ready for “FAT” testing. See
“BOM” for proper “FAT” document number.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 1 of 9

ASSEMBLY PROCEDURE

DRILLING VALVE, 1/2”, 5 KSI WP,

4-WAY 2-POSITION, SUBPLATE MOUNTED,
DUAL 3 KSI PILOT, SPRING DETENTED

CAMERON PART NO.

2232114-03
DRAWING NO.
SK-154396-03

Originator: S. Ward Date: May 17, 2004

Checked: T. Bell Date: March 22, 2005
Approved: J. Wilkirson Date: March 22, 2005
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 2 of 9

TABLE OF CONTENTS

1.0 PURPOSE OF THIS DOCUMENT ........................................................................3

2.0 DOCUMENTS / MATERIALS REQUIRED .............................................................3

3.0 DRG VALVE PREPARATION PRIOR TO ASSEMBLY ............................................3

4.0 DISASSEMBLED DRG VALVE COMPONENT INSPECTION ....................................3

5.0 DRG VALVE ASSEMBLY.................................................................................4

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 3 of 9

1.0 Purpose of This Document

The purpose of this document is to provide guidelines for the assembly

of a 1/2”, 5 KSI WP, 4 Way 2-Position, Spring Detent, Subplate
Mounted, Dual 3 KSI Pilot, Drilling (DRG) Valve.

2.0 Documents / Materials Required

• Cameron Assembly Drawing; No. SK-154396-03, (latest revision)

• Bill of Materials (BOM); 2232114-03, (latest revision)
• Part Identification Document: X-043764-01, (latest revision)
• Lint-free rags or cleaning tissues
• Calibrated torque wrench capable of 0-50 ft-lbs. of torque
• Adapter, appropriate torque wrench drive x 5/16” male hex
• 5/16” hex (Allen) wrenches
• Small open end adjustable wrench or 0.50” & 0.625” open end
wrench
• Thread sealing compound or PTFE tape
• Light grease

3.0 DRG Valve Preparation Prior to Assembly

All components of the DRG valve must be cleaned thoroughly prior to

assembly. The use of an ultrasonic cleaner is highly recommended.
Caustic baths MUST NOT be used.

The DRG valve should be assembled in a clean area, free from all dirt
and other foreign material. It is important to eliminate any external
influences that could cause a valve functional failure during bench
testing or shorten the expected life of the DRG valve in field operation.

Personnel working on the DRG valve shall wear clean clothing, safety
shoes, and safety glasses. This shall also apply to all personnel
participating or operating within the locality of the DRG valve assembly
area.

4.0 Disassembled DRG Valve Component Inspection

• Follow the inspection requirements specified in QP-000160-21.

PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 4 of 9

5.0 DRG Valve Assembly

CAUTION
Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of the
valve.

NOTE
• IN ALL CASES, THE LATEST REVISION OF ASSEMBLY DRAWING SHALL TAKE
PRECEDENCE.

• Refer to assembly drawing for orientation of components and item number references. Refer to
“BOM” to cross-reference item numbers with their respective part numbers and descriptions.

5.1 Lubricate back-up rings (Item 35) and o-rings (Item16) with light
grease. Install back-up rings (Item 35) into the OD groove on
each end of the piston (Item 2). Inspect the installed back-up
rings to ensure that the angled edges of the scarf cut (Figure 1)
are aligned and in contact. Install an o-ring (Item 16) into the
same groove adjacent to the back-up rings in the bore on the
pistons OD. Refer to the assembly drawing for the correct
orientation of the o-ring and back-up ring.

Figure 1 – Back-up Ring Scarf Cut Edge Alignment

5.2 Place body (item 1) on a clean flat surface with the top (side with
the four counter bores for the thru holes and name tag mounting
holes) up.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 5 of 9

5.3 Apply light grease to all four o-rings (Item 17) and adjacent body
(Item 1) internal bore surfaces. Install o-rings into their proper
seal grooves in the end caps (item 3). See the assembly drawing
for correct orientation of the o-rings.

5.4 Apply light grease to the outer o-ring diameter, internal starting
bevel and ID piston bore of both end caps (Item 3). Install one
end cap into the body (Item 1), until it is fully seated, see
assembly drawing. Make sure mounting holes in the end cap
align with the tapped holes in body and the manual relief valves
(Item 26) hole is positioned at the top of the body. See the
assembly drawing for correct orientation.

NOTE
It is not necessary to use anti-seize compound. All socket head cap screws are coated with
an anti-galling/low friction coating.

5.5 Install four socket head cap screws (Item 23), through the holes
in the end cap (Item 3), and hand tighten (Do not torque).

5.6 Apply a light coating of grease to the outer diameters of piston

(Item 2) around the o-rings on both sides. Insert the piston
through the body until it is fully seated in the end cap. The
transverse bore through the piston should be perpendicular to
the seal plate holes. See the assembly drawing for correct
orientation.

5.7 Install the second end cap (Item 3) over the piston into the body,
until it is fully seated. Make sure mounting holes in the end cap
align with the tapped holes in body and the manual relief valves
(Item 26) hole is positioned at the top of the body.

5.8 Install four socket head cap screws (Item 23), through the holes
in the end cap (Item 3), and hand tighten (Do not torque).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 6 of 9

WARNING
USE CAUTION WHEN INSTALLING SEAL RINGS, THE INNER AND OUTER EDGES OF THE
LAPPED END OF EACH SEAL RING IS VERY SHARP. FAILURE TO COMPLY MAY RESULT IN
SERIOUS INJURY TO PERSONNEL.

CAUTION
• Orientation of o-rings and back-up rings is critical for proper sealing, function and operation of
the valve.

• Extreme care must be taken to avoid any contact with the lapped surface of each seal ring. Any
damage to these surfaces will cause the valve to leak.

NOTE
During installation, do not press directly on the lapped surface of the seal ring. Use both thumbs to
press against the bevelled ID surface of the seal ring

5.9 Lubricate back-up rings (Item 36) and o-rings (Item 19) with light
grease and install a back-up ring onto each of the two seal rings
(Item 8) in the assembly drawing. For each seal ring, slide the
back-up ring towards the lapped face of the seal ring. Inspect
the installed back-up ring (Figure 1) to ensure that the angled
edges of the scarf cut are aligned and in contact. Install o-ring
into the same groove adjacent to the back-up ring. See the
assembly drawing for orientation of the o-ring and back-up ring.

5.10 To install the first seal ring subassembly (Items 8, 19 and 36)
with its o-ring and back-up ring in place, apply light grease to the
entire transverse bore of the piston (Item 2). Position the seal
ring over the piston in the top bore of the body (item 1), lapped
end facing outwards, and press it into the piston bore using
thumb pressure. If insertion is difficult, be sure that the piston
bore is not pinching the o-ring (Item 19) or back-up ring (Item
36). Push the seal ring downwards until its flush with the piston
bore.
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 7 of 9

5.11 Install one dowel pin (item 28) into the dowel pin hole located at
the bottom of the blind seal plate bore in the top of the body.

CAUTION
Extreme care must be taken to avoid any contact with the lapped surface of each seal plate.
Small dings or raised edges will cause the valve to leak.

5.12 Lightly grease o-ring (Item 18) and its respective groove in the
blind seal plate (item 6). Install o-ring into the o-ring groove.
Apply light grease to the lapped surface of the blind seal plate.

5.13 Position the blind seal plate (Item 6), over the top opening in the
body (Item 1) with its lapped surface facing inwards. Align the
dowel pin hole, in the lapped surface, of the blind seal plate with
the dowel pin in the body. Lower the seal plate into its bore in the
body until fully seated, being careful not to scratch or otherwise
damage the lapped sealing surface.

5.14 Install the blind seal plate flange (item 5) with its four mounting
bolts (item 24), and hand tighten (Do not torque). See the
assembly drawing for correct orientation.

5.15 Place body (item 1) with the blind seal plate flange (item 5)
facing down.

5.16 Place the seal ring spring (Item 13) on top of the seal ring (Item
8) just inserted. Push the seal ring downwards until it contacts
the blind seal plate (Item 6).

5.17 Carefully install the remaining seal ring subassembly (Item 8, 19

and 36) with its o-ring and back-up ring already installed.
Position the seal ring over the bore in the piston, lapped end
facing out, and press it into the piston bore. If insertion is
difficult, be sure that the piston bore is not pinching the o-ring or
back-up ring. Push the seal ring downwards until it contacts the
seal ring spring (Item 13).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 8 of 9

5.18 Using the center bore of the seal ring move the piston towards
either end until it bottoms against one of the end caps (item 3).

5.19 Install the other dowel pin (item 28) into the dowel pin hole
located at the bottom of the outlet seal plate bore in the bottom
of the body.

5.20 Lightly grease o-ring (Item 18) and its respective groove in the
outlet seal plate (item 7). Install o-ring into the o-ring groove.
Apply light grease to the lapped surface of the outlet seal plate.

5.21 Position the outlet seal plate (Item 7), over the bottom opening in
the body (Item 1) with its lapped surface facing inwards. Align
the dowel pin hole, in the lapped surface, of the outlet seal plate
with the dowel pin (item 28) in the body. Lower the seal plate into
its bore in the body until fully seated, being careful not to scratch
or otherwise damage the lapped sealing surface.

5.22 Install dowel pin (Item 32), into its respective hole in the body
(Item 1). See the assembly drawing for correct orientation.

5.23 Position dust cover (Item 31), over the outlet seal plate (Item 7)
and attach it to the body (Item 1) using four socket head cap
screws (Item 22) and hex nuts (Item 25). The hex nuts only
need to be tightened sufficiently so that the dust cover is held flat
and snug against the side of the body. A piece of tape should be
placed over the dowel pin hole to prevent it from falling out.

5.24 Torque socket head cap screws for both end caps and the blind
seal plate flange to 25 ft-lbs. (300 in-lbs.) using a criss-cross
pattern.

5.25 Apply sealing compound or several wraps of PTFE tape to the

tapered threads on the manual relief valves (Item 26). Using the
1/2” wrench, tighten both manual relief valves properly into the
end cap.

5.26 Place component tag (Item 29) onto the valve body in the
location shown on the assembly drawing and secure it in place
with two drive screws (Item 30). Stamp the tag per Part
Identification Spec D-000100-09-04, per document: X-043764-
01, (latest revision).
PROPERTY OF ORIGINATOR REVISION
S. Ward 01
DATE SHEET AP-000014-03
May 17, 2004 9 of 9

5.27 Place body (item 1) with the side of the body (item 1) with the
spring detent hole facing up.

5.28 Lightly grease the detent ball (item 27) and place it through the
detent hole in the body until it lands in the detent ball seat on the
piston (item 2). A detent ball seat should be aligned with the
body spring detent hole if the piston is moved against either end
cap.

5.29 Lubricate o-ring (Item20) and o-ring groove on the OD of the

spring detent plug (item 11) with light grease. Install the o-ring
into the OD groove of the spring detent plug.

5.30 Coat the OD of the detent spring (item 12) with light grease and
install into the ID bore of the spring detent plug. The grease
should keep the spring from falling out during installation.

5.31 Screw the spring detent plug into the body until fully seated.
Torque to 10 ft-lbs. (120 in-lbs.)

5.32 The DRG Valve Assembly is now ready for “FAT” testing. See
“BOM” for proper “FAT” document number.
 REVISED BY: REVISION
PROPERTY OF
N. Cooper 04
Document No.
DATE: SHEET
X-093325-01
17 June 2009 1 OF 28

DSDM CANBUS NODE I.D. CONFIGURATION

AND

CAN BUS FAULT-TOLERANCE VERIFICATION

PROCEDURE,

FOR

MULTIPLEX SECTION, CONTROL POD (MARK III)

ORIGINATED BY: Nathan Cooper DATE: 14 May 2007

CHECKED BY: Richard Coronado DATE: 29 May 2007

APPROVED BY: Mac Kennedy DATE: 29 May 2007

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
PROPERTY OF
N. Cooper 04
Document No.
DATE: SHEET
X-093325-01
17 June 2009 2 OF 28

TABLE OF CONTENTS

1 INTRODUCTION 3
1.1 SAFETY WARNING 3
1.2 DOCUMENTATION 4
2 TEST EQUIPMENT 5

3 CAN BUS NODE I.D. CONFIGURATION 5

4 WIRING INSPECTION AND INSULATION RESISTANCE TEST 9

5 VERIFICATION OF CAN BUS FAULT-TOLERANCE 14

5.1 SYSTEM POWERED BY SEM A 14
5.2 SYSTEM POWERED BY SEM B 18
5.3 SYSTEM POWERED BY SEM A AND SEM B 21

6 FUNCTION TEST, WITH WATER IN SVM'S AND PTM'S 23

7 FAULT-TOLERANCE TEST WITH FULLY-ASSEMBLED SVM'S 25

8 CERTIFICATE 28

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
PROPERTY OF
N. Cooper 04
Document No.
DATE: SHEET
X-093325-01
17 June 2009 3 OF 28

1 INTRODUCTION

The purpose of this procedure is to provide a process for assigning the CANBUS Node I.D.’s to the Drilling
Solenoid Driver Modules (DSDM’s) and to verify fault-tolerance of the CAN Busses of the Multiplex Section
prior to the integration of the Multiplex and Modular Sections of the Drilling Control Pod.

The Subsea Electronic Module (SEM) that is associated with this Pod MUX Section must be used for this
test.

1.1 SAFETY WARNING

PERSONNEL AND PRODUCT SAFETY ARE PRIMARY OBJECTIVES AND THEREFORE THE
FOLLOWING PRECAUTIONS MUST BE TAKEN PRIOR TO CARRYING OUT THIS TEST
PROCEDURE:-

1. All test personnel must acquaint themselves fully and strictly adhere to all company sites’
HEALTH AND SAFETY AT WORK REGULATIONS’ together with other specific requirements
detailed in this procedure.

2. All tests are to be carried out within either a dedicated test bay area with authorized personnel
entry points, or an area adequately protected from unauthorized access in a general workshop
with a visible cordoned zone and adequately displayed warning signs detailing the test type and
associated hazards.

3. The lifting and handling of all items must be carried out with extreme caution and due regard to
the safety regulations, due to the inherent high unit weights, which can easily cause permanent
injury to personnel not exercising extreme care and due diligence.

4. All test personnel in contact with the hydraulic fluid must wear suitable protective clothing and
gloves if required, together with taking all the necessary precautions detailed on the fluid data
sheets.

5. The tests which involve the use of medium pressure fluid, compressed inert gas and medium
voltage electricity supplies, necessitate suitable and adequate precautions are to be taken prior
to commencement of tests and due diligence is to be maintained during the tests.

1.2 ABBREVIATIONS

CAN Controller Area Network

CCP Cable Connector Plug
DDTM Drilling Digital Transducer Module
DSDM Drilling Solenoid Driver Module
GUI Graphical User Interface
MOD Modular
MSSL Metal Shell Series, size L
MUX Multiplex
NAS National Aerospace Standard
PTM Pressure Transducer Module
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
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SVM Solenoid Valve Module

VDC Voltage Direct Current

1.2 DOCUMENTATION

Ensure that the following documents are available. Record the revision level.

Item Description CAMERON CAM

Doc. No. Rev.
2020708-____-01
1 Bill Of Materials
Blue Pod / Yellow Pod (Circle One)

2 Assembly Drawing SK-122140-____-04

3 Electrical Schematic SK-122178-____-06

Note: The DSDM serial numbers are required when programming the CAN Node I.D.’s.
Write down the serial numbers of each DSDM in the table below according to its position in the
Drilling Control Pod (reference Assembly Drawing ‘Riser’ and ‘Stack’ side views). The DSDM serial
number will be needed when configuring the CAN Bus Node ID. A maximum of 15 DSDM’s are
possible in the Drilling Control Pod.
If a DSDM position is not used, write ‘N/A’ for the serial number.
Position Serial Number
1 (Riser Side)
2 (Riser Side)
3 (Riser Side)
4 (Riser Side)
5 (Riser Side)
6 (Riser Side)
7 (Riser Side)
8 (Stack Side)
9 (Stack Side)
10 (Stack Side)
11 (Stack Side)
12 (Stack Side)
13 (Stack Side)
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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14 (Stack Side)
15 (Stack Side)

2 TEST EQUIPMENT
Verify that the following test equipment is available:

Multimeter Ser.No.: __________________

Calibration Date: __________________

24VDC Power Supply

Megger, for Insulation Resistance test
Laptop PC, with ‘CAN PETU’, ‘Device Monitor’, and Win TSim or M3 program
Modem rack, with 2 Modems (A & B) and associated power supplies
Test Cables and Hook-up wire
Ethercan gateway (CAN to Ethernet adapter: Cam P/N 2725612-03)
Adapter, CANbus high speed to low speed
Oscilloscope, with 2 channels
Test lead/jumper, with 100Ω resistor (1W) in series (see sketch in Section 5.1)
Test lead/jumper, with 100Ω resistor (1W) in series and 0.01µF capacitor (min 50V) in parallel (see
sketch in Section 5.1)
Water supply, for filling-up of SVM’s and PTM’s for the ‘water test’

3 CAN BUS NODE I.D. CONFIGURATION

Any CAN BUS device in a network requires a unique Node ID so that a correct identification is
possible. All DSDM’s should have a pre-programmed Node I.D. of 1 due to testing at a lower level of
assembly.
For each DSDM, do the following steps. If a particular Node I.D. is not required to be assigned based
on the unused corresponding position in the Pod, write N/A in the chart below.
Connect the test cables to the “POWER/CANBUS END of the DSDM. Connect the output of a
24VDC supply to “ + ” and “ - “. Do not switch on the power supply yet. The CAN Node ID’s will be
programmed via “CH” and “CL”. Please see Figure 1 for a test set-up configuration.
Verify: ________
Using the CAN Bus test equipment, connect the CAN Bus to wire numbers “CH” and “CL”.
Verify: ________
Switch on power supply and CAN test equipment. Verify that EtherCAN has been set-up, and verify
that the Ethernet settings (TCP/IP) have been set-up.
Verify: ________
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loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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From the laptop PC, use ‘CAN PETU’ to re-program the ID of each DSDM (the serial number will be
needed when re-programming the ID – reference Figure 2 below), and write down the ID in the chart
below. Reboot the device after each flash operation to ensure that the value has been stored in a
non-volatile memory.

New ID after flash operation ID after reboot

Node-ID Detected ID Verify Detected ID Verify
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

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loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Figure 1

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loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Figure 2

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loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
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4 WIRING INSPECTION and INSULATION RESISTANCE TEST

4.1 INSULATION RESISTANCE TEST

Perform an “insulation resistance” test of all wiring that is routed through the PBOF hose / conduit
connections between the PTM’s and SVM’s. Test voltage should be 500 VDC.
Verify: ________

4.2 WIRING INSPECTION

After each of the DSDM’s have had CAN Bus Node ID’s assigned per Section 3, they should be
installed in the corresponding Solenoid Valve Module (SVM) positions in the MUX Section of the
Control Pod, and wiring terminations shall be made-up to the ‘Power/CANBUS’ end of each DSDM.
Verify: ________

The DSDM’s contain electrical connections that utilize glass/metal connector assemblies which are
sealed into the DSDM housing outlets to withstand external pressure.
To make a connection:
1) Slide a boot seal onto the wire
2) Set the wire stripper at the correct setting based on the wire size (20AWG)
3) Strip the insulation 4mm for the (size 20) female socket contact, ensuring that the wire
strands are cleanly cut.
4) Visually inspect stripped wire ends to ensure no nicks/cuts/abrasions, and then insert the
contact over the strands and crimp, ensuring that no roll/twist occurs in the crimped portion.
5) Push the contact into the connection point at the DSDM.
6) To ensure a water-tight seal, gently push the boot seal fully over the female contact.
Resistance shall be felt which signifies the ‘bottoming out’ of the boot seal onto the contact.
There shall be no exposed strands/conductors at the rear of boot seal. If so, the termination
process must be re-done.

The following checks will be used to verify proper installation of boot seals and will serve as a
verification record.
Project: ________________________
MUX Section, Serial No: __________________________
Technician name: ___________________________
Inspector name: ___________________________

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Drilling Solenoid
Driver Module

Connection

Connection

Connection

Connection
Technician

Technician

Technician

Technician
Inspector

Inspector

Inspector

Inspector
Visual inspection for exposed conductors at rear of contact crimp, and Visual Inspection of boot seal installation
1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
1
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
2 C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
3
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
4
C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Drilling Solenoid
Driver Module

Connection

Connection

Connection

Connection
Technician

Technician

Technician

Technician
Inspector

Inspector

Inspector

Inspector
Visual inspection for exposed conductors at rear of contact crimp, and Visual Inspection of boot seal installation
1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
5
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
6 C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
7
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
8
C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Drilling Solenoid
Driver Module

Connection

Connection

Connection

Connection
Technician

Technician

Technician

Technician
Inspector

Inspector

Inspector

Inspector
Visual inspection for exposed conductors at rear of contact crimp, and Visual Inspection of boot seal installation
1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
9
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
10 C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
11
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
12
C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Drilling Solenoid
Driver Module

Connection

Connection

Connection

Connection
Technician

Technician

Technician

Technician
Inspector

Inspector

Inspector

Inspector
Visual inspection for exposed conductors at rear of contact crimp, and Visual Inspection of boot seal installation
1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
13
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind

A F CL Blind
2 7 CH
B G CL
3 8 Blind
14 C H Blind
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

1 6 CH Blind
A F CL Blind
2 7 CH
B G CL
3 8 Blind
C H Blind
15
4 + Blind
D - Blind
+
5 Blind
( Blind)
-
E Blind
( Blind)

Verify that the CANBUS High (CH) and CANBUS Low (CL) wire pairs that are installed between each
DSDM are adequately protected with shrink tubing and spiral wrap / plastic tubing. Inspect as much
of the protected wire pair as possible to verify that there is no physical damage.
Verify: ________
Verify that the bundles that include +24VDC and 0VDC wire pairs are adequately protected with spiral
wrap / plastic tubing. Inspect as much of the protected bundles as possible to check for no physical
damage.
Verify: ________

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loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify that all unused wires (i.e. wire #’s 23 & 24 or #’s 25 & 26 on the ‘Riser Side’ of the Pod, as
applicable) have “wire-end seals” correctly installed over the ends, and that the unused wires are
properly secured to the manifold to prevent physical damage during assembly and disassembly.
Verify: ________

5 VERIFICATION OF CAN BUS FAULT-TOLERANCE

The Protective Cover of the SEM should be removed, and the SEM should be installed on a suitable
test stand and placed directly next to side of the MUX Section with the PTM’s; this is so the SEM can
be connected to the PTM(s) via the PBOF cables that are supplied with the Pod. Additionally, the
DSDM electrical connections should still be accessible.
Verify: ________
Verify that the following cables/wires are connected:
1) PBOF cable from SEM connector -2X5 to PTM 1 (for Mark III Model 80, to PTM 1 -5X2)
2) PBOF cable from SEM connector -15X3.1 to PTM 2 (for Mark III Model 80, to PTM 1 -17X2)
3) cable with MSSL-22 (or -12 depending on what is installed at SEM) from input power & signal to
SEM connector -2X1.2
4) Laptop serial cable to modem test rack (A or B) serial connection
5) test rack Modem A and B communication connections to the SEM via connector -2X1.2
Verify: ________

5.1 System Powered by SEM A

Begin the Win TSim or M3 application on the laptop PC. Ensure that Modem A of the test rack is
communicating to the laptop PC. Then, turn on input power to SEM A.
Verify: ________
Verify that SEM system A powers-up correctly, and that all installed DSDM’s and DDTM’s are
available and statuses are displayed correctly via the Win TSim / M3 program.
Verify: ________
CAN Bus 0
Note: The oscilloscope channels 1 and 2 can be connected to CAN 0 terminals –X5: 5, 6 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, energize all solenoid valves (four at a time) that are connected to each
DSDM, and verify that each solenoid valve energizes and that the corresponding statuses are
correctly displayed on the laptop PC.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at five different
places/locations on the CAN 0 bus. Record the location (i.e. “DSDM 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 0 bus to a normal
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy and for no solenoid valves to change state. During the course of at least 1 minute in fault
condition, no solenoid valves shall change state and each DSDM shall remain available on the CAN
bus.
Note: For any CAN Bus (0, 1, 2) at any location, create the fault ‘CH/CL shorted to 24VDC’ using a
test jumper and multimeter (set to mA), as per the following sketch:

Note: For any CAN Bus (0, 1, 2) at any location, create the fault ‘CH/CL shorted to 0VDC’ using a test
jumper and multimeter (set to mA), as per the following sketch:

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

3. fault location:

4. fault location:

5. fault location:

CAN Bus 1
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Note: The oscilloscope channels 1 and 2 can be connected to CAN 1 terminals –X5: 3, 4 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 1 are available
and that the statuses are displayed correctly. If displayed correctly, raw counts of Analog Channels
1-10 should indicate a value between 819 – 825. If not, then the DDTM(s) must be “woken up”; to
“wake up” the DDTM’s, reference procedure X-262036-01.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at two different
places/locations on the CAN 1 bus. Record the location (i.e. “TP 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 1 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy. During the course of at least 1 minute in fault condition, all DDTM’s shall remain available on
the CAN bus.

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

CAN Bus 2
Note: The oscilloscope channels 1 and 2 can be connected to CAN 2 terminals –X5: 1, 2 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 2 are available
and that the statuses are displayed correctly. If displayed correctly, raw counts of Analog Channels
11-20 should indicate a value between 819 – 825. If not, then the DDTM(s) must be “woken up”; to
“wake up” the DDTM’s, reference procedure X-262036-01.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at two different
places/locations on the CAN 2 bus. Record the location (i.e. “TP 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 2 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy. During the course of at least 1 minute in fault condition, all DDTM’s shall remain available on
the CAN bus.
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

Turn off input power to SEM A.

Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.2 System Powered by SEM B

Begin the Win TSim or M3 application on the laptop PC. Ensure that Modem B of the test rack is
communicating to the laptop PC. Then, turn on input power to SEM B.
Verify: ________
Verify that SEM system B powers-up correctly, and that all installed DSDM’s and DDTM’s are
available and statuses are displayed correctly via the Win TSim / M3 program.
Verify: ________
CAN Bus 0
Note: The oscilloscope channels 1 and 2 can be connected to CAN 0 terminals –X5: 5, 6 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, energize all solenoid valves (four at a time) that are connected to each
DSDM, and verify that each solenoid valve energizes and that the corresponding statuses are
correctly displayed on the laptop PC.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at five different
places/locations on the CAN 0 bus. Record the location (i.e. “DSDM 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 0 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy and for no solenoid valves to change state. During the course of at least 1 minute in fault
condition, no solenoid valves shall change state and each DSDM shall remain available on the CAN
bus.

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

3. fault location:

4. fault location:

5. fault location:

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Document No.
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CAN Bus 1
Note: The oscilloscope channels 1 and 2 can be connected to CAN 1 terminals –X5: 3, 4 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 1 are available
and that the statuses are displayed correctly.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at two different
places/locations on the CAN 1 bus. Record the location (i.e. “TP 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 1 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy. During the course of at least 1 minute in fault condition, all DDTM’s shall remain available on
the CAN bus.

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

CAN Bus 2
Note: The oscilloscope channels 1 and 2 can be connected to CAN 2 terminals –X5: 1, 2 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 2 are available
and that the statuses are displayed correctly.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at two different
places/locations on the CAN 2 bus. Record the location (i.e. “TP 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 2 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy. During the course of at least 1 minute in fault condition, all DDTM’s shall remain available on
the CAN bus.

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

Turn off input power to SEM B.

Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.3 System Powered by SEM A and SEM B

Begin the Win TSim or M3 application on the laptop PC. Ensure that Modems A or B of the test rack
is communicating to the laptop PC. Then, turn on input power to SEM A and SEM B.
Verify: ________
Verify that SEM systems A and B power-up correctly, and that all installed DSDM’s and DDTM’s are
available and statuses are displayed correctly via the Win TSim program.
Verify: ________
CAN Bus 0
Note: The oscilloscope channels 1 and 2 can be connected to CAN 0 terminals –X5: 5, 6 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, energize all solenoid valves (four at a time) that are connected to each
DSDM, and verify that each solenoid valve energizes and that the corresponding statuses are
correctly displayed on the laptop PC.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at five different
places/locations on the CAN 0 bus. Record the location (i.e. “DSDM 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 0 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy and for no solenoid valves to change state. During the course of at least 1 minute in fault
condition, no solenoid valves shall change state and each DSDM shall remain available on the CAN
bus.

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

3. fault location:

4. fault location:

5. fault location:

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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CAN Bus 1
Note: The oscilloscope channels 1 and 2 can be connected to CAN 1 terminals –X5: 3, 4 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 1 are available
and that the statuses are displayed correctly.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at two different
places/locations on the CAN 1 bus. Record the location (i.e. “TP 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 1 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy. During the course of at least 1 minute in fault condition, all DDTM’s shall remain available on
the CAN bus.

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

CAN Bus 2
Note: The oscilloscope channels 1 and 2 can be connected to CAN 2 terminals –X5: 1, 2 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 2 are available
and that the statuses are displayed correctly.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at two different
places/locations on the CAN 2 bus. Record the location (i.e. “TP 2”), and after verification of fault-
tolerance, place a check in the corresponding table cell and then restore the CAN 2 bus to a normal
condition (no fault). A fault-tolerant bus will allow for communication between all devices to remain
healthy. During the course of at least 1 minute in fault condition, all DDTM’s shall remain available on
the CAN bus.

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
1. fault location:

2. fault location:

Turn off input power to SEM A and SEM B.

Verify: ________

6 FUNCTION TEST, WITH WATER IN SVM’S AND PTM’S

The SVM’s and PTM’s will now be filled with water, and then a function test will be performed in the
following steps. This will be done to verify that the boot seals are properly installed over the contacts,
that splices and wire-end seals are properly assembled/terminated, and that the solenoid valve coils
are properly assembled such that water does not enter the boot/cap.

Electrical power to the system to be off, then fill-up all SVM’s and PTM’s per procedure X-262167-02,
but use WATER instead of Dielectric Fluid.
Verify: ________
Connect a flowmeter P/N 2232048-01 to the SEM at the associated SEM connector. The flowmeter
is not to be connected hydraulically.
Verify: ________
Begin the Win TSim or M3 application on the PETU laptop PC. Ensure that the PETU is connected to
the laptop PC. Then, turn on input power to SEM A and SEM B.
Verify: ________
Establish communications with the SEM’s A and B using the PETU, and ensure that all DSDM's and
DDTM's are available/online.
Verify: ________
The next steps will be done with only SEM A powered on. Ensure that SEM B is powered off.
Upon powering on, verify that all DSDM’s and DDTM’s are available/online.
Verify: ________

Activate solenoids in groups of fives. In between activation sets, wait for two minutes and observe
that the DDTM values are within 80 raw value points of 819 (i.e. that the values do not fluctuate
beyond 80 points from 819), and that the flowmeter value does not continually increment.

Verify: ________
Continue with solenoid activations until all are energized. Wait for three hours and observe the values
of the DDTM’s and flowmeter, that there aren’t DDTM value fluctuations outside of 80 raw counts nor
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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Document No.
DATE: SHEET
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continual incrementing of flowmeter value.

Verify: ________
De-energize all solenoid valves.
Verify: ________

The next steps will be done with only SEM B powered on. Ensure that SEM A is powered off.
Upon powering on, verify that all DSDM’s and DDTM’s are available/online.
Verify: ________

Activate solenoids in groups of fives. In between activation sets, wait for two minutes and observe
that the DDTM values are within 80 raw value points of 819 (i.e. that the values do not fluctuate
beyond 80 points from 819), and that the flowmeter value does not continually increment.

Verify: ________
Continue with solenoid activations until all are energized. Wait for three hours and observe the values
of the DDTM’s and flowmeter, that there aren’t DDTM value fluctuations outside of 80 raw counts nor
continual incrementing of flowmeter value.

Verify: ________
De-energize all solenoid valves.
Verify: ________

The next steps will be done with SEM A and SEM B powered on.
Upon powering on, verify that all DSDM’s and DDTM’s are available/online.
Verify: ________

Activate solenoids in groups of fives. In between activation sets, wait for two minutes and observe
that the DDTM values are within 80 raw value points of 819 (i.e. that the values do not fluctuate
beyond 80 points from 819), and that the flowmeter value does not continually increment.

Verify: ________
Continue with solenoid activations until all are energized. Wait for three hours and observe the values
of the DDTM’s and flowmeter, that there aren’t DDTM value fluctuations outside of 80 raw counts nor
continual incrementing of flowmeter value.

Verify: ________

De-energize all solenoid valves, and power off the system.

Verify: ________

The SVM’s and PTM’s can now be drained of water, and opened to allow drying. The modules
should be dried as much as it is possible. At a later stage, the modules will be filled with di-electric
fluid.

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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Verify: ________
The DSDM’s along with the solenoid valve manifolds can now be placed into their respective SVM
housings, taking special care not to damage wire bundles as the Manifolds are placed inside the
housings.
Verify: ________

7 FAULT-TOLERANCE TEST WITH FULLY-ASSEMBLED SVM’S

After the SVM’s are fully assembled into the MUX Section, CAN Bus fault-tolerance will now be
verified. The SEM is still required to be placed next the MUX Section and remain connected as
before.

Begin the Win TSim or M3 application on the laptop PC. Ensure that Modem A or B of the test rack is
communicating to the laptop PC. Then, turn on input power to SEM A and SEM B.
Verify: ________
Verify that SEM systems A and B power-up correctly, and that all installed DSDM’s and DDTM’s are
available and statuses are displayed correctly via the Win TSim / M3 program.
Verify: ________

CAN Bus 0
Note: The oscilloscope channels 1 and 2 can be connected to CAN 0 terminals –X5: 5, 6 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, energize all solenoid valves (four at a time) that are connected to each
DSDM, and verify that each solenoid valve energizes and that the corresponding statuses are
correctly displayed on the laptop PC.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at a location on the
CAN 0 bus in the SEM. Record the location (i.e. “removed I/O Board A connection to –X5:5”), and
after verification of fault-tolerance, place a check in the corresponding table cell and then restore the
CAN 0 bus to a normal condition (no fault). A fault-tolerant bus will allow for communication between
all devices to remain healthy and for no solenoid valves to change state. During the course of at
least 1 minute in fault condition, no solenoid valves shall change state and each DSDM shall remain
available on the CAN bus.
Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
fault location:

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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Document No.
DATE: SHEET
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CAN Bus 1
Note: The oscilloscope channels 1 and 2 can be connected to CAN 1 terminals –X5: 3, 4 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 1 are available
and that the statuses are displayed correctly .
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at a location on the
CAN 1 bus in the SEM. Record the location (i.e. “removed I/O Board A connection to –X5:3”), and
after verification of fault-tolerance, place a check in the corresponding table cell and then restore the
CAN 1 bus to a normal condition (no fault). A fault-tolerant bus will allow for communication between
all devices to remain healthy. During the course of at least 1 minute in fault condition, all DDTM’s
shall remain available on the CAN bus.
Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC
fault location:

CAN Bus 2
Note: The oscilloscope channels 1 and 2 can be connected to CAN 2 terminals –X5: 1, 2 (CH and
CL respectively) of the SEM to view the CAN Bus waveforms. Ensure that the oscilloscope channel
reference is connected to 0VDC of the SEM.

Using Win TSim or M3, verify that all installed DDTM’s (i.e. TP1 through TP10) in PTM 2 are available
and that the statuses are displayed correctly.
Verify: ________
Create each of the faults that are listed in the following table (one fault at a time) at a location on the
CAN 2 bus in the SEM. Record the location (i.e. “removed I/O Board A connection to –X5:1”), and
after verification of fault-tolerance, place a check in the corresponding table cell and then restore the
CAN 2 bus to a normal condition (no fault). A fault-tolerant bus will allow for communication between
all devices to remain healthy. During the course of at least 1 minute in fault condition, all DDTM’s
shall remain available on the CAN bus.

Fault Type
CH CL CH shorted to CH shorted CL shorted CH shorted CL shorted
disconnected disconnected CL to 0VDC to 0VDC to 24VDC to 24VDC

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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Document No.
DATE: SHEET
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fault location:

Turn off input power to SEM A and SEM B.

Verify: ________

The SEM can be prepared for installation into the MUX Section, and the MUX Section can be
prepared for the next level of assembly / testing.

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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Document No.
DATE: SHEET
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8 CERTIFICATE

Unit tested: Multiplex Section (Mark III), Control Pod

Cameron P/N: 2020708-____-01 Blue or Yellow (circle one)

This test was witnessed and the results were accepted by:

_____________________________________________________________________________
CAMERON INSPECTOR SIGNATURE DATE

_____________________________________________________________________________
MANUFACTURING ENGINEER SIGNATURE DATE

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF DRAWN BY: REVISION
J.Redding 02
Document No.
DATE: SHEET
X-145945-01
May 16, 2008 1 OF 3

Procedure to Establish

Ethernet Netw ork Functionality

Checked by: Nathan Cooper Date: May 16, 2008

Approved by: Richard Coronado Date: May 16, 2008

PROPERTY OF DRAWN BY: REVISION
J.Redding 02
Document No.
DATE: SHEET
X-145945-01
May 16, 2008 2 OF 3

Procedure to Establish Network Functionality

This procedure can be used to gain functionality of the Drilling Control System whenever
all other means have been exhausted or when the availability of the four SEMs has been
lost due to network being overloaded. Refer to the appropriate electrical schematics for
the Toolpusher’s Control Panel and the Communication/Power Distribution Cabinet B for
disconnection points. The disconnecting of the fiber optic cables will effectively create two
Ethernet networks that will allow the operator to re-establish communication with the sub-
sea pods.

Communication/Power Distribution Cabinet B:

The fiber optic connections to point labeled P6 on the Ethernet Switch labeled X-204
should be completely disconnected.

Toolpusher’s Control Panel:

The fiber optic connections to point labeled P5 on the Ethernet Switch labeled X-204
should be completely disconnected.

After disconnecting the fiber optic connections in the Toolpusher’s Control Panel, review
Toolpusher’s Control Panel. If SEM Blue B and Yellow B are healthy (i.e. heartbeats are
green and SEM Blue B and Yellow B are available) sub-sea functions can be operated
from Toolpusher’s Control Panel.

If SEM Blue B and Yellow B are NOT healthy (i.e. heartbeats are red and SEM Blue B and
Yellow B are unavailable) sub-sea functions cannot* be operated from Toolpusher’s
Control Panel. Proceed to Driller’s Control Panel. At the DCP, if SEM Blue A and Yellow
A are healthy (i.e. heartbeats are green and SEM Blue A and Yellow A are available) sub-
sea functions can be operated from Driller’s Control Panel. **

*If the TCP was not able to communicate with SEM Blue B & Yellow B, the problem with
the network (consisting of TCP, SCP, Event Logger, Diverter Control Unit, Comm/Power
Dist Panel B) must be identified and repaired.

**If the DCP was not able to communicate with SEM Blue A & Yellow A, the problem with
the network (consisting of DCP, Comm/Power Dist Panel A) must be identified and
repaired.
PROPERTY OF DRAWN BY: REVISION
J.Redding 02
Document No.
DATE: SHEET
X-145945-01
May 16, 2008 3 OF 3
PROPERTY OF REVISED BY REVISION
M. CLAESSENS 02
DATE SHEET X-200111-65
24 JUNE, 2010 1 of 6

PROCEDURE FOR
BOP CONTROL POD
HARDWARE INSTALLATION

CHECKED BY: A. Rose 15 JANUARY, 2010

APPROVED BY: N. Cooper 18 JANUARY, 2010

PROPERTY OF REVISED BY REVISION
M. CLAESSENS 02
DATE SHEET X-200111-65
24 JUNE, 2010 2 of 6

TABLE OF CONTENTS

1.1 INTRODUCTION

1.2 APPLICABLE DOCUMENTS

1.3 REQUIRED EQUIPMENT

1.4 INSTALLATION PROCEDURE

1.5 TEST PROCEDURE

1.6 VISUAL INSPECTION

PROPERTY OF REVISED BY REVISION
M. CLAESSENS 02
DATE SHEET X-200111-65
24 JUNE, 2010 3 of 6

1. SCOPE

1.1 This document outlines a step-by-step procedure for the installation of a BOP
Control Pod female receptacles and alignment brackets onto the BOP Stack and
LMRP.

2. APPLICABLE DOCUMENTS

2.1 SK-122397-65 Details, Pod Installation

2.2 SK-122170-04 Assembly, Riser Female Receptacle

2.3 SK-122171-03 Assembly, Stack Female Receptacle

3. REQUIRED EQUIPMENT

3.1 2021007-03 Riser Female Receptacle, Two (2)

3.2 2021008-03 Stack Female Receptacle, Two (2)

3.3 2020708-65 BOP Control Pod

3.4 2232958-02-01 Lift Frame

3.5 2021545-13-01 Lift Eye for Lift Frame

3.6 2021545-12-01 Lift Eye for Control Pod

3.7 2021355-01 Guide Pin

3.8 2021335-01 Nut for Guide Pin

4. INSTALLATION PROCEDURE

4.1 Prepare the LMRP Stab Plate and the Stack Receiver Plate as shown on Pod
Installation Details drawing, SK-122397-65.

4.2 Install the four lift eyes (2021545-12-01) to the lower (hydraulic) section of the
Pod. Assemble the lift eye (2021545-13-01) to the lifting frame (2232958-02-01)
and connect proper rigging hardware (shackles, slings, etc.).

4.3 Install all 4 guide pins and nuts per drawing SK-122397-65 on LMRP plate.

4.4 With both stingers retracted set one of the Control Pods on the Pod Support Plate
on the LMRP. While lowering the Pod, confirm that the stack stinger test ring is
centered over the stack stinger hole in the LMRP plate. When lowered on the
LMRP plate, confirm that the center of the stack and riser stinger test rings are in
the two holes on the LMRP plate. Confirm location of alignment pins and fit up of
PROPERTY OF REVISED BY REVISION
M. CLAESSENS 02
DATE SHEET X-200111-65
24 JUNE, 2010 4 of 6

alignment pins to the pod.

4.5 Remove the rubber springs and metal spacers from the Riser Female Receptacle
support brackets, leaving the support brackets and 5/8” bolts still installed.

4.6 Extend the Riser Stinger. Visually identify an appropriate set of seal ports on the
Stinger that is accessible and can be used for the Receptacle alignment. With a
soft tip marker, draw a line using a 90 degree square through the center of the seal
ports on the Stinger and on the mating Receptacle. Retract the Stinger until it is
extended approximately halfway out of the Test Ring. The Stinger must then be
lowered onto three equal length spacers that allow the Stinger to align itself as it
would if it were completely extended.

4.7 Lubricate the inside of the Riser Receptacle. Place the receptacle under the riser
stinger using wood blocks. Align the Receptacle so that the line through the center
of the seal ports matches the line on the Stinger. Raise the Receptacle using the
forklift so that the Receptacle is in firm contact with the bottom surface of the
Test Ring.

4.8 Position the four support brackets and the four shim plates so that the 5/8” bolts
are centered in the holes in the mounting brackets. Tack-weld the brackets in
place.

4.9 Remove spacers and slowly extend the riser stinger into the female receptacle.
Check the alignment of the ports with the corresponding outlets of the stinger. All
seals on the stinger should be aligned on the female ports such that there is no
elastomer visible in the Receptacle port in the energized position. If rotation of the
female Receptacle is necessary, repeat steps 4.5 through 4.8.

4.10 Energize the riser stinger seals.

4.11 Verify that the four support brackets and the four shim plates are located vertically
in such a manner that the Receptacle will achieve the required preload in
accordance with note 5 of drawing SK-122397-65. The measurement should be
between 1/16”-1/4” for each location. This range of dimensions is to ensure that
the Test Ring and the Receptacle have good repeatable contact. The preload is
determined by the gap between the riser receptacle bracket and the stud plate
when loaded. Ensure that the location of Port 54 is as shown in SK-122397-65.
The receptacle ring must also be centered as exactly as possible to prevent binding
when the stinger is extended.

4.12 De-energize the seals and retract the riser stinger. Remove the pod and riser
female receptacle from the LMRP. Complete the welding of the four support
brackets and four shim plates as shown on drawing SK-122397-65.

4.13 Install the riser receptacle as shown on drawings SK-122170-04 and SK-122397-
65.
PROPERTY OF REVISED BY REVISION
M. CLAESSENS 02
DATE SHEET X-200111-65
24 JUNE, 2010 5 of 6

4.14 Install the pod onto the LMRP and check for proper riser stinger operation as it is
extended. If everything is aligned properly, energize the riser stinger seals.

Note: Steps 4.2 through 4.13 can be made with the LMRP alone (not installed on
the lower BOP Stack). The remaining steps must be done with the LMRP installed
and locked onto the stack with the Riser Connector. All alignment features
between the LMRP and the stack must have been completed before these steps are
attempted. Repeat steps 4.2 through 4.13 for other pod.

4.15 Set the LMRP (with the pod installed) onto the BOP stack and latch the Riser
Connector.

4.16 Extend the Stack Stinger. Visually identify an appropriate set of seal ports on the
Stinger that is accessible and can be used for the Receptacle alignment. With a
soft tip marker, draw a line using a 90 degree square through the center of the seal
ports on the Stinger and on the mating Receptacle. Retract the Stinger until it is
extended approximately halfway out of the Test Ring. The Stinger must then be
lowered onto three equal length spacers that allow the Stinger to align itself as it
would if it were completely extended.

4.17 Lubricate the inside of the stack female receptacle. Remove the rubber springs
from the supports of the stack female receptacle. Orient port 112 as shown on SK-
122397-65. Support the receptacle on blocks as was done in Step 4.6. Align the
Receptacle so that the line through the center of the seal ports matches the line on
the Stinger. Raise the Receptacle using the forklift so that the Receptacle is in
firm contact with the bottom surface of the Test Ring.

4.18 Position Stack receptacle as shown in drawings SK-122171-03 and SK-122397-65

and shim the height so that the top surface of the receptacle is against the lower
surface of the pod test ring and preloaded in accordance with note 5 of drawing
SK-122397-65. The measurement should be between 1/16”-1/4” at each location.
This range of dimensions is to ensure that the Test Ring and the Receptacle have
good repeatable contact. The preload is determined by the differential of the top
of the receptacle to the Stack Receiver Plate with the Pod removed and with the
Pod landed. Tack weld receptacle mounting blocks (4X) in position after shim up.

4.19 Slowly extend the stack stinger into the female receptacle. Check the hydraulic
connection ports for proper positioning. All seals on the stinger should be aligned
on the female ports such that there is no elastomer visible in the Receptacle port in
the energized position. Rotate the receptacle as necessary.

4.20 When the ports are properly aligned, de-energize the stack stinger seals and retract
the stringer.

4.21 Remove the pod from the LMRP.

4.22 Repeat the above procedures 4.15 to 4.20 for the other set of receptacles.
PROPERTY OF REVISED BY REVISION
M. CLAESSENS 02
DATE SHEET X-200111-65
24 JUNE, 2010 6 of 6

4.23 Remove the Pods from the LMRP plate.

4.24 Remove Pod assembly and Pod Guide Frame from LMRP plate.

5. TEST PROCEDURE

5.1 Install the Pods.

5.2 While observing the operation closely, extend the riser stingers into the riser
receptacles and energize the stinger seals.

5.3 Lower the LMRP onto the stack and latch the Riser Connector.

5.4 While observing the operation closely, extend the stack stingers into the stack
receptacles and energize the stinger seals.

6. VISUAL INSPECTION

6.1 Following test operation of the hydraulic LMRP and BOP Stack functions,
remove the pods from the LMRP. Die Pen. inspect all welds on brackets for
indications.

6.2 Check all riser and stack female receptacles for damage.
 REVISED BY: REVISION
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Document No.
DATE: SHEET
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11/14/02 1 OF 19

Procedures Manual

Section No: Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title: Page: 1 of 18
HOSE ASSEMBLIES

INDEX

1.0 HYDRAULIC HOSE TO JIC FITTING

TERMINATION

2.0 CCP TO CCR CONNECTOR PREPARATION

3.0 INSERT & BOOT PREPARATION

4.0 CONNECTOR ASSEMBLY

5.0 FINAL ASSEMBLY PROCEDURE

6.0 HELIUM LEAK TEST

7.0 OIL FILL PROCEDURE

Notes Initials Rev Date Comment

0 17/09/02 NEW

Note: Please refer to Appendix on page 19 for reference of SeaCon drawings.

Prepared By: Nathan Cooper Date: July 16, 2002

Checked By: Rodger Bubenheim Date: November 19, 2002

Approved By: Mac Kennedy Date: November 19, 2002

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 REVISED BY: REVISION
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DATE: SHEET
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Procedures Manual

Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 2 of 18
HOSE ASSEMBLIES

1.0 Hydraulic Hose to JIC Fitting Termination

1.1 Using a sharp knife, cut the required length of hydraulic hose.

1.2 Push the hose onto the JIC fitting and butt it up to the rear shoulder.

1.3 Place a jubilee clip over the hose and onto the JIC fitting. Tighten the clip until
it begins to depress the hose and cover with a length of heatshrink. Refer to Figure 1.
DO NOT OVERTIGHTEN.

Fig 1.

1.4 Repeat operation 1.2 and 1.3 for the opposite end.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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DATE: SHEET
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 3 of 18
HOSE ASSEMBLIES
2.0 CCP & CCR Connector Preparation
1.1.1 CCR
2.1 Refer to SCE Drawing No. 2091-1-D for the CCR connector.

2.2 Take the two ‘O’ rings item 2 and place in position onto the rear of the
CCR shell.

2.3 Take ‘O’ ring item 8 and position into the bore of the CCR shell.
1.1.2 CCP
2.4 Refer to drawing No. 2090-1-D for the CCP connector.

2.5 Take the two ‘O’ rings item 16 and place in position onto the rear of the
CCP shell.

2.6 Take ‘O’ ring item 8 and position into the bore of the CCP shell.

2.7 Place the engaging nut split washer item 10, followed by the split
washer item 9 onto the CCP shell.

2.8 Hold the two split halves in place between the washers and slide the
locking sleeve over them. Refer to figure 2.

2.9 Align the holes in the locking sleeves with the split halves, apply Loctite
243 to the M4 x 5 CSK machine screws and secure them through the
sleeve. Tighten to 1.9-2.1 N/m.

2.10 Apply a small amount of silicone grease to the ‘O’ rings on the rear of
the connector and with reference to the applicable assembly drawing,
attach the connector to the hose JIC fitting and hand tighten.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 4 of 18
HOSE ASSEMBLIES

Fig. 2

3.0 Insert & Boot Preparation

3.1 Take the cable boot and apply silicone grease to the face. Refer to
figure 3.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 5 of 18
HOSE ASSEMBLIES

Fig 3

3.2 Inspect each wire for any sharp protrusions and carefully thread
individually through the rear of the cable boot.

3.3 Once complete, strip the first 6-7mm of insulation from each wire.

3.4 Tin each wire with solder. Refer to figure 4.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 6 of 18
HOSE ASSEMBLIES

Fig.4

3.5 Depending on which connector, CCP or CCR, is being terminated, take the
relevant insert and fill the solder buckets with solder. Once complete remove any
traces of flux using a specialised cleaner or Methyl Ethyl Ketone.

3.6 Taking careful note of the orientation of the solder buckets and the face of
the cable boot align pin 1 with the relevant wire as it exits the boot.

3.7 Take the wire immediately below this one and solder it to pin 17 of the
insert. Continue in a clockwise manner for the remainder of the inner ring of
wires. Ensuring that none of the wires cross.

3.8 Once complete, solder the remaining outer wires to the relevant contact,
again ensuring that none cross each other. Refer to figure 5.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 7 of 18
HOSE ASSEMBLIES

3.9 Clean all traces of flux from the soldered terminations.

Fig.5

3.10 Apply a layer of silicone grease around the solder buckets. Refer to
figure 6.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No
Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title: Page: 8 of 18
HOSE ASSEMBLIES

Fig 6

3.11 Push the cable boot onto the rear of the insert and locate into position.
Refer to figure 7.

Fig. 7

Notes Initials Rev Date Comment

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 9 of 18
HOSE ASSEMBLIES

4.0 Connector Assembly

4.1 Before assembly electrically test the insert for continuity and
insulation resistance in accordance with the relevant drawing.

4.2 Lay the hose assembly out to its full length along a workbench.

4.3 Take the free end of the wires and trim them all level then bind them
together with 2 layers of PVC tape.

4.4 Push a draw line through the connector and into the hose until it
protrudes from the opposite end.

4.5 Clean the wires thoroughly using Isopropanol and dry with an air line.

4.6 Attach the taped wires to the end of the draw line using PVC tape and
gently continue to pull through the hose until the wires exit the opposite
end.

4.7 Remove the draw line.

4.8 Secure the connector body in a soft jaw vice.

4.9 Apply a small amount of silicone grease to the internal ‘O’ seal.

4.10 Align the locating ‘bippies’ on the rear of the insert with the slots in the
connector body and press firmly into place. The insert should sit flush
with face of the CCP and flush with the inner shoulder of the CCR. Refer to
figure 8.

4.11 Take the locking ring, item 1 and apply a small amount of anti-galling
d t th th d
Notes Initials Rev Date Comment
0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 10 of 18
HOSE ASSEMBLIES

Fig. 8 CCP connector

4.12 At the opposite end of the hose pull the wires tight and mark the point
at which they exit the connector body with an indelible marker. Refer to figure 9.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 11 of 18
HOSE ASSEMBLIES

Fig 9

4.13 Roll the hose assembly into a tight coil and secure with Ty-raps. Refer
to figure 10.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 12 of 18
HOSE ASSEMBLIES

Fig 10

4.14 Secure the assembly in a vice so that there is easy access to the
terminated connector body.

4.15 Apply a small amount of silicone grease to the second cable boot as
per figure 3.

4.16 Using a continuity tester, locate wire number 1 and pass through the
relevant hole in the cable boot. Continue for the remaining wires. Refer
to figure 11.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 13 of 18
HOSE ASSEMBLIES

Fig 11

4.17 Pull all the wires taught and cut them flush at the mark made in 4.12.

4.18 Continue to prepare and solder the wires as per operations 3.3 to 3.11.

4.19 Once complete perform a continuity test on the assembly in

accordance with the relevant drawing.

4.20 Apply a small amount of silicone grease to the internal ‘O’ seal.

4.21 Cut the Ty-raps and slowly un-coil the assembly.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 14 of 18
HOSE ASSEMBLIES

4.22 Proceed to locate the insert into the connector shell as per
operations 4.7 to 4.11.

4.23 Perform electrical continuity and insulation resistance tests in

accordance with the relevant drawing.

5.0 Final Assembly Procedure

5.1 Refer to the relevant drawing and align the connector keyways with
each other and if applicable to the hose JIC fitting.

5.2 Refer to SCE Wi 74 and tighten the hose nut to the connector shell.

6.0 Helium Leak Test

6.1 Place the ‘O’ rings onto the cavity seal screws and lubricate them with
a small amount of silicone grease.

6.2 Secure 3 off screws into the connector shells and tighten to 1.4-1.6
N/m.

6.3 Place the ‘O’ rings on the fill test adaptor, SCE Drg. No. 1669-1-A and
screw it into the remaining cavity seal port. Refer to figure 12

6.4 Attach the helium test rig to the adaptor and pressurise the hose
assembly to 15 p.s.i Hold the pressure for 10 minutes and observe for
any leakage, which will be cause for rejection.

6.5 Once complete remove the adaptor and insert the remaining cavity
seal screw.
Notes Initials Rev Date Comment
0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 15 of 18
HOSE ASSEMBLIES

Fig 12

7.0 Oil Fill Procedure

7.1 Elevate and secure one end of the hose, making sure that the cavity
seal screws sit at 12 and 6 o’ clock respectively. Refer to figure 13.

7.2 Trail the remainder of the hose away at an angle of approximately 45

degrees.

7.3 Remove the cavity seal screw which is in the 12’oclock position at the
secured end.

7.4 Screw into the cavity hole the funnel and valve assembly, SCE Drg. No.
SK11, leaving the valve open. Refer to figure 13.

Notes Initials Rev Date Comment

0 17/09/02

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loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No
Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title: Page: 16 of 18
HOSE ASSEMBLIES

Fig 13

7.5 Fill the oil pump with DC200/100cs silicone oil.

7.6 Remove one of the cavity seal screws from the free end of the hose
assembly.

7.7 Ensuring the ‘O’ rings are in position, screw the filling handle from the
pump into the cavity port. Refer to figure 14.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No
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ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title: Page: 17 of 18
HOSE ASSEMBLIES

Fig 14

7.7 Pressurise the pump and start to fill the hose assembly.

7.8 Observe the funnel at the top of the hose. When it is half full cease
filling.

7.9 Close the valve at the top of the assembly.

7.10 Position the cavity seal screw next to the cavity hole and begin to
unscrew the filling handle. Once removed immediately replace the seal screw
and tighten to the specified torque.
Notes Initials Rev Date Comment
0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Procedures Manual
Section No : Wi98

ASSEMBLY PROCEDURE for MSSL HYDRAULIC

Title : Page : 18 of 18
HOSE ASSEMBLIES

7.11 Open the valve at the top of the assembly and gently agitate the hose
to remove any trapped air.

7.12 Leave the hose for a period of one hour whilst periodically agitating the
assembly to remove any air.

7.13 Upon completion remove the funnel assembly and replace the cavity
seal screw.

7.14 Test the assembly for electrical continuity and insulation resistance in
accordance with the relevant drawing.

Notes Initials Rev Date Comment

0 17/09/02

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Appendix

For SCE Drawing No. 2091-1-D: Please refer to Cameron Drawing SK-122867-01.

For SCE Drawing No. 2090-1-D: Please refer to Cameron Drawing SK-122868-01.

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Document No.
DATE: SHEET
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07/16/02 1 OF 3

Procedures Manual
Section No: 7 wi63

Title: Re-Fill Procedure for P.B.O.F. Assemblies Page: 1 of 3

INDEX

1.0 Scope

2.0 Equipment

3.0 Oil Preparation

4.0 Helium Testing

5.0 Equipment Preparation

6.0 Oil Filling

Notes Initials Rev Date Comment

Prepared By: Nathan Cooper Date: July 16, 2002

Checked By: Rodger Bubenheim Date: July 31, 2002

Approved By: Mac Kennedy Date: July 31, 2002

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Document No.
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07/16/02 2 OF 3

Procedures Manual
Section No: 7 wi63

Title: Re-Fill Procedure for P.B.O.F. Assemblies Page: 2 of 3

1.0 SCOPE

1.1 This procedure covers the required “top up” procedure for P.B.O.F. assemblies.

2.0 EQUIPMENT

• Vacuum Pump
• DC 200 Silicone Oil
• As per parts list detailed on drawing 1748-1-B

3.0 OIL PREPARATION

3.1 Evacuate the DC 200 Silicone Oil in a vacuum chamber prior to use. 0.5 litres of oil
will be sufficient to “top up” the assembly.

4.0 HELIUM TESTING

4.1 If any of the connector ‘O’ seals have been compromised or the hose has been
disassembled prior to re-fill etc, the assembly should be Helium tested in accordance
with WI 53 before re-filling.

NOTE: Refer to the parts list on the appropriate GA drawing for ‘O’ seal details

5.0 EQUIPMENT PREPARATION

5.1 Pre-assemble equipment, items 2 to 10, in accordance with drawing 1748-1-B.

6.0 OIL FILLING

6.1 Elevate and secure one end of the hose, making sure that the cavity seal screw in
the connector body sit is sitting in the uppermost position (12 O’clock)
6.2 Trail the remainder of the hose away at an angle.
6.3 Remove the cavity seal screw, which is in the 12 ‘o clock position at the secured end
and replace it with the Test / Filling adapter (item 6).
6.4 Decant some of the pre-evacuated oil into the Plunger Body (item 2) and replace the
Syringe Plunger (Item 1).
Notes Initials Rev Date Comment

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
01
Document No.
DATE: SHEET
X-200136-03
07/16/02 3 OF 3

Procedures Manual
Section No: 7 wi63

Title: Re-Fill Procedure for P.B.O.F. Assemblies Page: 3 of 3

6.5 Slowly depress the Syringe Plunger (item 1) until resistance is felt, whilst at the same
time gently moving the hose from side to side etc, to free any trapped air.

6.6 Depress the plunger in the Insert Valve until the oil bleeds through. At this point allow
the plunger to resume it’s normal closed position

6.7 Repeat 6.4 (if necessary) and 6.5

6.8 Leave to settle for 1 hour and top up if necessary

6.9 Remove the Syringe Tube assembly, and re-fit the cavity seal screw.

Notes Initials Rev Date Comment

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any right to
loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This
document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF DRAWN BY REVISION
Richard Coronado 01
DATE SHEET X-200136-05
17 June 2004 1 of 6

TEST PROCEDURE

FOR

VERIFYING SEAL INTEGRITY

BETWEEN MATED PBOF CABLE AND

MATING CONNECTOR

CHECKED BY: Nathan Cooper DATE: 17 June 2004

APPROVED BY: Ike Estes DATE: 17 June 2004

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey
any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission
from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF DRAWN BY REVISION
Richard Coronado 01
DATE SHEET X-200136-05
17 June 2004 2 of 6

Table of Contents

1.0 SCOPE ...................................................................................................................... 3

2.0 EQUIPMENT NEEDED .............................................................................................. 3

3.0 TEST .......................................................................................................................... 3

4.0 SET-UP PROCEDURE .............................................................................................. 4

5.0 PROCEDURE ............................................................................................................ 4

6.0 CERTIFICATE ........................................................................................................... 6

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey
any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission
from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
Richard Coronado 01
DATE SHEET X-200136-05
17 June 2004 3 of 6

1.0 SCOPE

This document outlines the procedure for testing a PBOF cable after it has been properly mated
with the FCP (Flange Connector Plug) or FCR (Flange Connector Receptacle). This procedure
can be used on any PBOF cable that has a test port.

Helium is the preferred gas to use for this test; however, Dry Nitrogen may also be used.

2.0 EQUIPMENT NEEDED

1. Helium or Dry Nitrogen

2. Regulator
3. Relief Valve
4. Gauges
5. Miscellaneous hoses w/fittings
6. M4 adapter, Cameron Part# 2762901-01

The above equipment should be in good working order and be compatible with Helium or Dry
Nitrogen. Additionally, the Shop Purge Kit (2021964-01) may be used (with some
modifications) to test the mated PBOF cable.

3.0 TEST

The following test is prepared for:

_______________________________________/ PN:______________________
(fill in the appropriate equipment as listed above)

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey
any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission
from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
Richard Coronado 01
DATE SHEET X-200136-05
17 June 2004 4 of 6

4.0 SET-UP PROCEDURE

5.0 PROCEDURE

1. Apply a small amount of silicone grease to two ‘O’ rings between PBOF cable and FCR
or FCP. Carefully install the PBOF cable connector and hand tighten the ENGAGING
NUT until the nut is fully seated. There should be no threads visible on either the FCR
or FCP.

2. DO NOT OVER TIGHTEN OR USE WRENCH! EXCESSIVE FORCE WILL

BREAK ADAPTER!
Remove the M4 cavity seal screw. Apply a small amount of silicone grease to ‘O’ring
and install adapter to PBOF cable test port hand tight only.

3. CARE SHOULD BE EXERCISED WHEN ASSEMBLING THE REMAINDER OF

FITTINGS TO ADAPTER! DO NOT APPLY EXCESSIVE FORCE TO

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey
any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission
from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF DRAWN BY REVISION
Richard Coronado 01
DATE SHEET X-200136-05
17 June 2004 5 of 6
ADAPTER OR USE ADAPTER TO TIGHTEN OTHER FITTINGS.
Assemble remainder of fittings and equipment per the above figure (Section 4). Care
should be exercised to assemble fittings and equipment to create a “leak” free apparatus.

4. Set the regulated gauge pressure to 15/13 Max./Min. psi. with needle valve closed.

5. The volume of gas required will be very small. Open needle valve slowly to allow the
gas to enter the test port. This will happen very quickly because of the very, very small
volume of the test port.

6. Close needle valve and verify 17/13 Max./Min. psi in the test port.

7. After pressure has stabilized. Hold the pressure for 10 minutes to verify no leakage.

8. After successful completion of test, carefully remove adapter and reinstall cavity seal
screw and ‘O’ ring.

9. Repeat steps 1-8 for other end of PBOF cable (if required).

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey
any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission
from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
Richard Coronado 01
DATE SHEET X-200136-05
17 June 2004 6 of 6

6.0 Certificate

SINGLE UNIT TEST CERTIFICATE

FOR

PBOF CABLE

PART#_______________________________

PROJECT: ______________________

CAMERON PART NUMBER: ______________________

TEST WITNESSED AND RESULTS ACCEPTED BY:

Test performed by: ______________________________ Date: _____________

(Cameron Technician)

Test performed by: ______________________________ Date: _____________

(Cameron QA/QC)

Test performed by: ______________________________ Date: _____________

(Other Inspector)

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey
any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission
from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 1 OF 92

COMMISSIONING PROCEDURE

FOR

BOP CONTROL SYSTEM

PROJECT: ODEBRECHT #1 (H3603) & #2 (H3604)

Created By: A. Rose Date: 31 March 2010

Checked By: J. Love Date: 31 March 2010

Approved By: N. Cooper Date: 31 March 2010

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 2 OF 92

Document Revision Status / Record

Rev. Date Description of Change

01 31 March 2010 Initial Release
02 05 May 2010 Sheet 6: Removed row for document SK-122101-65-02
Sheet 7: Changed ‘GA, Acoustic Valve Module SK-122113-65/66-03’
to ‘Assembly Drawing SK-122113-65/66-04’
In section 6.8 thru 6.11, corrected the expected voltage measurement
from 230VAC to 250VAC, as the output voltage of the isolation
transformers in the Comm/Power Distribution Panels, is 250VAC.
03 13 May 2010 In section 8.16, added interface –W49.
04 09 July 2010 - On cover sheet, added hull numbers
- In section 4.1 and 4.4 changed BOP Concentrate to Erifon HD
603 HP
- In Seciton 6.1 removed “the UPS ‘REPO’ connector pins must be
reconnected”
- In Section 6.2, 6.3, 6.4, 6.5, and 6.6 revised verification to ensure
version and revision level of PLC software
- In section 6.8, 6.9, 6.10, and 6.11 changed 250 VAC +/-5% to be
+10%, -0%
- In Section 8.3 changed frequency of test sampling HPU reservoir
fluid from daily to twice weekly
- In Section 8.5 changed values in table for the repeated test
- In Section 8.6.1 added drawing numbers and to verify that alarm
condition clears after 5 bar
- In Section 8.18 added section for verification of revision level of
software
- Added Section 8.20 UPS Capacity Test
- In Section 8.21 added section for verification of revision level of
software
- In Section 8.22 changed verbiage to be lifting the LMRP from the
lower BOP stack

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 3 OF 92

Table of Contents
DOCUMENT REVISION STATUS / RECORD ....................................................................................................................... 2
1 ABBREVIATIONS................................................................................................................................................................... 5
2 INTRODUCTION ..................................................................................................................................................................... 6
2.1 SCOPE .................................................................................................................................................................................. 6
2.2 REFERENCE DOCUMENTS/DRAWINGS .................................................................................................................................. 6
2.3 ORDER OF TESTING AND PRECAUTIONS ............................................................................................................................... 8
3 SAFETY WARNINGS............................................................................................................................................................. 9
4 TEST PREPARATION ......................................................................................................................................................... 10
4.1 EQUIPMENT REQUIRED ...................................................................................................................................................... 10
4.2 ELECTRICAL INTERCONNECT ............................................................................................................................................. 11
4.3 HYDRAULIC/ PNEUMATIC INTERCONNECT .......................................................................................................................... 12
4.4 ADDITIONAL PREPARATIONS ............................................................................................................................................. 12
5 PROTECTIVE GROUND TEST, INSULATION RESISTANCE TEST, OPTICAL CABLE TEST ........................... 16
5.1 PRECAUTIONS .................................................................................................................................................................... 16
5.2 PROTECTIVE GROUND TEST ............................................................................................................................................... 16
5.2.1 Communication / Power Distribution Panel A........................................................................................................... 16
5.2.2 Communication / Power Distribution Panel B........................................................................................................... 17
5.2.3 Driller’s Control Panel.............................................................................................................................................. 17
5.2.4 Toolpusher’s Control Panel....................................................................................................................................... 17
5.2.5 Event Logger.............................................................................................................................................................. 17
5.2.6 Diverter Control Unit................................................................................................................................................. 18
5.2.7 Hydraulic Power Unit................................................................................................................................................ 18
5.2.8 Fluid Mixing Unit ...................................................................................................................................................... 18
5.2.9 Blue Cable Reel.......................................................................................................................................................... 19
5.2.10 Yellow Cable Reel .................................................................................................................................................... 19
5.2.11 BOP Test Pump Unit................................................................................................................................................ 19
5.3 SYSTEM INSULATION TEST ................................................................................................................................................. 20
5.3.1 Communication/ Power Distribution Panel A............................................................................................................ 20
5.3.2 Communication/ Power Distribution Panel B........................................................................................................... 21
5.3.3 Driller’s Control Panel.............................................................................................................................................. 22
5.3.4 Toolpusher’s Control Panel...................................................................................................................................... 22
5.3.5 Event Logger.............................................................................................................................................................. 23
5.3.6 Diverter Control Unit................................................................................................................................................. 23
5.3.7 Hydraulic Power Unit................................................................................................................................................ 24
5.3.8 Mixing Unit ................................................................................................................................................................ 25
5.3.9 Blue Cable Reel.......................................................................................................................................................... 25
5.3.10 Yellow Cable Reel .................................................................................................................................................... 26
5.3.11 BOP Test Pump Unit................................................................................................................................................ 26
5.4 OPTICAL CABLE TEST ......................................................................................................................................................... 27
6. POWER-UP PROCEDURE ................................................................................................................................................. 27
6.1 UPS SYSTEM ...................................................................................................................................................................... 27
6.2 COMMUNICATION/POWER DISTRIBUTION PANELS ............................................................................................................. 29
6.3 DRILLER’S CONTROL PANEL.............................................................................................................................................. 29
6.4 TOOLPUSHER’S CONTROL PANEL....................................................................................................................................... 30
6.5 EVENT LOGGER ................................................................................................................................................................. 30
6.6 HPU SYSTEM ..................................................................................................................................................................... 31
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 4 OF 92

6.7 ‘HPU SYSTEM’ MOTORS ................................................................................................................................................... 33

6.8 BLUE COMM/POWER JUNCTION BOX .................................................................................................................................. 33
6.9 BLUE CABLE REEL ............................................................................................................................................................. 34
6.10 YELLOW COMM/POWER JUNCTION BOX ........................................................................................................................... 34
6.11 YELLOW CABLE REEL ...................................................................................................................................................... 35
6.12 SUBSEA EQUIPMENT ......................................................................................................................................................... 35
7 POWER SUPPLY MONITORING........................................................................................................................................ 36
7.1 UPS A ................................................................................................................................................................................ 36
7.2 UPS B................................................................................................................................................................................. 36
7.3 DCP.................................................................................................................................................................................... 36
7.4 TCP .................................................................................................................................................................................... 36
7.5 COMM/POWER DIST PANEL A ............................................................................................................................................ 37
7.6 COMM/POWER DIST PANEL B............................................................................................................................................. 37
7.7 DIVERTER CONTROL UNIT .................................................................................................................................................. 37
7.8 HPU ................................................................................................................................................................................... 37
7.9 MIXING UNIT ...................................................................................................................................................................... 38
7.10 BLUE CONTROL POD......................................................................................................................................................... 38
7.11 YELLOW CONTROL POD ................................................................................................................................................... 38
8 SYSTEM INTEGRATION TEST ......................................................................................................................................... 39
8.1 BLEED PROCEDURE............................................................................................................................................................ 39
8.2 TESTING OF HOTLINE HOSE, RISER FILL VALVE & MUX CABLE REELS ............................................................................ 39
8.2.1 Hotline Hose Reel ...................................................................................................................................................... 39
8.2.2 Mux Cable Reels ........................................................................................................................................................ 40
8.2.3 Riser Fill Valve Reel .................................................................................................................................................. 40
8.3 PREPARATION OF MIXED FLUID FOR THE HPU .................................................................................................................. 41
8.4 HPU................................................................................................................................................................................... 42
8.5 MIXING UNIT ..................................................................................................................................................................... 47
8.6 DIVERTER CONTROL UNIT FUNCTION TESTS........................................................................................................ 48
8.6.1 REGULATORS.......................................................................................................................................................... 48
8.6.2 DIVERTER FUNCTION TESTS ............................................................................................................................... 52
8.7 BOP TEST PUMP INTERFACE.............................................................................................................................................. 55
8.8 INTERLOCK VERIFICATION TEST ........................................................................................................................................ 56
8.8.1 Drilling Mode............................................................................................................................................................. 56
8.9 BOP STACK AND BOP STACK CONTROL CONTINUITY TEST ............................................................................................. 57
8.10 STACK WORKING PRESSURE LEAK TEST ......................................................................................................................... 64
8.11 POD REGULATOR FUNCTIONALITY TEST.......................................................................................................................... 70
8.12 ROV PANEL FUNCTION TEST........................................................................................................................................... 72
ACOUSTIC/AUTOSHEAR ISOLATION ROV PANEL ..................................................................................................................... 73
8.13 POD ROV FUNCTION TEST ............................................................................................................................................. 73
8.14 EMERGENCY DISCONNECT SEQUENCES ........................................................................................................................... 74
8.15 ACOUSTIC CONTROL SYSTEM ......................................................................................................................................... 77
8.16 ‘RISER MESSAGE STRING’ INTERFACE ............................................................................................................................. 78
8.17 ELECTRICAL MINI-POD (HYDRAULIC/ELECTRICAL STAB) POWER AND SIGNAL TEST ..................................................... 78
8.18 BOP TEST BOX ................................................................................................................................................................ 79
8.19 SURFACE NETWORK INTEGRITY....................................................................................................................................... 79
8.20 UPS CAPACITY TEST ........................................................................................................................................................ 80
8.21 PETU INTERFACE TEST ............................................................................................................................................ 86
8.22 AUTOSHEAR FUNCTION TEST .......................................................................................................................................... 89
8.23 ‘RISER RECOIL’ TEST ....................................................................................................................................................... 90
8.24 INCLINATION TEST ........................................................................................................................................................... 91
9 TEST CERTIFICATE........................................................................................................................................................... 92
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
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09 July 2010 5 OF 92

1 Abbreviations

API American Petroleum Institute

BACC Blue A Communication Controller
BBCC Blue B Communication Controller
BOP Blow Out Preventer
CPU Central Processing Unit
DCP Driller’s Control Panel
DCU Diverter Control Unit
EDS Emergency Disconnect Sequence
EL Event Logger
E-Pump Electric-driven Pump
HMI Human Machine Interface
HOA Hand-Off-Auto
HPU Hydraulic Power Unit
I/O Input/Output
LMRP Lower Marine Riser Package
LOTO Lock out tag out
MOD Modular
MUX Multiplex
N.O. Normally Open
PBOF Pressure Balanced Oil Filled
PETU Portable Electronic Test Unit
PLC Programmable Logic Controller
SEM Subsea Electronic Module
T-JOINT Telescoping Joint
TCP Toolpusher’s Control Panel
UPS Uninterruptible Power Supply
VAC Voltage Alternating Current
VDC Voltage Direct Current
YACC Yellow A Communication Controller
YBCC Yellow B Communication Controller

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
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09 July 2010 6 OF 92

2 Introduction
2.1 Scope
This document outlines the procedure for function testing the MUX BOP Control System supplied for
the Odebrecht #1 & #2 projects. The purpose is to verify fit and function of the Control System prior to
operation onboard the vessel, and to verify pressure integrity and proper hook-up of all electrical
interconnections, as well as pipe, tubing, hoses, and hydraulic interconnections.

The overall job safety analysis to be performed prior to commencement of this test. Task specific job
safety analysis to be performed as required.

2.2 Reference Documents/Drawings

Description Odebrecht #1 Odebrecht #2 Revision

Cameron Drawing No. Cameron Drawing No.
Interconnection Block Diagram SK-122100-65-02 SK-122100-66-02
Hydraulic/Pneumatic Interconnect Diagram SK-122100-65-01 SK-122100-66-01
Scope of Supply Drawing SK-122100-65-13 SK-122100-66-13
GA, UPS System SK-122111-65-03 SK-122111-66-03
Electrical Schematic, UPS System SK-122111-65-06 SK-122111-66-06
GA, Comm/Pwr Dist Panel A SK-122141-65-03 SK-122141-66-03
GA, Comm/Pwr Dist Panel B SK-154382-65-03 SK-154382-66-03
Elect Schematic, Comm/Pwr Dist Panel A SK-122141-65-06 SK-122141-66-06
Elect Schematic, Comm/Pwr Dist Panel B SK-154382-65-06 SK-154382-66-06
GA, DCP SK-122106-65-03 SK-122106-66-03
Electrical Schematic, DCP SK-122106-65-06 SK-122106-66-06
GA, TCP SK-122107-65-03 SK-122107-66-03
Electrical Schematic, TCP SK-122107-65-06 SK-122107-66-06
GA, Event Logger SK-122125-65-03 SK-122125-66-03
Electrical Schematic, Event Logger SK-122125-65-06 SK-122125-66-06
GA, BOP Test Box SK-122128-65-03 SK-122128-66-03
Electrical Schematic, BOP Test Box SK-122128-65-06 SK-122128-66-06
GA, Diverter Control Unit SK-122159-65-03 SK-122159-66-03
P&ID, Diverter Control Unit SK-122159-65-16 SK-122159-66-16
Electrical Schematic, Diverter Control Unit SK-122159-65-06 SK-122159-66-06
GA, HPU SK-122160-65-03 SK-122160-66-03
P&ID, HPU SK-122160-65-16 SK-122160-66-16
Electrical Schematic, HPU SK-122160-65-06 SK-122160-66-06
GA, Mixing Unit SK-122110-65-03 SK-122110-66-03
P&ID, Mixing Unit SK-122110-65-16 SK-122110-66-16
Electrical Schematic, Mixing Unit SK-122110-65-06 SK-122110-66-06
GA, Accumulator Rack (24 bottle) SK-122117-65-03 SK-122117-66-03
GA, Accumuluator Rack (7 bottle) SK-122117-65-05 SK-122117-66-05
P&ID, Accumulator Racks SK-122117-65-16 SK-122117-66-16
GA, Blue MUX Cable Reel SK-122104-65-03 SK-122104-66-03
Electrical Schematic, Blue Cable Reel SK-122104-65-06 SK-122104-66-06
GA, Yellow MUX Cable Reel SK-122105-65-03 SK-122105-66-03

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 7 OF 92

Description Odebrecht #1 Odebrecht #2 Revision

Cameron Drawing No. Cameron Drawing No.
Electrical Schematic, Yellow Cable Reel SK-122105-65-06 SK-122105-66-06
GA, Hot Line Hose Reel SK-122102-65-03 SK-122102-66-03
GA, Riser Fill-Up Valve Reel SK-122103-65-03 SK-122103-66-03
GA, Blue Comm/Power J-Box SK-122190-65-03 SK-122190-66-03
Elect Schematic, Blue Comm/Power J-Box SK-122190-65-06 SK-122190-66-06
GA, Yellow Comm/Power J-Box SK-122192-65-03 SK-122192-66-03
Elect Schematic, Yellow Comm/Power J-Box SK-122192-65-06 SK-122192-66-06
GA, Roller Type Turn Down Sheave SK-154660-65-03
GA, MUX Control Pod SK-122108-65-03 SK-122108-66-03
P&ID, MUX Control Pod SK-122108-65-16 SK-122108-66-16
Electrical Schematic, MUX Control Pod SK-122178-65-06 SK-122178-66-06
Assembly Drawing, MUX Section, Control Pod SK-122140-65-04 SK-122140-66-04
Assembly Drawing, MOD Section, Control Pod SK-122367-65-04 SK-122367-66-04
Stack P&ID SK-122124-65-16 SK-122124-66-16
Interconnection Diagram, Riser (LMRP) Instrumentation SK-122366-65 SK-122366-66
Electrical Schematic, Blue RCB SK-122121-65-06 SK-122121-66-06
Electrical Schematic, Yellow RCB SK-122122-65-06 SK-122122-66-06
Assembly Drawing, Conduit Valve Module SK-122120-65-04 SK-122120-66-04
Assembly Drawing, Hotline Valve Module SK-122120-65-03 SK-122120-66-03
Assembly Drawing, Acoustic Valve Module SK-122113-65-04 SK-122113-66-04
Flow Diagram, Acoustic Valve Module SK-122113-65-05 SK-122113-66-05
GA, Acoustic Control System SK-122113-65-17 SK-122113-66-17
GA, ROV Panel (Ram Operations) SK-122158-65-01 SK-122158-66-01
GA, ROV Panel (LMRP Operations) SK-122158-65-02 SK-122158-66-02
GA, ROV Panel (Wellhead Connector) SK-122158-65-03 SK-122158-66-03
GA, ROV Panel (Acoustic/ Autoshear Isolation) SK-122158-65-04 SK-122158-66-04
GA, ROV Panel (Conduit Flush Isolation) SK-122158-65-05 SK-122158-66-05
GA, Pod Test Stand SK-122109-65-03 SK-122109-66-03
GA, BOP Test Pump Unit SK-122114-65-03 SK-122114-66-03
Electrical Schematic, BOP Test Pump Unit SK-122114-65-06 SK-122114-66-06
P&ID, BOP Test Pump Unit SK-122114-65-16 SK-122114-66-16
Procedure for verifying Seal integrity between PBOF cable
X-200136-05
mated connections
Dielectric Fluid Filling Procedure, for MUX Section of Subsea
X-262167-02
Control Pod
Dielectric Fluid Filling Procedure, for Acoustic Electronic
X-262167-01
Module (Acoustic Valve Package)
Subsea Accumuluator Precharge Values X-093667-65
Software Logic (Interlocks, Sequences) X-261720-65

Record the actual revision level of the documents/drawings.

Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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2.3 Order of Testing and Precautions

Note that the order of testing in the function lists is generally by function number. The order of function
tests or sections of this test may be deviated from to minimize the number of times the test tool joint
must be installed or removed, or for any other relevant reason. Warning notes have been inserted in
sections where specifically where the test tool needs to be inserted or removed (i.e. autoshear, EDS,
etc.) However, due to the nature of the function tests it is incumbent on all test personnel to be aware
of the status of the tool joint and the effects of the function about to be actuated before that action is
undertaken. Pipe must be in the bore during annular and pipe ram closures to prevent unnecessary
wear on the packers. Conversely pipe must not be in the bore for shear ram closures, to prevent
damage to the test tool joint.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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3 SAFETY WARNINGS

PERSONNEL AND PRODUCT SAFETY ARE PRIMARY OBJECTIVES AND THEREFORE THE
FOLLOWING PRECAUTIONS MUST BE TAKEN PRIOR TO CARRYING OUT THIS
PROCEDURE:
All personnel must acquaint themselves fully and strictly adhere to all company sites’ HEALTH AND
SAFETY AT WORK REGULATIONS, together with other specific requirements detailed in this
procedure.

All work is to be carried out within either a dedicated test bay area with authorized personnel entry
points, or an area adequately protected from unauthorised access with a visible cordoned zone and
adequately displayed warning signs detailing the test type and associated hazards.

The lifting and handling of the equipment must be carried out with extreme caution and with regard
to the safety regulations.

All personnel in contact with the hydraulic fluid must wear suitable protective clothing, safety glasses
and gloves if required; regarding all the necessary precautions detailed on the fluid data sheets.
Ensure an eyewash station is in the immediate vicinity.

For work, which includes the use of pressurised fluid, compressed gas and/or electrical voltage, all
necessary suitable and adequate precautions must be taken prior beginning of work.

All personal working on the equipment must have the required experience, training and
qualifications.

ENSURE THAT NO HYDRAULIC PRESSURE IS APPLIED TO ANY OF THE CONNECTIONS

BEFORE COUPLINGS ARE MADE – UP OR DISCONNECTED.

ENSURE THAT NO ELECTRICAL POWER IS APPLIED TO ANY OF THE CONNECTIONS

BEFORE CONNECTIONS ARE MADE – UP OR DISCONNECTED.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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4 Test Preparation
4.1 Equipment Required

 2 x 230 VAC / 60 HZ Power Source, to power UPS A and UPS B

 690 VAC, 3ph, 60Hz supplies with capacity to power the following motors
 2 x 75 kW Motor Starter, with 3 volt-free contacts for interface to DCU
 2 x 3.75 kW Motor Starter, with 3 volt-free contacts for interface to DCU
 2 x 2.2 kW Motor Starter, with 3 volt-free contacts for interface to DCU
 1 x 1.5 kW Motor Starter, with 3 volt-free contacts for interface to DCU
 Interconnect cables, refer to SK-122100-65-02 (SK-122100-66-02 for Odebrecht #2)
 Interconnect piping/tubing/hoses (for interconnects between HPU system skids, Hose Reels,
etc. Reference SK-122100-65-01 or SK-122100-66-01 for corresponding Odebrecht project)
 Water-based BOP Concentrate fluid shall be used (Erifon HD 603 HP), Qty 300 Gal, to fill
Mixing Unit Concentrate reservoir
 Glycol, Qty 600 Gal, to fill Mixing Unit Glycol reservoir
 Potable Water supply, to Mixing Unit connection
 Rig air supply, 100psi (max 145 psi)
 Stopwatch, for verifying EDS times and Conduit supply valve time delays
 Hydraulic Test Pump capable of 5,000 PSI at 5 GPM minimum.
 Necessary gauges, 1,000 PSI and a 20,000 PSI or greater, with current calibration records.
 Chart recorders, 1,000 PSI and a 20,000 PSI or greater, with current calibration records.
 Adequate filtration capable of maintaining cleanliness level of NAS 8 or better.
 Proper ROV Hot Stab for OIdebrecht Stack.
 Test Tool Joint, or other suitable device for closing Rams.
 Two-way radios, for communication between various stations during the test
 Insulation measuring device, Megger (AVO Megger or equal)
 Optical Cable Tester (HP-E5970A, HP-E59702A and HP-E5974A or equal)
 Spare parts (filters, seal and repair kits, etc.) 2020700-65-66
 Equipment to measure NAS class of mixed fluid (mixed fluid must meet a NAS class 8 or
better)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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4.2 Electrical Interconnect

Ensure that all units are powered down and that all circuit breakers are in the ‘off’ position.

Verify: ________

Ensure that breakers are ‘off’ at the rig utility panel that feeds UPS Systems A & B.
Verify: ________

Ensure that all HOA switches at the Diverter Control Unit panel are in the ‘Off’ position.
Verify: ________

Ensure that all dip switch settings are correctly set in all surface equipment enclosures, per the unit
Electrical Schematics.
Verify: ________

Surface Equipment
Using the Interconnection Block diagram (SK-122100-65-02 or SK-122100-66-02), install all
interconnect cables, and mark every checked line on the diagram as the cables are connected. The
HPU System Interconnect Diagram (SK-122100-65-01 or SK-122100-66-01) and individual unit
Electrical Schematics can also be referenced for termination point details.
Verify: ________

There are a considerable quantity of cable glands to be field-installed on the enclosure-mounted gland
plates during the installation of interconnect cables. Care should be exercised to avoid damage to
internal components, and to ensure that the interior of the enclosures remain clean.

Subsea Equipment
The BOP Stack is on the surface for this test. The subsea Controls equipment (Pods, RCB’s, etc) are
already installed on the LMRP/BOP Stack.
The MUX Cables must be connected to the subsea equipment. Once the MUX Cable end connectors
(FITA’s) are installed on the LMRP brackets, connect the following PBOF cables per the Riser
Instrumentation diagram (SK-122366-65 or SK-122366-66):

1) –W6
2) –W7
3) –W14
4) –W15

Note: When the above-listed PBOF cables are installed prior to actual operation (running of the
Stack), the connections must be seal tested per Cameron procedure X-200136-05.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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4.3 Hydraulic/ Pneumatic Interconnect

Ensure that all pneumatic and hydraulic interconnects are made-up. Refer to the Hydraulic
Interconnect Diagram (SK-122100-65-01 or SK-122100-66-01), as well as individual unit GA’s and
P&ID’s for detailed hook-up locations.

Preservation fluid that has been added for shipment and storage purposes must be drained.

It is assumed that all interconnect piping/tubing is rated and properly sized to accommodate the
pressures and volumes generated by the control system.

All hydraulic couplings should be carefully inspected prior to making up the connections, to ensure that
all seals are in good condition and that the fittings are clean and undamaged.

All made-up connections shall be cleaned with a proprietary cleaning fluid or with clean hydraulic
system fluid.

Ensure that the LMRP connector and Mini-connector gaskets are retained by the Connectors before
landing the LMRP onto the Stack receiver plate.

It is assumed for the duration of the test, that the Control Pods (Blue and Yellow) are installed on the
LMRP, and the LMRP is mated to the BOP Stack.

4.4 Additional Preparations

At the Mixing Unit, ensure that Glycol reservoir drain valve (Item 15.1) and sample valve (Item 36.1)
are closed. Fill the Glycol reservoir (Item 3) with 600 gallons of glycol. The fluid level can be
monitored by the level gauge on the side of the reservoir.
Verify: ________
At the Mixing Unit, ensure that Concentrate reservoir drain valve (Item 15.2) and sample valve (Item
36.2) are closed. Fill the Concentrate reservoir (Item 2) with 300 gallons of the concentrate chosen for
operation (Erifon HD 603 HP). The fluid level can be monitored by the level gauge on the side of the
reservoir.
Verify: ________
The HPU reservoir will be filled via the Mixing Unit during a later section of this procedure.

Ensure that oil is in the Air Filter/Regulator unit (Item 71) at the Diverter Control Unit. Use Shell Tellus
T15 or similar.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Before air is connected to the Diverter Control Unit, and before any electrical power is switched on, set
all valves to the positions shown in the P&ID’s for the Diverter Control Unit (SK-122159-65-16 or SK-
122159-66-16), Hydraulic Power Unit (SK-122160-65-16 or SK-122160-66-16), and Mixing Unit (SK-
122110-65-16 or SK-122110-66-16), and the Accumulator Racks (SK-122117-65-16 or SK-122117-
66-16).

Verify: ________

Surface Accumulators
Check / charge the bladder-type accumulators on the surface accumulator racks:
24-Bottle Accumulator Rack: Precharge pressure is 1955 psi (135 bar). Tolerance of Precharge
Pressure ±5%.

Ambient Temperature °F
Gas Precharge Bottle No. 2.1 psi
Gas Precharge Bottle No. 2.2 psi
Gas Precharge Bottle No. 2.3 psi
Gas Precharge Bottle No. 2.4 psi
Gas Precharge Bottle No. 2.5 psi
Gas Precharge Bottle No. 2.6 psi
Gas Precharge Bottle No. 2.7 psi
Gas Precharge Bottle No. 2.8 psi
Gas Precharge Bottle No. 2.9 psi
Gas Precharge Bottle No. 2.10 psi
Gas Precharge Bottle No. 2.11 psi
Gas Precharge Bottle No. 2.12 psi
Gas Precharge Bottle No. 2.13 psi
Gas Precharge Bottle No. 2.14 psi
Gas Precharge Bottle No. 2.15 psi
Gas Precharge Bottle No. 2.16 psi
Gas Precharge Bottle No. 2.17 psi
Gas Precharge Bottle No. 2.18 psi
Gas Precharge Bottle No. 2.19 psi
Gas Precharge Bottle No. 2.20 psi
Gas Precharge Bottle No. 2.21 psi
Gas Precharge Bottle No. 2.22 psi
Gas Precharge Bottle No. 2.23 psi
Gas Precharge Bottle No. 2.24 psi
Verify: ______

24-Bottle Accumulator Rack: Precharge pressure 1955 psi (135 bar). Tolerance of Precharge
Pressure ±5%
Ambient Temperature °F
Gas Precharge Bottle No. 2.1 psi
Gas Precharge Bottle No. 2.2 psi
Gas Precharge Bottle No. 2.3 psi
Gas Precharge Bottle No. 2.4 psi
Gas Precharge Bottle No. 2.5 psi
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Gas Precharge Bottle No. 2.6 psi

Gas Precharge Bottle No. 2.7 psi
Gas Precharge Bottle No. 2.8 psi
Gas Precharge Bottle No. 2.9 psi
Gas Precharge Bottle No. 2.10 psi
Gas Precharge Bottle No. 2.11 psi
Gas Precharge Bottle No. 2.12 psi
Gas Precharge Bottle No. 2.13 psi
Gas Precharge Bottle No. 2.14 psi
Gas Precharge Bottle No. 2.15 psi
Gas Precharge Bottle No. 2.16 psi
Gas Precharge Bottle No. 2.17 psi
Gas Precharge Bottle No. 2.18 psi
Gas Precharge Bottle No. 2.19 psi
Gas Precharge Bottle No. 2.20 psi
Gas Precharge Bottle No. 2.21 psi
Gas Precharge Bottle No. 2.22 psi
Gas Precharge Bottle No. 2.23 psi
Gas Precharge Bottle No. 2.24 psi
Verify: ______
24-Bottle Accumulator Rack: Precharge pressure 1955 psi (135 bar). Tolerance of Precharge
Pressure ±5%
Ambient Temperature °F
Gas Precharge Bottle No. 2.1 psi
Gas Precharge Bottle No. 2.2 psi
Gas Precharge Bottle No. 2.3 psi
Gas Precharge Bottle No. 2.4 psi
Gas Precharge Bottle No. 2.5 psi
Gas Precharge Bottle No. 2.6 psi
Gas Precharge Bottle No. 2.7 psi
Gas Precharge Bottle No. 2.8 psi
Gas Precharge Bottle No. 2.9 psi
Gas Precharge Bottle No. 2.10 psi
Gas Precharge Bottle No. 2.11 psi
Gas Precharge Bottle No. 2.12 psi
Gas Precharge Bottle No. 2.13 psi
Gas Precharge Bottle No. 2.14 psi
Gas Precharge Bottle No. 2.15 psi
Gas Precharge Bottle No. 2.16 psi
Gas Precharge Bottle No. 2.17 psi
Gas Precharge Bottle No. 2.18 psi
Gas Precharge Bottle No. 2.19 psi
Gas Precharge Bottle No. 2.20 psi
Gas Precharge Bottle No. 2.21 psi
Gas Precharge Bottle No. 2.22 psi
Gas Precharge Bottle No. 2.23 psi
Gas Precharge Bottle No. 2.24 psi

Verify: ______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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7-Bottle Accumulator Rack: Precharge pressure 1296 psi (89 bar). Tolerance of Precharge Pressure
±5%

Ambient Temperature °F
Gas Precharge Bottle No. 2.1 psi
Gas Precharge Bottle No. 2.2 psi
Gas Precharge Bottle No. 2.3 psi
Gas Precharge Bottle No. 2.4 psi
Gas Precharge Bottle No. 2.5 psi
Gas Precharge Bottle No. 2.6 psi
Gas Precharge Bottle No. 2.7 psi

Verify: ______

Verify that the 5 Gallon Accumulators on the Diverter Control Unit are pre-charged to the following
pressures. Record data.
Ambient Air Temperature °F
Gas Precharge Bottle 75.1, Precharge Press: 500 psi (34.5 bar) psi
Gas Precharge Bottle 75.2, Precharge Press: 1000 psi (68.9 bar) psi

Verify: ______
Verify that the Suppressors on the HPU are pre-charged to the following pressures. Record data.
Ambient Air Temperature °F
Gas Precharge Bottle 4.1, Precharge Press: 2800 psi (193 bar) psi
Gas Precharge Bottle 4.2, Precharge Press: 2800 psi (193 bar) psi

Verify: ______
Connect rig air supply to port N18 at the Diverter Control Unit.
Verify: ______

Subsea Accumulators
At each Control Pod, ensure that all Accumulators are installed per SK-122108-65-16 (or SK-122108-
66-16) and pre-charged in accordance to the table in X-093667-65. For function test of the Pod
Valves & regulator function test, pre-charge for the surface. Also, ensure that all other subsea
accumulators are precharged per the table in X-093667-65.

If any fittings have been loosened since the pod was last bled the pilot lines must be bled.

Control Pod (MUX Section) Compensation Systems

At each Control Pod MUX Section (Upper Section), verify that the visual indicators of each
compensator (Qty 4, Item 9.1 – 9.4, ref SK-122108-65-16 or SK-122108-66-16) are approximately
halfway positioned within the visual range.
Verify:______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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If the positions of the compensator indicators signify for dielectric fluid to be added, reference the
Dielectric Fluid Filling procedure (X-262167-02) to add fluid to the Pod MUX Section.

Acoustic Valve Package Compensation System

At the Acoustic Electronic Module sub-assembly of the Acoustic Valve Package, verify that the visual
indicator of the compensator (Item 14, ref SK-122113-65-05 or SK-122113-66-05) is approximately
halfway positioned within the visual range.
Verify:______
If the position of the compensator indicator signifies for dielectric fluid to be added, reference the
Dielectric Fluid Filling procedure (X-262167-01) to add fluid to the Module.

5 Protective Ground Test, Insulation Resistance Test, Optical Cable Test

5.1 Precautions
Before proceeding, the following should be verified:
1) All copper and fiber-optic connections have been connected and are securely fastened to terminal
blocks, fiber-optic connectors, and grounding points.
2) All ground wires have been secured to grounding lugs, studs, or terminals.
5.2 Protective Ground Test
This test will verify the integrity of protective ground for personnel and equipment safety.
Using a multi-meter set on OHM’s, measure the resistance between the metallic cabinets, terminals,
assemblies and system ground. Verify that all readings are R<2.0ohms. Using the green terminal at
terminal input –X1ground (PE, or other ground reference) as one test point, verify the following.

5.2.1 Communication / Power Distribution Panel A

FROM TO R<2.0ohms Verify

-X1 ground (3/PE) Other Gnd. Ref.
-X3 ground (3/PE) –X1ground (PE)
-X5 ground (3/PE), –X1ground (PE)
-X6 ground (3/PE), –X1ground (PE)
-X9 ground (3/PE), –X1ground (PE)
-X10 ground (3/PE), –X1ground (PE)
-X11 ground (3/PE), –X1ground (PE)
-X12 ground (3/PE), –X1ground (PE)
-X15 ground (PE), –X1ground (PE)
-X16 ground (3/PE), –X1ground (PE)
-X17 ground (PE), –X1ground (PE)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.2.2 Communication / Power Distribution Panel B

FROM TO R<2.0ohms Verify

-X1 ground (3/PE) Other Gnd. Ref.
-X3 ground (3/PE) –X1ground (PE)
-X5 ground (3/PE), –X1ground (PE)
-X6 ground (3/PE), –X1ground (PE)
-X9 ground (3/PE), –X1ground (PE)
-X10 ground (3/PE), –X1ground (PE)
-X11 ground (3/PE), –X1ground (PE)
-X12 ground (3/PE), –X1ground (PE)
-X15 ground (PE), –X1ground (PE)
-X16 ground (3/PE), –X1ground (PE)
-X17 ground (PE), –X1ground (PE)

5.2.3 Driller’s Control Panel

FROM TO R<2.0ohms Verify

-X1 ground (PE) Other Gnd. Ref.
-X4 ground (PE) –X1ground (PE)

5.2.4 Toolpusher’s Control Panel

FROM TO R<2.0ohms Verify

-X1 ground (PE) Other Gnd. Ref.
-X4 ground (PE) –X1ground (PE)

5.2.5 Event Logger

FROM TO R<2.0ohms Verify

-X1 ground (PE) Other Gnd. Ref.
-X2 ground (PE) –X1ground (PE)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.2.6 Diverter Control Unit

Measure the resistance @ Main Control Box:

FROM TO R<2.0ohms Verify

-X1 ground (PE) Other Gnd. Ref.
-X2 ground (PE) –X1ground (PE)
-X3 ground (PE), –X1ground (PE)
-X4 ground (PE), –X1ground (PE)
-X5 ground (PE), –X1ground (PE)
-X6 ground (PE), –X1ground (PE)
-X7 ground (PE), –X1ground (PE)
-X8 ground (PE), –X1ground (PE)

5.2.7 Hydraulic Power Unit

Measure the resistance @ Main Control Box:

FROM TO R<2.0ohms Verify

-X1 ground (PE) Other Gnd. Ref.
-X2 ground (PE) –X1ground (PE)

Measure the resistance @ MCC & Pump:

FROM TO R>10 MΩ Verify

-W80 (each leg) Ground Lug
-W81 (each leg) Ground Lug
-W82 (each leg) Ground Lug
-W84 (each leg) Ground Lug
-W85 (each leg) Ground Lug
-W86 (each leg) Ground Lug
-W119 (each leg) Ground Lug

5.2.8 Fluid Mixing Unit

Measure the resistance @ Main Control Box:

FROM TO R<2.0ohms Verify

-X1 ground (PE) Other Gnd. Ref.
-X2 ground (PE) –X1ground (PE)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Measure the resistance @ MCC:

FROM TO R<2.0ohms Verify @MCC @ Pump

-W121 PE Ground Lug
-W123 PE Ground Lug

5.2.9 Blue Cable Reel

Measure the resistance @ Junction Box:

FROM TO R<2.0ohms Verify

-1X1 ground (PE) Other Gnd. Ref.

5.2.10 Yellow Cable Reel

Measure the resistance @ Junction Box:

FROM TO R<2.0ohms Verify

-1X1 ground (PE) Other Gnd. Ref.

5.2.11 BOP Test Pump Unit

Measure the resistance @ MCC & Pump:

FROM TO R<2.0ohms Verify @MCC @Pump

-X1 ground (PE), Other Gnd. Ref.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.3 System Insulation Test

Ensure there is not power to next units prior to start insulation test!

This test will verify the insulation integrity of the electrical equipment. Using a Megger device set at
500VDC, verify that the insulation resistance is R>10 MOhms.

WARNING: Keep hands away from test leads and other metallic components of the system while
the tester is active. Allow the circuit to discharge before removing the test leads.

5.3.1 Communication/ Power Distribution Panel A

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PLCs modules,
Modems, etc. Otherwise they can be damaged.
Verify: ______

Close (Turn ON) Circuit Breaker -2Q1

Verify:_______
Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X3 ground (PE) -X3(1)
-X3 ground (PE) -X3(2)
-X4 ground (PE) -X4(1)
-X4 ground (PE) -X4(2)
-X5 ground (PE) -X5(1)
-X5ground (PE) -X5(2)
-X6 ground (PE) -X6(1)
-X6 ground (PE) -X6(2)
-X9 ground (PE) -X9(1)
-X9 ground (PE) -X9(2)
-X10 ground (PE) -X10(1)
-X10 ground (PE) -X10(2)
-X11 ground (PE) -X11(1)
-X11 ground (PE) -X11(2)
-X12 ground (PE) -X12(1)
-X12 ground (PE) -X12(2)
-X16 ground (PE) -X16(1)
-X16 ground (PE) -X16(2)
-X17 ground (PE) -X17(1)
-X17 ground (PE) -X17(2)
-X17 ground (PE) -X17(3)
-X17 ground (PE) -X17(4)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Open (Turn off) Circuit Breaker –2Q1

Verify: ______
Reconnect/plug in the Power Supplies, PLCs modules, Modems etc.
Verify: ______

5.3.2 Communication/ Power Distribution Panel B

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PLCs modules,
Modems, etc. Otherwise they can be damaged.

Verify: ______

Close (Turn ON) Circuit Breaker -2Q1

Verify: _______

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X3 ground (PE) -X3(1)
-X3 ground (PE) -X3(2)
-X4 ground (PE) -X4(1)
-X4 ground (PE) -X4(2)
-X5 ground (PE) -X5(1)
-X5ground (PE) -X5(2)
-X6 ground (PE) -X6(1)
-X6 ground (PE) -X6(2)
-X9 ground (PE) -X9(1)
-X9 ground (PE) -X9(2)
-X10 ground (PE) -X10(1)
-X10 ground (PE) -X10(2)
-X11 ground (PE) -X11(1)
-X11 ground (PE) -X11(2)
-X12 ground (PE) -X12(1)
-X12 ground (PE) -X12(2)
-X16 ground (PE) -X16(1)
-X16 ground (PE) -X16(2)
-X17 ground (PE) -X17(1)
-X17 ground (PE) -X17(2)
-X17 ground (PE) -X17(3)
-X17 ground (PE) -X17(4)

Open (Turn off) Circuit Breaker –2Q1

Verify: ______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Reconnect/plug in the Power Supplies, PLCs modules, Modems etc.

Verify: ______

5.3.3 Driller’s Control Panel

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PCs,
Touchscreens, PLCs modules, Transformers, etc. Otherwise they can be damaged.

Verify: ______

Close (Turn ON) Circuit Breakers -2Q1 & -2Q5

Verify: ______

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X4 ground (PE) -X4(1)
-X4 ground (PE) -X4(2)

Open (turn off) both circuit breakers & reconnect power supplies, PCs, Touch screens, PLCs,
transformers, etc
Verify: _____

5.3.4 Toolpusher’s Control Panel

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PCs,
Touchscreens, PLCs modules, Transformers, etc. Otherwise they can be damaged.

Verify: ______

Close (Turn ON) Circuit Breakers -2Q1 & -2Q5

Verify: ______

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X4 ground (PE) -X4(1)
-X4 ground (PE) -X4(2)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Open (turn off) both circuit breakers & reconnect power supplies, PCs, Touch screens, PLCs,
transformers, etc
Verify: _____

5.3.5 Event Logger

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PCs, monitor,
modules, etc. Otherwise they can be damaged.
Verify: ______

Close (Turn ON) Circuit Breakers -2Q1 & -2Q2

Verify: ______

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X2 ground (PE) -X2(1)
-X2 ground (PE) -X2(2)

Open (turn off) both circuit breakers & reconnect power supplies, PCs, monitor, modules, etc.

Verify: _____

5.3.6 Diverter Control Unit

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PLCs modules,
Modems, etc. Otherwise they can be damaged.
Verify: ______

Close (Turn ON) Circuit Breakers -3Q5 and -4Q5

Verify: _______
Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X2 ground (PE) -X2(1)
-X2 ground (PE) -X2(2)
-X3 ground (PE) -X3(1)
-X3 ground (PE) -X3(2)
-X4 ground (PE) -X4(1)
-X4 ground (PE) -X4(2)
-X5 ground (PE) -X5(1)
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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-X5ground (PE) -X5(2)

-X6 ground (PE) -X6(1)
-X6 ground (PE) -X6(2)
-X7 ground (PE) -X7(1)
-X7 ground (PE) -X7(2)
-X8 ground (PE) -X8(1)
-X8 ground (PE) -X8(2)

Open (Turn off) Circuit Breakers -3Q5 and -4Q5

Verify: ______

Reconnect/plug in the Power Supplies, PLCs modules, etc.

Verify: ______

5.3.7 Hydraulic Power Unit

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PLCs modules,
barriers, etc. Otherwise they can be damaged.
Verify: ______

Close (Turn ON) Circuit Breakers -3Q1 and -3Q2

Verify: _______

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X2 ground (PE) -X2(1)
-X2 ground (PE) -X2(2)

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-W80 (each leg) Ground Lug
-W81 (each leg) Ground Lug
-W82 (each leg) Ground Lug
-W84 (each leg) Ground Lug
-W85 (each leg) Ground Lug
-W86 (each leg) Ground Lug
-W119 (each leg) Ground Lug

Open (turn off) both circuit breakers & reconnect power supplies, PLCs modules, etc.
Verify: _______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.3.8 Mixing Unit

Open (Turn OFF) all Circuit Breakers, and then unplug/disconnect all Power Supplies, PLCs modules,
barriers, etc. Otherwise they can be damaged.
Verify: ______
Close (Turn ON) Circuit Breakers -3Q1 and -3Q2
Verify: _______

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-X1 ground (PE) -X1(1)
-X1 ground (PE) -X1(2)
-X2 ground (PE) -X2(1)
-X2 ground (PE) -X2(2)

Measure insulation resistance:

FROM TO R>10 MΩ Verify

-W121 (each leg) Ground Lug
-W123 (each leg) Ground Lug

Open (turn off) both circuit breakers & reconnect power supplies, PLCs modules, etc.
Verify: ______

5.3.9 Blue Cable Reel

Unplug the FITA connector and disconnect wires on Communication/Power Distribution Panel “A” (-W25
& -W29) and Communication/Power Distribution Panel “B” (-W26 & -W30).

Verify: _________

Measure insulation resistance @ Blue Cable Reel Junction Box:

FROM TO R>10 MΩ Verify

-1X1 ground (PE) -1X1(1)
-1X1 ground (PE) -1X1(2)
-1X1 ground (PE) -1X1(3)
-1X1 ground (PE) -1X1(4)
-1X1 ground (PE) -1X1(5)
-1X1 ground (PE) -1X1(6)
-1X1 ground (PE) -1X1(7)
-1X1 ground (PE) -1X1(8)

Reconnect cables -W25 & -W29 and -W26 & -W30, and plug the FITA connector.
Verify: _________
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.3.10 Yellow Cable Reel

Unplug the FITA connector and disconnect wires on Communication/Power Distribution Panel “A” (-W27
& -W31) and Communication/Power Distribution Panel “B” (-W28 & -W32).
Verify: _________
Measure insulation resistance @ Yellow Cable Reel Junction Box:

FROM TO R>10 MΩ Verify

-1X1 ground (PE) -1X1(1)
-1X1 ground (PE) -1X1(2)
-1X1 ground (PE) -1X1(3)
-1X1 ground (PE) -1X1(4)
-1X1 ground (PE) -1X1(5)
-1X1 ground (PE) -1X1(6)
-1X1 ground (PE) -1X1(7)
-1X1 ground (PE) -1X1(8)

Reconnect cables -W27 & -W31 and -W28 & -W32, and plug the FITA connector.
Verify: _______

5.3.11 BOP Test Pump Unit

Open (Turn OFF) all circuit breakers, and then unplug/disconnect all power supplies, VFD, etc; otherwise
they can be damaged.
Verify:_______

Close (Turn ON) Main Disconnect Switch

Verify:_______
Measure insulation resistance:

FROM TO R>10 MΩ Verify

-1X1 ground (PE) -1X1(1)
-1X1 ground (PE) -1X1(2)
-1X1 ground (PE) -1X1(3)

Open (Turn OFF) all circuit breakers, and re-connect power supplier, VFD, etc.
Verify:_______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5.4 Optical Cable Test

Using the fiber-optic test equipment, verify suitability of the fiber-optic interconnect cables.
Connect source (HP E5972A) to one end of the cable and the power meter (HP E5970A) at the other end
of the cable. For all optical cable tests, verify that the attenuation is < 6dbm.

Refer to Interconnection Block Diagram (SK-122100-65-02 or SK-122100-66-02).

A person with a two-way radio shall be positioned at each of the two required locations during the test.

a. Interconnect Cable -W41 (DCP to TCP) Verify:_______

b. Interconnect Cable -W43 (TCP to EL) Verify:_______
c. Interconnect Cable -W44 (EL to DCU) Verify:_______
d. Interconnect Cable -W45 (DCU to Comm./Pwr. Dist. Cabinet B) Verify:_______
e. Interconnect Cable -W46 (Comm./Pwr. Dist. Cabinet A to B) Verify:_______
f. Interconnect Cable -W47 (TCP to BOP Test Box) Verify:_______
g. Interconnect Cable -W48 (TCP to Converteam System) Verify:_______

6. POWER-UP PROCEDURE

6.1 UPS System

The purpose of this section is to ensure that the UPS, UPS Bypass Panel, and Battery cabinets are
correctly interconnected and operational from a completely powered down condition. Get the UPS
manufacturers manual if needed.
Ensure a wiring check has been performed before proceeding (reference SK-122111-65-06 or SK-
122111-66-06).
Verify: ______

Ensure that all circuit breakers in both Communication/Power Distribution Panels are ‘off’.

Verify: ______

Once rig power supply that feeds UPS A (230 VAC) has been switched on, energize UPS A and check
for proper operation (check manual for correct start-up). The output should be 230VAC (+/- 5%).
Allow the batteries to charge for 24 hours before performing further testing.
Verify: ______

Turn off input power to UPS A and check alarm output at the UPS display (follow procedure from UPS
manual). Ensure that the UPS display has the correct indication for ‘UPS on batteries’, and verify that
the output is 230VAC (+/- 5%).
Verify: ______

Once rig power supply that feeds UPS B (230 VAC) has been switched on, energize UPS B and check
for proper operation (check manual for correct start-up). The output should be 230VAC (+/- 5%).
Allow the batteries to charge for 24 hours before performing further testing.
Verify: ______
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Turn off input power to UPS B and check alarm output at the UPS display (follow procedure from UPS
manual). Ensure that the UPS display has the correct indication for ‘UPS on batteries’, and verify that
the output is 230VAC (+/- 5%).
Verify: ______
Restore 230VAC input power to both UPS systems.
Verify: ______

Switch UPS’s to bypass mode (for more details see SK-122111-65-06 or SK-122111-66-06, and also
UPS manufacturer’s manuals) and check UPS operation and front panel indicators.

Verify: ______
Return UPS Systems to normal operation (ref. manual).

Verify: ______

Verify that a N.O. switch (customer supplied) is connected to the X-Slot 2 (1, 2) connection of UPS A
(reference UPS Electrical Schematic SK-122111-65-06 or SK-122111-66-06, cable –W93).

Verify: ______

Activate this switch (upon activation, 24 VDC will be supplied by customer); this will shut-down UPS A
within 10-15 seconds. Verify that the UPS A output is 0VAC.
Verify: ______

To reset the UPS, the external customer-supplied switch must be de-activated and the UPS must be
switched on manually. Verify that a N.O. switch is connected to the X-Slot 2 (1, 2) connection of UPS
B (reference UPS Electrical Schematic SK-122111-65-06 or SK-122111-66-06, cable –W94).

Verify: ______

Activate this switch (upon activation, 24 VDC will be supplied by customer); this will shut-down UPS B
within 10-15 seconds. Verify that the UPS B output is 0VAC.
Verify: ______

To reset the UPS, the external customer-supplied switch must be de-activated and the UPS must be
switched on manually.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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6.2 Communication/Power Distribution Panels

Ensure that all interconnect cabling has been run and checked per preceding sections of this
procedure.
Verify: ______

Ensure that the circuit breakers in both Communication/Power Distribution Panels are switched off.
Verify: ______
UPS System A should be supplying power to Communication/Power Distribution Panel A. Verify that
the voltage level between terminals –X1(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Ensure that the circuit breakers which supply power to the DCP, TCP, Event Logger, Diverter Control
Unit, Pod, and RCB are switched off. Turn on circuit breaker -2Q1 at Comm/Power Distribution Panel
A.
Verify: ______
At Comm/Power Distribution Panel A, turn on the circuit breakers for power distribution (-2Q3, -2Q4, -
2Q5, -3Q1, -3Q4) and verify that the output voltage level at each is 230VAC (+/- 5%).
Verify: ______

UPS System B should be supplying power to Communication/Power Distribution Panel B. Verify that
the voltage level between terminals –X1(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Ensure that the circuit breakers which supply power to the DCP, TCP, Event Logger, Diverter Control
Unit, Pod, and RCB are switched off. Turn on circuit breaker -2Q1 at Comm/Power Distribution Panel
B.
Verify: ______
At Comm/Power Distribution Panel B, turn on the circuit breakers for power distribution (-2Q3, -2Q4, -
2Q5, -3Q1, -3Q4) and verify that the output voltage level at each is 230VAC (+/- 5%).
Verify: ______
Verify that the latest version (compare with that on file with Cameron engineering dept) of the project-
specific PLC software has been loaded onto Panels A & B prior to further testing.
Verify: ______
Software file name & rev level, Panel A (PLC -5A1.2): _________________
Software file name & rev level, Panel A (PLC -5A5.1): _________________
Software file name & rev level, Panel B (PLC -5A1.2): _________________
Software file name & rev level, Panel B (PLC -5A5.1): _________________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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6.3 Driller’s Control Panel

At the DCP, verify that the voltage level between terminals –X1(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Verify that the voltage level between terminals –X4(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Turn on circuit breakers -2Q1 and -2Q5 one at a time, and ensure that the touchscreens, PC’s, and
PLC boot-up correctly.
Verify: ______
Verify that the latest version (compare with that on file with Cameron engineering dept) of the project-
specific software (PLC, PC) has been loaded prior to further testing.
Verify: ______
Software file name & rev level (PLC): _________________
Software file name & rev level (for HMI (wonderware), loaded on PC -4A2.1): _________________
Software file name & rev level (for HMI (wonderware), loaded on PC -4A6.1): _________________
Software file name & rev level (for Top Server, loaded on PC -4A2.1): _________________
Software file name & rev level (for Top Server, loaded on PC -4A6.1): _________________

6.4 Toolpusher’s Control Panel

At the TCP, verify that the voltage level between terminals –X1(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Verify that the voltage level between terminals –X4(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Turn on circuit breakers -2Q1 and -2Q5 one at a time, and ensure that the touchscreens, PC’s, and
PLC boot-up correctly.
Verify: ______
Verify that the latest version (compare with that on file with Cameron engineering dept) of the project-
specific software (PLC, PC) has been loaded prior to further testing.
Verify: ______
Software file name & rev level (PLC): _________________
Software file name & rev level (for HMI (wonderware), loaded on PC -4A2.1): _________________
Software file name & rev level (for HMI (wonderware), loaded on PC -4A6.1): _________________
Software file name & rev level (for Top Server, loaded on PC -4A2.1): _________________
Software file name & rev level (for Top Server, loaded on PC -4A6.1): _________________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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6.5 Event Logger

At the Event Logger, verify that the voltage level between terminals –X1(1) and (2) is 230VAC (+/-
5%).
Verify: ______
Verify that the voltage level between terminals –X2(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Turn on circuit breakers -2Q1 and -2Q2 one at a time, and ensure that the PC, Monitor, and Printer
boot-up correctly.
Verify: ______
Verify that the latest version (compare with that on file with Cameron engineering dept) of the project-
specific software has been loaded prior to further testing.
Verify: ______
Software file name & rev level (PLC): _________________
Software file name & rev level (for HMI (wonderware), loaded on the PC): _________________
Software file name & rev level (for Top Server, loaded on the PC): _________________

6.6 HPU System

At the Diverter Control Unit Main Control Box (EEx-e), verify that the voltage level between the
following terminals is 230VAC (+/- 5%).

VOLTAGE VERIFY

–X1(1) –X1(2)

–X2(1) –X2(2)

–X3(1) –X3(2)

–X4(1) –X4(2)

–X5(1) –X5(2)

–X6(1) –X6(2)

–X7(1) –X7(2)

–X8(1) –X8(2)

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Turn on circuit breakers -3Q5 and -4Q5 one at a time, and verify that the indicators for ‘UPS A
POWER SUPPLY’, ‘UPS B POWER SUPPLY’, AND ‘POWER SUPPLY 24VDC’ are illuminated at the
Diverter Control Unit panel.
Verify: ______
Verify that the latest version (compare with that on file with Cameron engineering dept) of the project-
specific PLC software has been loaded onto the Diverter Control Unit PLC prior to further testing.
Verify: ______
Software file name & rev level (PLC): ___________________

NOTE: During start-up of the Diverter Control Unit, several alarm indications will occur. The operator
responds to the alarm by pushing the ‘ALARM QUIT’ button. The buzzer silences and the indicator
lamp stops flashing. The lamp will extinguish when normal operating conditions are attained.
At the HPU Main Control Box, verify that the voltage level between terminals –X1(1) and (2) is
230VAC (+/- 5%).
Verify: ______
Verify that the voltage level between terminals –X2(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Turn on circuit breakers -3Q1 and -3Q2, one at a time.
Verify: ______

At the Mixing Unit Main Control Box, verify that the voltage level between terminals –X1(1) and (2) is
230VAC (+/- 5%).
Verify: ______
Verify that the voltage level between terminals –X2(1) and (2) is 230VAC (+/- 5%).
Verify: ______
Turn on circuit breakers -3Q1 and -3Q2, one at a time.
Verify: ______
On the ‘Power Supply Status’ subscreen of the Utilities screen at the operator stations (DCP, TCP),
verify that all power supply indicators are green for the surface equipment.
Verify: ______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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6.7 ‘HPU System’ Motors

The rig-supplied motor starters should be connected to the various electric motors on the HPU and
Mixing Unit. The starters should also be interconnected to the Diverter Control Unit Main Control Box
(EEx-e) for the following interfaces: start/stop, running indication, and starter availability. Reference
the Diverter Control Unit Electrical Schematic (SK-122159-65-06 or SK-122159-66-06) as well as HPU
System Interconnect diagram (SK-122101-65-02 or SK-122101-66-02) for connection details. Verify
that the motor starters are correctly configured and connected to the various motors and to the
Diverter Control Unit Main Control Box.
Verify: ________
Ensure that the HOA switches at the Diverter Control Unit panel are all in the ‘Off’ position.
Verify: ________
Verify motor source voltage prior to interconnection. The voltage supplied to each motor should be
690VAC, 3ph, 60Hz (+/- 5%).
Verify: ________
Switch on the main motor supply at the distribution switchboard.
Verify: ________
Check and verify voltage level and correct orientation of the 3-phase input at the motor terminals of
each motor.
Verify: ________

Verify the correct rotation of the motors by flick starting the motors at the HOA switch.

NO. MOTOR TAG NO. VERIFY

1. HPU E-PUMP 1 B30-EM-120A
2. HPU E-PUMP 2 B30-EM-120B
3. CHARGE PUMP 1 B30-EM-120D
4. CHARGE PUMP 2 B30-EM-120E
5. HPU RECIRCULATION PUMP B30-EM-120C
6. GLYCOL PUMP B30-EM-101A
7. BOP CONCENTRATE PUMP B30-EM-101B

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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6.8 Blue Comm/Power Junction Box

At the blue Comm/ Power Junction Box, verify that the voltage between the following terminals is 250
VAC (+10%, -0%).

Measure Voltage @ Blue Comm/Power Junction Box:

FROM TO Voltage Verify

-X1 (1) -X1(2)
-X2 (1) -X2(2)
-X3 (1) -X3(2)
-X4 (1) -X4(2)

6.9 Blue Cable Reel

At the Blue Cable Reel J-Box, verify that the voltage between the following terminals is 250 VAC
(+10%, -0%). The Blue Cable Reel is now supplying electrical power to the Blue Pod and Blue RCB.

FROM TO Voltage Verify

-1X1 (1) -1X1(2)
-1X1 (3) -1X1(4)
-1X1 (5) -1X1(6)
-1X1 (7) -1X1(8)

6.10 Yellow Comm/Power Junction Box

At the Yellow Comm/Power Junction Box, verify that the voltage between the following terminals is
250 VAC (+10%, -0%).

Measure Voltage @ Yellow Comm/Power Junction Box:

FROM TO Voltage Verify

-X1 (1) -X1(2)
-X2 (1) -X2(2)
-X3 (1) -X3(2)
-X4 (1) -X4(2)

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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6.11 Yellow Cable Reel

At the Yellow Cable Reel J-Box, verify that the voltage between the following terminals is 250 VAC
(+10%, -0%). The Yellow Cable Reel is now supplying electrical power to the Yellow Pod and Yellow
RCB.

FROM TO Voltage Verify

-1X1 (1) -1X1(2)
-1X1 (3) -1X1(4)
-1X1 (5) -1X1(6)
-1X1 (7) -1X1(8)

6.12 Subsea Equipment

When the Comm/Power Distribution Panels A & B were switched on in Section 6.2, electrical power
and communication was established to the Blue and Yellow Control Pods.
At the control panels (DCP, TCP), verify the availability of SEM’s A and B in each of the Blue and
Yellow Control Pods. Data from the RCB’s (P/T Sensors) should also be available due to
communication between the Blue Pod, Yellow Pod, Blue RCB, and Yellow RCB.

Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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7 Power Supply Monitoring

At the ‘Power Supply Status’ subscreen of the System Utilities screen, the indicators for all power
supplies and statuses should be green. The following steps will verify that the system correctly
monitors the status of the power supplies.

7.1 UPS A

Switch off 230VAC input power to UPS System A. The UPS is now being powered by the Batteries,
and the ‘UPS A LOSS OF INPUT POWER’ indication should change to red at the control stations.
After verification, switch on 230VAC input power.
Verify: ________

At Comm/Power Distribution Panel A, remove the input to terminal –X17(4). The ‘UPS A INTERNAL
FAILURE’ indication should change to red at the control stations. After verification, reinstate the input
to terminal –X17(4).
Verify: ________
7.2 UPS B

Switch off 230VAC input power to UPS System B. The UPS is now being powered by the Batteries,
and the ‘UPS B LOSS OF INPUT POWER’ alarm should be indicated at the control stations. After
verification, switch on 230VAC input power.
Verify: ________

At Comm/Power Distribution Panel B, remove the input to terminal –X17(4). The ‘UPS B INTERNAL
FAILURE’ indication should change to red at the control stations. After verification, reinstate the input
to terminal –X17(4).
Verify: ________
7.3 DCP

Switch off circuit breaker -2Q1 at the DCP. Verify that the ‘DCP A 24V’ indicator changes to red at all
control stations. After verification, switch on circuit breaker -2Q1.
Verify: ________
Switch off circuit breaker -2Q5 at the DCP. Verify that the ‘DCP B 24V’ indicator changes to red at all
control stations. After verification, switch on circuit breaker -2Q5.
Verify: ________

7.4 TCP

Switch off circuit breaker -2Q1 at the TCP. Verify that the ‘TCP A 24V’ indicator changes to red at all
control stations. After verification, switch on circuit breaker -2Q1.
Verify: ________

Switch off circuit breaker -2Q5 at the TCP. Verify that the ‘TCP B 24V’ indicator changes to red at all
control stations. After verification, switch on circuit breaker -2Q5.
Verify: ________
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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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7.5 Comm/Power Dist Panel A

Turn off the power to the Blue Communication Controller A PLC by setting the switch on power supply
module -5A1.1 to ‘off’. Verify that the ‘CC Blue A 24V’ indicator changes to red at all control stations.
After verification, switch on the power at power supply module -5A1.1.
Verify: ________

Turn off the power to the Yellow Communication Controller A PLC by setting the switch on power
supply module -5A4 to ‘off’. Verify that the ‘CC Yellow A 24V’ indicator changes to red at all control
stations. After verification, switch on the power at power supply module -5A4.
Verify: ________
7.6 Comm/Power Dist Panel B

Turn off the power to the Blue Communication Controller B PLC by setting the switch on power supply
module -5A1.1 to ‘off. Verify that the ‘CC Blue B 24V’ indicator changes to red at all control stations.
After verification, switch on the power at power supply module -5A1.1.
Verify: ________

Turn off the power to the Yellow Communication Controller B PLC by setting the switch on power
supply module -5A4 to ‘off’. Verify that the ‘CC Yellow B 24V’ indicator changes to red at all control
stations. After verification, switch on the power at power supply module -5A4.

Verify: ________
7.7 Diverter Control Unit

Switch off circuit breaker -3Q5 at the EEx-e Main Control Box. Verify that the ‘DIV A 24V’ indicator
changes to red at all control stations. Also verify that the ‘POWER SUPPLY 24VDC’ indicator is
flashing on the Diverter Control Unit panel. After verification, switch on circuit breaker -3Q5.
Verify: ________

Switch off circuit breaker -4Q5 at the EEx-e Main Control Box. Verify that the ‘DIV B 24V’ indicator
changes to red at all control stations. Also verify that the ‘POWER SUPPLY 24VDC’ indicator is
flashing on the Diverter Control Unit panel. After verification, switch on circuit breaker -4Q5.
Verify: ________

7.8 HPU

Switch off circuit breaker -3Q1 at the HPU Main Control Box. Verify that the ‘HPU A 24V’ indicator
changes to red at all control stations. After verification, switch on circuit breaker -3Q1.
Verify: ________

Switch off circuit breaker -3Q2 at the HPU Main Control Box. Verify that the ‘HPU B 24V’ indicator
changes to red at all control stations. After verification, switch on circuit breaker -3Q2.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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7.9 Mixing Unit

Switch off circuit breaker -3Q1 at the Mixing Unit Main Control Box. Verify that the ‘MIX A 24V’
indicator changes to red at all control stations. After verification, switch on circuit breaker -3Q1.
Verify: ________

Switch off circuit breaker -3Q2 at the Mixing Unit Main Control Box. Verify that the ‘MIX B 24V’
indicator changes to red at all control stations. After verification, switch on circuit breaker -3Q2.
Verify: ________
7.10 Blue Control Pod

Verify that the 3 indicators for ‘Blue SEM A’ at the ‘Power Supply Status’ screen are green.
Verify: ________

Verify that the 3 indicators for ‘Blue SEM B’ at the ‘Power Supply Status’ screen are green.

Verify: ________
7.11 Yellow Control Pod

Verify that the 3 indicators for ‘Yellow SEM A’ at the ‘Power Supply Status’ screen are green.

Verify: ________

Verify that the 3 indicators for ‘Yellow SEM B’ at the ‘Power Supply Status’ screen are green.

Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8 System Integration Test

Verify that proper communication is established between all surface stations and the subsea Pods
before proceeding with testing.
Verify: ________

NOTE: Before start of any pump/motor, verify fluid at pump inlet and bleed air from pump.

Turn off power for each motor starter at MCC, and then remove wires @ each motor starter to avoid
running the pumps. Simulate a start, and then use the Emergency-Stop that is located on the
associated skid/unit to de-energize each contactor for the correspondent motor starter. To be able to
start the pump again, the E-Stop button must be released.
Verify: _______

NOTE: Loop testing of all instrumented functions within the BOP Control System has been
accomplished at the individual unit FAT’s, the surface SIT, and the subsea SIT, all which
have taken place prior to this test, and will be reconfirmed onboard the vessel via
complete functional tests of the BOP Control System during this Commissioning
Procedure.

8.1 Bleed Procedure

All pumps need to be primed during the initial start. All hydraulic lines need to be bled both internal to
the units and interconnected lines. Highlight each line on the coinciding P&ID’s to ensure all lines are
bled for both the surface equipment and Subsea equipment.
Verify: _______
8.2 Testing of Hotline Hose, Riser Fill Valve & Mux Cable Reels

8.2.1 Hotline Hose Reel

Verify that all the interfaces are per the interconnection diagram (SK-122100-65-01 or SK-122100-66-
01).
Verify: ________

Verify the pneumatic lubricator is filled with misting type oil rated 150-200 SSU at 100 degrees

Verify: ________

Set the pneumatic pressure regulator on the reel drive air supply to 90 PSIG

Verify: ________

Move “Reel In/ Reel Out” control valve to rotate the reel in both directions to verify proper reel
operation.
Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.2.2 Mux Cable Reels

Verify that all the interfaces are per the interconnection diagram: electrical, pneumatic and hydraulic
(SK-122100-65-01 or SK-122100-66-01 & SK-122100-65-02 or SK-122100-66-02).
Verify: ________

Ensure that the power supply to the reels is turned off at the Comm. & Power Dist. Panels
(SK-122141-65-06 or SK-122141-66-06 & SK-154382-65-06 or SK-154382-66-06).

Verify: ________

Verify that the cable reels are properly interfaced with the control system on the LMRP
(SK-122100-65-02 or SK-122100-66-02)

Verify: ________

Verify the pneumatic lubricator is filled with misting type oil rated 150-200 SSU at 100 degrees

Verify: ________

Set the pneumatic pressure regulator on the reel drive air supply to 90 PSIG
Verify: ________

Move “Reel In/ Reel Out” control valve to rotate the reel in both directions to verify proper reel
operation.
Verify: ________

Ensure that the power supply to the reels is turned on at the Comm. & Power Dist. Panels.
(SK-122141-65-06 or SK-122141-66-06 & SK-154382-65-06 or SK-154382-66-06).
Verify: ________

8.2.3 Riser Fill Valve Reel

Verify that all the interfaces are per the interconnection diagram (SK-122100-65-01 or SK-122100-66-
01).
Verify: ________

Verify the pneumatic lubricator is filled with misting type oil rated 150-200 SSU at 100 degrees

Verify: ________

Set the pneumatic pressure regulator on the reel drive air supply to 90 PSIG

Verify: ________

Move “Reel In/ Reel Out” control valve to rotate the reel in both directions to verify proper reel
operation.
Verify: _______
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.3 Preparation of Mixed Fluid for the HPU

In order to begin testing of the HPU, its reservoir must first be filled with mixed fluid, per the steps in
this section.

Based on full reservoirs at the Mixing Unit, the HIGH GLYCOL LEVEL and HIGH CONCENTRATE
LEVEL alarms should be activated and indicated at the Diverter Control Unit and control panels.

Verify: ________

Before mixed fluid batches are prepared, the Mixing Unit pumps and motor interfaces must be
checked, as follows:
Set the HOA switch for the GLYCOL PUMP to ‘HAND’ mode and press and hold the ‘GLYCOL PUMP
RUNNING/HAND’ button. The pump should start and the GLYCOL PUMP RUNNING indicator should
be illuminated at the Diverter Control Unit panel. Verify that this operation occurs, and check that it is
monitored at the control panels. Then release the RUNNING/HAND button and set the HOA switch to
‘Off’.
Verify: ________

Set the HOA switch for the CONCENTRATE PUMP to ‘HAND’ mode and press and hold the
‘CONCENTRATE PUMP RUNNING/HAND’ button. The pump should start and the CONCENTRATE
PUMP RUNNING indicator should be illuminated at the Diverter Control Unit panel. Verify that this
operation occurs, and check that it is monitored at the control panels. Then release the
RUNNING/HAND button and set the HOA switch to ‘Off’.
Verify: ________

Simulate Motor Starter Unavailable conditions by removing input power to the rig-supplied motor
starters connected to each of the Pump motors on the Mixing Unit. Verify that each alarm condition is
indicated at the Diverter Control Unit panel and control panels. Then reinstate power to the starter
and verify that the alarm condition is cleared.

PUMP MOTOR VERIFY

GLYCOL PUMP
CONCENTRATE PUMP

Verify: ________

Mixed fluid batches will now be prepared: At the Diverter Control Unit panel, ensure the totalized
flows for Glycol, Concentrate, and Potable Water are reset to ‘zero’ at all locations. Set the Glycol ‘%
Selector’ switch to 5% and the Concentrate ‘% Selector’ switch to 3%. Then set the HOA switches for
Glycol, Concentrate, and Potable Water to ‘Auto’. Due to the fluid level of the HPU reservoir, the
Mixing Unit will automatically begin preparing batches of mixed fluid per settings of the ‘% selector’
switches until the fluid level of the HPU reservoir reaches 1000mm from the Low Low level.

NOTE: The resolution of the % selector switch is XX.X%. Each batch of fluid from the Mixing Unit is
composed of 100L of potable water. The ratios of Glycol and Concentrate in the batch are based on
the operator settings.
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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify that the Mixing Unit has prepared batches of fluid for the HPU until the fluid level of the HPU
reservoir is 1000mm from the Low Low level.
Verify: ________

From one of the control panels (DCP, TCP), run more batches of mixed fluid until the HIGH MIXED
FLUID LEVEL alarm is activated and displayed at the Diverter Control Unit and control panels.

Verify: ________

When the HPU reservoir fluid level has reached the HIGH MIXED FLUID LEVEL, reset the totalized
flow displays at all locations and set the HOA switches for Glycol, Concentrate, and Potable Water to
‘Off’.

Verify: ________

Obtain a test sample from the HPU reservoir of mixed fluid and have it tested to ensure that it meets a
NAS class 8 or lower. This should be done twice weekly.

Verify: ________

8.4 HPU

Prior to operation of the HPU E-Pumps, the HPU motor interfaces must be checked:

Set the HOA switch for HPU E-Pump 1 to ‘HAND’ mode and press and hold the ‘HPU E-PUMP 1
RUNNING/HAND’ button. HPU Charge Pump 1 should start and the HPU CHARGE PUMP 1
RUNNING indicator should be illuminated at the Diverter Control Unit panel. Followed by a delay,
HPU E-Pump 1 RUNNING indicator should be illuminated at the Diverter Control Unit panel. Verify
that this operation occurs, and check that it is monitored at the control panels. Then release the
RUNNING/HAND button and set the HOA switch to ‘Off’.
Verify: ________

Set the HOA switch for HPU E-Pump 2 to ‘HAND’ mode and press and hold the ‘HPU E-PUMP 2
RUNNING/HAND’ button. HPU Charge Pump 2 should start and the HPU CHARGE PUMP 2
RUNNING indicator should be illuminated at the Diverter Control Unit panel. Followed by a delay,
HPU E-PUMP 2 RUNNING indicator should be illuminated at the Diverter Control Unit panel. Verify
that this operation occurs, and check that it is monitored at the control panels. Then release the
RUNNING/HAND button and set the HOA switch to ‘Off’.

Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Set the HOA switch for HPU RECIRCULATION PUMP to ‘HAND’ mode and press and hold the ‘HPU
RECIRCULATION RUNNING/HAND’ button. The Recirculation pump should start and the HPU
RECIRCULATION PUMP RUNNING indicator should be illuminated at the Diverter Control Unit panel.
Verify that this operation occurs, and check that this it is monitored at the control panels. Also verify
that the pump does not leak. Then release the RUNNING/HAND button and set the HOA switch to
‘off’.
Verify: ________

Simulate Motor Starter Unavailable conditions by removing input power to the rig-supplied motor
starters connected to each of the Pump motors on the HPU. Verify that each alarm condition is
indicated at the Diverter Control Unit panel and control panels. Then reinstate power to the starter
and verify that the alarm condition is cleared.

PUMP MOTOR VERIFY

HPU E-Pump 1
HPU E-Pump 2
HPU Recirculation Pump

Verify: ________

At the Diverter Control Unit, several alarm conditions should be indicated including ‘LOW MAIN
ACCUMULATOR PRESSURE’ and ‘LOW DIVERTER ACCUMULATOR PRESSURE’. Verify at each
control panel (DCP, TCP) and Event Logger that these alarms are indicated.
Verify: ________

Switch off power (set to ‘Off’) for E-Pump 2. Set the HPU E-Pump 1 as the ‘Primary’ pump system,
and set the HOA switch for HPU E-Pump 1 to ‘Auto’. Note: When one E-Pump is selected as Primary,
one of the other two E-Pumps can then be selected as the ‘Secondary’ pump system.
Verify: ________

HPU E-Pump 1 will begin charging the Accumulator Racks. Verify at each control panel that this
process is being monitored, via the pressure readings of the surface accumulator pressures, as well
as the status at the ‘HPU’ screen.
Verify: ________

As E-Pump 1 charges the accumulators, check pump to make sure there is no leakage.
Verify: ________

As the fluid in the HPU reservoir decreases, verify that the ‘HIGH MIXED FLUID LEVEL’ alarm
condition clears at the control panels.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Per API16D, one pump system (in this case, E-Pump 1) shall be capable of charging the entire
accumulator system (only surface accumulators) from pre-charge pressure to working pressure within
30 minutes. Verify that HPU E-Pump 1 will automatically stop when reaching a working pressure of
5000 psi (+0 %, -5%) / 345 bar (+0 %, -5%).
Verify: _________
Record time: _________

Verify the ‘Surface Main Accumulator Pressure’, ‘Diverter Accumulator Pressure’ indications at the
Diverter Control Unit, DCP, and TCP.

Surface Main Diverter

Pressure Indication – Div Unit: PSI PSI
Pressure Indication – DCP: PSI PSI
Pressure Indication – TCP: PSI PSI

Slowly bleed the Accumulator pressure and verify that E-Pump 1 will automatically start at 4500 psi
(310 bar).
Verify: ________

Set the HOA switch for HPU E-Pump 1 to ‘Off’. Continue bleeding accumulator pressure until the
Accumulator pressure indications are at 0 psi (0 bar).
Verify: ________

Repeat the initial mixing operation, if necessary, (See section 6.1) to ensure that the HPU reservoir
contains enough fluid in order to charge all bottles in the Accumulator racks.
Verify: ________

Switch off power (set to ‘Off’) for E-Pump 1. Set the HPU E-Pump 2 as the ‘Primary’ pump system,
and set the HOA switch for HPU E-Pump 2 to ‘Auto’ mode.
Verify: ________

HPU E-Pump 2 will begin charging the Accumulator Racks. Verify at each control panel that this
process is being monitored.
Verify: ________

As E-Pump 2 charges the accumulators, check pump to make sure there is no leakage.
Verify: ________

Per API16D, one pump system (in this case, E-Pump 2) shall be capable of charging the entire
accumulator system (only surface accumulators) from pre-charge pressure to working pressure within
30 minutes. Verify that HPU E-Pump 2 will automatically stop when reaching a working pressure of
5000 psi (+0 %, -5%) / 345 bar (+0 %, -5%).
Verify: _________
Record time: _________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify the ‘Surface Main Accumulator Pressure’, ‘Diverter Accumulator Pressure’ indications at the
Diverter Control Unit, DCP, and TCP.

Surface Main Diverter

Pressure Indication – Div Unit: PSI PSI
Pressure Indication – DCP: PSI PSI
Pressure Indication – TCP: PSI PSI

Slowly bleed the Accumulator pressure and verify that E-Pump 2 will automatically start at 4500 psi /
310 bar.
Verify: ________
When E-Pump 2 automatically stops, set the HOA switch for HPU E-Pump 2 to ‘Off’.
Verify: ________

Bleed accumulator pressure until the Accumulator pressure indications are 0 psi (0 bar).
Verify: ________

Repeat the initial mixing operation, if necessary, (See section 6.1) to ensure that the HPU reservoir
contains enough fluid in order to charge all bottles in the Accumulator racks.
Verify: ________

At a Control Panel, select an E-Pump (i.e. E-Pump 1) as ‘Primary’, and another (i.e. E-Pump 2) as
secondary.
Verify: ________

Set the 2 HOA switches for E-Pumps 1 and 2 to ‘Auto’ mode.

Verify: ________

The pump systems (E-Pumps 1 and 2) should start charging the Accumulator racks. Verify that this
process is being monitored at the Control Panels. Monitor the volume, as it will be recorded below.

Verify: ________

Per API 16D, both pump systems shall be capable of charging the entire accumulator system (only
surface accumulators) from pre-charge pressure to working pressure within 15 minutes. When
working pressure has been reached, verify that the elapsed time has been within 15 minutes.
Verify: _________
Record time: _________
Record volume:_________

Ensure that the fluid level in the HPU reservoir is below 13 ¾ in (350mm) from the Low Low level. The
‘LOW MIXED FLUID LEVEL’ alarm condition should be indicated on the Diverter Control Unit panel
and control panels.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Enable the E-Pumps to run, and decrease the fluid level in the HPU reservoir until it reaches the Low
Low level. Verify that the E-Pumps stop running.
Verify: ________

Increase the fluid level in the HPU reservoir to check that the pumps start running (there must be a
demand for the pumps to start when in ‘Auto’ mode).
Verify: ________
Set the HOA switches for HPU E-Pumps 1 and 2 to ‘Off’.
Verify: ________

Add fluid to the HPU reservoir, and stop when the fluid level is above 17 ½ in (445mm) from the Low
Low level.
Verify: ________

Simulate a ‘HPU HP FILTER 1 SERVICE NEEDED’ condition by removing the connection from
terminal –X6(1) in the HPU Main Control Box. Verify that the alarm condition is indicated at the
Diverter Control Unit panel and control panels. After verification, reinstate the connection to –X6(1).
(Note: Pump must be running in order for alarm to go off)

Verify: ________

Simulate a ‘HPU HP FILTER 2 SERVICE NEEDED’ condition by removing the connection from
terminal –X6(3) in the HPU Main Control Box. Verify that the alarm condition is indicated at the
Diverter Control Unit panel and control panels. After verification, reinstate the connection to –X6(3).

Verify: ________

Simulate a ‘HPU CIRCULATION FILTER SERVICE NEEDED’ condition by removing the connection
from terminal –X6(5) in the HPU Main Control Box. Verify that the alarm condition is indicated at the
Diverter Control Unit panel and control panels. After verification, reinstate the connection to –X6(5).

Verify: ________

Simulate a ‘HPU E-PUMP 1 SUCTION FILTER SERVICE NEEDED’ condition by removing the
connection from terminal –X7(9) in the HPU Main Control Box. Verify that the alarm condition is
indicated at the Diverter Control Unit panel and control panels. After verification, reinstate the
connection to –X7(9).
Verify: ________

Simulate a ‘HPU E-PUMP 2 SUCTION FILTER SERVICE NEEDED’ condition by removing the
connection from terminal –X7(11) in the HPU Main Control Box. Verify that the alarm condition is
indicated at the Diverter Control Unit panel and control panels. After verification, reinstate the
connection to –X7(11).
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Simulate a ‘HPU E-PUMP 1 LOW OIL PRESSURE” condition by removing the connection from
terminal –X7(5) in the HPU Main Control Box while the pump is running. Verify that the alarm
condition is indicated at the control panels. After verification, reinstate the connection to –X7(5).

Verify: ________

Simulate a ‘HPU E-PUMP 2 LOW OIL PRESSURE” condition by removing the connection from
terminal –X7(7) in the HPU Main Control Box while the pump is running. Verify that the alarm
condition is indicated at the control panels. After verification, reinstate the connection to –X7(7).

Verify: ________

8.5 Mixing Unit

At the Diverter Control Unit panel, set the Glycol and Concentrate ‘% Selector’ switches to the values
per the table below. Ensure the totalized flows for Glycol, Concentrate, and Potable Water are reset
to ‘zero’ at all locations. Then set the HOA switches for Glycol, Concentrate, and Potable Water to the
‘Auto’ position. Press ‘Run Batch’ at one of the Control Panels (DCP and TCP) to run a batch of
mixed fluid per the operator settings.

Verify from the totalizer displays on the Diverter Control Unit panel that the measured totalized flow
corresponds with the settings. Also verify that the values of totalized flow are displayed on all of the
operator stations.

% Selected Predicted Flow (L) Measured Flow (L)

Glycol 10.0 11.5
Concentrate 3.0 3.5
Potable Water N/A 100

Verify: ________

Press the RESET buttons for the Concentrate, Glycol, and Potable Water totalizer displays, at all
locations.
Verify: ________

The HPU reservoir may require for some additional fluid to be drained, or else the mixing process may
be interrupted before it is complete.

Repeat the mixing operation per the table below. Verify from the totalizer displays on the Diverter
Control Unit panel that the measured totalized flow corresponds with the settings. Also verify that the
values of totalized flow are displayed on all of the operator stations.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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% Selected Predicted Flow (L) Measured Flow (L)

Glycol 8.0 8.9
Concentrate 2.0 2.2
Potable Water N/A 100

Verify: ________

Press the RESET buttons for the Concentrate, Glycol, and Potable Water totalizer displays, at all
locations.
Verify: ________

Decrease the fluid levels in each reservoir until the ‘LOW GLYCOL LEVEL’ and ‘LOW
CONCENTRATE LEVEL’ alarms are activated and indicated at the Diverter Control Unit and control
panels.
Verify: ________

Continue decreasing the fluid in both reservoirs until the levels are below Low Low level. The ‘MIXING
SYSTEM FAILURE’ alarm should activate and be indicated at the Diverter Control Unit and control
panels.
Verify: ________

Verify it is not possible to start the Glycol and Concentrate pumps via the HOA switches at the Diverter
Control Unit.
Verify: ________

Set the HOA switches for Glycol, Concentrate, and Potable Water to ‘Off’.

Verify: ________

8.6 DIVERTER CONTROL UNIT FUNCTION TESTS

8.6.1 REGULATORS

Set all hydraulic and air pressure regulators to minimum outlet pressure.
Verify: ________

Check REGULATED AIR PRESSURE and record pressure indication at the Diverter Control Unit and
the control panels.
Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Slowly decrease the air pressure below 70 psi (5 bar) via the regulator (Item 71, SK-122159-65-16 or
SK-122159-66-16). Verify that the LOW AIR SUPPLY PRESSURE alarm is activated and indicated at
the Diverter Control Unit and control panels.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Increase the air pressure (via Item 71, SK-122159-65-16 or SK-122159-66-16) to 145 psi (10 bar), and
verify that the alarm condition clears past 5 bar.
Verify: ________

At the Diverter Control Unit, operate the hydraulic regulator for DIVERTER PACKER PRESSURE from
minimum to maximum pressure level. Verify the pressure indication on the local gauge and check the
indications at the control panels.
Verify: ________

Set the DIVERTER PACKER PRESSURE to 1500 ± 75 psi (103 ± 5 bar). Verify pressure indications
at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operation from the DCP:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operation from the TCP:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Set the LOWER TELESCOPING JOINT PACKER HYDRAULIC PRESSURE to 100 ± 15 psi (6.9 ± 1
bar). Verify pressure indications at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operation from the DCP:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operation from the TCP:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Set the UPPER TELESCOPING JOINT PACKER AIR PRESSURE to 50 ± 7 psi (3.45 ± .5 bar). Verify
pressure indications at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operation from the DCP:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operation from the TCP:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operate the hydraulic regulator for DIVERTER PANEL HYDRAULIC PRESSURE from minimum to
maximum pressure level. Verify the pressure indication on the local gauge and check the indications
at the control panels.
Verify: ________

Set the DIVERTER PANEL HYDRAULIC PRESSURE to 1500 ± 75 psi (103 ± 5 bar). Verify pressure
indications at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Set the RISER FILL-UP SUPPLY HYDRAULIC PRESSURE to 3000 ± 75 psi (204 ± 5 bar). Verify
pressure indications at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: psi
Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Operate the hydraulic regulator (Item 42.1) for DIVERTER FLOWLINE SEALS SUPPLY PRESSURE
from minimum to maximum pressure level. Verify the pressure indication on the local gauge and
check the indications at the control panels.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Set the DIVERTER FLOWLINE SEALS SUPPLY PRESSURE to 750 ± 25 PSI. Verify pressure
indications at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: PSI

Pressure Indication – DCP: PSI
Pressure Indication – TCP: PSI

Operate the hydraulic regulator (Item 42.2) for TENSION RING LOAD SHOULDER DOGS SUPPLY
PRESSURE from minimum to maximum pressure level. Verify the pressure indication on the local
gauge and check the indications at the control panels.

Verify: ________

Set the TENSION RING LOAD SHOULDER DOGS SUPPLY PRESSURE to 750 ± 25 PSI. Verify
pressure indications at the Diverter Control Unit and control panels.

Operation from the Diverter Control Unit:

Pressure Indication – Div Unit: PSI

Pressure Indication – DCP: PSI
Pressure Indication – TCP: PSI

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.6.2 DIVERTER FUNCTION TESTS

For each function listed in the table below, operate from the Diverter Control Unit and from each of the
control panels (DCP/ TCP). Check correspondence at the Diverter valves, Control Panels, and Event
Logger, and then place a check in the table cell (below) for the panel that is being operated.

(At each Control Panel, the User log-on level should be set to either ‘Testing & BOP Handling’ or
‘Administrator’ so that all functions are able to be operated. A test to verify any greyed-out functions of
the ‘Drilling’ User Level will be checked towards the end of this section.) The log-in level determines
which functions are not available for the currently logged-on user.

NOTE: The following six functions do not have local (Diverter Control Unit installed) pressure
readbacks, thus a customer-supplied limit switch installed on the associated valve has been
connected to the Diverter Control Unit Main Control Box at the following termination points. Reference
SK-122159-65-06 or SK-122159-66-06.
1) Port/Starboard Select Valve: connected to –X35:1 & 3 (PORT), and –X35:2 & 3 (STARBOARD)
2) Diverter Flowline Valve: connected to –X35:4 & 6 (OPEN), and –X35:5 & 6 (CLOSE)
3) Overboard Vent Valve: connected to –X35:7 & 9 (OPEN), and –X35: 8 & 9 (CLOSE)
4) Diverter Fill Valve: connected to –X35:10 & 12 (OPEN), and –X35:11 & 12 (CLOSE)
5) Trip Tank Return Valve: connected to –X35:13 & 15 (OPEN), and –X35:14 & 15 (CLOSE)
6) Mud/Gas Separator Valve: connected to –X35:16 & 18 (OPEN), and –X35: 17 & 18 (CLOSE)
Verify: ________
WARNING: Panel valve handles will move abruptly!

NOTE: When the DIVERTER PACKER ‘CLOSE’ function (the auto-sequence) is operated (from the
Diverter Unit panel this is done by pressing ‘Diverter Close Auto Sequence’ pushbutton), the correct
sequence should occur if the ‘Overboard Preselect’ mode is set to ‘Overboard Vent Valve’. Please
refer to document X-261720-65 to verify the auto-sequence, then place check in table below.

NOTE: When the DIVERTER PACKER ‘CLOSE’ function (the auto-sequence) is operated (from the
Diverter Unit panel this is done by pressing ‘Diverter Close Auto Sequence’ pushbutton), the correct
sequence should occur if the ‘Overboard Preselect’ mode is set to ‘Mud/Gas Separator Valve’. Please
refer to document X-261720-65 to verify the auto-sequence, then place check in table below.

Test Pipe / Drill pipe must be in the hole when closing the Diverter Packer.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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NOTE: During testing of these functions (*), ensure that the corresponding interlocks are in place per
X-261720-65.

Diverter DCP TCP

Control
Function Position
Unit

Open
Close (using panel valve) N/A N/A
No sequence will occur.
Close (with ‘Overboard Vent Valve’
selected via Preselect at the
Div.Unit/DCP/TCP )
Verify against X-261720-65.
Verify that diverter close sequence occurs within the required time
Diverter Packer * of 45 seconds.
Verify: ________
Close (with ‘Mud/Gas Separator’
selected via Preselect at the
Div.Unit/DCP/TCP)
Verify against X-261720-65.
Verify that diverter close sequence occurs within the required time
of 45 seconds.
Verify: ________
Open
Diverter Flowline Valve
Close
Energize
Diverter Flowline Seals *
Vent
Diverter Lockdown Retract
Dogs*
Extend
Port/Starboard Select Port
Valve Starboard
Open
Diverter Fill Valve
Close
Open
Overboard Vent Valve *
Close
Unlock
T-Joint Barrel Lock Auto-Lock
Secure
Vent
T-Joint Upper Packer *
Energize
Vent
T-Joint Lower Packer *
Energize
Tension Ring Load Retract
Shoulder Dogs Extend
Tension Ring Storage Retract
Lock Dogs * Extend
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Tension Ring to T-Joint Retract

Lock Dogs * Extend
Mud/Gas Separator Open
Valve * Close
Open
Trip Tank Return Valve
Close
Open
Riser Fill-Up Valve Auto-Open
Close/Reset
Open
Blue Conduit Supply
Close
Open
Yellow Conduit Supply
Close

Verify Time Delay setting for Supply Conduit Select ‘Blue’. Verify: ________

Verify Time Delay setting for Supply Conduit Select ‘Yellow’. Verify: ________

Verify the pressure indication of HOT LINE PRESSURE at the Diverter Control Unit and at each
control panel, verify that they correspond.

Pressure Indication – Div Unit: psi

Pressure Indication – DCP: psi
Pressure Indication – TCP: psi

Change the log-on User Level to ‘Drilling’, and verify that per X-261720-65, certain Diverter functions
are grayed out and are unable to be operated (Note: Customer to advise if this list should be different):

Verify: ________

Set all HOA switches (except for HPU Recirc Pump) on the Diverter Control Unit panel to the ‘OFF’
position.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.7 BOP Test Pump Interface

The BOP Test Pump should be hydraulically and electrically connected to the system, as well as to rig
power supply. At the BOP Test Pump Unit, ensure that the ‘HPU Recirc Remote Start’ selector switch
is in the ‘Off’ position.
Verify: _______

At the Diverter Control Unit, set the ‘HOA’ switch for the HPU Recirculation Pump to ‘Auto’ mode.
Verify: _______

At the BOP Test Pump Unit, set the ‘HPU Recirc Remote Start’ switch (located at VFD Panel) to the
‘On’ position.
Verify: _______
Verify that the HPU Recirc Pump has started by observing illumination of the indicator lamp ‘HPU
Recirc Pump Running’ at the BOP Test Pump Unit.
Verify: _______
Once boost pressure has built-up at the inlet of the BOP Test Pump Unit to at least 30-40 psi, activate
the BOP Test Pump Unit at the VFD Panel (note that the Unit fluid outlet connection should be routed
to a suitable location). Note: Do not start BOP Test Pump Unit unless inlet boost pressure is at least
30 psi.
Verify: _______

At the BOP Test Pump Unit, set the ‘HPU Recirc Remote Start’ switch to the ‘Off’ position, and verify
that the indicator lamp ‘HPU Recirc Pump Running’ is extinguished.
Verify: _______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.8 Interlock Verification Test

Caution: All Interlocks can be bypassed by deleting or renaming the Procedure Script Language (PSL)
file.

IN ORDER TO CONFIRM EACH INTERLOCK, READ THE DESCRIPTION OF THE INTERLOCK

AND PLACE INTERLOCKED FUNCTION(S) IN OPPOSITE POSITION.

Verify that each interlock listed in X-261720-65, Section 3 “LMRP/BOP Stack Function Interlocks”
function correctly.

Verify: _______

8.8.1 Drilling Mode

Log into Drill Mode and verify the functions listed in Section 2 of X-261720-65 are disabled.

Verify: _______

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.9 BOP Stack and BOP Stack Control Continuity Test

A 5-7/8” Test Joint will be used to simulate the drill pipe in the BOP bore.

Note: Before operating Pod functions, verify that LMRP and Stack Stingers are ‘Extended’ and LMRP
and Stack Stinger Seals are ‘Energized’.

Prior to installation of the Test Joint, complete the table up to Function 61 CHOKE AND KILL
CONNECTOR LATCH.
Verify: ________

Install a 5-7/8” Test Joint or other suitable device to simulate the drill pipe in the BOP bore.
Verify: ________

All pod regulators should be adjusted to 1500 PSI. (Pod regulator functionality will be verified in a later
section.)
Verify: ________

Autoshear regulator should be adjusted to 3000 PSI (Note: Stack accumulator charge must be open for
verification)
Verify: ________

Activate each function in accordance with the following table. When performing the functions per the
table below, alternate usage the Control Panels (DCP, TCP).

Check that the desired function actuated on the Stack.

Verify that the function has been operated for each Pod SEM A by repeating the list with one Pod
selected first, and then again with the other (record visual verification in Appendix A at the end of this
procedure if appropriate for the function). Record the fluid volume required to operate each function.
Record and verify that the time to operate each function complies with API 16D. These times are as
follows:

 Ram BOP’s to close within 45 seconds or less.

 Annular BOP’s to close within 60 seconds or less.
 Operating response time for Choke and Kill valves shall not exceed the minimum response
times of the Rams.
 LMRP Connector to unlatch within 45 seconds or less.

Visually verify that the functions activated properly, per the chart below, and also verify activation at the
Control Panels and Event Logger.
After verifying the function, de-activate the function, except for those with “Do not de-activate” in
parenthesis in the description.
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify Proper Operation and Record

Description
Function Time (s) and Volume (l) from each Pod
Number These Tests conducted with Blue Blue Blue Yellow Yellow
Verify
SEM A and Yellow SEM A Time Vol. Time Vol.

NO PIPE IN HOLE
LMRP STINGER EXTEND
14 N/A N/A N/A N/A
(Do not de-activate)
LMRP STINGER SEALS ENERGIZE
16 N/A N/A N/A N/A
(Do not de-activate)
POD SELECT
13 N/A N/A N/A N/A
(Do not de-activate)
STACK STINGER EXTEND
183 N/A N/A N/A N/A
(Do not de-activate)
STACK STINGER SEALS ENERGIZE
185 N/A N/A N/A N/A
(Do not de-activate)
182 SOLENOID PILOT DUMP N/A N/A N/A N/A
YELLOW CONDUIT YELLOW POD SUPPLY
63 OPEN N/A N/A N/A N/A
(Do not de-activate)
BLUE CONDUIT YELLOW POD SUPPLY OPEN
72 N/A N/A N/A N/A
(Do not de-activate)
BLUE CONDUIT BLUE POD SUPPLY OPEN
68 N/A N/A N/A N/A
(Do not de-activate)
YELLOW CONDUIT BLUE POD SUPPLY OPEN
67 N/A N/A N/A N/A
(Do not de-activate)
114 STACK ACCUMULATOR CHARGE N/A N/A N/A N/A
73 HOTLINE ISOLATION VALVE CLOSE N/A N/A N/A N/A
77 WELLBORE P/T CONNECTOR EXTEND
76 WELLBORE P/T CONNECTOR RETRACT
162 ACOUSTIC SYSTEM ISOLATE N/A N/A N/A N/A
163 ACOUSTIC SYSTEM RESET N/A N/A N/A N/A
Isolate Hydraulic Supply to Conduit Inlet
71 BLUE CONDUIT FLUSH OPEN N/A N/A N/A N/A
64 YELLOW CONDUIT FLUSH OPEN N/A N/A N/A N/A
121 AUTOSHEAR ARM N/A N/A N/A N/A
118 AUTOSHEAR DISARM N/A N/A N/A N/A
114 STACK ACCUMULATOR CHARGE N/A N/A N/A N/A
125 STACK TRANSPONDER ARM EXTEND N/A N/A N/A N/A
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify Proper Operation and Record

Description
Function Time (s) and Volume (l) from each Pod
Number These Tests conducted with Blue Blue Blue Yellow Yellow
Verify
SEM A and Yellow SEM A Time Vol. Time Vol.
122 STACK TRANSPONDER ARM RETRACT N/A N/A N/A N/A

Operate both of the following functions in order before venting

104 UPPER BLIND SHEAR RAM CLOSE
113 UPPER BLIND SHEAR ST LOCKS LOCK

103 UPPER BLIND SHEAR RAM OPEN

Operate both of the following functions in order before venting
116 LOWER BLIND SHEAR RAM CLOSE
117 LOWER BLIND SHEAR ST LOCKS LOCK

115 LOWER BLIND SHEAR RAM OPEN

Operate both of the following functions in order before venting
126 UPPER BLIND SHEAR RAM HP CLOSE
113 UPPER BLIND SHEAR ST LOCKS LOCK

103 UPPER BLIND SHEAR RAM OPEN

Operate both of the following functions in order before venting
131 LOWER BLIND SHEAR RAM HP CLOSE
117 LOWER BLIND SHEAR ST LOCKS LOCK

115 LOWER BLIND SHEAR RAM OPEN

Operate both of the following functions in order before venting
106 CASING SHEAR RAM CLOSE
105 CASING SHEAR RAM OPEN

Operate both of the following functions in order before venting

153 CASING SHEAR RAM HP CLOSE
105 CASING SHEAR RAM OPEN

57 LMRP CONNECTOR PRIMARY UNLATCH

Record stroke of indicator ________________in
58 LMRP CONNECTOR LATCH
Record stroke of indicator ________________in
53 LMRP CONNECTOR SECONDARY UNLATCH
Record stroke of indicator ________________in
58 LMRP CONNECTOR LATCH
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify Proper Operation and Record

Description
Function Time (s) and Volume (l) from each Pod
Number These Tests conducted with Blue Blue Blue Yellow Yellow
Verify
SEM A and Yellow SEM A Time Vol. Time Vol.
Record stroke of indicator ________________in
98 LMRP CONNECTOR GASKET RELEASE
98 LMRP CONNECTOR GASKET VENT N/A N/A N/A N/A
CHOKE & KILL CONNECTOR PRIMARY
62
UNLATCH
Record stroke of indicator ________________in
61 CHOKE & KILL CONNECTOR LATCH
Record stroke of indicator ________________in
59 CHOKE & KILL CONN. SECONDARY UNLATCH
Record stroke of indicator ________________in
61 CHOKE & KILL CONNECTOR LATCH
Record stroke of indicator ________________in

TEST PIPE 5-7/8”, IN HOLE

55 UPPER ANNULAR PREVENTER CLOSE
54 UPPER ANNULAR PREVENTER OPEN
102 LOWER ANNULAR PREVENTER CLOSE
101 LOWER ANNULAR PREVENTER OPEN
95 KILL ISOLATION VALVE OPEN
94 KILL ISOLATION VALVE CLOSE
Verify Valve Opens when Vented

89 UPPER INNER BLEED VALVE OPEN

Verify Valve Closes when Vented
86 UPPER INNER BLEED VALVE CLOSE

85 UPPER OUTER BLEED VALVE OPEN

Verify Valve Closes when Vented
82 UPPER OUTER BLEED VALVE CLOSE

157 LOWER INNER BLEED VALVE OPEN

Verify Valve Closes when Vented
156 LOWER INNER BLEED VALVE CLOSE

155 LOWER OUTER BLEED VALVE OPEN

Verify Valve Closes when Vented
152 LOWER OUTER BLEED VALVE CLOSE

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify Proper Operation and Record

Description
Function Time (s) and Volume (l) from each Pod
Number These Tests conducted with Blue Blue Blue Yellow Yellow
Verify
SEM A and Yellow SEM A Time Vol. Time Vol.
81 MUD BOOST VALVE OPEN
80 MUD BOOST VALVE CLOSE
Verify Valve Opens when Vented

91 CHOKE ISOLATION VALVE OPEN

90 CHOKE ISOLATION VALVE CLOSE
Verify Valve Opens when Vented

Operate both of the following functions in order before venting

112 LOWER PIPE RAM CLOSE
137 LOWER PIPE RAM ST LOCKS LOCK

111 LOWER PIPE RAM OPEN

Operate both of the following functions in order before venting

110 MIDDLE PIPE RAM CLOSE
141 MIDDLE PIPE RAM ST LOCKS LOCK

109 MIDDLE PIPE RAM OPEN

Operate both of the following functions in order before venting

108 UPPER PIPE RAM CLOSE
120 UPPER PIPE RAM ST LOCKS LOCK

107 UPPER PIPE RAM OPEN

133 WELLHEAD CONNECTOR PRIMARY UNLATCH

Record stroke of indicator ________________in
165 WELLHEAD CONNECTOR LATCH
Record stroke of indicator ________________in
WELLHEAD CONNECTOR SECONDARY
164
UNLATCH
Record stroke of indicator ________________in
165 WELLHEAD CONNECTOR LATCH
Record stroke of indicator ________________in

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Verify Proper Operation and Record

Description
Function Time (s) and Volume (l) from each Pod
Number These Tests conducted with Blue Blue Blue Yellow Yellow
Verify
SEM A and Yellow SEM A Time Vol. Time Vol.

136 UPPER OUTER KILL VALVE OPEN

Verify Valve Closes when Vented
140 UPPER OUTER KILL VALVE CLOSE

145 UPPER INNER KILL VALVE OPEN

Verify Valve Closes when Vented
149 UPPER INNER KILL VALVE CLOSE

151 LOWER OUTER KILL VALVE OPEN

Verify Valve Closes when Vented
148 LOWER OUTER KILL VALVE CLOSE

147 LOWER INNER KILL VALVE OPEN

Verify Valve Closes when Vented
144 LOWER INNER KILL VALVE CLOSE

143 UPPER OUTER CHOKE VALVE OPEN

Verify Valve Closes when Vented
142 UPPER OUTER CHOKE VALVE CLOSE

139 UPPER INNER CHOKE VALVE OPEN

Verify Valve Closes when Vented
138 UPPER INNER CHOKE VALVE CLOSE

127 MIDDLE OUTER CHOKE VALVE OPEN

Verify Valve Closes when Vented
132 MIDDLE OUTER CHOKE VALVE CLOSE

123 MIDDLE INNER CHOKE VALVE OPEN

Verify Valve Closes when Vented
119 MIDDLE INNER CHOKE VALVE CLOSE

135 LOWER OUTER CHOKE VALVE OPEN

Verify Valve Closes when Vented
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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09 July 2010 63 OF 92

Verify Proper Operation and Record

Description
Function Time (s) and Volume (l) from each Pod
Number These Tests conducted with Blue Blue Blue Yellow Yellow
Verify
SEM A and Yellow SEM A Time Vol. Time Vol.
134 LOWER OUTER CHOKE VALVE CLOSE

130 LOWER INNER CHOKE VALVE OPEN

Verify Valve Closes when Vented
129 LOWER INNER CHOKE VALVE CLOSE

161 WELLHEAD CONNECTOR GASKET RELEASE

161 WELLHEAD CONNECTOR GASKET VENT N/A N/A N/A N/A
96/160 STACK ACCUMULATOR DUMP N/A N/A N/A N/A

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.10 Stack Working Pressure Leak Test

This test will verify that there are no visible signs of fluid leakage from the following components on the
Stack:
Hoses
Fittings
Shuttle valves.

Functions to be actuated based on the following two conditions:

Condition 1: BOP set-up (see table)

Condition 2: BOP set-up (see table)

Condition 1 (Yellow Conduit Module to supply both Pods; Activate functions 63 & 67, functions
68 & 72 to be in vent)

Set all pod piloted regulators to 1500 PSI (104 BAR).

Verify ______________

Set POD SELECT to BLUE B.

Actuate functions with 1,500 PSI (104 BAR). Verify each function is in the proper position per the
table below.
Verify ______________

After actuation of ALL BOP Stack functions has been completed, increase regulators to 3,000 PSI
(206 BAR).
Verify ______________

Verify no visible signs of fluid leakage from the hoses, fittings and shuttles for a period of 15 minutes.
After verification, insert check mark under column “Verify B” for each function listed in the table below.

Verify ______________

Set all pod piloted regulators to 1500 PSI.

Verify ______________

Set POD SELECT to YELLOW B. (stack should still be in condition 1 except for pod specific
functions)
Verify ______________

Increase pod piloted regulators to 3000 PSI (206 BAR).

Verify ______________

Verify no visible signs of fluid leakage from the hoses, fittings and shuttles for a period of 15 minutes.
After verification, insert check mark under column “Verify Y” for each function listed in the table below.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Set all pod piloted regulators to 1500 PSI (104 BAR).

Set POD SELECT to BLUE B.

Condition 1 Table
NO PIPE IN HOLE
FUNC. VFY VFY These Tests conducted with Blue SEM B
NO. B Y and Yellow SEM B
63 YELLOW CONDUIT YELLOW POD SUPPLY OPEN
67 YELLOW CONDUIT BLUE POD SUPPLY OPEN
13 POD SELECT (activate)
14 LMRP STINGER EXTEND
16 LMRP STINGER SEAL ENERGIZE
65 RISER RECOIL ARM
183 STACK STINGER EXTEND
185 STACK STINGER SEALS ENERGIZE
54 UPPER ANNULAR PREVENTER OPEN
101 LOWER ANNULAR PREVENTER OPEN
57 LMRP CONNECTOR PRIMARY UNLATCH
62 CHOKE & KILL CONNECTOR PRIMARY UNLATCH
95 KILL ISOLATION VALVE OPEN
89 UPPER INNER BLEED VALVE OPEN
85 UPPER OUTER BLEED VALVE OPEN
157 LOWER INNER BLEED VALVE OPEN
155 LOWER OUTER BLEED VALVE OPEN
53 LMRP CONNECTOR SECONDARY UNLATCH
59 CHOKE & KILL CONN. SECONDARY UNLATCH
81 MUD BOOST VALVE OPEN
91 CHOKE ISOLATION VALVE OPEN
76 WELLBORE P/T CONNECTOR RETRACT
107 UPPER PIPE RAM OPEN
109 MIDDLE PIPE RAM OPEN
111 LOWER PIPE RAM OPEN
133 WELLHEAD CONNECTOR PRIMARY UNLATCH
164 WELLHEAD CONNECTOR SECONDARY UNLATCH
136 UPPER OUTER KILL VALVE OPEN
145 UPPER INNER KILL VALVE OPEN
151 LOWER OUTER KILL VALVE OPEN
147 LOWER INNER KILL VALVE OPEN
143 UPPER OUTER CHOKE VALVE OPEN
139 UPPER INNER CHOKE VALVE OPEN
127 MIDDLE OUTER CHOKE VALVE OPEN
123 MIDDLE INNER CHOKE VALVE OPEN
135 LOWER OUTER CHOKE VALVE OPEN
130 LOWER INNER CHOKE VALVE OPEN
161 WELLHEAD CONNECTOR GASKET RELEASE
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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NO PIPE IN HOLE
FUNC. VFY VFY These Tests conducted with Blue SEM B
NO. B Y and Yellow SEM B
122 STACK TRANSPONDER ARM RETRACT
121 AUTOSHEAR ARM
162 ACOUSTIC SYSTEM ISOLATE
104 UPPER BLIND SHEAR RAM CLOSE
116 LOWER BLIND SHEAR RAM CLOSE
106 CASING SHEAR RAM CLOSE
126 UPPER BLIND SHEAR RAM HP CLOSE
131 LOWER BLIND SHEAR RAM HP CLOSE
153 CASING SHEAR RAM HP CLOSE
113 UPPER BLIND SHEAR RAM ST LOCKS LOCK
117 LOWER BLIND SHEAR RAM ST LOCKS LOCK

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
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Condition 2 (Blue Conduit Module to supply both Pods; Activate functions 68 & 72, functions
63 & 67 to be in vent)

Set all pod piloted regulators to 1500 PSI (104 BAR).

Verify ______________

Actuate functions with 1,500 PSI (104 BAR). Verify each function is in the proper position per the
table below.
Verify ______________

After actuation of ALL BOP Stack functions has been completed, increase BOP manifold, LMRP
Connector and Wellhead Connector regulators to 3,000 PSI (207 BAR).
Verify ______________

Verify no visible signs of fluid leakage from the hoses, fittings and shuttles for a period of 15 minutes.
After verification, insert check mark under column “Verify B” for each function listed in the table below.

Verify ______________

Set all pod piloted regulators to 1500 PSI (104 BAR).

Verify ______________

Set POD SELECT to YELLOW B. (stack should still be in condition 2 except for pod specific
functions)

Verify ______________

Increase BOP manifold, LMRP Connector and Wellhead Connector regulators to 3000 PSI (207 BAR).

Verify ______________

Verify no visible signs of fluid leakage from the hoses, fittings and shuttles for a period of 15 minutes.
After verification, insert check mark under column “Verify Y” for each function listed in the table below.

Verify ______________

Set all pod piloted regulators to 1500 PSI (104 BAR).

Verify ______________

Set POD SELECT to BLUE B.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
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09 July 2010 68 OF 92

Condition 2 Table
5-7/8” TEST PIPE IN HOLE
FUNC. VFY VFY These Tests conducted with Blue SEM B
NO. B Y and Yellow SEM B
72 BLUE CONDUIT YELLOW POD SUPPLY OPEN
68 BLUE CONDUIT BLUE POD SUPPLY OPEN
73 BLUE HOT LINE SUPPLY ISOLATION CLOSE
73 YELLOW HOT LINE SUPPLY ISOLATION CLOSE
13 POD SELECT (activate)
14 LMRP STINGER EXTEND
16 LMRP STINGER SEAL ENERGIZE
183 STACK STINGER EXTEND
185 STACK STINGER SEALS ENERGIZE
55 UPPER ANNULAR PREVENTER CLOSE
102 LOWER ANNULAR PREVENTER CLOSE
58 LMRP CONNECTOR PRIMARY LATCH
61 CHOKE & KILL CONNECTOR PRIMARY LATCH
94 KILL ISOLATION VALVE CLOSE
86 UPPER INNER BLEED VALVE CLOSE
82 UPPER OUTER BLEED VALVE CLOSE
156 LOWER INNER BLEED VALVE CLOSE
152 LOWER OUTER BLEED VALVE CLOSE
80 MUD BOOST VALVE CLOSE
90 CHOKE ISOLATION VALVE CLOSE
77 WELLBORE P/T CONNECTOR EXTEND
108 UPPER PIPE RAM CLOSE
110 MIDDLE PIPE RAM CLOSE
112 LOWER PIPE RAM CLOSE
165 WELLHEAD CONNECTOR PRIMARY LATCH
140 UPPER OUTER KILL VALVE CLOSE
149 UPPER INNER KILL VALVE CLOSE
148 LOWER OUTER KILL VALVE CLOSE
144 LOWER INNER KILL VALVE CLOSE
142 UPPER OUTER CHOKE VALVE CLOSE
138 UPPER INNER CHOKE VALVE CLOSE
132 MIDDLE OUTER CHOKE VALVE CLOSE
119 MIDDLE INNER CHOKE VALVE CLOSE
134 LOWER OUTER CHOKE VALVE CLOSE
129 LOWER INNER CHOKE VALVE CLOSE
114 STACK ACCUMULATOR CHARGE
125 STACK TRANSPONDER ARM EXTEND
118 AUTOSHEAR DISARM
163 ACOUSTIC SYSTEM RESET
98 LMRP GASKET RELEASE
117 LOWER PIPE RAM ST LOCKS LOCK
141 MIDDLE PIPE RAM ST LOCKS LOCK
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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5-7/8” TEST PIPE IN HOLE

FUNC. VFY VFY These Tests conducted with Blue SEM B
NO. B Y and Yellow SEM B
120 UPPER PIPE RAM ST LOCKS LOCK
105 CASING SHEAR RAM OPEN
103 UPPER BLIND SHEAR RAM OPEN
115 LOWER BLIND SHEAR RAM OPEN

Conduit Flush Isolation Valve ROV Panel

Note: Before testing ROV Panel, ensure that both valves have been moved to the “CLOSED’ position.

Activate each function and hold pressure for 15 minutes. Verify no visible signs of fluid leakage for 15
minute period.

Port Description Location Verify

64 Yellow Conduit Flush Valve LMRP

71 Blue Conduit Flush Valve LMRP

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
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8.11 Pod Regulator Functionality Test

(Note: Stack to be in drilling mode during regulator functionality test)

Before operating regulators, verify LMRP & STACK STINGERS are EXTENDED and LMRP & STACK
STINGER SEALS are ENERGIZED. Select Pod and SEM instructed by table. Complete table and
record readings from pilot and read-back gauges on Touch Panel and Event Logger. All readings will
be in PSI and should be set to +/- 200 PSI of set-point. Acceptance criteria is as follows: Error
between SEM pilot (P) and read-back (R) should be less than or equal 185 PSI.

The following regulator table is for an “automatic” regulation achieved by sending a set-point to the
SEM. The SEM will then “set” the desired pressure by monitoring the pilot pressure and energizing the
“increase” or “decrease” functions.

Blue Pod Select, SEM A

POD Set point SEM SEM EL EL Acceptable
Operation BA (P) BA (R) BA (P) BA (R) (Y/N)
Upper 0
Annular 1000
Regulator 2000
3000
Lower 0
Annular 1000
Regulator 2000
3000
Pod 0
Manifold 1000
Regulator 2000
3000
Wellhead 0
Connector 1000
Regulator 2000
3000
LMRP 0
Connector 1000
Regulator 2000
3000

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Yellow Pod Select, SEM B

POD Set-point SEM SEM EL EL Acceptable

Operation YB (P) YB (R) YB (P) YB (R) (Y/N)
Upper 0
Annular 1000
Regulator 2000
3000
Lower 0
Annular 1000
Regulator 2000
3000
Pod 0
Manifold 1000
Regulator 2000
3000
Wellhead 0
Connector 1000
Regulator 2000
3000
LMRP 0
Connector 1000
Regulator 2000
3000

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
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8.12 ROV Panel Function Test

A 5-7/8” Test Joint or other suitable device will be used to simulate the drill pipe in the BOP bore.
Prior to installation of the Test Joint, perform a Blind Shear Ram Close / Shear Ram ST Lock ROV
function (104 ROV) and after pressure testing, open the ram.

Attach Hydraulic Pressure Source to the ROV Hot Stab. For each ROV Panel Function, install Hot
Stab into the appropriate Panel Receptacle. Activate each function using the Hot Stab by bringing the
hot stab supply pressure to 3000 PSI. Hold pressure for 15 minutes and verify no leaks from tubing,
hoses shuttles, etc. Return each function to its previous position using the Control Pod.

Port Description Location Verify

98 LMRP Connector Gasket Release LMRP

57* LMRP Connectors Primary Unlatch LMRP
53* LMRP Connectors Secondary Unlatch LMRP
104** Upper Blind Shear Ram Close / Upper Blind Shear Ram Stack
ST Lock Lock
116** Lower Blind Shear Ram Close/ Lower Blind Shear Ram Stack
ST Lock Lock
108 Upper Pipe Ram Close Stack
Pipe Rams ST Locks Lock Stack
133 Wellhead Connector Primary Unlatch Stack
164 Wellhead Connector Secondary Unlatch Stack
Wellhead Connector Glycol Injection Stack
161 Wellhead Connector Gasket Release Stack
160 Stack Accumulator Dump Open Stack

* Fill in the table below for these functions

No. CHECK 57 53
1 Verify electrical mini pods retract
2 Verify acoustic mini pod stab retracts
3 Verify choke/ kill connectors unlatch
4 Verify LMRP connectors unlatch

** Do not have pipe in the stack bore during this test

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Acoustic/Autoshear Isolation ROV Panel

Verify Stack Mounted Accumulators are charged

Verify ________

Close ball valve to isolate Stack Mounted Accumulators (item 14.1) and dump Stack Mounted
Accumulators
Verify ________

Verify gauges on ROV panel read 0 psi

Verify ________

Close ROV ball valves then open 14.1 and verify gauges read 0 psi
Verify ________

Open ROV ball valves and verify gauges read 5000 psi
Verify ________

8.13 POD ROV Function Test

Attach Hydraulic Pressure Source to the ROV Hot Stab. For each ROV Panel Function, install Hot
Stab into the appropriate Panel Receptacle.

NOTE: All lower BOP functions to be vented prior to de-energizing Stack Stingers via ROV stab.

Verify “de-energize” before retracting & activate the function using the Hot Stab by bringing the hot
stab supply pressure to 3000 PSI (207 BAR). Return the function to its previous position using the
Control Pod.

Verify
Port Description Location
B Y
N/A Stack Stinger Retract Pod

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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8.14 Emergency Disconnect Sequences

This section will test the various Emergency Disconnect Sequences that have been set-up for the
BOP Control System. Verify that the correct functions occurred and that the statuses are updated at
each Control Panel and the Event Logger.

Within each sequence, verify that each function is executed at the correct time (in sec), and that the
overall execution time does not exceed the requirement.

Fill BOP borehole, and choke and kill lines with water (or mixed fluid) above the Upper Blind Shear
Ram.

Remove all Lockouts Verify _________

Provide print-out of the sequence from the Event Logger. To be included with the documentation.

Record starting pressure in the stack mounted accumulators.

Pressure: ____________

Each EDS (per document X-261720-65) will be tested in this section. The system to be set-up in the
Drilling mode.

Warning: Do Not Have Pipe in the Stack Bore During this Test.

Recorded time to complete EDS 1

Time: ____________secs

Record the pressure in the stack mounted bottles.

Pressure: ____________

Provide print out of sequence from the Event Logger to be included with test documentation.

Record the initial pressure in the stack mounted accumulators.

Pressure: ____________

Test EDS 2. The system to be set-up in the Drilling mode.

Warning: Do Not Have Pipe in the Stack Bore During this Test.

Recorded time to complete EDS 2

Time:____________secs

Record the pressure in the stack mounted bottles.

Pressure ___________
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Prior to the following pressure test, set-up the following: Latch the LMRP and Choke/Kill Connectors,
Open Fail Safe Valves, Close the Isolation Valves, and fill the Choke lines with water.

Perform following pressure test after sequence has been completed on closed and locked
Shear Ram (Note: ensure that BOP is filled with water above the Shear Ram).

Verify that the Pressure/Temperature Sensors are properly connected with the PBOF cable
attached to the Mini-Pod.

Verify ______________

Verify communication from the P/T Sensors to the Touchscreen panel.

Verify ______________

Record the pressure in the P/T sensors per the following table as the pressure is increased

APPLIED PRESSURE PSI (BAR) RECORDED

FUNCTION 300 2500 5000 10000 15000 TEMP.
(21) (172) (345) (689) (1034)
LMRP KILL
RECORDED PRESSURE

LMRP CHOKE

UPPER BLIND
SHEAR RAM
LOWER BLIND
SHEAR RAM
UPPER PIPE
RAM

Increase pressure to 15,000 PSI. Hold for 15 minutes after stabilization.

Bleed off pressure to 0 PSI.
Verify ______________

Pressure Wellbore below Shear Ram and C/K lines. Pressure to 300 PSI. Hold for 10 minutes.

Verify ______________

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Ensure that all the lock-outs are removed. Provide print-out of the sequence from the Event Logger
(To be included with the documentation)

Record the initial pressure in the stack mounted accumulators.

Pressure: ____________

Test EDS 3. Visual verification required in the wellbore that the Upper Blind Shear Rams do not over-
run and begin closing prior to the Casing Shear Rams being fully closed.

Warning: Do Not Have Pipe in the Stack Bore During this Test.

Recorded time to complete EDS 3

Time:____________secs

Record the pressure in the stack mounted bottles.

Pressure _____________

Prior to the following pressure test, set-up the following: Latch the LMRP and Choke/Kill Connectors,
Open Fail Safe Valves, Close the Isolation Valves, and fill the Choke lines with water.

Perform following pressure test after sequence has been completed on closed and locked Upper
Blind
Shear Ram (Note: ensure that BOP is filled with water above the Shear Ram).

Pressure Wellbore below Upper Shear Ram and C/K lines. Pressure to 300 PSI [21 Bar]. Hold for 10
minutes.
Verify ______________

Increase pressure to 15,000 PSI [1035 Bar]. Hold for 15 minutes after stabilization.
Bleed off pressure to 0 PSI.

Verify _____________

Test EDS 4. Visual verification required in the wellbore that the Lower Blind Shear Rams do not over-
run and begin closing prior to the Casing Shear Rams being fully closed.

Warning: Do Not Have Pipe in the Stack Bore During this Test.

Recorded time to complete EDS 4

Time:____________secs

Record the pressure in the stack mounted bottles.

Pressure _____________

Prior to the following pressure test, set-up the following: Latch the LMRP and Choke/Kill Connectors,
Open Fail Safe Valves, Close the Isolation Valves, and fill the Choke lines with water.
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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Perform following pressure test after sequence has been completed on closed and locked Lower
Blind
Shear Ram (Note: ensure that BOP is filled with water above the Shear Ram).

Pressure Wellbore below Lower Shear Ram and C/K lines. Pressure to 300 PSI [21 Bar]. Hold for 10
minutes.
Verify ______________

Increase pressure to 15,000 PSI [1035 Bar]. Hold for 15 minutes after stabilization.
Bleed off pressure to 0 PSI.

Verify _____________

8.15 Acoustic Control System

Extend the Stack transponder Arms. Place the Acoustic Transmitters on top of the Receivers
with a membrane full of water in-between (e.g. bag or rubber glove).

Activate the ‘Acoustic System Arm’ function using the Acoustic Control System Portable
Command Unit with a Dunking Transducer. This ‘arms’ the Acoustic System.
Verify _________

Activate the functions from the Acoustic Control System in accordance with the following function
table. Verify that the functions occurred by visually checking the status at the valve/connector
actuators/indicators.

Warning: Functions A1 and A2 must have a test pipe in the hole and for Function A3 no
pipe is permitted

VERIFY VERIFY
VERIFY
FUNCTION DESCRIPTION R/B WITH R/B WITH
FUNCTION
UNIT 1 UNIT 2
A1 Lower Pipe Ram (Close)
A2* LMRP Connectors (Unlatch)
Upper Blind Shear Ram (Close)
A3
ST Locks (Lock)
A4 Upper Pipe Ram (Close)
Lower Blind Shear Ram (Close)
A5
ST Locks (Lock)
A6 Pipe Rams ST Locks (Lock)

* Fill in the table below for these functions

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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No. CHECK A2 A2
UNIT 1 UNIT 2
1 Verify electrical mini-pods retract
2 Verify choke / kill connectors Unlatch
3 Verify LMRP Connectors Unlatch
4 Verify stack stingers retract

Using a Control Pod via a Control Panel, vent the functions which have been activated by the
Acoustic Control System.
Verify _________
8.16 ‘Riser Message String’ Interface
The Riser Message String signals originate from the Toolpusher’s Control Panel in the form of serial links
(RS-232) via fiber-optic cables –W48 and –W49. The signal is sent to the rig-supplied Converteam
system to provide the rig with inclination data and a pressure measurement from the upper wellbore
(below Shear Ram at Shear Ram cavity).

In each interface (-W48 and –W49) two alternating strings are output from the TCP: one for the Blue Pod,
and one for the Yellow Pod.
With the system powered-up, verify that the RMS interfaces have been established, i.e. that the data
from the BOP Control System is being received from the Converteam system in the previously agreed-
upon format.
Verify _________

8.17 Electrical Mini-Pod (Hydraulic/Electrical Stab) Power and Signal Test

The various (qty 4) Pressure/Temperature Sensor interfaces have been tested at previously-held
integration tests, and the associated PBOF cables have been connected and seal-tested.
Verify communication from the P/T Sensors to the DCP and TCP.
Verify _________
Record the pressure and temperature reading of each P/T Sensor.

No. FUNCTION PRESSURE TEMPERATURE

1. CHOKE line
2. KILL line
UPPER BLIND SHEAR
3.
RAM cavity
4. UPPER PIPE RAM cavity

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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8.18 BOP Test Box

Turn on the laptop computer associated with the BOP Test Box, and allow the program to start-up.
Verify: ________

At the BOP Test Box laptop PC, verify that the latest version (compare with that on file with Cameron
engineering dept) of the project-specific software been loaded prior to further testing.
Verify: ______
Software file name & rev level (HMI (wonderware)): _________________
Software file name & rev level (Top Server): _________________

At the Toolpusher’s Control Panel, open the cabinet and set the ‘BOP TEST BOX’ switch -3S1 to ‘1’
(On). This switch provides electrical power to the BOP Test Box Interface Panel and disables
functionality from the DCP and TCP.
Verify: ________

Verify that it is not possible to execute any functions from each of the three control panels.
Verify DCP: ________

Verify TCP: ________

Verify that wireless communication is established between the Laptop and Interface Panel, and
execute various subsea functions from the Laptop. Confirm that the functions are successfully
executed by observing the status at all control panels and Event Logger.
Verify: ________

After several function tests have been successfully carried out, set the ‘BOP TEST BOX’ switch -3S1
inside the TCP to the ‘0’ (Off) position.
Verify: ________

Verify that it is possible to execute functions from any of the three control panels.
Verify: ________
8.19 Surface Network Integrity

For each item in the table below:

1) Disconnect the corresponding fiber-optic interconnect cable, one at a time, between the
components listed, and verify that the status of this link is displayed as being unavailable on the
‘Network Status’ subscreen of the ‘Utilities’ screen at one of the Control Panels. Verify that
communication between all stations on the network remains healthy.

2) During each disconnection, at the control panels execute various Diverter and subsea functions and
verify that there is no execution delay due to the loss of a link in the network configuration.

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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3) Then, reinstate the cable connection between the components, and verify that the status of the
corresponding link is displayed as healthy on the ‘Network Status’ subscreen of the ‘Utilities’ screen at
one of the Control Panels. Turn off electrical power (both ‘A’ and ‘B’ power) at the Component ‘B’

4) Verify that communication is still established amongst all other stations on the surface network.

5) At an available Control Panel, execute various Diverter and Subsea functions, and verify that there
is no execution delay due to the loss of a Station in the network configuration. NOTE: If Diverter
Control Unit is powered down (No’s 4 and 5 below) it will not be possible to execute Diverter Unit
functions.

6) Reinstate electrical power (both ‘A’ and ‘B’ power) at the Component ‘B, and place a check in the
Verify column of the table below.

NO. COMPONENT ‘A’ COMPONENT ‘B’ VERIFY

1. (-W41) DCP TCP
2. (-W43) TCP Event Logger
3. (-W44) Event Logger Diverter Control Unit
4. (-W45) Diverter Control Unit Comm/Power Dist Panel B
5. (-W46) Comm/Power Dist Panel B Comm/Power Dist Panel A

8.20 UPS Capacity Test

This section will verify that each UPS provides at least 2 hours of battery backup time to power
the BOP Control System should the main rig power supplies (that feed the UPS’s) become
unavailable.

For these tests, the UPS’s (A and B) must each have their battery systems fully charged.
Verify: ________

A capacity test will first be conducted for UPS A, followed by the same type of test for UPS B.

The first test will be with UPS A. It will be carried out with ‘B’ power removed from the control
system. Therefore, complete the following steps to shut down ‘B’ power. As the breakers are
switched off, various alarms will enunciate indicating loss of the ‘B’ power supplies, as expected.

 In DCP, open (turn off) breaker -2Q5 (one PC and the bottom screen will shut off,
this is expected as those are supplied by UPS B).
Verify: ________
 In TCP, open (turn off) breaker -2Q5. (one PC and the bottom screen will shut off,
this is expected as those are supplied by UPS B).
Verify: ________
 In Event logger J-box, open (turn off) breaker -2Q5.
Verify: ________
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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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 In the Diverter Control Unit Main Control Box, open (turn off) breaker -4Q5.
Verify: ________
 In the HPU Main Control Box, open (turn off) breaker -3Q2.
Verify: ________
 In the Mixing Unit Main Control Box, open (turn off) breaker -3Q2.
Verify: ________
 In Communication/Power Distribution Panel B, turn off breakers -2Q3, -2Q4, -2Q5,
-3Q1, -3Q4.
Verify: ________

 Lastly, in Communication/Power Distribution Panel B, open (turn off) breaker -

2Q1.
Verify: ________

Blue SEM B and Yellow SEM B will not be available, however, confirm that Blue SEM A and
Yellow SEM A are available (as they are powered by UPS A).
Verify: ________

UPS A

Choose the Blue pod via activating ‘Pod Select’ for that pod, so that it has hydraulic power on its
MOD/lower section.
Verify: ________

For the LMRP and BOP Stack functions, from the DCP/TCP, configure the system to a drilling
mode set of functions.
Verify: ________

For the Diverter functions, position the functions in a typical operational configuration.
Verify: ________

Check the status of UPS A, at the LCD screen, and record the values:
Input voltage: ___________
Output voltage: __________
Capacity (kVA): __________
Battery charge status: __________

Now, the rig source 230VAC to the UPS A will be switched off so that the UPS A can run on
batteries: switch off the breakers for UPS A at the switchboard (cable –W1), doing this will switch
off power to the UPS A system.
Verify: ________

Record the time: _____________________

Note: This test will be completed 2 hours from this recorded time.

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Check that the system is running, i.e. that the DCP, TCP, Ev Logger, and DCU/HPU/Mix Unit are
operational, and that the Blue SEM A and Yellow SEM A are available and functions remaining
functioned as previously.
Verify: ________

Check that the UPS A has given the alarm status ‘Loss of Input power’ to the system (this is via
cable –W56 from UPS A to Comm/Power Dist Panel A).
Verify: ________

Within 2 hours, using the Blue Pod SEM (A), perform random functions and verify the effect/result
of the executed functions. Verify that the SEM’s are confirming execution of functions.

Function Function performed Verify SEM Verify function

x minutes on response execution
batteries
____min
____min
____min
____min
____min

Within 2 hours, using the Yellow Pod SEM (A), perform random functions and verify the
effect/result of the executed functions. Verify that the SEM’s are confirming execution of
functions.

Function Function performed Verify SEM Verify function

x minutes on response execution
batteries
____min
____min
____min
____min
____min

At the end of 2 hours, note the time: _________________

And, note the following information from UPS A.
Input voltage: ___________
Output voltage: __________
Capacity (kVA): __________
Battery charge status: ___________

Switch on power to UPS A from the rig source (via cable, -W1), and verify that the UPS A is
running OK and that the ‘Loss of Input Power’ alarm clears.
Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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The ‘B’ system components will be switched on at this time. In Comm/Power Distribution Panel
B, with the breakers -2Q3, -2Q4, -2Q5, -3Q1, and -3Q4 still in ‘off’ position, turn on breaker -2Q1.

Verify: ________

In the Comm/Power Distribution Panel B, turn on (one at a time), breakers: -2Q3 (DCU), -2Q4
(DCCP), -2Q5 (TCP), -3Q1 (Ev. Logger), and -3Q4 (DCP).
Verify: ________

In DCP, close (turn on) breaker -2Q5. Verify: ________

In TCP, close (turn on) breaker -2Q5. Verify: ________

In DCCP, close (turn on) breaker -2Q7. Verify: ________

In Event logger J-box, close (turn on) breaker -2Q5. Verify: ________

In the Diverter Control Unit Main Control Box, close (turn on) breaker -4Q5.
Verify: ________
In the HPU Main Control Box, close (turn on) breaker -3Q2.
Verify: ________
In the Mixing Unit Main Control Box, close (turn on) breaker -3Q2.
Verify: ________

Verify that system ‘B’ components are functioning correctly, that the ‘B’ power-supply related
alarms have cleared.
Verify: ________
UPS B

Now, UPS B will be tested. It will be carried out with ‘A’ power removed from the control system.
Therefore, complete the following steps to shut down ‘A’ power. As the breakers are switched off,
various alarms will enunciate indicating loss of the ‘A’ power supplies, as expected.
 In DCP, open (turn off) breaker -2Q1 (one PC and the upper screen will shut off,
this is expected as those are supplied by UPS A).
Verify: ________
 In TCP, open (turn off) breaker -2Q1. (one PC and the upper screen will shut off,
this is expected as those are supplied by UPS A).
Verify: ________
 In Event logger J-box, open (turn off) breaker -2Q1.
Verify: ________
 In the Diverter Control Unit Main Control Box, open (turn off) breaker -3Q5.
Verify: ________
 In the HPU Main Control Box, open (turn off) breaker -3Q1.
Verify: ________
 In the Mixing Unit Main Control Box, open (turn off) breaker -3Q1.
Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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
In Communication/Power Distribution Panel A, turn off breakers -2Q3, -2Q4, -2Q5,
-3Q1, -3Q4.
Verify: ________
 Lastly, in Communication/Power Distribution Panel A, open (turn off) breaker -
2Q1.
Verify: ________
Blue SEM A and Yellow SEM A will not be available, however, confirm that Blue SEM B and
Yellow SEM B are available (as they are powered by UPS B).
Verify: ________
Choose the Blue pod via activating ‘Pod Select’ for that pod, so that it has hydraulic power on its
MOD/lower section.
Verify: ________

For the LMRP and BOP Stack functions, from the DCP/TCP, configure the system to a drilling
mode set of functions.
Verify: ________

For the Diverter functions, position the functions in a typical operational configuration.
Verify: ________

Check the status of UPS B, at the LCD screen, and record the values:
Input voltage: ___________
Output voltage: __________
Capacity (kVA): __________
Battery charge status: __________

Now, the rig source 230VAC to the UPS B will be switched off so that the UPS B can run on
batteries: switch off the breakers for UPS B at the switchboard (associated with cable –W2),
doing this will switch off power to the UPS B system.
Verify: ________

Record the time: _____________________

Note: This test will be completed 2 hours from this recorded time.

Check that the system is running, i.e. that the DCP, TCP, Ev Logger, and DCU/HPU/Mix Unit are
operational, and that the Blue SEM B and Yellow SEM B are available and functions remaining
functioned as previously.
Verify: ________

Check that the UPS B has given the alarm status ‘Loss of Input power’ to the system (this is via
cable –W57 from UPS B to Comm/Power Dist Panel B).
Verify: ________

Within 2 hours, using the Blue Pod SEM (B), perform random functions and verify the effect/result
of the executed functions. Verify that the SEM’s are confirming execution of functions.

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
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Function Function performed Verify SEM Verify function

x minutes on response execution
batteries
____min
____min
____min
____min
____min

Within 2 hours, using the Yellow Pod SEM (B), perform random functions and verify the
effect/result of the executed functions. Verify that the SEM’s are confirming execution of
functions.

Function Function performed Verify SEM Verify function

x minutes on response execution
batteries
____min
____min
____min
____min
____min

At the end of 2 hours, note the time: _________________

And, note the following information from UPS B.
Input voltage: ___________
Output voltage: __________
Capacity (kVA): __________
Battery charge status: ___________

Switch on power to UPS B from the rig source (cable, -W2), and verify that the UPS B is running
OK and that the ‘Loss of Input Power’ alarm clears.
Verify: ________

The ‘A’ system components will be switched on at this time. In Comm/Power Distribution Panel
A, with the breakers -2Q3, -2Q4, -2Q5, -3Q1, and -3Q4 still in ‘off’ position, turn on breaker -2Q1.

Verify: ________

In the Comm/Power Distribution Panel A, turn on (one at a time), breakers: -2Q3 (DCU), -2Q4
(DCCP), -2Q5 (TCP), -3Q1 (Ev. Logger), and -3Q4 (DCP).
Verify: ________

In DCP, close (turn on) breaker -2Q1. Verify: ________

In DCCP, close (turn on) breaker -2Q1. Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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In TCP, close (turn on) breaker -2Q1. Verify: ________

In Event logger J-box, close (turn on) breaker -2Q1. Verify: ________

In the Diverter Control Unit Main Control Box, close (turn on) breaker -3Q5.
Verify: ________
In the HPU Main Control Box, close (turn on) breaker -3Q1.
Verify: ________
In the Mixing Unit Main Control Box, close (turn on) breaker -3Q1.
Verify: ________

Verify that system ‘A’ components are functioning correctly, that the ‘A’ power-supply related
alarms have cleared.
Verify: ________

8.21 PETU INTERFACE TEST

This section will test the PETU interface to each of the Pod SEM’s via the interfaces at the
Comm/Power Distribution Panels A & B. The 15-pin connectors located at the bottom left of each
Distribution Panel are the interfaces for the PETU to the SEM’s.

At the PETU laptop PC, verify that the latest version (compare with that on file with Cameron
engineering dept) of the ‘Mark III PETU Simulator “ini” file has been loaded prior to further testing.
Verify: ______
Software file name & rev level: _________________

Blue Pod, SEM A

At Communication/Power Distribution Panel A, open (turn off) circuit breakers -2Q3, -2Q4, -2Q5, -
3Q1, and -3Q4. Then, open (turn off) circuit breaker -2Q1 (this will turn off electrical power to the
Blue Pod SEM A and Yellow Pod SEM A.
Verify: ________

Remove the cap that covers connector –X25 in the bottom left side of Comm/Power Distribution
Panel A. Install the appropriate interconnect cable (supplied with the PETU) between the PETU and
Comm/Power Panel A at connector –X25.
Verify: ________

The PETU must be powered by a rig electrical source (230V 50/60Hz, 1ph). When the rig supply has
been connected to the PETU, set the voltage (via the multiple position selector switch) to 220V,
connect the PETU laptop to the PETU (allow the laptop to power up, and open application Win
Tsim/M3) and then switch on power at the PETU via the switch -1S2.
Verify: ________

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information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
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Using the Win Tsim / M3 application on the PETU, verify that Blue SEM A is available, and that the
‘analogs’ and DSDM’s are available.
Verify: ________

Activate various functions and confirm that the functions were successfully carried-out.
Verify: ________

Switch off power at the PETU, and remove the interconnect cable connection at Comm/Power
Distribution Panel A connector –X25, and replace the cap. Do not change the position of any circuit
breakers inside of Comm/Power Distribution Panel A.
Verify: ________

Yellow Pod, SEM A

Remove the cap that covers connector –X26 in the bottom left side of Comm/Power Distribution
Panel A. Install the appropriate interconnect cable (supplied with the PETU) between the PETU and
Comm/Power Panel A at connector –X26.
Verify: ________

Switch on power at the PETU via the switch -1S2.

Verify: ________

Using the Win Tsim / M3 application on the PETU, verify that Yellow SEM A is available, and that the
‘analogs’ and DSDM’s are available.
Verify: ________

Activate various functions and confirm that the functions were successfully carried-out.
Verify: ________

Switch off power at the PETU, and remove the interconnect cable connection at Comm/Power
Distribution Panel A connector –X26, and replace the cap.
Verify: ________

At Comm/Power Distribution Panel A, close (turn on) circuit breaker -2Q1.

Verify: ________

At Comm/Power Distribution Panel A, close (turn on) one at a time circuit breakers -2Q3, -2Q4, -2Q5,
-3Q1, and -3Q4.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 88 OF 92

Blue Pod, SEM B

At Communication/Power Distribution Panel B, open (turn off) circuit breakers -2Q3, -2Q4, -2Q5, -
3Q1, and -3Q4. Then, open (turn off) circuit breaker -2Q1 (this will turn off electrical power to the
Blue Pod SEM B and Yellow Pod SEM B.
Verify: ________

Remove the cap that covers connector –X25 in the bottom left side of Comm/Power Distribution
Panel B. Install the appropriate interconnect cable (supplied with the PETU) between the PETU and
Comm/Power Panel B at connector –X25.
Verify: ________

The PETU must be powered by a rig electrical source (230V 50/60Hz, 1ph). When the rig supply has
been connected to the PETU, set the voltage (via the multiple position selector switch) to 220V,
connect the PETU laptop to the PETU (allow the laptop to power up, and open application Win
Tsim/M3) and then switch on power at the PETU via the switch -1S2.
Verify: ________

Using the Win Tsim / M3 application on the PETU, verify that Blue SEM B is available, and that the
‘analogs’ and DSDM’s are available.
Verify: ________

Activate various functions and confirm that the functions were successfully carried-out.
Verify: ________

Switch off power at the PETU, and remove the interconnect cable connection at Comm/Power
Distribution Panel B connector –X25, and replace the cap. Do not change the position of any circuit
breakers inside of Comm/Power Distribution Panel B.
Verify: ________

Yellow Pod, SEM B

Remove the cap that covers connector –X26 in the bottom left side of Comm/Power Distribution
Panel B. Install the appropriate interconnect cable (supplied with the PETU) between the PETU and
Comm/Power Panel A at connector –X26.
Verify: ________

Switch on power at the PETU via the switch -1S2.

Verify: ________

Using the Win Tsim / M3 application on the PETU, verify that Yellow SEM B is available, and that the
‘analogs’ and DSDM’s are available.
Verify: ________

Activate various functions and confirm that the functions were successfully carried-out.
Verify: ________

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 89 OF 92

Switch off power at the PETU, and remove the interconnect cable connection at Comm/Power
Distribution Panel B connector –X26, and replace the cap.
Verify: ________

At Comm/Power Distribution Panel B, close (turn on) circuit breaker -2Q1.

Verify: ________

At Comm/Power Distribution Panel B, close (turn on) one at a time circuit breakers -2Q3, -2Q4, -2Q5,
-3Q1, and -3Q4.
Verify: ________
8.22 AutoShear Function Test
(Can be run concurrently with Riser Recoil Test)

Charge the stack mounted accumulators to a working pressure of 5000 PSI.

Verify ________

Fill the Wellbore with water above blind shear rams.

Verify ________

The Control system is to be aligned in the Drilling Mode, with the exception of the Choke and Kill
Valves on the Lower BOP Stack which are to be in the open position.

Verify ________

Set up the AutoShear System per the following table

No. VALVE/ LINES CONDITION

1. Stack Accumulators Charged
2. Accumulator Readback B Pilot Pressure
3. Accumulator Readback Y Pilot Pressure
4. Stack Acc. Dump (1/2” SPM) Closed
5. Autoshear Arm (3/4” Valve) Armed

Verify that the Auto-Shear regulator is set to 3,000 PSI. Adjust if necessary.
Verify _________
Warning: Do Not Have Pipe in the Stack Bore During this Test.

Activate the AutoShear system by lifting the LMRP from the lower BOP stack. Verify the activation of
this AutoShear function.
Verify _________

Record the pressure left in the accumulator bottles.

Pressure _________

Perform the following pressure test after the AutoShear sequence has been completed on closed
and locked Upper Blind Shear Ram (Note: ensure that BOP is filled with water above the Upper Blind
Shear Ram).
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
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09 July 2010 90 OF 92

Pressure Wellbore below Upper Blind Shear Ram and C/K lines.

Pressure to 300 PSI. Hold for 10 minutes.

Verify _________
Increase pressure to 15,000 PSI. Hold for 15 minutes after stabilization.
Bleed off pressure to 0 PSI

Verify _________

8.23 ‘Riser Recoil’ Test

In order to test the ‘Riser Recoil’ feature of the Control System, the LMRP must be lifted off of the BOP
Stack.

Do not have pipe in the Stack Bore during this test.

Prepare to verify Riser Recoil ‘Warning’ and ‘Disconnect’ volt-free contact closure signals from
Comm/Power Distribution Panels A & B via the corresponding interconnect cables.

On each Control Pod, activate the following function:

Riser Recoil ‘Arm’
and confirm function activation at the Control Panels (DCP, TCP) and Event Logger. The Pod Pressure
readback ‘Riser Recoil Pressure’ should indicate 0 psi (+65, -0) at each Pod.
Verify: ________

At one of the Control Panels, activate an EDS sequence. (Detailed test and verification of Emergency
Disconnect Sequences will be checked in a different section). At the initiation of the EDS sequence,
verify that the ‘Warning’ signal outputs (in the form of volt-free contact closures) from the BOP Control
System at the following locations:

Comm/Power Distribution Panel A (via cable –W77) Verify: ________

Comm/Power Distribution Panel B (via cable –W102) Verify: ________

When the sequence of functions within the EDS has been completed, lift the LMRP from the BOP
Stack. This will allow the Riser Recoil trigger valves (one valve associated with each Control Pod) to
stroke and activate the Riser Recoil response within the Control System.

Verify that as the LMRP is lifted from the BOP Stack, the ‘Confirmation’ signals (in the form of volt-free
contact closures) are then output from the BOP Control System at the following locations:

Comm/Power Distribution Panel A (via cable –W78) Verify: ________

Comm/Power Distribution Panel B (via cable –W103) Verify: ________

Verify that the value of pressure readback ‘Riser Recoil Pressure’ in each Pod is equal to the Pod
‘Regulated Supply Readback Pressure’ (+/- 65 psi).
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
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09 July 2010 91 OF 92

Verify ‘Riser Recoil Pressure’ readback at Blue Pod: ________

Verify ‘Riser Recoil Pressure’ readback at Yellow Pod: ________

Reinstall the LMRP onto the BOP Stack. The Control System can be configured so that the Stack is in
a ‘Drilling Mode’ of functions.

8.24 Inclination Test

Incline the LMRP or LMRP+Stack per the table below, and verify the inclination angles via the readings
on the Control Panels vs. a calibrated level.
Verify _________
Record the inclination readings of the inclinometers at each Panel and verify that the readings are
within ± 1 degree:

ZERO ANGLE TEST: USE DCP

YELLOW POD BLUE POD

INCLINOMETER
X Y X Y
ACTUAL
STACK
RISER

TRANSVERSE ANGLE TESTS (PORT OR STARBOARD +/- Y DIRECTION): USE TCP

YELLOW POD BLUE POD

INCLINOMETER
X Y X Y
ACTUAL
STACK
RISER

LONGITUDINAL ANGLE TEST (FWD OR AFT +/- X DIRECTION): USE TCP

YELLOW POD BLUE POD

INCLINOMETER
X Y X Y
ACTUAL
STACK
RISER

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION
A. Rose 04
Document No.
DATE: SHEET
X-200917-65
09 July 2010 92 OF 92

9 TEST CERTIFICATE

COMMISSIONING PROCEDURE

PROJECT (CIRCLE ONE): ODEBRECHT #1 ODEBRECHT #2

The BOP Control System has been successfully tested per this document X-200917-65 and has met the
requirements listed herein.

TEST WITNESSED AND RESULTS ACCEPTED BY:

Cameron Inspector/Witness SIGNATURE DATE

__________________________________________________________________________________
Other Inspector SIGNATURE DATE

Client Representative SIGNATURE DATE

Note: Upon completion of this procedure and signatures from all parties, return this original to Cameron
Q.A. department.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned
to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
Nancy Tran 04
DATE SHEET X-200934-01
May 28, 2009 1 of 6

PROCEDURE

FOR

NITROGEN PURGED

SUBSEA EQUIPMENT

CHECKED BY: Adam Rose DATE May 28, 2009

APPROVED BY: Nathan Cooper DATE May 28, 2009

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any
right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
Nancy Tran 04
DATE SHEET X-200934-01
May 28, 2009 2 of 6

TABLE OF CONTENTS

1.0 SCOPE .................................................................................................................................................................................... 3

2.0 EQUIPMENT REQUIRED .................................................................................................................................................... 3
3.0 REFERENCE DOCUMENTS ............................................................................................................................................... 3
4.0 TEST ........................................................................................................................................................................................ 4
5.0 SET-UP PROCEDURE ......................................................................................................................................................... 4
6.0 SHOP PROCEDURE ............................................................................................................................................................ 4
7.0 FIELD PROCEDURE: ........................................................................................................................................................... 5

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any
right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
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DATE SHEET X-200934-01
May 28, 2009 3 of 6

1.0 SCOPE

This document outlines the procedure for purging with dry Nitrogen concerning of sub sea
equipment as follow:

- SUBSEA ELECTRONIC MODULE (SEM), Mark I, II and III

- SUBSEA TRANSMITTER MODULE (STM)
- RISER CONTROL BOX (RCB)
- RISER MONTED JUNCTION BOX (RMJB)
- RISER INCLINOMETER MODULE (RIM)

A complete test procedure and all necessary test equipment will be specified in this
procedure.
NOTE: “Shop” or “Field” procedure can be used in a “Shop” or “Field” environment.

2.0 EQUIPMENT REQUIRED

During the procedure, Shop or Field Kit and possibly Tool Set will be required:

1. Shop Purge Kit: (Cameron PN: 2021964-01)

2. Field Purge Kit: (Cameron PN: 2021964-02)

3. Tool Set for installation and extraction of (Cameron PN: 2711651-01)

check valves (for SEM only)

Also required are:

• Miscellaneous hoses w/fittings
• Nitrogen supply

3.0 REFERENCE DOCUMENTS

During the procedure, the following documents will be required:

1. Appropriate subsea equipment assembly drawing described in item 2

2. Connection Drawing SK-122460-01 for:

• SUBSEA ELECTRONIC MODULE

• SUBSEA TRANSMITTER MODULE
• RISER CONTROL BOX
• RISER MONTED JUNCTION BOX
• RISER INCLINOMETER MODULE

3. Details, Purge Fittings (SK-122080-01)

This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any
right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
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DATE SHEET X-200934-01
May 28, 2009 4 of 6

4.0 TEST

The following test is prepared for:

___________________________________________/ PN:_______________________
(fill in the appropriate equipment as listed above)

5.0 SET-UP PROCEDURE

5.1. The cracking pressure of the “IN” and “OUT” check valves can possibly prevent
purging if the cracking pressure is on the high tolerance side. If this is the case, no
nitrogen flow can be established, and the check valves have to be removed. Check
the valves. The “IN” and “OUT” purge ports shall be removed using Item 2 above, if
crack open pressure impedes proper purge operation per Step 6.4 of Shop Procedure.

5.2 Connect the Nitrogen Supply, Needle Valve, Gauges, Regulator Kit and Vacuum
Pump per Drawing SK-122460-01.

5.3 Close Needle Valve (1).

NOTE: The regulator (downstream from Nitrogen supply) should NEVER be set to exceed 10
PSI (0.69 bar) output.

NOTE: Desiccant bags (Mark I and II, Qty. 6-8, Mark III, Qty 4) must be installed inside the
Module prior to purging. Prior to installation in the Module, the desiccant bags must be dried
in an oven, set to a minimum temperature of 194 – 203oF (90 – 95oC), for a period of 2 hours.
Bags can be temporarily stored (less than 1 hour) in airtight bag(s) or container(s)
manufactured by Ziploc or Rubbermaid.
Purging should begin within 45 minutes after the desiccant bags have been installed.

6.0 SHOP PROCEDURE

6.1 Set the regulated gauge pressure to 10/8 Max /Min psi (0.69/0.55 bar)
with needle valve (1) closed. Verify________

6.2 Prepare the unit for purging by removing “IN” and “OUT” caps, connecting
hoses and fittings, and opening needle valves. Verify________

CAUTION: Ensure electrical power to the Module is OFF during vacuum.

6.3 Operate vacuum pump, bringing up suction slowly. Hold vacuum reading
for approximately 5 minutes or until vacuum gauge indicates about –25”
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any
right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
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DATE SHEET X-200934-01
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Hg or –12 psig. Verify________

6.4 Purge the unit by supplying Nitrogen and circulating through at 10/9 psi
(0.69/0.62 bar) for approximately 60 minutes. Monitor gauge – the pressure must never
exceed 10 psig or 25 psia. Assure flow from the “OUT” port. Keep vacuum pump running.

Verify________

6.5 Turn off vacuum pump and close needle valve (2). Verify_______

6.6 Allow nitrogen pressure to build up to regulated pressure, close needle

valve (1) and disconnect nitrogen supply. Verify_______

6.7 Allow at least one minute before turning on electrical power to the Module. Then turn on
power to the module. Monitor humidity level inside unit. Humidity should be less than
40%
(SEM only). Verify_______

6.8 Disconnect “OUT” and install purge port cover & O-rings per
SK-122080-01. Pressure test to 5000 psi through this ¼” SAE port (7/16-20UNF) and hold
for 5 minutes.
Immediately install plug (Item 4). Verify________

6.9 Disconnect “IN” and test this port per Step 6.8. Verify________

7.0 FIELD PROCEDURE

NOTE: This Section to be used if Vacuum Pump is not available.

7.1 Disregard this step for Mark III SEM

Turn on the unit for 1 hour to warm and suspend moisture. Verify________

7.2 Set the regulated gauge pressure to 10/8 Max /Min psi (0.69/0.55 bar)
with needle valve (1) closed. Verify________

7.3 Prepare the unit for purging by removing “IN” and “OUT” caps, connecting
hoses and fittings, and opening needle valves. Verify________

7.4 Purge the unit by supplying Nitrogen and circulating through at 10/9 psi
(0.69/0.62 bar) for approximately 120 minutes. Monitor gauge ; the pressure must never
exceed 10 psig or 25 psia. Assure flow from the “OUT” port. Verify________

7.5 Allow nitrogen pressure to build up to regulated pressure, close needle

valve (1) and disconnect nitrogen supply. Verify_______
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any
right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 PROPERTY OF DRAWN BY REVISION
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DATE SHEET X-200934-01
May 28, 2009 6 of 6

7.6 Disregard this step for Mark III SEM

Re-warm for an additional 1 hour. Verify________

7.7 Disregard this step for Mark III SEM

Repeat steps 7.2 through 7.5. Verify________

7.8 Monitor humidity level inside unit. Humidity should be less than 40%
(SEM only). Repeat purge as necessary if humidity is too high. Verify_______

7.9 Disconnect “OUT” and install purge port cover & O-rings per
SK-122080-01. Pressure test to 5000 psi through this ¼” SAE port
(7/16-20UNF) and hold for 15 minutes. Record the pressure for 15 minutes.
Total pressure drop should not exceed 50 psi (3.5 bar). Immediately install
plug (Item 4). Verify________

7.10 Disconnect “IN” and test this port per Step 7.9. Verify________

CERTIFICATE
SINGLE UNIT PURGE CERTIFICATE

For

__________________________________________________________________________

PROJECT : ______________________

CAMERON PART NUMBER : ______________________

TEST WITNESSED AND RESULTS ACCEPTED BY:

Test performed by: ______________________ Date: ________________

(Cameron Technician)

Test witnessed by: ______________________ Date: ________________

(Cameron QA/QC)

Test witnessed by: ______________________ Date: ________________

(Other Inspector)
This document contains confidential and trade secret information which is the sole property of CAMERON, a division of COOPER CAMERON CORPORATION. Receipt or possession does not convey any
right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
 DRAWN BY: REVISION
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Document No.
07
DATE: SHEET
X-200934-02
11/13/2009 1 OF 8

SEAL TEST PROCEDURE

FOR
SUBSEA EQUIPMENT

CHECKED BY: A. Rose 05/28/2009

Date

APPROVED BY: N. Cooper 05/28/2009

Date

1
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DATE: SHEET
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TABLE OF CONTENTS

1.0 INTRODUCTION 3
1.1 Scope 3
1.2 Safety Warning 3
1.3 Test Equipment Required 4
1.4 Visual Inspection 4

2.0 HYDROSTATIC TEST 5

2.1 Seal Test of Main Seal 5
2.2 Seal Test of Individual Connector Seal 6
2.3 Seal Test of Purge Port/Overpressure Relief Valve 7

3.0 SINGLE UNIT CERTIFICATE 8

2
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1.0 Introduction

1.1 Scope

This document outlines the procedure for testing of the seals for a one-atmosphere subsea
housing. The purpose of the test is to verify the main housing seal integrity, individual
connector seal integrity, and the purge port/overpressure relief valve seal integrity.

1.2 Safety Warning

PERSONNEL AND PRODUCT SAFETY ARE PRIMARY OBJECTIVES AND

THEREFORE THE FOLLOWING PRECAUTIONS MUST BE TAKEN PRIOR TO
CARRYING OUT THIS TEST PROCEDURE:

1. All test personnel must acquaint themselves fully and strictly adhere to all company sites’
HEALTH AND SAFETY AT WORK REGULATIONS together with other specific
requirements detailed in this procedure.

2. All tests are to be carried out within either a dedicated test bay area with authorized
personnel entry points, or an area adequately protected from unauthorized access in a general
workshop with a visible cordoned zone and adequately displayed warning signs detailing the
test type and associated hazards.

3. The lifting and handling of all items must be carried out with extreme caution and due regard
to the safety regulations, due to the inherent high unit weights, which can easily cause
permanent injury to personnel not exercising extreme care and due diligence.

4. All test personnel in contact with the hydraulic fluid must take all the necessary precautions
detailed on the fluid data sheets, which may include wearing suitable protective clothing and
gloves.

5. Tests which involve the use of pressure fluid, compressed inert gas and electrical supplies
necessitate suitable and adequate precautions are to be taken prior to commencement of tests
and due diligence is to be maintained during the tests.

3
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1.3 Test Equipment Required

Hydraulic Pump capable of 7500 psi

Hoses and fittings to interconnect test equipment
Gauges
Chart recorder, with current calibration records

Chart Recorders Calibration Information (only one is required)

S/N____________ Calibration Date____________ Accuracy____________

S/N____________ Calibration Date____________ Accuracy____________

1.4 Visual Inspection

Visually verify that the housing is completely assembled and ready for testing. All connectors
should be properly fitted. Any disconnected fittings, loose fasteners, or other potential
problems must be corrected before proceeding with the test.

1.5 Nitrogen Purge

Along with this Seal Test, following the completion of the unit’s Factory Acceptance Test the
unit housing must also be purged per X-200934-01, unless otherwise stated on the Factory
Acceptance Test. The housing may be purged during or after the Main Seal Test.

4
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2.0 HYDROSTATIC PRESSURE TEST

2.1 Connector Seal Test

This is a hydrostatic pressure test of the o-ring seals for the connector(s).

Connect an appropriate pressure source to the connector port(s).

Start the Chart Recorder.

Increase test pressure to 362 psi (25 bar) maximum and stabilize between 290 psi (20 bar) and
362 psi (25 bar).

Record the pressure for 15 minutes. Total pressure drop should not exceed 30 psi (2.1 bar).

Increase test pressure to 3335 psi (230 bar) maximum and stabilize between 3045 psi (210 bar)
and 3335 psi (230 bar).

Record the pressure for 15 minutes. Total pressure drop should not exceed 50 psi (3.5 bar).

Bleed test pressure to 0 psi (0 bar). Verify:______________________

Stop the Chart Recorder.

5
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2.2 Main Seal Test

This is a hydrostatic pressure test of the o-ring seal between the protective housing and base
plate. This test may be performed simultaneously with the Connector Seal Test.

Connect an appropriate pressure source to the flange seal test port.

Remove plug from the other seal test port. Operate the pressure source to get enough pressure
and bleed the air out between the o-ring grooves. Do this enough times to bleed the air
completely out. Verify constant stream of hydraulic fluid from the bleed port.

Verify:_________________________

While maintaining pressure, close the bleed port.

Start the Chart Recorder.

Increase test pressure to 362 psi (25 bar) maximum and stabilize between 290 psi (20 bar) and
362 psi (25 bar).

Record the pressure for 15 minutes. Total pressure drop should not exceed 30 psi (2.1 bar).

Increase test pressure to 5300 psi (365 bar) maximum and stabilize between 5000 psi (345 bar)
and 5300 psi (365 bar).

Record the pressure for 15 minutes. Total pressure drop should not exceed 50 psi (3.5 bar).

Bleed test pressure to 0 psi (0 bar). Verify:_________________________

Stop the Chart Recorder.

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2.3 Purge Port / Overpressure Relief Valve Seal Test

This is hydrostatic pressure test of the o-ring seal for the purge ports and overpressure relief
valve. This test may be performed simultaneously with the Main Seal Test.

Connect an appropriate pressure source to the purge and overpressure relief seal test ports.

Start the Chart Recorder.

Increase test pressure to 5300 psi (365 bar) maximum and stabilize between 5000 psi (345 bar)
and 5300 psi (365 bar).

Record the pressure for 15 minutes. Total pressure drop should not exceed 50 psi (3.5 bar).

Bleed test pressure to 0 psi (0 bar). Verify:_________________________

Stop the Chart Recorder.

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3.0 SINGLE UNIT CERTIFICATE

CAMERON PART NUMBER OF ASSEMBLY ____________________________________

SERIAL NUMBER OF ASSEMBLY ____________________________________

The above listed unit has been successfully tested and has met all requirements listed therein.

TEST WITNESSED AND RESULTS ACCEPTED FOR CUSTOMER BY:

TEST CONDUCTOR

_____________________________________________________ _________________
NAME SIGNATURE DATE

CAMERON CONTROLS QUALITY INSPECTOR:

_____________________________________________________ _________________
NAME SIGNATURE DATE

8
PROPERTY OF: CREATED BY: SHEET:
N. TRAN 01 OF 02 CAMERON DOC. NO.:
DATE: CAMERON REVISION: X-260421-65
02/02/2010 01

LUBRICATION POINT LIST

for
BOP CONTROL SYSTEM

PROJECT: ODEBRECHT #1 & #2

INITIATED BY: N. TRAN Date: 02/02/2010

CHECKED BY: I. TODD Date: 02/02/2010

APPROVED BY: A. ROSE Date: 02/02/2010

 CREATED BY: CHECKED BY: APPROVED BY:
PROPERTY OF

N. TRAN I. TODD A. ROSE REVISION: DOCUMENT NO.

DATE: DATE: DATE: LUBRICATION POINT LIST
01 X-260421-65
02/02/2010 02/02/2010 02/02/2010

Recommended Recommended Initial Oil Normal Normal Oil

Seq # Lubrication Point P&ID Item # Remarks Suppl. Oil Type First Quantity
Lubricant Manufacturer Change Quantity Change Freq.

HYDRAULIC POWER UNIT

Ecosyn HTX 100 or 1000 hours or 6 4000 Hours or
1 Triplex Pumps 3.1, 3.2 Oil Changes BP BM100 As Required 1.13 gal
equivalent months Yearly
2 Triplex Pump Motor 3.1, 3.2 Grease for bearings Esso Unirex N3 Esso Grease As Required None 1.41 oz 8000 Hours
3 Charge Pump 1 Motor 3.1, 3.2 Grease for bearings Esso Unirex N3 Esso Grease As Required None 0.3 oz 20000 Hours
4 Pump Motor 5 Grease for bearings Esso Unirex N3 Esso Grease As Required None 0.3 oz 20000 Hours
DIVERTER CONTROL UNIT

Air Lubricator Unit (FRL), Mobil DTE Lite 10Weight

5 71 Air Oiler Mobil Non Detergent As Required - As required As required
Diverter Control Unit - Non detergent
BOP TEST PUMP UNIT
Ecosyn HTX 150 or 1000 hours or 6 4000 Hours or
6 Main Pump N/A Oil Changes BP PE150 As Required 4.3 liter
equivalent months Yearly
7 Main Pump Motor N/A Grease for bearings Esso Unirex N3 Esso Grease As Required None 0.3 oz 20000 Hours
8 Lube Pump Motor N/A Grease for bearings Esso Unirex N3 Esso Grease As Required None 0.3 oz 20000 Hours
HOTLINE HOSE REEL

Air Conditioner/ Filter Mobile Almo 525 Air

9 N/A Lubricator Any Misting As Required As Required 0.25 Gal. Daily
Regulator Tool Oil or Equivalent

Engine Lube Oil, API

Service Classified "SC"
Motor Above 32F use SAE Shell N/A As Required 25 Hours 0.375 Gal. 200 Hours
10 Air Motor N/A 30W, Below 32F use
SAE 10W

2500 Hours/
Planetary Reducer Mobilube HD LS Mobil SAE 80W/90 As Required 50 Hours As required
12 months
MUX CABLE REEL
Mobile Almo 525 Air
11 Air Lubricator Unit (FRL) N/A Lubricator Any Misting As Required As Required 0.25 Gal. Daily
Tool Oil or Equivalent
Engine Lube Oil, API
Service Classified "SC"
Motor Above 32F use SAE Shell N/A As Required 25 Hours 0.375 Gal. 200 Hours
12 Air Motor Assembly N/A 30W, Below 32F use
SAE 10W
2500 Hours/
Planetary Reducer Mobilube HD LS Mobil SAE 80W/90 As Required 50 Hours As required
12 months
RISER FILL VALVE HOSE REEL
Engine Lube Oil, API
Service Classified "SC"
Motor Above 32F use SAE Shell N/A As Required 25 Hours 0.375 Gal. 200 Hours
13 Air Motor Assembly N/A 30W, Below 32F use
SAE 10W
2500 Hours/
Planetary Reducer Mobilube HD LS Mobil SAE 80W/90 As Required 50 Hours As required
12 months
Note: The recommended lubricants can be replaced by their equivalents unless otherwise specified.
This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction or use of said information for any purpose other than that for which it is
intended may not be made without written permission from CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 1 of 22

SOFTWARE LOGIC

(INTERLOCKS, SEQUENCES)

ODEBRECHT #1 (H3603) AND ODEBRECHT #2 (H3604)

Originated by: Nancy Tran 24 August 2009

Checked by: Ian Todd 24 August 2009

Approved by: Nathan Cooper 25 August 2009

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 2 of 22

Table of Contents

1 Diverter Close Auto Sequence 3

2 Drilling Mode 3
3 System Software Interlocks 5

4 Emergency Disconnect Sequences (EDS) 7

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 3 of 22

1 Diverter Close Auto Sequence

When the ‘Overboard Preselect’ is set to ‘Overboard Vent Valve’, the
following sequence of functions will occur when the Diverter Packer is
commanded to ‘Close’ (from DCP/TCP or by using ‘DIVERTER CLOSE
AUTO SEQUENCE’ pushbutton at Diverter Control Unit panel):

 Diverter Lockdown Dogs EXTEND

 Diverter Flowline Valve CLOSE
 Trip Tank Return Valve CLOSE
 Overboard Vent Valve OPEN
 Mud/Gas Separator Valve CLOSE
 Diverter Packer CLOSE
 Telescoping Joint Lower Packer ENERGIZE
 Diverter Flowline Seals Energize

Note that ‘Diverter Packer CLOSE’ will only occur after feedback is received
for the ‘Overboard Vent Valve Open’ position, and, ‘T-Joint Lower Packer
ENERGIZE’ will occur simultaneously with the ‘Diverter Packer CLOSE’
function.

When the ‘Overboard Preselect’ is set to ‘Mud/Gas Separator Valve’, the

following sequence of functions will occur when the Diverter Packer is
commanded to ‘Close’ (from DCP/TCP or by using ‘DIVERTER CLOSE
AUTO SEQUENCE’ pushbutton at Diverter Control Unit panel):

 Diverter Lockdown Dogs EXTEND

 Diverter Flowline Valve CLOSE
 Trip Tank Return Valve CLOSE
 Mud/Gas Separator Valve OPEN
 Overboard Vent Valve CLOSE
 Diverter Packer CLOSE
 Telescoping Joint Lower Packer ENERGIZE
 Diverter Flowline Seals ENERGIZE

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 4 of 22

Note that ‘Diverter Packer CLOSE’ will only occur after feedback is received
for the ‘Mud/Gas Separator Valve Open’ position, and, ‘T-Joint Lower Packer
ENERGIZE’ will occur simultaneously with the ‘Diverter Packer CLOSE’
function.

2 Drilling Mode
At “Drilling Mode”, the following functions cannot be activated (they are
grayed out):
Diverter functions
 Diverter Lockdown Dogs
 Telescoping Joint Collet Connector
 Tension Ring Lock/Unlock

LMRP/Stack functions
 Wellhead Connector Primary
 Wellhead Connector Secondary
 Wellhead Connector Gasket
 LMRP Connector Gasket

3 System Software Interlocks

Diverter function interlocks

1. “Mud/Gas Separator Valve” shall be opened before “Overboard Vent Valve”

closes.

2. “Overboard Vent Valve” shall be opened before “Mud/Gas Separator Valve”

closes.
3. “Diverter Packer ‘Close’” shall not be possible if the “Diverter Lockdown Dogs”
are ‘Retracted’.

4. Before “Diverter Lockdown Dogs” can be ‘Retracted’, the “Diverter Packer” must
be ‘Open’.

5. When the ‘Diverter Packer’ is Closed, hydraulic pressure to be sent to the T-Joint
Lower Packer at preset pressure (T-Joint Lower Packer – Energize).

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 5 of 22

6. “Diverter Flowline Seals” shall be energized before “Diverter Packer” closes.

7. “Diverter Packer” shall be opened before “Diverter Flowline Seals” vent.

8. “Tension Ring To T-Joint Lock Dogs” shall be extended before “Tension Ring
Storage Lock Dogs” retracts.

9. “Tension Ring Storage Lock Dogs” shall be retracted before “Tension Ring To T-
Joint Lock Dogs” extends.

10. If air pressure for Upper TJ Packer falls below the entered set-point, the lower
packer will be energized with hydraulic supply and the pressure setting will be at
the last setting it was set to. An alarm will also alert the operator that the air
pressure dropped below the set point.

LMRP/BOP Stack function interlocks

1. Blue Stack Stinger Seals must be De-energized before Blue Stack Stinger
can be Extended.
2. Blue Stack Stinger Seals must be De-energized before Blue Stack Stinger
can be Retracted.
3. Blue LMRP Stinger Seals must be De-energized before Blue LMRP Stinger
can be Extended.
4. Blue LMRP Stinger Seals must be De-energized before Blue LMRP Stinger
can be Retracted.
5. Yellow Stack Stinger Seals must be De-energized before Yellow Stack
Stinger can be Extended.
6. Yellow Stack Stinger Seals must be De-energized before Yellow Stack
Stinger can be Retracted.
7. Yellow LMRP Stinger Seals must be De-energized before Yellow LMRP
Stinger can be Extended.
8. Yellow LMRP Stinger Seals must be De-energized before Yellow LMRP
Stinger can be Retracted.
9. De-energizing the Blue Stack Stinger Seals will “Vent” all functions on that
stinger.
10. De-energizing the Blue LMRP Stinger Seals will “Vent” all functions on that
stinger.
11. De-energizing the Yellow Stack Stinger Seals will “Vent” all functions on that
stinger.
This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 6 of 22

12. De-energizing the Yellow LMRP Stinger Seals will “Vent” all functions on that
stinger.
13. Blue Pod can only be selected (Open) if Blue A or Blue B SEMs are available.
Active SEM is changed from Yellow to Blue.
14. Yellow Pod can only be selected (Open) if Yellow A or Yellow B SEMs are
available. Active SEM is changed from Blue to Yellow.
15. Close HP Upper Blind Shear Ram but for proper indication Upper Blind Shear
Ram must be “Closed” and “Vented”.
16. Wellhead Connector “Latch”. “Vent” Wellhead Connector Secondary, then
“Latch” Wellhead Connector Primary.
17. Wellhead Connector “Unlatch”. “Vent” Wellhead Connector if in “LATCH”
position, then “Unlatch” Wellhead Connector
18. LMRP Connector “Latch”. “Vent” LMRP Connector Secondary if in ‘Unlatch’
position, then “Latch” LMRP Connector Primary.
19. LMRP Connector “Unlatch”. “Vent” LMRP Connector if in “LATCH” position,
then “Unlatch” LMRP Connector
20. Blind Shear Ram “Open”. “Vent” Blind Shear ST Locks and HP Blind Shear
Ram.
21. Casing Shear Ram “Open”. “Vent” HP Casing Shear Ram.
22. Close HP Casing Shear Ram but for proper indication Casing Shear Ram
must be “Closed” and “Vented”.
23. Choke/Kill Connector “Latch”. “Vent” Choke/Kill Connector Secondary if in
‘Unlatch’ position, then “Latch” C/K Connector Primary.
24. Upper Pipe Ram “Open”. “Vent” ST Lock.
25. Middle Pipe Ram “Open”. “Vent” ST Lock.
26. Lower Pipe Ram “Open”. “Vent” ST Lock.
27. N/A
28. N/A
29. N/A
30. Choke/Kill Connector Secondary Unlatch. “Vent” C/K Connector Primary if in
“Latch” position, then “Secondary Unlatches” C/K Connector.
31. Stack Accumulator “Charge” command will go to ‘Charge’ if the Stack
Accumulator Dump function is ‘isolated’.
32. Stack Accumulator “Dump” command will go to ‘Dump’ if the Stack
Accumulator Charge command is ‘isolated’.
33. Close HP Lower Blind Shear Ram but for proper indication Lower Blind Shear
Ram must be “Closed” and “Vented”.

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 7 of 22

4 Emergency Disconnect Sequences (EDS)

EDS 1: NO RAMS CLOSE EDS

NO RAMS CLOSE EDS
Time
Function Position
(sec)
0 Stack Accumulators Dump Isolate
Wellbore P/T Connector Retract
Stack Accumulator Charge Charge
Autoshear Disarm
Riser Recoil Arm
LMRP Connector Primary Vent
Lower Outer Bleed Valve Close
Lower Outer Choke Valve Close
Middle Outer Choke Valve Close
Upper Outer Choke Valve Close
Lower Outer Kill Valve Close
Upper Outer Kill Valve Close
LMRP Connector Regulator Increase
3 Choke/Kill Connector Primary Unlatch
Choke/Kill Connector Secondary Unlatch
Stack Transponder Arms Extend
Lower Inner Bleed Valve Close

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 8 of 22

NO RAMS CLOSE EDS

Time
Function Position
(sec)
Lower Inner Choke Valve Close
Middle Inner Choke Valve Close
Upper Inner Choke Valve Close
Lower Inner Kill Valve Close
Upper Inner Kill Valve Close
15 Upper Blind Shear Ram Vent
Upper HP Blind Shear Ram Vent
Upper Blind Shear Ram St Locks Vent
Lower Blind Shear Ram Vent
Lower HP Blind Shear Ram Vent
Lower Blind Shear Ram St Locks Vent
Upper Annular Vent
Lower Annular Vent
HP Casing Shear Ram Vent
Casing Shear Ram Vent
Lower Inner Bleed Valve Vent
Lower Outer Bleed Valve Vent
Upper Inner Kill Valve Vent
Upper Outer Kill Valve Vent
Upper Inner Choke Valve Vent
Upper Outer Choke Valve Vent

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 9 of 22

NO RAMS CLOSE EDS

Time
Function Position
(sec)
Upper Pipe Ram Vent
Middle Inner Choke Valve Vent
Middle Outer Choke Valve Vent
Lower Inner Choke Valve Vent
Lower Outer Choke Valve Vent
Middle Pipe Ram Vent
Lower Pipe Ram Vent
Lower Inner Kill Valve Vent
Lower Outer Kill Valve Vent
Upper Pipe Rams St Lock Vent
Middle Pipe Rams St Lock Vent
Lower Rams St Lock Vent
Acoustic System Isolate Vent
Acoustic System Reset Vent
Wellhead Connector Gasket Vent
Wellhead Connector Secondary Vent
Wellhead Connector Primary Vent
Stack Accumulator Charge Isolate
Autoshear Vent
Stack Transponder Arm Vent
18 Stack Stinger Seals Deenergize

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 10 of 22

NO RAMS CLOSE EDS

Time
Function Position
(sec)
21 Stack Stinger Retract
LMRP Connector Primary Unlatch
LMRP Connector Secondary Unlatch

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 11 of 22

EDS 2: UPPER AND LOWER BLIND SHEAR RAMS EDS

UPPER AND LOWER BLIND SHEAR RAMS EDS
Time
Function Position
(sec)
0 Lower Blind Shear Ram Vent
Stack Accumulators Dump Isolate
Lower HP Blind Shear Ram Close
Wellbore P/T Connector Retract
Stack Accumulator Charge Charge
Autoshear Arm
Riser Recoil Arm
LMRP Connector Primary Vent
Lower Blind Shear Ram St Lock Lock
2 Lower Outer Bleed Valve Close
Lower Outer Choke Valve Close
Middle Outer Choke Valve Close
Upper Outer Choke Valve Close
Lower Outer Kill Valve Close
Upper Outer Kill Valve Close
LMRP Connector Regulator Increase
5 Choke/Kill Connector Primary Unlatch
Choke/Kill Connector Secondary Unlatch
Stack Transponder Arms Extend
Lower Inner Bleed Valve Close

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 12 of 22

UPPER AND LOWER BLIND SHEAR RAMS EDS

Time
Function Position
(sec)
Lower Inner Choke Valve Close
Middle Inner Choke Valve Close
Upper Inner Choke Valve Close
Lower Inner Kill Valve Close
Upper Inner Kill Valve Close
18 Upper Annular Vent
Lower Annular Vent
Upper Blind Shear Ram Vent
HP Casing Shear Ram Vent
Casing Shear Ram Vent
Lower Bleed Inner Bleed Valve Vent
Lower Bleed Outer Bleed Valve Vent
Upper Inner Kill Valve Vent
Upper Outer Kill Valve Vent
Upper Inner Choke Valve Vent
Upper Outer Choke Valve Vent
Upper Pipe Ram Vent
Middle Inner Choke Valve Vent
Middle Outer Choke Valve Vent
Lower Inner Choke Valve Vent
Lower Outer Choke Valve Vent

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 13 of 22

UPPER AND LOWER BLIND SHEAR RAMS EDS

Time
Function Position
(sec)
Middle Pipe Ram Vent
Lower Pipe Ram Vent
Lower Inner Kill Valve Vent
Lower Outer Kill Valve Vent
Upper Pipe Rams St Lock Vent
Middle Pipe Rams St Lock Vent
Lower Pipe Rams St Lock Vent
Acoustic System Isolate Vent
Acoustic System Reset Vent
Stack Transponder Arms Vent
Autoshear Vent
Wellhead Connector Gasket Vent
Wellhead Connector Secondary Vent
Wellhead Connector Primary Vent
25 Lower HP Blind Shear Ram Vent
Lower Blind Shear Ram St Lock Vent
Upper HP Blind Shear Ram Close
Upper Blind Shear Ram St Lock Lock
50 Upper HP Blind Shear Ram Vent
Upper Blind Shear Ram St Lock Vent
Stack Accumulator Charge Isolate

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 14 of 22

UPPER AND LOWER BLIND SHEAR RAMS EDS

Time
Function Position
(sec)
53 Stack Stinger Seals Deenergize
56 Stack Stinger Retract
LMRP Connector Primary Unlatch
LMRP Connector Secondary Unlatch

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 15 of 22

EDS 3: CASING SHEAR RAM AND UPPER SHEAR RAM EDS

CASING SHEAR RAM AND UPPER SHEAR RAM EDS

Time
Function Position
(sec)
0 Casing Shear Ram Vent
HP Casing Shear Ram Close
Stack Accumulators Dump Isolate
Wellbore P/T Connector Retract
Stack Accumulator Charge Charge
Autoshear Arm
Riser Recoil Arm
LMRP Connector Primary Vent
2 Lower Outer Bleed Valve Close
Lower Outer Choke Valve Close
Middle Outer Choke Valve Close
Upper Outer Choke Valve Close
Lower Outer Kill Valve Close
Upper Outer Kill Valve Close
LMRP Connector Regulator Increase
5 Choke/Kill Connector Primary Unlatch
Choke/Kill Connector Secondary Unlatch
Stack Transponder Arms Extend
Lower Inner Bleed Valve Close
Lower Inner Choke Valve Close
This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 16 of 22

CASING SHEAR RAM AND UPPER SHEAR RAM EDS

Time
Function Position
(sec)
Middle Inner Choke Valve Close
Upper Inner Choke Valve Close
Lower Inner Kill Valve Close
Upper Inner Kill Valve Close
18 Upper Annular Vent
Lower Annular Vent
Lower Inner Bleed Valve Vent
Lower Outer Bleed Valve Vent
Upper Inner Kill Valve Vent
Upper Outer Kill Valve Vent
Upper Inner Choke Valve Vent
Upper Outer Choke Valve Vent
Lower HP Blind Shear Ram Vent
Lower Blind Shear Ram Vent
Lower Blind Shear Rams ST Lock Vent
Upper Pipe Ram Vent
Upper Pipe Rams ST Lock Vent
Middle Pipe Rams ST Lock Vent
Lower Pipe Rams ST Lock Vent
Acoustic System Isolate Vent
Acoustic System Reset Vent

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 17 of 22

CASING SHEAR RAM AND UPPER SHEAR RAM EDS

Time
Function Position
(sec)
Middle Inner Choke Valve Vent
Middle Outer Choke Valve Vent
Lower Inner Choke Valve Vent
Lower Outer Choke Valve Vent
Middle Pipe Ram Vent
Lower Pipe Ram Vent
Lower Inner Kill Valve Vent
Lower Outer Kill Valve Vent
Stack Transponder Arm Vent
Wellhead Connector Gasket Vent
Wellhead Connector Secondary Vent
Wellhead Connector Primary Vent
Autoshear Vent
27 HP Casing Shear Ram Vent
Upper Blind Shear Ram Vent
Upper HP Blind Shear Ram Close
Upper Blind Shear Ram ST Lock Lock
52 Upper HP Blind Shear Ram Vent
Upper Blind Shear Rams ST Lock Vent
Stack Accumulator Charge Isolate
55 Stack Stinger Seals Deenergize

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 18 of 22

CASING SHEAR RAM AND UPPER SHEAR RAM EDS

Time
Function Position
(sec)
58 Stack Stinger Retract
LMRP Connector Primary Unlatch
LMRP Connector Secondary Unlatch

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 19 of 22

EDS 4: CASING SHEAR RAM AND LOWER SHEAR RAM EDS

CASING SHEAR RAM AND LOWER SHEAR RAM EDS

Time
Function Position
(sec)
0 Casing Shear Ram Vent
HP Casing Shear Ram Close
Stack Accumulators Dump Isolate
Wellbore P/T Connector Retract
Stack Accumulator Charge Charge
Autoshear Arm
Riser Recoil Arm
LMRP Connector Primary Vent
2 Lower Outer Bleed Valve Close
Lower Outer Choke Valve Close
Middle Outer Choke Valve Close
Upper Outer Choke Valve Close
Lower Outer Kill Valve Close
Upper Outer Kill Valve Close
LMRP Connector Regulator Increase
5 Choke/Kill Connector Primary Unlatch
Choke/Kill Connector Secondary Unlatch
Stack Transponder Arms Extend
Lower Inner Bleed Valve Close
Lower Inner Choke Valve Close
This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 20 of 22

CASING SHEAR RAM AND LOWER SHEAR RAM EDS

Time
Function Position
(sec)
Middle Inner Choke Valve Close
Upper Inner Choke Valve Close
Lower Inner Kill Valve Close
Upper Inner Kill Valve Close
18 Upper Annular Vent
Lower Annular Vent
Lower Inner Bleed Valve Vent
Lower Outer Bleed Valve Vent
Upper Inner Kill Valve Vent
Upper Outer Kill Valve Vent
Upper Inner Choke Valve Vent
Upper Outer Choke Valve Vent
Upper HP Blind Shear Ram Vent
Upper Blind Shear Ram Vent
Upper Blind Shear Rams ST Lock Vent
Upper Pipe Ram Vent
Upper Pipe Rams ST Lock Vent
Middle Pipe Rams ST Lock Vent
Lower Pipe Rams ST Lock Vent
Acoustic System Isolate Vent
Acoustic System Reset Vent

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 21 of 22

CASING SHEAR RAM AND LOWER SHEAR RAM EDS

Time
Function Position
(sec)
Middle Inner Choke Valve Vent
Middle Outer Choke Valve Vent
Lower Inner Choke Valve Vent
Lower Outer Choke Valve Vent
Middle Pipe Ram Vent
Lower Pipe Ram Vent
Lower Inner Kill Valve Vent
Lower Outer Kill Valve Vent
Stack Transponder Arm Vent
Wellhead Connector Gasket Vent
Wellhead Connector Secondary Vent
Wellhead Connector Primary Vent
Autoshear Vent
27 HP Casing Shear Ram Vent
Lower Blind Shear Ram Vent
Lower HP Blind Shear Ram Close
Lower Blind Shear Ram ST Lock Lock
52 Lower HP Blind Shear Ram Vent
Lower Blind Shear Rams ST Lock Vent
Stack Accumulator Charge Isolate
55 Stack Stinger Seals Deenergize

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF REVISED BY: REVISION Document No.
A. Rose 03 X-261720-65
DATE: SHEET

04 May 2010 22 of 22

CASING SHEAR RAM AND LOWER SHEAR RAM EDS

Time
Function Position
(sec)
58 Stack Stinger Retract
LMRP Connector Primary Unlatch
LMRP Connector Secondary Unlatch

This document contains confidential and trade secret information which is the sole property of CAMERON INTERNATIONAL
CORPORATION. Receipt or possession does not convey any right to loan, sell or otherwise disclose said information. Reproduction
or use of said information for any purpose other than that for which it is intended may not be made without written permission from
CAMERON. This document is to be returned to CAMERON upon request and in all events upon completion of the use for which it is
intended.
PROPERTY OF DRAWN BY: REVISION
Sriram Vengalathur 01
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DIELECTRIC FLUID FILLING PROCEDURE

FOR

ACOUSTIC ELECTRONIC MODULE

Originated By: Sriram Vengalathur Date: March 4th, 2007

Checked By: Daniel Valentine Date: March 4th, 2007

Approved By: Mac Kennedy Date: March 4th, 2007

PROPERTY OF DRAWN BY: REVISION
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DATE:
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Document Revision Status / Record

Rev. Date Description of Change
01 4th March 2007 Initial Release
PROPERTY OF DRAWN BY: REVISION
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TABLE OF CONTENTS

1.0 INTRODUCTION .......................................................................................................................... 4

1.1 SCOPE .......................................................................................................................................... 4

1.2 REFERENCE DOCUMENTS/DRAWINGS .......................................................................................... 4

2. TEST EQUIPMENT ................................................................................................................................ 4

3. FILLING PROCEDURE ......................................................................................................................... 5

PROPERTY OF DRAWN BY: REVISION
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1.0 Introduction

1.1 Scope
This document outlines the procedure for filling the Acoustic Electronic Module (AEM)
with DC 200 silicone dielectric fluid.

1.2 Reference Documents/Drawings

No. Description Doc. No. Rev.

1. BOM, Acoustic Electronic Module

2. Flow Diagram, Acoustic Valve Module
3. Electrical Schematic, Acoustic Valve Package
4. Assembly Drawing, Acoustic Electronic Module

2. Test Equipment

Note: Plumbing items listed below, not readily available in a field environment,
can be substituted with like items.

• DC200 Fluid: As required.

• ¼” Needle Valve (Qty.1)
• Regulator, Pneumatic: 0-150 PSI (Qty.1)
• Gauge, Vacuum 0-30”
• Gauge, Low pressure: 0-30 PSI (Qty.1)
• Pump, Vacuum (Qty.1): Cameron PN.: 2711614-02 or equivalent
• Hand Pump w/ gauge-Enerpac Type: 0-50 PSI (Qty.1)
• Miscellaneous adapter fittings: as required
• Tubing, clear surgical hose: as required
PROPERTY OF DRAWN BY: REVISION
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3. Filling Procedure

Ensure that the AEM is properly installed & that all electrical & hydraulic
connections have been made.
Verify: ________

Install hydraulic plumbing per the schematic below (Fig.1). Ensure that the hose
inside the DC200 fluid supply container is well below the fluid line in the container
& that the vacuum pump is above the level of AEM. (Note: It is preferable to use
transparent hose for the fill line from the dielectric supply reservoir & for the
vacuum line.)
Verify: ________

ISOLATION
VALVE

TO VACUUM
PUMP
COMPENSATOR

FILL
VALVE

DI-ELECTRIC FLUID
RESERVOIR ACOUSTIC
ELECTRONIC
MODULE

ACOUSTIC VALVE PACKAGE

FIGURE 1

With the fill valve closed, open the isolation valve on the top of the AEM & begin
to evacuate the AEM. Open the fill valve temporarily to allow the fill hose to fill
with fluid. Close the fill valve & continue to pull a vacuum on the AEM until
approximately ~28” of mercury is indicated on the vacuum gauge.
Verify: ________
PROPERTY OF DRAWN BY: REVISION
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When a sufficient vacuum has been reached open the fill valve. Monitor the
intake of fluid to ensure that air is not being pulled into the AEM.
Verify: ________

The AEM should not require more than one iteration of the above steps, however
if air is noticed in the fill line during filling, repeat the vacuum steps to ensure that
as much of the air as possible is removed (Note: It is not practical nor necessary
to get absolutely all of the air out of the AEM, & the design allows for some
amount so reasonable effort to remove the air is all that is required.)
Verify: ________

When the fluid comes up through the hose on the vaccum pump, turn the pump
off & disconnect the fill-valve & vacuum plumbing.
Verify: ________

Connect a hand pump filled with di-electric fluid to the isolation valve per figure 2
& cap-off the “Tee”.
Verify: ________

ISOLATION
VALVE
HAND
PUMP

COMPENSATOR

FILL
VALVE

ACOUSTIC
ELECTRONIC
MODULE

ACOUSTIC VALVE PACKAGE

FIGURE 2
PROPERTY OF DRAWN BY: REVISION
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Close the isolation valve on top of the AEM & disconnect the hand pump. Install
the plug in the isolation valve.

Verify: ________

Charge the di-electric system to approximately 8 PSI. The compensator should

be approximately 2/3 full at 70oF

Verify: ________

Close the isolation valve & disconnect the pump

Verify: ________

Check the package for leaks

Verify: ________
PROPERTY OF REVISED BY: REVISION
C. Earhart 05 Document No.
DATE: SHEET
X-262167-02
th
6 February 2009 1 OF 7

DIELECTRIC FLUID FILLING PROCEDURE

FOR

MUX SECTION OF THE SUBSEA CONTROL POD

Originated By: Sriram Vengalathur Date: April 20th, 2007

Checked By: Daniel Valentine Date: April 20th, 2007

Approved By: Mac Kennedy Date: April 20th, 2007

PROPERTY OF REVISED BY: REVISION
C. Earhart 05 Document No.
DATE: SHEET
X-262167-02
th
6 February 2009 2 OF 7

Document Revision Status / Record

Rev. Date Description of Change
01 20th April 2007 Initial Release.
02 3rd January 2008 1.) Added additional steps to bleed the modules after initial
filling.
2.) Included notes to ensure that the vacuum pump is higher
than the modules & also to prime the hoses before filling.
3.) Section 3.1 deleted the line to close the isolation valve to
the vacuum pump after the necessary level of vacuum is
reached.
03 4th January 2008 Added sign off sheet for quality
04 6th February 2009 Opened in Error
05 6th February 2009 Rewrote section 3.1 to clarify the procedure and deleted
section 3.2
PROPERTY OF REVISED BY: REVISION
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DATE: SHEET
X-262167-02
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6 February 2009 3 OF 7

TABLE OF CONTENTS

1.0 INTRODUCTION ........................................................................................................................... 4

1.1 SCOPE ............................................................................................................................................ 4
1.2 REFERENCE DOCUMENTS/DRAWINGS ............................................................................................ 4
2. TEST EQUIPMENT ................................................................................................................................ 4
3. FILLING PROCEDURE ......................................................................................................................... 5
3.1 INITIAL FILLING .................................................................................................................................... 5
4. CERTIFICATE OF CONFORMANCE................................................................................................. 7
PROPERTY OF REVISED BY: REVISION
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DATE: SHEET
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6 February 2009 4 OF 7

1.0 Introduction

1.1 Scope
This document outlines the procedure for filling a di-electric module (single or multiple
units) with DC 200 silicone dielectric fluid.

1.2 Reference Documents/Drawings

Description Doc. No. Rev.

1. BOM, Mux Section, Control Pod

2. Flow Diagram, Pod
3. Electrical Schematic, Mux Section, Control Pod
4. Assembly Drawing, Mux Section, Control Pod

2. Test Equipment

Note: Plumbing items listed below, not readily available in a field environment,
can be substituted with like items. Hose lengths & sizes should be kept to the
absolute minimum possible.

• DC200 Fluid: As required.

• ¼” Needle Valve (Qty.1)
• Gauge, Low pressure: 0-30 PSI (Qty.1)
• Miscellaneous adapter fittings (including isolation valves if necessary) : as
required
• Tubing, clear surgical hose: as required
• Pump
PROPERTY OF REVISED BY: REVISION
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DATE: SHEET
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3. Filling Procedure

3.1 Initial Filling

Ensure all hoses, fittings, plugs & other components are installed correctly.

Verify: ________

Remove the caps from the top port of each module

Verify: ________

Open the compensator isolation valves.

Verify: ________

Install the pump & siphon connections per Figure 1.

Verify: ________

Turn on the pump and push fluid continuously into the system.

Verify: ________

Note: Watch the pressure gauge. Slow the pump if the pressure approaches 10
psi. Pressure in the system should not exceed 12 psi.

As fluid appears at the top port of each module, cap it off.

Verify: ________

When all of the modules are capped, other than the first, increase the system
pressure to 8-9 psi.

Verify: ________

Shut off the compensator isolation valves

Verify: ________

Starting with the module closest to the pump, open each module cap one at a
time. If a module needs to be topped off, crack one of the compensator valves
slightly until the module tops off, and close it again. Recap the module. Do this
for all modules.
PROPERTY OF REVISED BY: REVISION
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Verify: ________

Disconnect the pump assembly from the first module

Verify: ________

Note: If the fluid level does not immediately top off the first module by itself, open
one of the compensator isolation valves slightly until fluid appears at the top of
the module.

Cap off the first module.

Verify: ________

Check for leaks

Verify: ________

Figure 1
PROPERTY OF REVISED BY: REVISION
C. Earhart 05 Document No.
DATE: SHEET
X-262167-02
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6 February 2009 7 OF 7

4. Certificate of Conformance

Assembly: Di- Electric Modules for Mux Section of the Control Pod

TEST WITNESSED AND RESULTS ACCEPTED BY:

________________________ ________________________
CAMERON WITNESS: SIGNATURE

________________________
Date
Section 6 - Glossary of Acronyms and Definitions
GLOSSARY

Acronyms and Definitions

Introduction The glossary lists definitions and acronyms used in the Cameron
Mark III Drilling System.

A Accumulator - A vessel for temporary storage of hydraulic fluid;

usually used to ensure continuous operation. Under pressure with
either helium or nitrogen, it allows the system to gather volume
and pressure to operate BOP functions. There are three types:
bladder, float or piston. Accumulators are located on the surface
in "banks" and on the pod subsea.

Accumulator Pre-charge - An initial helium or nitrogen charge in

an accumulator which is further compressed when the hydraulic
control fluid is pumped into the accumulator, storing potential
energy.

ACS - Acoustic Control System. A subsea control system that uses

coded acoustic signals for communications. An acoustic control
system is normally used as an emergency backup having control
of a few selected critical functions.

AMF - Automatic Mode Function. See Deadman System.

Analog - Technique of representing a sensor's input as amplitude

modulated electrical signal (e.g., analog profiles are output on
sweep recorders, as opposed to digital).

TC8225, Volume 7, Section 6 1

Acronyms and Definitions, continued
Analog Data Transmitters - An intrinsically safe device that
transmits standard current signals (0 - 20 mA) from safe areas to
hazardous area. They are typically used to drive I/P converters (for
valve control) or display devices in hazardous locations.

Annular Blowout Preventer - A large valve, usually installed

above the ram preventers, that forms a seal in the annular space
between the pipe and well bore or, if no pipe is present, on the
well bore itself. Compare with Ram Blowout Preventer.

API - American Petroleum Institute. An organization whose

purpose is to advance the oil and gas industry worldwide.
It publishes a wide range of specifications, standards,
recommended practices, and other technical documents
which define requirements and best practices for the industry.
Cameron's drilling control systems are designed in accordance
with API Specification 16D: Control Systems for Drilling Well
Control Equipment.

Atm - Atmosphere. A unit of measure for pressure. One atm =

1.01325 bar or 14.696 psi.

B Ball Valve - A type of quick-opening valve constructed with a

bored-through rotating ball which seals against the valve seats,
placed perpendicular to the valve bore in the valve's inlet and
outlet ports. The valve can be opened or closed with a one-
quarter turn of the ball.

Batch Controller - A device that controls and measures the flow

of liquids or solids in a batch-type operation. A typical example is
the BEKA Model BA 350, used to control and measure batches of
hydraulic fluid in a Hydraulic Power Unit (HPU). The intrinsically
safe Model BA 350B displays batch total, rate, and grand total,
using pulse or 4 - 20 mA input signals.

TC8225, Volume 7, Section 6 2

Acronyms and Definitions, continued
Blowout - An uncontrolled flow of pressurized wellbore fluids.

BOM - Bill of Material. An itemized listing of all of the parts of

a particular unit, system or assembly. It provides component
numbers, descriptions, quantities, drawing item numbers, and
latest revision information for each part. Cameron Controls
BOM's also list the Engineering Specifications applicable to the
unit, system, or assembly to which the BOM pertains.

BOP - Blowout Preventer. A hydraulically operated wellhead

device designed to ensure that a blowout cannot occur. One
of several large, quick-closing valves installed at the wellhead
to prevent the escape of pressure, either in the annular space
between the casing and drill pipe, or in open hole during drilling
or completion operations.

BOP Stack - Blowout Preventer Stack. The assembly of well-

control equipment including BOP's, spools, valves, connectors and
Controls which is installed on the subsea wellhead for drilling and
completing subsea wells.

BOP Test Box - An electrical assembly that connects to the MUX

system for the purpose of testing BOP functions. When enabled,
it disables BOP Stack functions from the Control Panels and, using
a handheld laptop PC and appropriate software, assumes control
of a limited number of stack functions that the panels normally
operate.

By-pass Valve -- A valve by which the flow of fluid in a system

may be shunted past a part of the system through which it
normally flows; a valve that controls an alternate route for liquid
or gas.

TC8225, Volume 7, Section 6 3

Acronyms and Definitions, continued
C Cable Reels - Yellow or blue reels which hold/store/take up/
dispense MUX cable that runs from the distribution panel to the
pod. See also Reel (Hose or Cable).

CAN Bus - Controller Area Network Bus. The Cameron Subsea

Mark III MUX Control Pod utilizes the fault-tolerant type of CAN
Bus communication protocol.

Check Valve - A valve that allows flow through it in one direction

only.

Choke Line - A high pressure line connected below a BOP to

transmit fluid flow to the choke manifold during well control
operations.

Choke and Kill Valves - BOP stack-mounted valves which are

connected below the BOP's to allow access to the wellbore to
either monitor, choke or kill the well.

CISC - Complex Instruction Set Computer. See also RISC.

Cleanliness Level - A measure, compared to a standard, of the

relative particulate contamination of a fluid. Cleanliness level
is most often reported based upon U.S. National Aerospace
Standard (NAS) 1638, using contamination limits of Class 00
through Class 12. Alternatively, ISO 4406 reports contamination
levels equivalent to NAS from 8/5 through 21/18.

TC8225, Volume 7, Section 6 4

Acronyms and Definitions, continued
Conduit Valve Module - Contains pod select valves that channel
the hydraulic fluid to the selected pod. Also allows for the
conduit to be flushed (controlled from Pods).

Control Fluid - See Hydraulic Control Fluid.

Control Panel - An enclosure displaying an array of switches, push

buttons, lights and/or valves and various pressure gages or meters
to control or monitor functions. Control panel types include:
diverter panel; driller’s control panel; master panel; toolpusher’s
control panel; and mini- or auxiliary remote panel. These can be
pneumatic, electric, or hydraulic powered.

Control Pod - See Subsea Control Pod.

CPU -- Central Processing Unit. In a control panel, the unit that

comprises the arithmetic logic unit and the control unit.

CXC - Controller eXtension Connector

CXM - Controller eXtension Module

D DCP - Driller's Control Panel. One of multiple panels that activate

and monitors BOP functions. Normally located on the drilling
floor in a hazardous area, the DCP has components rated for
installation in a hazardous area. Typcial HMI pages available
at the DCP: BOP Stack/LMRP Functions; Hydraulic Power Unit;
Diverter System.

TC8225, Volume 7, Section 6 5

Acronyms and Definitions, continued
DCU - Diverter Control Unit - The assembly of a control
panel, valves, gauges, solenoid valves, flowmeters, and other
instrumentation, used to operate the diverter system.

DDTM - Drilling Digital Transducer Module

Deadman System - Also known as AMF, on a drilling rig, this is

a system for shutting in a well when all three, or sometimes two
out of three, of the following conditions are detected: (1) loss
of power; (2) loss of communications; and (3) loss of pressure in
the hydraulic system. The deadman system is controlled by a card
in the SEM and may be also actuated or disabled manually by a
pushbutton on the surface at the Control Panels.

Diagnostic Point - See Pie Connector. Each of the connections in

the Pie Connector provides a potential diagnostic point to report
the function mode of a specific solenoid valve in the hydraulic
portion of the subsea control pod.

Digital - Technique of representing a sensor's input as a numeric

data stream (after conversion from analog input signal); e.g., all
marine seismic, including high resolution, relies on multi-channel
digital techniques (as opposed to analog).

DIN - Deutsche Industrie-Normen. German Industrial Standards,

comparable to British Standards and standards published in the
USA by ANSI, ASME, and API. Used to specify some components in
the MUX drilling controls system (e.g., 96 way DIN 41612 style C
electronic pin connectors).

TC8225, Volume 7, Section 6 6

Acronyms and Definitions, continued
Diode - A rectifier (a device for converting alternating current
into direct current) that consists of a semi-conducting crystal with
two terminals and that is analogous in use to an electron tube
diode. See also LED.

Distribution Panel (Cabinet/Box) - A device that receives

communications signals and/or power supplies from centralized
or primary sources and distributes them to other locations.

Diverter - A device attached to the wellhead or marine riser used

to close the vertical flow path and direct flow (typically shallow
gas) into a vent line that conducts the flow downwind, away
from the rig.

Diverter System - The assemblage of an annular sealing device,

flow control means, vent system components, and control system
which facilitates closure of the upward flow path of the well fluid
and opening of the vent to atmosphere. See Diverter.

DMA - Direct Memory Access. A technique for transferring data

from main memory to a device without passing it through the
CPU.

DSDM - Drilling Solenoid Driver Module.

DTE - Data Terminal Equipment. Devices used as nodes in

PROFIBUS network topology.

TC8225, Volume 7, Section 6 7

Acronyms and Definitions, continued
DUART - Dual Universal Asynchronous Receiver/Transmitter.

E EEPROM - Electrically Erasable Programmable Read Only Memory.

EID-Display - Error, Interlock and Diagnostic Display.

Electronic MUX Package - The upper portion of the subsea

control pod, designated as Mark III. It consists of the Subsea
Electronics Module (SEM), the Solenoid Valve Modules (SVM's),
the Pressure Transducer Modules (PTM's), and hydraulic pilot
supply circuitry. It also contains a Subsea Battery Module (SBM) if
the system includes the AMF/Deadman feature.

Event Logger - A device that records all messages between

Control Panel communication controllers and the blue and yellow
pods, the HPU and auxiliary equipment. It enables the operator
to review sequences/occurrences and provides online monitoring
and offline data diagnostics. It monitors the BOP control system
continuously without interfering with control system functions.

F FISO - Fieldbus isolation..FITA - Field Installable Termination

Assembly. An assembly (e.g., a connector cable) that is supplied
by Cameron for installation in the field by client personnel and/or
the Cameron field service technician.

Flow Meter - A meter which measures the rate of flow (e.g.,

gallons/minute) of a gas or liquid through a pipe. A Totalizing
Flow Meter measures the total quantity (e.g., gallons) of flow
over a given time period.

TC8225, Volume 7, Section 6 8

Acronyms and Definitions, continued
FOC - Fiber Optic Cable. An option in lieu of copper cable for
transmitting data. Optical fibers, which may be glass or plastic,
are unidirectional. Glass fibers can operate at connection lengths
up to 15,000 m, while plastic fibers are limited to 80 m for OLM
and 25 m for OLP.

FPR (Field Performance Report) System - The tracking system

used by Cameron Controls to record and report part failures or
malfunctions in the field, to record corrective action taken in the
field (if any), to assign responsibility for further investigation and
corrective action, and to document the results. Individual FPR's
are maintained in Cameron's global database for generation of
status reports and record purpose.

FRU - Fluid Recovery Unit - The Fluid Recovery Unit receives

returns control fluid from subsea and collects it in its
reservoir. The FRU allows the rig to operate in waters deemed
environmentally sensitive to contamination by drilling control
fluid.

G  all - To damage or destroy a finished metal surface (e.g., a shaft

G
journal scored due to moving contact with a bearing without
sufficient lubrication). To chafe by friction and heat as two
pieces of metal are forcibly rubbed together in the absence of
lubrication.

Gate Valve - A valve which employs a sliding gate to open or

close the flow passage.

Glycol Concentration - A measure of the percentage by

weight of glycol present in a hydraulic fluid. The addition of
glycol is required for low temperature applications. See Mix
Concentration.

TC8225, Volume 7, Section 6 9

Acronyms and Definitions, continued

H HFT - High Frequency Transmitter.

Hot Line - An auxiliary hydraulic supply line used in start up and

in emergency situations when the conduit valve package is not
available or will not function.

HMI - Human Machine Interface

HOA - Hand Off Auto switch

HPU - Hydraulic Power Unit.

Hydraulic Control Fluid (water-based) - A control liquid mixture

composed mainly of water with additives to provide lubricity,
anti-foaming, anti-freeze, anti-corrosion and anti-bacterial
characteristics. Under pressure, it provides the motive power for
valve actuation in the MUX control system and ultimately, for the
functioning of the drilling system. (See "Usable Hydraulic Fluid".)
Hydraulic control fluid for land type or closed loop systems is
sometimes oil-based.

Hydraulic Module - (Mod Pod) The lower portion of a control

pod. In the Cameron design, it is a standard modular pod that
is identical to the piloted hydraulic control units that have been
used on offshore drilling rigs since 1981. It contains large valves
and regulators that control the subsea BOP and LMRP functions.

I IDC - Insulation Displacement Connector. Press-fit connector for

flat ribbon cable.

TC8225, Volume 7, Section 6 10

Acronyms and Definitions, continued
Interflow - The power control fluid lost (vented to the sea) during
the travel of the piston in a control pod valve.

I/O - Input/Output (electronic signals).

IRQ - Interrupt ReQuest line.

Isometer - A resistance monitor, normally located in the

Communication/Power Distribution Panels, that detects
degradation of the MUX cable.

J JB or J-Box - Junction Box (Electrical). An enclosure used to house

the termination points of electrical cables and components. It
may also contain some electrical components required for system
operation.

JB or J-Box - Junction Box (Hydraulic or Pneumatic). A bolt-on

plate having multiple stab-type terminal fittings used for quick
connection of the multi-hose bundle to a pod, hose reel, or
manifold.

JIC - An SAE standard that indicates a part has a 37-degree flare.

JIC fittings (3/4" male 37o flare tube end) are used on the hose
end of the PBOF electrical connector. The hose assembly is a
flexible hose with a ¾" 37o JIC female swivel/hose barb type
fitting at each end.

TC8225, Volume 7, Section 6 11

Acronyms and Definitions, continued
JIC/AN. (Joint Industry Council/Army-Navy) - JIC/AN plumbing is
the industry standard for automotive and aerospace use - all over
the world. When properly assembled it will not leak, become
loose, burst, collapse, wear through, corrode or wear out. It
is heat and flame resistant, it will not chafe - it is specifically
designed for the job. It is versatile and if treated with care, can
be re-used. As most fittings are manufactured to a common
standard, plumbing components rarely become obsolete. In
summary: Steel, aluminum and stainless plumbing constitutes
the best, safest and most economical way of doing the job
properly. All JIC/AN fittings have a mating flare seat at 37º but
are not interchangeable with some similar SAE fittings which
have a flare seat at 45º. Most performance fittings employ the
37º flare seat but it is always advisable to check prior to assembly
as these fittings will thread together but will not seat correctly,
tightening the joint will damage the seat of both fittings and the
joint will leak. This catalogue uses the "JIC" name to refer to the
standard equipment but the term "AN" is interchangeable. The
single most common cause of a leaking hose is the insufficient
or over tightening of the hose end, if in doubt, call us and we'll
guide you. Check the general recommendations for sealing
any particular fitting and always fit a sealing washer or apply
compound where specified. If unsure, you can usually order
pre-assembled hoses to your specifications at little or no extra
cost. JIC fittings do not require additional sealing compound or
washers.

K Kick - The situation that occurs when the formation pressure in

a well exceeds the hydrostatic head of the mud column, thus
allowing formation fluid to enter the well bore.

Kill Line - A high pressure line between the mud pumps to a

connection below a BOP. This line allows drilling fluid to be
pumped into the well or annulus with the BOP closed during well
control operations.

TC8225, Volume 7, Section 6 12

Acronyms and Definitions, continued
L LAN - Local Area Network.

LCD - Liquid Crystal Display. A type of display used in digital

watches and many portable computers. LCD displays utilize
two sheets of polarizing material with a liquid crystal solution
between them. An electric current passed through the liquid
causes the crystals to align so that light cannot pass through
them. Each crystal, therefore, is like a shutter, either allowing
light to pass through or blocking the light.

LED - Light Emitting Diode. An electronic device that illuminates

when electricity is passed through it. LEDs are usually red. They
are good for displaying images because they can be relatively
small, and they do not burn out. However, they require more
power than LCDs.

LFT - Low Frequency Transmitter.

LMRP (Lower Marine Riser Package) - The upper section of a two-

section subsea BOP stack consisting of the hydraulic connector,
annular BOPs, flex/ball joint, riser adapter, flexible choke and
kill lines, and subsea control pods. This interfaces with the lower
subsea BOP stack.

LRP (Lower Riser Package) - See LMRP.

M Manifold - A piping arrangement that allows one stream of liquid

or gas to be divided into two or more streams.

TC8225, Volume 7, Section 6 13

Acronyms and Definitions, continued
Marine Riser System - The extension of the wellbore from the
subsea blowout preventer stack to the floating drilling vessel
which provides for fluid returns to the drilling vessel, supports
the choke, kill and control lines, guides tools into the well, and
serves as a running string for the blowout preventer stack.

MCP (Modular Control Pod) - See Subsea Control Pod.

MF - Medium Frequency

Mix Concentration - A measure of the percentage of hydraulic

fluid concentrate to water based on weight. Mix concentration is
probably the most important factor in producing a hydraulic fluid
with the desired properties.

MOD - Modular

Module - An integrated package of plant, equipment, etc.,

installed (1) on an offshore structure such as a production/drilling
platform or (2) subsea, as a part of a drilling or production system
(e.g., the Hydraulic Module in the MUX drilling controls system).

MCP - Modular Control Pod

TC8225, Volume 7, Section 6 14

Acronyms and Definitions, continued
MUX (Multiplex) Cables - Umbilicals: one blue/one yellow. The
wire-armored cable with a minimum of four cores for data
transmission and twelve cores for power that runs from the cable
reels on the drilling vessel to the pod SEM.

MUX (Multiplex) Control Pod - See Subsea Control Pod.

MP - Multiplex Package

MUX (Multiplex) System - A system that uses electronic signals

that are re-coded and transmitted through a conductor pair.
This eliminates the need for a dedicated conductor pair for each
required signal.

N NAS - National Aerospace Standard. Procurement Specification

NAS 1638, "Cleanliness Requirements of Parts Used in Hydraulic
Systems", is used by Cameron Controls to define the cleanliness
level pertaining to the operating fluid. A NAS Level 10, which
corresponds to ISO Code SAE J1165 Level 19/16, is recommended.

Needle Valve - A globe valve with shut-off capability that

incorporates a needle-point disk to produce extremely fine
regulation of flow.

NEMA - National Electrical Manufacturers Association

NPD - Norwegian Petroleum Directorate

TC8225, Volume 7, Section 6 15

Acronyms and Definitions, continued

O OLM - Optical Link Module. A fiber optic device that converts

conventional signals to light pulses that can be transmitted on
glass or plastic fiber optic cable

OLP - Optical Link Plug. A fiber optic device that provides a cost
effective way of connecting passive PROFIBUS DTE's (slaves) using
an optical fiber ring.

Orifice Meter - A flow rate measuring device in a line that

measures the pressures upstream and downstream of a restricting
orifice placed in the line, enabling the rate of fluid flow to be
calculated.

P PBOF (Pressure Balanced Oil-filled) Connector/Cable - The

assembly used to make the subsea connections that are external
to pods.

PC - IBM compatible computer

PCB - Printed Circuit Board. In the MUX drilling systems PLC, the
PCB's are I/O Boards which are located in the Pod SEM's, and also
Modems located in the Communication/Power Distribution Panels
and SEM's.

TC8225, Volume 7, Section 6 16

Acronyms and Definitions, continued
PETU - Portable Electronic Test Unit. A testing device that informs
the operator about the complete status of the pod. The PETU
consists of a laptop PC, an electrical power supply, a modem
and interconnection test cables. All control panel commands are
available on the PETU, as well as additional test functions and
test control sequences. It can be used to simulate a control pod
for testing of either control panel without a pod, or it can be
used in place of a panel to operate any BOP stack function.

Pilot Fluid - Hydraulic control fluid that is dedicated to the pilot

supply system.

Pilot Line - A hydraulic line that transmits pilot fluid to a control

valve. Pilot lines are often grouped in a common bundle or
umbilical.

PLC - Programmable Logic Controller.

Pod - See Subsea Control Pod.

Pre-charge - See Accumulator Pre-charge.

Pressure Relief Valve - A device that is built into a hydraulic

or pneumatic system to relieve (dump) any excess pressure. It
is set to relieve at a prescribed specific pressure above normal
operating pressure; also called a relief valve, safety valve, or pop
valve.

TC8225, Volume 7, Section 6 17

Acronyms and Definitions, continued

PRV - Pressure Regulating Valve.

PROFIBUS - Name for the communications system, based upon

local area networks (LANs), used to distribute signals to various
parts of the Cameron MUX control system. Refer to vendor-
furnished information describing PROFIBUS networks, including
governing standards, topologies, components and transmission
techniques, in the Operation and Maintenance Manual.

PSU - Power Supply Unit.

PSL - Procedural Script Language.

PT - Pressure and Temperature.

PTM - Pressure Transducer Module.

Pumps -- Mechanical devices to transport fluids from one vessel

to another along pipelines. There are a wide variety of pumps
of three general types: reciprocating, gear, and centrifugal.
The choice depends on the pressure to which the liquid is to
be pumped (delivery head), quantity and nature of the liquid
(viscosity, corrosive nature, etc.) and availability of prime movers
(electric motors, pneumatic supply, etc.).

TC8225, Volume 7, Section 6 18

Acronyms and Definitions, continued
R  am - The closing and sealing component on a blowout
R
preventer. There are three types: blind, pipe, or shear. Blind
rams, when closed, form a seal on a hole that has no drill pipe in
it; pipe rams, when closed, seal around the pipe; shear rams cut
through casing or drill pipe and then form a seal.

RCB - Riser Control Box. Mounted on the LMRP riser adapter. It

collects pressure and temperature data from the LMRP choke and
kill lines and the riser adapter. It also collects inclinometer data
from Riser Inclinometer Modules installed on the flex joint.

Reel (Hose or Cable) - A reel, usually power driven, that stores,

pays out and takes up umbilicals, either control hose bundles or
electrical cables.

Regulator (Pressure) - A hydraulic device that reduces upstream

supply pressure to a desired (regulated) level. It may be manual
or remotely operated and, once set, will automatically maintain
the regulated output pressure unless it is reset.

Relief Valve - See Pressure Relief Valve.

RIS - Riser Instrumentation System.

Riser Connector (LMRP Connector) - A hydraulically operated

connector that joins the LMRP to the top of the lower BOP stack.

TC8225, Volume 7, Section 6 19

Acronyms and Definitions, continued
RS 485 Repeater - An RS 485 Repeater amplifies data signals on
LAN shielded, twisted pair cables and connects bus segments. An
RS 485 Repeater is required: (1) when there are more than 32
stations connected to the bus; (2) when electrically isolated bus
segments are required; or (3) when the maximum cable length of
a segment (standard LAN cable) is exceeded. The maximum cable
length of a segment varies with the transmission rate. Refer to
vendor-furnished information about PROFIBUS networks in the
Operation and Maintenance Manual.

ROV - Remotely Operated Vehicle

RTC - Real Time Clock.

S Sacrificial Anode - A ring or slab of metal placed on a key part

of an underwater structure in order to protect it from corrosion;
the sea water attacks the anode rather than the structure and its
components.

SAE - Society of Automotive Engineers.

SC - Serial Communication.

SCP - Supervisor's Control Panel. One of multiple panels that

activate and monitors BOP functions. It is normally located in the
supervisor's office in a non-hazardous area. Typcial HMI pages
available: BOP Stack/LMRP Functions; Hydraulic Power Unit;
Diverter System.

TC8225, Volume 7, Section 6 20

Acronyms and Definitions, continued
SCSI (pronounced "scuzzy") - Small Computer Systems Interface.

Seacon - The name of a supplier of wetmate connectors. Seacon

connections are used on subsea equipment.

SEM - Subsea Electronics Module. A major component of the

Electronic MUX Package, which is located in the upper portion
of the subsea control pod. It is housed in a dry, nitrogen-purged
atmosphere for easy maintenance. It contains dual, redundant
electronics that provide communication via modem with the
surface electronic system. It also monitors system pressures and
voltages.

SFSK - Spaced Frequency Shift Key

Sheave (pronounced "shiv") - A wheel or series of rollers with a

cross-section designed to allow a specific size of rope, cable, wire
line or hose bundle to be routed around it at a fixed bend radius.
Normally used to safely change the direction of, and support, the
line.

Shuttle Valve - A valve that receives fluid from either of the two
supply sources and directs it to a single outlet.

Skid Mounted - Refers to a pumping unit or other oil field

equipment that has no permanent or fixed foundation but is
welded or bolted to metal runners. Skid-mounted offshore units
are usually readily movable by pulling as a sled or by hoisting
onto a vessel. They are then normally welded into their operating
positions.

TC8225, Volume 7, Section 6 21

Acronyms and Definitions, continued
Slip Joint - also known as a telescopic joint. A special sleeve-like
section of pipe run in the drill string to absorb the vertical motion
of a floating drilling vessel caused by wave action.

SMD - Surface Mount Device.

SOV -- Solenoid Valve. An electrical coil operated valve that

controls a hydraulic or pneumatic function or pilot signal.

Stab -- To guide the male end of a device into a female receptacle

when making up a connection.

Stinger -- The male half of a device used to communicate

electrical or hydraulic signals or power to a mating female
receptacle. Stingers are found on the bottom of a subsea control
pod.

Subsea Control Pod - The unit that houses the MUX drilling
control system's Electronic MUX Package and its Hydraulic
Package. Two identical, independent pods ("Blue" and "Yellow")
are employed to provide complete redundancy in the control
of the BOP and LMRP functions. Cameron offers a Mark III pod,
available with up to 120 hydraulic functions. The Pod features
high integrity, saltwater-tolerant components for use in ultra-
deepwater environments.

Supply Unit (2-wire loop isolator type) - Devices used to operate

intrinsically safe 2-wire, loop-powered transducers in hazardous
areas.

TC8225, Volume 7, Section 6 22

Acronyms and Definitions, continued
SVM - Solenoid Valve Module A major component of the MUX
Section, which is located in the upper portion of the subsea
control pod. It is a bank of eight solenoid valves that convert
electronic commands into the hydraulic signals that actuate the
large valves and regulators in the Hydraulic Module, as well as
additional functions on the riser and stack. Each SVM contains
a Solenoid Driver Module, and is filled with dielectric fluid. All
electrical connections within the SVM are booted, such that
water intrusion will not impair operation.

ST - Socket Type

T  CP - Toolpusher's Control Panel. One of multiple panels that

T
activate and monitors BOP functions. It is normally located in the
toolpusher's office in a non-hazardous area. Typcial HMI pages
available: BOP Stack/LMRP Functions; Hydraulic Power Unit;
Diverter System.

Telescopic (Slip) Joint Packer - A torus-shaped, hydraulically or

pneumatically actuated, resilient element between the inner and
outer barrels of the telescopic (slip) joint which serves to retain
drilling fluid inside the marine riser.

Transducer -- A device that is actuated by power from one system

and supplies power, usually in another form, to a second system.
Both hydraulic pressure transducers and hydrophones (which
convert electronic signals to acoustic signals, and vice versa) are
used in Cameron MUX drilling control systems.

TC8225, Volume 7, Section 6 23

Acronyms and Definitions, continued
Transmission Rates - PROFIBUS networks using shielded, twisted-
pair cables operate at the following rates: 9.6 Kbps, 19.2 Kbps,
93.75 Kbps, 187.5 Kbps, 500 Kpbs, 1.5 Mbps, 3 Mbps, 6 Mbps, and
12 Mbps. PROFIBUS networks using optical components operate
at the following rates. For OLM: 9.6 Kbps, 19.2 Kbps, 93.75 Kbps,
187.5 Kbps, 500 Kpbs, 1.5 Mbps. For OLP: 93.75 Kbps, 187.5 Kbps,
500 Kpbs, 1.5 Mbps.

Transponder - A radio or radar set that, upon receiving a

designated signal, emits a radio signal of its own. It is used
especially for the detection, identification, and location of
objects.

Triplex Pump - A single acting, three cylinder, constant

displacement, reciprocating plunger pump.

U  mbilical - A control hose bundle or multi-conductor electrical

U
cable used to control subsea functions.

UPS - Uninterruptible Power Supply. A system which converts

normal AC power to DC and then, using an inverter, reconverts it
to AC to provide a continuous, reliable source of power in critical
situations. It contains a battery backup system that supplies the
DC power to the inverter for emergency use when the normal
power supply fails.

Usable Hydraulic Fluid - The hydraulic fluid volume recoverable

from the accumulator system between the maximum designed
accumulator pressure and the minimum operating pressure.

TC8225, Volume 7, Section 6 24

Acronyms and Definitions, continued
V VAC - Voltage Alternating Current

Valve - A device to control or regulate the flow of fluids through

pipes. The main types are needle, gate, globe, shuttle, check, ball,
plug, relief, and shear-type sealing.

VDC - Voltage Direct Current

VFD - Variable Frequency Drive

W Wetmate Connector - A connector designed to be connected and

disconnected underwater.

WP - Working Pressure

X XFMR - Transformer (electrical). A device which converts electrical

power from one voltage level to another.

TC8225, Volume 7, Section 6 25

TC8225, Volume 7, Section 6 26