Subsea - Page 5

BOP Multiplex
Control Systems
Subsea Engineers Handbook Section 5
I n-Spec I nc. 2000 BOP Multiplex Control System 3
Table Of Contents
Section 5
Page
1. Location of Control System Components 1
2. Adding More Details to the Electrical System 8
3. Shuttle Valves for Redundancy 10
4. Cameron Controls Stepping thru the Electrical Section 12
5. System Genera Arrangement Interconnect Drawing 13
6. Electrical System Interconnect Drawing 18
7. Stepping thru the Hydraulic System 19
8. Hydraulic Power Unit (HPU) 23
9. HPU Fluid Handling Portion 28
10. Diverter Pannel 29
11. Operation of Bladder Accumulator Bottles 33
12. Operation of Float Accumulator Bottles 35
13. Hydrostatic Effects on Accumulator Bottles 37
14. Hydraulic Conduit Valve Module 39
15. Cameron Control Pods 41
16. Operation of Dual Coil Solenoid Valves 45
17. Pod E/H Section Schematic 46
18. Multiplex Modular Control Pod Hydraulic Section 49
19. Pod Hydraulic Schematic 51
20. Operation of Slide Valves 55
21. ROV Operation of Selected Functions 59
22. Stack Schematic Drawings 62
23. Operational Notes 66
24. Hydril Multiplex BOP control System 68
25. System General Arrangement Pictorial Drawing 70
26. Drillers Remote Control Panel 74
27. Mixing System 76
28. Hydraulic Power Unit (HPU) 78
29. Diverter Panel 80
30. Hydril Mux Pod 85
31. LMRP Hydraulic Schematic 89
32. Stack Hydraulic Schematic 90
33. Family of Functions Ram 91
34. Family of Functions Shear Ram 92
Location of Control System Components
A Full System Drawing
In other sections of this manual we have seen the major BOP components which the
control system must operate..
..We now look at the major components of the control system to see their
functions and where they are located. For this discussion we will be looking at the
Cameron multiplex BOP control system.
How the Hydraulic And Electric Portions of the System Work Together
The diagram on the opposite page shows the multiplex control system major
components and how they connect to one another. Later in the section we will add
more detail to the diagram as we walk through the system.
1) We start with the BOP stack and LMRP which need to be controlled. They
are in black on the diagram
2) We next add the hydraulic system in red.
To the upper left is the hydraulic power unit (HPU) usually located in an
equipment room not too far from the moonpool The HPU is divided into a
mixing and pumping portion. Depending upon design and space
requirements the HPU may be placed on one or more skids.
The mixing skid mixes concentrated water soluble oil (also called lube or
concentrate) with potable water, and in cold climates it adds glycol for
freeze protection.
The pumps are 3 or 4 electrically driven triplex pumps. They pump the
fluid up to system pressure of 5,000 psi
1
through filters and into the
surface accumulator bottles, on the right. The surface 13 gal or 35 gal
accumulator bottles typically provide a capacity of 1,000 to 1,500 gal,
depending upon stack configuration.
Operation of remotely controlled rigid conduit supply valves directs
hydraulic fluid on the surface and subsea to the desired subsea multiplex

1
The new generation of deepwater BOP control systems use 5,000 psi WP systems. Older mux systems and some
new generation systems use the more traditional 3,000 psi WP system.
pod, either the blue or yellow pod. Both riser mounted hydraulic conduits
lines are normally pressurized at the surface
2
. The subsea conduit valve
modules determine which pod receives hydraulic fluid. The pod which is
currently receiving hydraulic power is called the active pod. If one of the
hydraulic conduit lines should develop a leak, that conduit can be isolated
from the system by closing the appropriate conduit select valve on the
surface and the conduit valve module on the LMRP. With the hydraulic
cross over line on the LMRP, one rigid conduit can supply hydraulic fluid
to either the blue or yellow pods.
Some systems use only one rigid conduit with one or 1 hydraulic hose,
hot line, run down clamped onto the riser. In this arrangement the
hydraulic hose powers the pod as the LMRP is lowered subsea and acts
as a back-up power source for the 2 pods if a problem should develop with
the single rigid conduit.
3) We need to control the hydraulic fluid at the pod to perform the desired
functions. For this we add the electronic control system, shown in blue.
We have a fiber optic
3
profibus system which has all of the surface
equipment daisy chained together in a communications network
4
. In the
umbilical cable reels the profibus communication is fed to a modem which
communicates to the subsea pod over copper wires
5
. The function
commands travel subsea to both pods through slip rings in the blue and
yellow cable reels and down the umbilicals.

2
If a leak should develop in the stand-by rigid conduit, having it online allows it to be recognized.
3
Not all systems use a fiber optic profibus system to distribute the surface commands. Some use a copper wired
profibus.
4
Some rigs like the Sedco Express series use a profibus loop which in the event of a cable breakage can still
communicate with the rest of the network through the remaining portion of the loop which now would look more
like a C than an O.
5
Fiber optic strands are occasionally used to send the signals through the subsea umbilicals. Copper wires must
always be used to transmit power for the pod electronics.
INC. IN-SPEC
File: Mux EHSystem-Cam.dwg
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Conduit Valve
Module
Diver
ter
HPU
Interface
Distribution
Box
Basic Hydraulic Schematic
Multiplex BOP Control System
HPU
Accumulator Bottle Skids
Typically
1,000 to
1,500 gallons
5,000 psi
Diverter
Panel
Cable
Reel
BOP
Stack
LMRP
Mux
Pod
Mux
Pod
UPS
Tool pusher
Panel
Drillers
Panel
B/Y
Conduit
Select
Accumulator
Isolator
Filter
12 micron
Pump
5,000 psi
output
Conc-
entrate
Glycol Mixed
Fluid
Potable
Water
Multiplex Control System
Electronics Overview
Driller's Panel
Analog Output
Digital Input
CPU
Interface
PROFIBUS
Power Supply
Digital Output
Digital Input
CPU
Interface
PROFIBUS
Power Supply
Digital Output
Analog Output
Toolpusher's Panel
Analog Output
Digital Input
CPU
PROFIBUS
Interface
Power Supply
Digital Output
Analog Output
Digital Input
CPU
PROFIBUS
Interface
Power Supply
Digital Output
Hydraulic Power Unit
Digital Input
CPU
PROFIBUS
Interface
Power Supply
Digital Output
Analog Output
CPU
PROFIBUS
Interface
Power Supply
PROFIBUS
Interface
Power Supply
Modem
CPU
PETU
Event Logger
etc . . .
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Modem
CPU
PROFIBUS
Interface
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Modem
CPU
PROFIBUS
Interface
Power Supply
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B
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CPU
Modem
PROFIBUS
Interface
UPS B
UPS A
YELLOW
CABLE
BLUE
CABLE
Power Supply
Power Supply
Analog Input
Solenoid Driver
Modem
Solenoid
CPU
RS485
Interface Interface
CPU
Modem
RS485
Power Supply
Solenoid Driver
Analog Input
Solenoid
Power Supply
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Pressure To
Riser Control Box Transducer
Solenoid Valve
Multiplex Package
Yellow Pod
Pressure
Transducer
Power Supply
Solenoid
Analog Input
Solenoid Driver
Power Supply
RS485
Modem
Interface
V
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B
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Riser Control Box
Multiplex Package
Blue Pod
Solenoid Valve To
Interface
Solenoid
Modem
Power Supply
Solenoid Driver
Analog Input
Power Supply
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BLUE
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A B B A
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A B B A
A B B A
FILE NAME: MUX ELEC OVERVIEW CAM
At the pod the command is received by the subsea equipment module
(SEM) which translates the received signal into discreet commands for
each solenoid valve. For a particular functions its assigned valve is fired.
For example, one solenoid valve is assigned to close a ram and it is
shown here in the energized state. The opposite solenoid valve assigned
to open the ram is shown in the de-energized, close and vented position.
The energized solenoid valve sends a few CCs (cubic centimeters) of
pilot fluid from the pilot pressure accumulator bottle to shift the pods 1
slide valve into the close position. The 1 slide valve now supplies the
25.9 gallons of hydraulic fluid necessary to close the ram after the fluid
has been through the pod regulator. The pod mounted regulator reduces
the incoming hydraulic pressure from 5,000 psi, colored red, to the 1,500
psi, colored orange, required for normal ram operation.
We see the 25.9 gallons of hydraulic fluid, colored orange, leaving out the
bottom of the pod, traveling through the pod receptacle to the stack and
closing the assigned rams.
Adding More Detail to the Electrical Portion of the System
The system diagrams in the Cameron brochure do not show several items which should
be noted :
1. The electronics in the drillers panel, toolpushers panel, and both the blue and
yellow pods are redundant with both an A and B electronics package at each
location.
This will be noted on the remote panels since we have there an indicator light for
both the A and B subsea electronics modules (SEMs) which indicate which SEM
is currently being used.
2. Each data bus is powered by its own separate power supply. The A and B
uninterruptible power supplies (UPS) supply their respective bus.
3. A fiber optic profibus interconnects the surface equipment, remote panels, and
subsea communications controllers.
The data highways are shown as parallel lines on the system diagram. These
cables should not physically run along side one another so a catastrophic
disaster can not sever both A and B system operation.
In a similar manner, the distribution cabinets, A and B, as well as the UPSes
should not be placed in the same room. If placed in the same room a fire in that
particular room will render the entire control system inoperable.
4. Event Logger
Event logging is not an integral part of the system function. It eves-drops on
the surface buss recording changes of state as they are detected.
The Cameron supplied event logging unit is capable of recording history
information as computer data files which can be stored and sent like typical data
files.
5. Portable Electronic Test Unit - PETU
The PETU is a portable computer which connects to the pods SEM when the
LMRP is at the surface for troubleshooting. It can function the pod as a
replacement for the surface electronics. It can also be connected to the surface
bus to replace a pod for troubleshooting.
Shuttle valves for redundancy
1. Shuttle valve - the point where the redundant systems, blue and yellow, come
together.
2. Shuttle makes a decision "Who is going to operate this function, the blue or
yellow pod"
3. Shuttle valve is passive. It is shifted by hydraulic pressure from the active
pod when pods are shifted.
4. Flow out through the shuttle into the inactive hose and pod is stopped by the
shuttle. If there should be a leaking hose on the inactive pod the shuttle valve
isolates it from the active pod.
5. Good engineering practice dictates that shuttles should be mounted directly
onto the preventer since redundancy stops at this point
6

6
With systems which are hard piped from the shuttle valve to the equipment port it is considered acceptable to
deviate from this general rule.
Shuttle Valve
Shuttle Valve
Cross section of an individual shuttle valve (available in 1/4. , 1, and 1 sizes)
Cameron Controls
We will step through the electronic portion of the system then we will step through the
hydraulic portions of the Cameron system. We will be concentrating in more detail on
the hydraulic portions of the control system.
Stepping Through the Electronics Section
Lets begin by looking at the overall system interconnection diagram. The electronics
section gets the commands subsea to the pods lets step through a brief over view of
the process.
Uninterruptible power supplies, UPS's
1. Located in upper right of system interconnection diagram.
2. Supply power to driller's panels, top center; HPU, upper left;
toolpusher's panel, top right; cable reels, center; and pods lower
center.
3. UPSs do not supply electric power to the hydraulic pump motors, we
have stored fluid in accumulator bottle for this propose.
4. Each UPS supplies a separate power bus
The surface electronics system intercommunication consists of PLC's located at
the HPU, each of the operator control panels and distribution cabinets, and any
other component requiring communications with the multiplex BOP control
system (event logger). Each controller consists of a Central Processing Unit
(CPU), Power Supply modules, Communication Controllers and the required
quantity and type of I/0 interface boards. The controllers are arranged in a
multi-master configuration to provide the required redundancy. Redundant A and
B busses are used between all controllers to provide maximum availability and to
prevent the possibility of a system failure should any single bus or controller fail.
Drillers and Toolpusher's panels are initiation points for electrical commands to
the system
1. Commands initiated at the remote panels are sent over F-O network to
the cable reels.
2. The F-O network connects also to the HPU as well. This is for diverter
operation and control of the HPU.
The surface signal bus connecting the surface components, both remote panels,
the HPU, distribution cabinets and both of the cable reels is typically a fiber optic
profibus. All controllers on the bus receive the same information at the same
time. For example, a command issued at the Driller's Panel is routed via the
busses to the appropriate subsea communication controller and is "seen" by all
other controllers. Other panel controllers update their system information and
display that a command was issued from another panel. The appropriate subsea
link communication controller transmits the command via modem to the Control
Pod Electronics.
The response from the Control Pod Electronics is received by the subsea link
communication controller via modem and is then routed as a broadcast message
to the surface bus system and simultaneously updates the controllers in the
Driller's and Toolpusher's panels. If, for any reason, the Driller's Panel cannot be
used, all functions may be controlled from the Toolpusher's panel which is a 100
percent redundant unit to the Driller's Control Panel. The surface data bus uses
standardized communication protocol, but the message format used on the
subsea communication links is a proprietary Cameron type which is designed for
optimum message security even on noisy communication links. This message
format assures that no incorrect responses are made in the subsea pods.
Cable reels and slip rings
1. On the cable reel shafts the fiber optic signal is converted to an
electrical signal for passage through slip rings on the cable reel. The
slip rings allow power and signals to be transmitted between the
surface equipment and pods as the stack is being lowered subsea.
2. Once the signals are inside the reel they are transmitted down the
umbilical over copper cores to the riser control boxes.
7
3. Instruct the roustabouts on proper umbilical handling. It is very easy to
twist and kink the cable when it is slack.
4. With stack on the surface disconnect the umbilical from the pod or be
doubly sure that the crew can handle it with out kinking and bird caging
the umbilical armor.

7
If the subsea umbilical contains fiber optic conductors once the signals are inside the reel they are converted back
to fiber optic for transmission down the umbilical to the riser control boxes.
Riser Junction Boxes
8
1. Located on the LMRP, these 2 boxes serve as the subsea
termination of each electrical cable.
9
2. They serve as the junction box to combine the communications
from the pod with the riser control box.
Riser Control Box
1. The 2 riser control boxes serve as the break-out junction box for
the cables leading to the subsea flow meters, riser
inclinometers, and wellbore pressure transducers.
2. The boxes also contain system subsea power supplies.

8
Cameron arranges the riser junction boxes and riser control boxes differently for various applications. The
arrangement shown here is one typical configuration.
9
If the subsea umbilical contains fiber optic conductors they are the point of conversion from fiber optic to electrical
signal.
Stepping Through the Hydraulic Section
The hydraulic portion of the system begins on the surface at the hydraulic power unit
(HPU) which typically consists of 3 portions placed on 3 separate skids.
10
These 3
portions are the mixing skid, the pump skid, and the diverter controls which include the
conduit line supplies.
The HPU has the same basic design as the HPU of a hydraulically piloted BOP control
system with the main exception that it does not include a hydraulic pilot control panel
since "piloting" is done subsea by the multiplex system and its solenoid valves.
Mixing Skid
1. 660 gal. (2,500 l)Lubricant (concentrate) reservoir
2. 790 gal. (3,000 l) Glycol reservoir
3. 3 flowmeters, for water, concentrate (lube), and glycol
4. Batch mixing system. When level sensors in the mixed fluid tank on the
pump skid detect a drop in the fluid level, 100 l. of potable water is sent
through the flow meter to the mixed fluid tank. Then pumps and flow
meters for the concentrate and glycol deliver the required volume into the
mixed fluid reservoir to generate the selected concentration.
5. Potable water is strained as it comes on to the skid
6. Water soluble oil concentrate is typically mixed at 1% or 2%
11
concentration with potable water, but adjustable mixing system allows
control of soluble oil concentrate strengths from selector pad, from 00.1 to
99.9 concentration percentage.
7. Glycol is added for freeze protection in cold weather. A 0 to 9 dial is used
to adjust the concentration percentage.

10
Some systems combine the pump skid with the Diverter panel to form the equipment on 2 skids
11
The concentration used may depend on the type soluble oil used.
Hydraulic Power Unit (HPU)
1. A 790 gal. (3,000 l) mixed fluid reservoir is typically situated on the HPU
skid. It is equipped with high (mix system start), high- high(mix system
stop) level switches plus low, and low-low level alarms.
2. 3 to 4 triplex pumps are installed, each with the capacity to output 15.8
gpm (60 lt/min) for a total capacity of 47.4 gpm. to 63,2 gpm.
3. Relief valves are set at 5,500 psi. (379 bar)
12
4. Dual 20 micron filters
13
are installed on the pump output with an integral
by-pass and clogged filter alarm (delta P alarm)
5. Multiple 13 gal bladder type or 40 gal float type surface accumulator
bottles typically provide a capacity of 1,000 to 1,500 gal. depending on the
stack size and equipment installed. The accumulator bottles are mounted
on 4 or more skids which can be isolated from the system and bled down
individually for maintenance.
6. Hydraulic fluid leaves the skid to the blue and yellow rigid conduits through
a pair of 1 conduit supply valves. Both of these vales are normally
open supplying fluid to both rigid conduits while drilling.
7. Some systems use only one rigid conduit mounted on the riser but have in
addition hot line. The 1 hot line is stored on a reel and strapped onto the
riser in a similar manner as the electrical cables. The hot line is used to
start operation of the pods after the stack has been run and can serve as
a backup rigid conduit if the riser mounted rigid conduit should fail.
8. The supply to both rigid conduits first passes through the surface flow
meter before travelling subsea. The fluid flow to the diverter functions on
the HPU does not pass through a flow meter.

12
For a 3,000 psi system the relief valves are set to 3,300 psi. ASME B-31.3, specification for power piping, calls
for relief valves to be set to a maximum of 110% above system working pressure.
13
The filter element rating can be specified by the drilling contractor
Fluid Handling Portion of the HPU & Diverter Skid Control Panel
Diverter portion of the control system
Up to 4 fluid regulators may be found on the diverter panel :
1. Diverter panel, 1,500 psi for those operations requiring standard
operating pressure
2. Diverter panel, 3,000 psi for those operations requiring high
pressure
3. Diverter packer
4. Lower telescopic joint packer
14
One air regulator is typically used :
1. Upper and lower telescopic joint packer
Function valves
1. Hydraulically operated functions flowline and diverter valves
2. Air operated functions flowline, trip tank and diverter valves
Typical interlocks
1. Closing the diverter packer sends hydraulic fluid to the lower
telescopic joint packer Air/Hydraulic selector valve. Hydraulic fluid
is used to close the lower telescopic joint packer only when the
Air/Hydraulic selector valve is in the hydraulic position.
2. The diverter packer can only be closed if the diverter packer insert
dogs are in the locked position.
3. Closing the flow line valve opens one or both of the port and
starboard overboard valves.
4. Closing one overboard valve opens the opposite overboard valve.
Remote read-back of valve position can be obtained on any
surface/diverter valve by placing limit switches to generate an electrical
signal when the valve has fully functioned.
HPU electric interface panels
1. Air solenoid valves operate the HPU and diverter functions remotely
2. Pressure switches used to inform the remote panels of system status
3. Pressure transducers used to drive pressure meters on electric remote
panels
4. Solenoid valves, pressure switches, and transducers interface with the
system surface data buss. Cameron use a fiber optic profibus (by
PEP) between the remote panels and the HPU.

14
Only pressurized with hydraulic fluid when the diverter packer is in the closed position.
Operation of Bladder Accumulator Bottles
50 Liter (13 Gallon) Bladder Type Bottles
Atmospheric Pressure
The accumulator bottle has a bladder of tough, synthetic rubber that is shaped like a
tapered cigar. It has this shape when there is no pressure on it. The tapered shape
is important because it gives a pushing or squeeze action when fluid is discharging.
The bladder completely separates the nitrogen precharge from the hydraulic fluid.
This prevents the gas from mixing with the hydraulic fluid.
Pre-Charged
Because of its inertness and availability, the bottle is precharged with nitrogen
through a valve at the top of the bottle. At the bottom is the port through which
hydraulic fluid is pumped. The fluid also leaves the bottle from this port. A poppet
valve closes the port when the bladder pushes against it. The 1,500 psi of nitrogen
precharge pushes the elastic bladder to the bottom of the bottle and closes the
poppet valve preventing the bladder from being pushed out of the port.
Initial Charge
Next, hydraulic fluid is pumped into the bottle, and the 1,700-psi minimum pressure
is reached quickly.
Fully Charged
At far right, the bottle is fully charged with fluid to 5,000-psi working pressure. The
additional fluid pumped into the bottle raises the pressure from the 1,700 psi initial
charge to the 5,000 psi fully charged state. As fluid is used from the bottle the
pressure will drop to 1,700 psi. The fluid delivered by the bottle during this process
is defined as the usable fluid available from the bottle.
Operation of Bladder Accumulator Bottles
Operation of Float Accumulator Bottles
35 or 40 Gallon Float Type Bottles
PRECHARGE
With no fluid in the bottle the float is at the bottom of the bottle blocking the inlet/outlet
port. Nitrogen is inserted into the bottle through the needle valve on the side of the port
assembly. Surface accumulator bottle precharge pressure is 1,500 to 1,600 psi for
5,000 psi WP systems
15
. To counteract the effects of hydrostatic pressure, additional
gas precharge is used at the rate of .445 psi per foot of water depth. The float prevents
the N
2
from escaping from the bottom of the bottle when all the fluid is used.
When the accumulator bottles are used in water at depths greater than 3,000 ft, it is
necessary to use helium in the accumulator bottles as the precharge gas. At water
depths greater than 3,000 ft. the nitrogen becomes so dense that it is not able to keep
the float above the surface of the hydraulic fluid. A sinking float closes the outlet port
rendering the accumulated fluid unobtainable by the system.

15
and 1,000 to 1,100 psi for a 3,000 psi WP system
CHARGING THE BOTTLE
Operating the pumps quickly raises the system pressure to the precharge pressure in
the bottles.
As the pumps continue to operate pressure rises and compresses the nitrogen until
system pressure is reached, at which point the pumps turn off. For example, in a 10
gallon bottle it requires 7.0 gallons of fluid to raise system pressure from precharge of
1,500 psi to 5,000 psi WP.
ACCUMULATOR BOTTLE SUPPLYING FLUID.
The system pressure will typically be around 5,000 psi (depending upon the pump
pressure switch start setting). When a preventer is closed, fluid leaves the accumulator
bottle and the gas (N
2
or He) expands. The accumulator bottles will continue to supply
fluid at the current internal gas pressure as the gas pressure expands.
Hydrostatic Effects
Subsea Accumulator Bottle Precharge
3000 psi WP System
Water Depth
Precharge, psi
(1,000 psi + (Water depth x .445
psi/ft))
Available Fluid from a
10 Gallon Subsea
Bottle
16
0 ft. 1,000 psi. 5.0 gal.
1,000 ft. 1,445 psi. 4.6 gal.
2,000 ft. 1,890 psi. 4.2 gal.
3,000 ft. 2,335 psi. 3.8 gal.
4,000 ft. 2,780 psi. 3.5 gal.
5,000 ft. 3,225 psi. 3.2 gal.
6,000 ft. 3,670 psi. 3.0 gal.
7,000 ft. 4,115 psi. 2.8 gal.

16
Calculated on a 3,000 psi WP system using 1,200 psi as the minimum usable fluid pressure. The % of
usable fluid delivered from the bottle is equal to:
(precharge + hydrostatic head) (-)minus (precharge + hydrostatic head)
(Min. pressure + hydrostatic head) (System WP + hydrostatic head)
Hydrostatic Effects
Why We Go to a 5,000 psi WP System
5000 psi WP System
Water Depth
Precharge, psi
(1,500 psi + (Water depth x .445
psi/ft))
Available Fluid from a
10 Gallon Subsea
Bottle
17
0 ft. 1,500 psi. 5.8 gal.
1,000 ft. 1,945 psi. 5.5 gal.
2,000 ft. 2,390 psi. 5.2 gal.
3,000 ft. 2,835 psi. 4.9 gal.
4,000 ft. 3,280 psi. 4.5 gal.
5,000 ft. 3,725 psi. 4.3 gal.
6,000 ft. 4,170 psi. 4.1 gal.
7,000 ft. 4,615 psi. 3.8 gal.

17
Calculated on a 5,000 psi WP system using 1,700 psi as the minimum usable fluid pressure. The % of
usable fluid delivered from the bottle is equal to:
(precharge + hydrostatic head) (-)minus (precharge + hydrostatic head)
(Min. pressure + hydrostatic head) (System WP + hydrostatic head)
Conduit Valve Module Components
1 Each rigid conduit terminates at a conduit valve package. Fluid must first pass through
the 1 3-way shear seal conduit isolation valve.
2 1 pilot operated check valves (POCVs) called, pod selector valves, are used to
control main hydraulic flow out of the manifold to the active pod.
3 As the main hydraulic supply fluid exits the POCV to the pod it passes through that
pods flowmeter.
4 A POCV is used to control the supply of hydraulic fluid to the pods solenoid valve
accumulator.
5 Ted from the line which connects both conduit valve manifolds is the bank of LMRP
mounted accumulator bottles.
6 One 1 POCVs allows either the blue or yellow rigid conduit to charge the LMRP
mounted system accumulator bottles. Only when the POCVs are piloted open can the
fluid be sent from the bottles back into the system.
Conduit flush and Pod Select Circuit on the LMRP
1. Prior to sending fluid to the pod, we must first flush the riser lines to clean debris from
them.
2. First the conduit isolation valve must be opened to send fluid into the conduit valve
module.
3. 1 Conduit flush POCVs are used to vent each conduit to sea for flushing. A function
in the pod is used to open the conduit flush POCV which is spring loaded to the closed
position. With the conduit flush valves open, the blue then the yellow conduits can be
selected to flush them. The conduit flushing time should be determined by the amount
of time required for the clean water to reach the conduit valve manifold for the water
depth at the current location.
4. After closing the flush valves, clean fluid can be sent to the solenoid valve supply
accumulator and main hydraulic supply to the pod by opening their respective POCVs.
5. If a flush POCV should leak, an ROV operated manual valve is placed on the flush vent
port which can be closed as a back-up to the flush valve.
18
6. But wait, this requires the pod to be active when operating these fluid marshaling
valves on the LMRP. How can we do this when the pod is not receiving hydraulic fluid?
7. Well, we have a solenoid valve supply accumulator containing hydraulic fluid mounted
in each pod These accumulators are charged at the surface, and recharged while
running the stack, to enable the pod to open and close the flush valve and then open
the supply valve to the pod.

18
If one is not on your system it is a good idea to add one.
Control Pod
Each Cameron pod is constructed of 2 modules. The upper module is the multiplex
package and the lower module is the BOP control pod. The BOP control pod is
basically a standard Cameron modular pod complete with hose bundle junction plate on
the top of the pod. Rather than receiving its pilot signals from a surface hydraulic
manifold on the rig 6,000 feet away, this pod receives its pilot commands from a
multiplex package mounted directly above it, roughly 3 feet away.
Tracing the flow of fluid and commands through the multiplex
package :
1. Pilot pressure is directed to the mux package from the conduit valve module by the
solenoid valve supply POCV. The hydraulic fluid at 5,000 psi is routed up through a
port in the LMRP receptacle and stinger.
19
2. Once in the pod the fluid passes through a check valve, then a 10 to 12 micron filter,
and is regulated down to 3,000 psi. The check valve prevents the solenoid supply
pressure from being lost if pressure should be lost in the conduit valve modules.
Once this fluid passes through the check valve it will always be pilot fluid and never
be used to fill a preventers open or close chamber.
3. The 3,000 psi fluid fills a 2.6 gal. (10 l) solenoid supply accumulator bottle located
inside the pod.
4. The solenoid valve supply header supplies pressure to all of the solenoid valves in
the mux package for function operation, regulator control, and those functions off the
pods, such as control of the conduit valve modules.
5. Remember that umbilicals are connected to the riser junction boxes where the fiber
optic profibus terminates and the electrical signals are generated. A cable connects
the junction boxes to the respective subsea electronics module (SEM) in each pod.
6. The one atmosphere electronics container (SEM ) in the pod contains the electronics
to decode the function commands and to power the appropriate solenoid valves to
the open position.
7. A separate container is for housing the pressure transducers.

19
If the pod is not designed to be retrievable the connection to the pod may be directly to a bulkhead connector on
the pod structure.
8.
Solenoid valves are mounted on stainless steel internally ported hydraulic
manifolds. They receive their hydraulic fluid from the solenoid supply
accumulator bottle. Flow from the energized solenoid valves travels to the
junction plate at the bottom of the upper pod section.
9. The hydraulic junction between upper and lower pod sections is by standard
hydraulic QD junction plate.
20
10. No pressure switches are used in this system to confirm system status.
Confirmation of a function is determined by usual means, flowmeter and drop in
manifold pressure.
11. Pod slide valves (shear seal valves) which react to the pilot signal by supplying
large amounts of fluid to actual operate the preventers are located in the lower
module.
12. Pod slide valves (shear seal valves) are available in 4 sizes for the various fluid
requirements of the function to which they are assigned , , 1, and 1.
21

20
That is true for the mark I pods. Mark II pods use flexible hoses with no QDs.
21
The valve is a new addition to the product line.
Operation of the Dual Coil Solenoid Valves
1. Hydraulic power for the solenoid valves is derived from the dedicated 10 liter pilot
supply accumulator bottle isolated from the rest of the control system by a check
valve.
2. Electrical power (220 VAC ) down the umbilical is transformed in the pod to
power the electronics with 5 VDC and drive the solenoids with 24 VDC
3. Subsea electronic packages A and B receive the multiplexed command string
and decipher it into a discreet solenoid command. Solenoid valves are energized
with 24 VDC, 12.5 watts required for either coil. SEM A will operate the solenoid
with coil A. If it should fail SEM B will continue to operate the solenoid with coil
B. Either coil alone can operate a solenoid valve.
4. In our typical example (beginning of previous section ), solenoid #3 (from the
right) is activated/energized which shifts pod valve #2 (from the right).
5. Solenoid valves are 2 position spring return valves. When the solenoid valve is
energized it applies pressure to its assigned larger pod slide valve.
6. Due to the spring return of the solenoid valve, when it is de-energized it vents
pressure off the slide valve to which it is connected.
7. Solenoid valve are mounted directly in sea water at hydrostatic pressure of the
surrounding seawater.
8. Cameron solenoids are not in an oil bath.
Separation of MHS and solenoid supply (pilot pressure)
A check valve separates the 2 systems in the event a function draws down the supply
pressure below the activation pressure of the 1 pod slide valves. They require 900-
1,000 psi pilot pressure from the solenoid valves to operate properly.
Caution - with the system "bled down" the pilot accumulator bottle may still have
pressure in it, if bleeding down was not performed properly ! Pressure in the solenoid
valve supply accumulator is bled down by activating both the regulator increase and
decrease functions simultaneously (regulator operation is covered later in the modular
pod section). This is a software operation which is initiated when pressure rises
abnormally high in the accumulator bottle as the stack is pulled to the surface.
Verification of Pod Valve Operation
There is no direct pressure switch readback from solenoid operation. Verify operation
from light indication on the remote panel (indicating the pod has received the
command), reduction in regulator output readback pressure (indicating fluid is flowing to
the function), and flowmeter operation (again, indicating fluid is flowing to the function).
Cameron Hydraulic Modular Pod
Tracing the flow of commands and fluid through the hydraulic section
Retractable stingers and receptacles
1. The two cylindrical hydraulic stingers are located on the bottom of each pod
connects the pod to the rest of the stack which it is controlling.
2. The large stinger stabs into a cylindrical stack mounted receptacle and the
smaller stabs into the LMRP mounted receptacle.
3. The stinger is expanded to energize the packer seals on the stinger OD with
the receptacle ID after it has been stabbed.
4. Prior to extending or retracting the stinger into the receptacle it must be de-
energized
5. When the stinger extends or retracts, those valves using that stab and the
mounting plate they are on travel with the stinger as a unit.
Flowmeter operation, subsea and surface
1. Flow meters are positioned on the surface in the HPU as the fluid leaves the
accumulator bottles and travels through the output valves to the blue and yellow
rigid conduits.
22
2. The subsea flowmeter is mounted on the rigid conduit valve package. Flow
from the rigid conduit passes through the subsea flow meter before entering the
pod.
3. For non-retrievable pods the main hydraulic fluid entrance to the pod is
typically located on the side of the pod. Retrievable pods receive the main flow
in through port S1 in the LMRP receptacle and stinger.
4. The surface flow meter may continue to show flow after a function has
completely operated if the subsea accumulator bottles are continuing to re-fill
after the flow to the function has stopped (and the subsea flowmeter has
stopped).

22
or to the rigid conduit and hot lines if that option is being used
Regulator increase/decrease circuit
1. 3 or more regulators are located in each pod :
Annular regulator (typically set at 1,500 psi)
23
Manifold regulator (typically set at 1,500 psi)
Wellhead connector regulator (typically set at 500 psi while drilling and 1,500 to
3,000 psi while operating the connector)
Ramlock regulator (the solenoid supply pressure regulator is set for 3,000 psi
and it directly supplies the Ramlock functions as well)
2. Regulator output is directly controlled by the pilot pressure force applied to the top of
the regulator.
3. Pressing on the top with 1,500 psi forces it to put out a regulated supply of fluid at
1,500 psi pressure.
4. The pilot pressure applied to the regulator is controlled in the mux portion of the pod.
An increase solenoid allows pressure to flow from the solenoid supply accumulator
to the top of the regulator, thus increasing the regulators output pressure. Also
connected to the top of regulator is a decrease solenoid. Operating the decrease
solenoid vents pressure on the regulator to the sea thus reducing regulator output
pressure. Due to the small volumes of fluid involved 3 surge bottles are also in the
line between increase decrease solenoids and the regulator. They allow the circuit
to operate smoothly. The 3 bottles have various precharge pressures to allow
smooth operation of the regulators on the surface and at depth.
5. The regulators drop pressure directly from the 5,000 psi supply down to the desired
output pressure. Each regulator (except the solenoid supply pressure regulator
which supplies the Ramlock functions) has an increase/decrease circuit and
pressure transmitter.
6. Connector regulator allows the connector to be maintained for long term at lower
locking pressure while drilling.
7. Pressing the enable button and the increase or decrease buttons establishes the
regulator set point. Releasing the enable button allows the regulator to go to the set
point. The software continues to maintain, with the increase decrease solenoids,
the pilot pressure to the regulator at the specified set point for up to 3 minutes. After
3 minutes, any leak in the pilot signal to the regulator will cause the regulator to
deviate from the desired set point. While pressing the enable button, the set point of
the regulator is displayed.

23
Some pods have a separate regulator for the upper as well as the lower annulars.
Operation of the 1 Slide Valve
24
(See diagram of 1 pod valve on opposite page)
1 In normal, un-operated position the 2 small springs hold the shear seal slide valve in the
centered position, preventing 1,500 psi hydraulic pressure (orange) from passing
through the valve to operate a function (Centered diagram on opposite page).
Hydraulic pressure from the 2 valve outlets (yellow) leading to a BOP is vented to sea
through the yellow outlet port in the center of the valve (which shows only as a yellow
circle in the very center of the valve in this drawing). The BOP open and close
chambers now are both vented to sea.

2 Approximately 10 cc's of 3,000 psi pilot fluid (red) are all that's needed to slide the
piston downwards and allow flow from the inlet port on the left to the lower outlet port on
the right of the valve. At the same time the upper outlet port on the right is connected to
the valves vent port on the side of the valve.

3 A large volume of 1,500 psi supply pressure can then flow through the valve to the
lower port to, lets say, close the desired ram. At the same time fluid is flowing to close
the preventer a large volume of opening fluid will be flowing out of the preventer to the
upper port in the slide valve and vented to sea through the yellow outlet port in the
center of the valve.

4 Dropping current to the coil in the solenoid allows the solenoid valve spring to return it to
the closed position. The solenoid valve vents pilot pressure on the slide valves pilot
pressure port.

5 The slide valves spring in combination with the 1,500 psi supply fluid returns the slide to
the center position when pilot pressure is removed from the valve. Hydraulic pressure
is vented from the preventer operating chamber through the slide valves side port
(which shows only as a yellow circle in the very center of the valve in this drawing).

6 Notice that, depending on their function, some slide valve output is routed to the LMRP
stinger (refer back to pod schematic) while other slide valves deliver fluid to the BOP
stack stinger.

7 When pilot pressure drops to only 900-1,000 psi the valves float into the open/closed
position, which allows fluid to leak from the supply port directly to the vent port, resulting
in rapid loss of hydraulic fluid from the accumulator bottles. This is called inter-flowing.
In this situation all accumulator pressure can quickly be lost.
8 Pilot pressure should always be at least 1,500 psi, the usual alarm set point.

24
This valve is typically used for ram BOP operation
Cameron 1, 4-Way, 3-Position, Tandem Valve
No Pilot Pressure Applied Pilot Pressure Applied To Top Port
Valve Venting Pressure at Both Output Ports Valve Sending Pressure to Lower Output Port
3-Position and 2-Position Functions
3-Position Functions
3-position functions on the driller's remote panel have 3 buttons or positions :
open, close, and center or block.
Examples of 3-position functions are the ram, annular, connector, and stack stinger.
1. 2 solenoids (the open and close solenoids) are used to control the pod slide
valve for each of these functions.
2. The center button de-energizes both the open and close solenoids assigned
to that functions slide valve. Springs and internal supply pressure center the
valve when pilot pressure is released.
3. Ram functions use a single 1 slide valve (as shown on the previous page) to
control a ram preventer
4. Connector and stack stinger functions use a single valve to control the
function. A 3-position valve is shown on the opposite page.
5. Annular functions use two 1 valves to control an annular. One valve
supplies opening fluid while the opposite is used for closing fluid.
2-Position Functions
2-position functions on the driller's remote panel have 2 buttons or positions :
function and vent.
Examples of 2-position functions are the wellhead connector secondary, connector
gasket release, and pod select.
1. These functions control only one solenoid.
2. When energized, that one solenoid sends pilot pressure to operate its
associated slide valve to the open position. That slide valve is typically a
valve as shown in the drawing on the opposite page.
3. When de-energized that solenoid vents pressure from the slide valve. The
slide valve is spring loaded into the closed and vented position. The
operating pressure is then released from the function being operated.
Accumulator Bottles to Start the System Subsea and Flush the Rigid Conduits
1. On systems without hot lines, power stored in the pod mounted pilot pressure
accumulator must occasionally be recharged as the stack is run subsea.
2. Failure to do this will not allow the pod to open the conduit supply
valves and render the pod pressureless and inoperable when it reaches
the wellhead.
Typical Slide Valve used for a 3-Position Function
Typical Slide Valve used for a 2-Position Function
ROV Operation of Selected Functions
1. An ROV offers an additional method of operating critical functions in the event the mux
system fails to operate.

2. Functions which may be controlled are :
B) On the LMRP we find :
1. LMRP connector primary unlatch
2. LMRP connector secondary unlatch
3. C&K mini connector primary unlatch
4. C&K mini connector secondary unlatch
5. Glycol injection, riser connector
6. Gasket release
7. Rigid conduit flush valve manual shut-off
B) On the sack we find an ROV panel to :
1. Wellhead connector primary unlatch
2. Wellhead connector secondary unlatch
3. Wellhead connector gasket release
4. Middle Pipe rams close
5. VBRs close
6. Shear rams close
7. Glycol injection, wellhead connector
8. Gasket release
3. To pump a pipe or shear ram closed or pump a connector open, an ROV can use an
intensifier pump using sea water or oil from an ROV mounted reservoir.

4. ROV operation requires an additional shuttle valve on those functions requiring
intervention.
5. Circuit must be installed and tested prior to being used subsea.
6. Does the stab fit the receptacle ? Industry standards relating to ROV stabs have only
recently been established in API Spec 17 D
25
. The drilling segment of the ROV industry
has been slow to adopt them.
7. For ROV or acoustic operations more decisions are require and therefore more shuttle
valves are used or a Gilmore Multiport design is used.
8. When multiple shuttle valves are used, the valve closest to the equipment port will
usually be used to decide whether to operate the equipment by the ROV or the pods.

25
API 17 D, Specifications for Subsea Wellheads and Trees, Sec. 921.2g
ROV Shuttle Valve Installation
Gilmore Multi-Port Shuttle Valve
Cameron Multiplex Control System
Operational Notes
Operating The Remote Panels
After pressing a function button along with an enable button, the slow flashing of the
function button indicates that the execution of the command is in progress. Once the
subsea electronics has confirmed firing the solenoid, the function illuminates
continuously. Fast flashing of the function button indicates that there is a problem with
the operation.
When holding the enable button, only one function can be energized at a time.
If the surface electronics does not receive confirmation from subsea electronics within
approximately 1 second, it will try an additional 2 times to operate the function after
release of the enable button.
2 Enable buttons may be present and are identical except that the button near the
increase/decrease buttons must be used for this I/D operation.
Pressing the enable button and increase or decrease buttons establishes a new set
point for the regulator. Releasing the enable button allows the regulator to go to that set
point.
Can not set 2 regulators with 1 press of the enable button.
Subsea Panel
The drillers control panel is divided into sections the following sections :
1. BOP Control Panel
2. Diverter Control Panel
3. System and pod controls
Sequences
LMRP Stinger De-energize
When the LMRP stinger is de-energized, the pod valves vent pressure off all LMRP
functions, closes the supply to the pod (S1), closes the solenoid valve supply, and
closes the LMRP accumulator isolator valve.
Stack Stinger De-energize
When the stack stinger is de-energized, the pod valves vent pressure off all stack
functions.
Ram Preventer Operation -
Each ram function has a short sequence associated with it. These are listed below :
OPEN VENT CLOSE
26
LOCK
27
Unlock Vent pressure Unlock Unlock
Pause off the Open, Pause Pause
Open Close, and Close (only) Close
Unlock ports Pause
Vent Unlock
Gasket Release -
After pressing the button, the function remains energized for 60 seconds when releasing
the gasket. The solenoid does not remain energized after the 60 seconds.

26
It may be named Strip
27
It may be named Close & Lock
The Hydril Multiplex BOP Control System
Reviewing the Similarities and Differences
The first 11 pages of this section on multiplex control systems (up to the point where we
began stepping through the Cameron Control system) dealt in generalities with the
basics of any BOP multiplex control system and applied equally as well to the Hydril as
the Cameron control system.
The differences in control systems only becomes apparent when we look at the detailed
configuration of the electrical and hydraulic components. In this portion of the multiplex
BOP controls section we will step through the Hydril multiplex control system and note
the similarities and differences with the Cameron system we just finished walking
through.
The following, page 70, is a pictorial over-view of the complete system.
In the pictorial, the most striking item to notice is that the Cameron distribution cabinets
have been replaced with the Hydril central control unit (CCU) which is located in the top
center of the drawing. It acts as the communication link between surface and subsea
components of the system.
Page 72 is a drawing of the drillers remote panel.
The Hydril Multiplex BOP Control System General Arrangement
E/H Back - Up System
Mixing Skid
Mixing Skid Flow Diagram
Hydraulic Power Unit (HPU)
Fluid Marshaling SPM Valve
Diverter Skid - Front Panel
Diverter Skid Side View
Diverter Schematic
Hydril Multiplex pod
With LMRP and Stack Receptacles
Pod E/H (Upper) Section
Hydraulic (Lower) Section
Pod Hydraulic Schematic
(Page 1 of 3)
LMRP Hydraulic Schematic
Stack Hydraulic Schematic
Family of Functions
Ram BOPs
Family of Functions
Shear Rams
Mul t i pl e x Dr i l l i ng Cont r ol S y s t e ms
Surface Equipment
Each of the two system control panels, the drillers panel
and the auxiliary (toolpushers) panel, is capable of full,
independent, control of the subsea drilling system. All
commands and status changes are transmitted to all
electrohydraulic control units over redundant data high-
ways. All status changes are received by each multiplex
control unit to ensure that they are all continuously updated
and have identical data. The use of redundant controllers
and data highways ensures that full subsea BOP control is
available even if either of the control panels or data
highways is inoperable.
The interfaces between the surface panel controllers
and the Subsea Electronic Modules (SEMs) are effected by
dedicated modem cards which convert all commands into a
proprietary message format for transmission to the SEMs in
the subsea control pods. The field-proven software
protocol incorporates enhanced security features, such as
extensive data checking and Cyclic Redundancy Code
generation. These techniques ensure that any possible
message corruptions are extremely unlikely to result in an
improper control action. Redundant, dedicated, uninter-
ruptible power supplies (UPS) are a Cameron standard.
Each one is able to power the complete electronic control
system for at least two hours. The redundant system is illus-
trated in the figure below.
Event Logger
SEM SEM
2 Independent
Data Highways
Power & Communication
Cables
Yellow
Pod
Blue
Pod
UPS A
Hydraulic
Power Unit
Toolpusher's
Panel
Communication
Controller
YELLOW
Communication
Subsea Link Subsea Link
Controller
BLUE
UPS B
Driller's
Panel
Portable Electronic
Test Unit
The Cameron Multiplex BOP Control System combines well-known, field-proven Cameron hydraulic components with
commercially available standard, high reliability electronic components in a configuration which provides the offshore drilling
industry with an extremely reliable and secure control system. The most up-to-date, field-proven hardware and software design and
manufacturing techniques are used throughout the system. The rough environment of offshore applications is considered during all
phases of system design and manufacture.
System Design
The system is designed to
provide control redundancy
throughout in accordance
with API standards for
drilling equipment. All criti-
cal control and power paths
are duplicated to minimize
the possibility of system
downtime in the event of
equipment malfunction or
damage. The Cameron
Multiplex System does not
rely on a single master
control unit because a
single failure in such a
system can cause complete
system shutdown. Each
control panel incorporates
the equipment required to
control and monitor the
entire system. When
plugged into the system,
the Portable Electronic Test
Unit can also be used to
carry out the same function
as the panels.
The master unit in each control panel is configured using
standard, rack mounting units which are readily accessible
in the panels for testing and maintenance. A typical
controller is shown in the photograph below. Repairs are
easily made by modular unit replacement.
Subsea Equipment
The redundant SEMs are located inside nitrogen-filled
pressure vessels in each of the subsea control pods.
The SEM printed circuit cards are based on high reliabili-
ty, industry standard hardware. The system is optimized
to use as few cards and components as possible to
ensure the highest MTBF rating possible.
The solenoid interfaces are digital output boards
equipped with enhanced diagnostic capabilities. Each
solenoid coil is continuously monitored for open circuit
(break-state detection) and short circuit.
System pressures, voltages and other important
housekeeping data are also continuously monitored by
the SEMs. Any parameter which is out of operator
designated safe range results in the initiation of an
alarm by the SEM.
Because subsea electrical connectors on the main
control cables are the most vulnerable items in the sub-
sea control data path, wet mateable connectors within
redundant seals on each pin are used for each of the
cable conductors to enhance system reliability.
Portable Electronic Test Unit
The Portable Electronic Test Unit permits the user to test all
Control Pod and other system functions with a pod either
fully installed on the BOP stack or with the pod sitting at
the surface. The unit can also be used to simulate a
Control Pod for testing of either Control Panel without a
pod. The unit is housed in a robust case, designed to IP 65
NEMA4
environmental standards.
For surface system software modifications Cameron
offers the Software Development Package which permits
the writing, modification, testing and debugging of system
operation programs to match reconfiguration of the BOP
stack or control functions. It uses a graphical interface
together with several different industry standard programs.
The program types include ladder diagrams (LD,) sequential
function charts (SFC) and function block diagrams (FBD) in
accordance with IEC 1131 industry standards.
VS110
VS111
VS112
VS113
VS114
VS115
VS116
VS117
VS118
VS119
VS110
VS111
VS112
VS113
VS114
VS115
VS116
VS117
VS118
VS119
VS10x >
Analog Data
Typical Controller
An example of
one of the
Portable
Electronic Test
Unit screens is
shown here,
showing system
status and analog
data readouts.
Supply voltage 28.7 V ok
Annular Preventer Pilot Pressure PT101
Status : Ok 8.8 mA
BOP Pilot Pressure PT102
Status : Ok 8.8 mA
Subsea Accumulator Pressure PT106
Status : Ok 8.8 mA
BOP Pilot Operating PT105
Status : Ok 8.8 mA = 112 barg
Annular Preventer Operating Pressure PT104
Status : Ok 8.8 mA = 112 barg
Switch VS110 on
Setup Analog Data Digital Data Valve Data Toggle Valve Quit
VS110
VS111
VS112
VS113
VS114 VS115
VS116
VS117 VS118
VS119
VS110
VS111
VS112
VS113
VS114
VS115
VS116
VS117
VS118
VS119
VS10x >
VS11x >
System Status
Analog Data
Optional Equipment
Cameron strongly recommends the use of an optional
Event Logger along with the MUX system. The Event
Logger is used to create a permanent log of all impor-
tant system events and status changes. It may be con-
nected either to the redundant BUS system or to the
communication links down to the SEMs.
Technical Specifications
All boards in the surface controllers use the well known,
standard VME interface and may be mixed with other
VME compatible cards from different suppliers. The
boards all mount in a 19 rack enclosure. Numerous
cards are available to provide a wide range of processors
and processor speeds.
The following features are common for all boards:
Temperature range, industrial E2 (-40 C to +80 C)
or better
Shock and vibration tested according to IEC 68-2
EMV protection according to IEC 801 / VDE 0871
ESD protection according to IEC 801-2
MTBF in excess pf 14.3 years for the dual processor
configuration. MTBF figures for other configura-
tions are available.
Equipment in accordance with EN 50014...50020
(IEC 79-0, 2...11)
Special ruggedized design
Optional conformal coating available
Supplier meets ISO 9001
A comprehensive component user list including offshore,
space and military applications is available on request.
Cooper Cameron Corporation, Cameron Division, Printed In USA, 3/97, 1CHC, WR6082/TC1146
Cameron P O Box 1212 Houston, Texas 77251 1212 Phone 713 683 4600 Fax 713 683 4306 http://www.camerondiv.com
Cameron GmbH Lueckenweg 1 29227 Celle Germany Phone 011 49 5141 8060 Fax 011 49 5141 806333
Control Pod
The Cameron Multiplex (MUX) BOP Control Pod is made
from two independent sections: the Hydraulic Module
and the Electronic MUX Package.
The lower portion of the MUX pod assembly, the
Hydraulic Module, is a standard Cameron modular pod,
identical with the well-known units which have been
installed on many offshore mobile drilling rigs since 1981.
The MUX package is mounted on top of the hydraulic
module and is easily removable for maintenance access. It
consists of the Subsea Electronics Module (SEM) and the
Solenoid Valve Package. The SEM is installed inside a
one-atmosphere pressure vessel.
Hydraulic Module
The main features of the Hydraulic Module are:
Hydraulic connections are made with extendable and
retractable, multi-port, hydraulic connectors.
With pods installed and connectors retracted, pod
function testing can be accomplished without
operating BOP stack functions.
All connector seals are retrievable with the pod.
All connector seals are recessed in a de-energized
position for protection during installation and retrieval.
Hydraulic connections are pressure balanced, pod locks
have no hydraulically induced loads.
All valves and pressure regulators use sliding,
metal-to-metal, shear type seals.
All valves are stainless steel.
1-1/2 valves and pressure regulators for operation of
annular preventers have the largest flow rates in the
industry.
All valves and pressure regulators are sub-plate or
seal-sub mounted for ease of maintenance.
Packing at all connector ports is blowout proof
even if disconnected at full pressure.
All pilot ports of valves and pressure regulator are fitted
with purge fittings.
Pods are offered in either a closed loop configura-
tion which returns all exhaust fluid to the surface
reservoir, or a vent-to-sea configuration which
exhausts fluid into the sea at the pod.
The module is designed so that all routine maintenance
can be performed without disturbing hydraulic hose or tub-
ing connections. This includes bleeding and purging of
hydraulic pilot lines after a valve has been reinstalled.
The unit has two, multi-port male connectors which
are individually retractable. One connector controls all the
functions of the lower riser package and connects the main
hydraulic supply from the surface via an auxiliary line on the
riser. The other retractable connector controls all the func-
tions of the lower BOP stack.
The female multi-port connectors are cylindrical with
the sealing surfaces on the insides. These surfaces are
wiped clean by elastomeric wiper rings located at the bot-
toms of the male connectors. Proper alignment of the
male and female connectors is assured by floating align-
ment mounts on the female receptacles; they are supported
by elastomeric springs. In guidelineless situations, an ROV
may be used for pod orientation and actuation of a
hydraulic electrical connector stab for the control cable.
Details of the retractable connectors and the control valve
installations are shown on the last page of this brochure.
Electronic MUX Package
The Electronic MUX Package is made up of two major
systems: the Subsea Electronics Module and the Solenoid
Valve Package.
Subsea Electronics Module (SEM) - The SEM con-
tains dual redundant electronics and communicates via
modem with the Subsea Link Communication Controllers in
the surface electronic system. The 230 VAC electrical
power supply voltage feeds two power supplies: 5VDC for
the PLC and 24 VDC for the solenoids and instrumentation.
The main features of the SEM are:
VME bus system
Two independent electronic systems
Reliable industrial standard electronic boards
Full online diagnostics
Control Pod
Female receptacle installation on a BOP stack receiver plate and lower
riser package stab plate
SD5416
The Cameron Multiplex BOP Control Pod incorporates the field-proven reliability of the Cameron Modular
Pod with a MUX package containing dual redundant electronics. The pod is intended to be fully retrievable
and most functions can be tested while installed subsea.
Sub-plate mounted solenoid valves
Weight set main electrical supply connection for
retrievable pods
No pressure compensation is required
The main control cable from the surface
equipment connects to an electrical
connector in the base plate of the
pod. The power conductors in the
cable connect to the power supplies
while the signal conductors connect
to the MUX system modem.
The modem handles both the
uplink and downlink communication processes
of the system. The strain reliefs are anchored
on the lower riser package for the standard
subsea retrievable pod design.
An analog-to-digital conversion module
receives analog data signals from pressure
transducers and other sensors and digitizes
them for transmission to the surface
system. All important system pressures
and voltages are monitored by this system.
Solenoid Valve Package - The Solenoid
Valve Package consists primarily of several
solenoid valve modules. The hydraulic sec-
tions of these valves use sliding metal-to-metal, shear-type
seals exactly like those in the main BOP control valves of the
pod. These valves have demonstrated their reliability in
many subsea installations since they were developed in
1975. In keeping with the dual redundancy philosophy
of the Cameron system, the solenoid valves each have dual
coils. The solenoid coils require only 12 watts of power each
for valve actuation. This results in significant savings in the
uninterruptible power supply (UPS) unit installed on the rig
for operation of the BOP control system. The solenoid
valves are installed and arranged so that the hydraulic
sections of the valves are accessible from the outside of the
MUX package.
The solenoid valves are sub-plate mounted and
equipped with electrical subsea environmental connectors.
The electrical connectors are connected directly to the SEM
pressure vessel lower housing assembly. No special instruc-
tions during installation or removal of the solenoid
valves must be followed. The system pressure
transducers for all the subsea read-back
functions are installed onto the SEM pres-
sure vessels lower housing assembly.
The complete MUX package bolts
onto the top of the hydraulic control
module. All of the hydraulic pilot con-
nections are made automatically through
a male hydraulic junction box installed in
the bottom of the MUX package. It
mates with the standard female junction
box of the hydraulic module which is nor-
mally used for connection with a hydraulic con-
trol umbilical when hydraulic pilot control is
used.
Accumulator Banks
In the standard configuration, two accu-
mulator banks, each containing four
small accumulators, provide pilot pres-
sures for the two pod pressure regula-
tors (for the annular preventers and the manifold). Both
accumulator banks are installed within the frame envelope
of the pod assembly. Each of the accumulators has a differ-
ent precharge pressure, prescribed in four ascending values
as a function of the operating water depth. The staggered
precharge pressures ensure that the charge pressure of the
bank can be easily controlled throughout the required set-
ting range by feeding and bleeding pressure with short
pulses of the controlling solenoid valves. If only a single,
small, pilot accumulator were used, the pressure in the high-
er range would change too rapidly to be controlled by the
solenoid valves.
Redundant Yellow
Hydraulic Module
Portion of Cameron
Multiplex Control
Pod Assembly
Complete pod with covers removed.
Electronics pressure vessel and regulator
pilot accumulators swung out for solenoid
valve access.
Redundant Blue
Hydraulic Module
Portion of Cameron
Multiplex Control
Pod Assembly
Optional Features
Optional equipment which can take advantage of the
flexibility of a multiplex communication and control system
include:
Riser inclination and tension monitoring system which
may include monitoring mud temperature and
pressure.
Subsea TV camera controls and lighting (requires an
additional signal cable in the control cable).
Monitor other electrical sensors on the lower riser
package and BOP stack, such as temperature,
pressures, etc.
All desired data from the riser instrumentation unit can
be transmitted via the SEM to the surface panels, and all
necessary television camera commands, such as pan, tilt,
focus, zoom and light commands, can also be transmitted
over the MUX control signal lines. No additional wires are
required for sensor data, only for visual display unit data.
1-1/2 valve shown being installed onto seal subs. Typical pilot
line purge fittings are visible on 1/4 valves visible at the left.
Purge fittings are provided for all pilot lines.
Stack and riser connector stingers extended in operating position.
BOP stack connector stinger retracted and riser stinger extended,
normal position for running or retrieval of the lower riser package.
BOP stack and riser connector stingers shown retracted in running
or testing position.
Cooper Cameron Corporation, Cameron Division, Printed In USA, 3/96 1CHC, WR6081/TC1145
Event Logger
The Event Logger monitors the BOP control system
continuously without interfering with control system func-
tions. The data is stored in permanent log files which may
be later reviewed and analyzed to determine actual
sequences of events during operation of the BOP control
system. The log file contains the following data:
Date
Time
Command source (i.e. Drillers Panel)
Command target (i.e. Blue Pod)
Command contents (i.e. Open Lower Annular Preventer)
Target answer
Discrepancy, if any
This information allows the operator to determine
what has happened during any period of time. The
complete log can be printed, or it can be printed using
filters such as printing the equipment status changes
only. Alarms, either all or those selected, can be printed
automatically.
Two different display modes can be selected. The text
mode continuously displays all logged commands as lines
of text. Alternatively, the graphics screen can be selected
to display the main status parameters of the system in a
graphic display similar to that shown on the front of this
brochure. The screen changes as soon as the new status
is reported from the pod or other operating equipment.
Event Logger
Cameron Data-Logger Version: 1.2 20.07.96
Date Time From To Message
-------------------------------------------------------------------------------------------------------------------------------
12.08.96 08:54:35 CCU ->BLUE #2A09010204C000EE0000FFFF\*
12.08.96 08:54:36 BLUE->CCU #000001000000000001000000000000383838383838FFFF\*
Initial Status Blue
Pod Set Supply (VS100) OFF WB OK
Annular Preventer Pilot Pressure Increase (VS101) OFF WB OK
BOP Pilot Pressure Increase (VS102) OFF WB OK
Pod Selector (VS103) OFF WB OK
Annular Preventer Pilot Pressure Decrease (VS104) OFF WB OK
BOP Pilot Pressure Decrease (VS105) OFF WB OK
Wellhead Connector Secondary Unlatch (VS108) OFF WB OK
Riser Connector Unlatch (VS109) OFF WB OK
Riser Connector Latch (VS110) OFF WB OK
Riser Connector Secondary Unlatch (VS111) OFF WB OK
Pod Lock (VS112) OFF WB OK
Upper Annular Preventer Open (VS113) OFF WB OK
Upper Annular Preventer Close (VS114) OFF WB OK
Shear Rams Open (VS115) ON WB OK
Shear Rams Close (VS116) OFF WB OK
Upper Pipe Rams Open (VS117) OFF WB OK
Command> *** Top of file *** Keys: PgUp PgDn ESC=Exit F1=Help
Cooper Cameron Corporation, Cameron Division, Printed In USA, 3/97, 1MCHC, TC1144
The Event Logger records all messages between both control panel communication controllers and the blue and yellow pods in a Cameron
Multiplex Drilling Control System. It enables the operator to review sequences/occurrences and provides online monitoring and offline
data diagnostics.
An example of
one of the
Event Logger
screens is
shown here,
showing sys-
tem status at a
specified date
and time.
Portable Electronic
Test Unit
The Portable Electronic Test Unit consists of an IBM
compatible laptop PC, a control pod electrical power supply,
a modem and interconnection test cables. The software is
written in a high level language which can be run on any
standard IBM compatible PC. The Test Unit is housed in a
robust case designed to IP65 environmental standards. An
optional, ruggedized, water-resistant case is also available.
All of the control panel commands are available on the
Test Unit. Additional test functions and test control
sequences are also provided. Information displayed on the
screen informs the operator about the complete status of
the pod. All analog values, solenoid coil status data and
diagnostic data are accessible with a simple keystroke or
mouse click.
The Portable Electronic Test Unit can be used to per-
form specified tests automatically. For example, a typical
test after changing out components in the control pod may
be to operate the component function several times (for
example 10 or 15) to confirm proper operation.
The Test Unit can also be used to control a pod while it
is on the BOP stack. This may be helpful when access to a
control panel is not possible.
An example of
one of the
Portable
Electronic Test
Unit screens is
shown here,
showing system
status and analog
data readouts.
Portable Electronic Test Unit
Supply Voltage 28.7 V OK
Annular Preventer Pilot Pressure PT101
Status : OK 8.8 mA
BOP Pilot Pressure PT102
Status : OK 8.8 mA
Subsea Accumulator Pressure PT106
Status : OK 8.8 mA
BOP Pilot Operating PT105
Status : OK 8.8 mA = 112 barg
Annular Preventer Operating Pressure PT104
Status : OK 8.8 mA = 112 barg
Switch VS110 on
Setup Analog Data Digital Data Valve Data Toggle Valve Quit
VS110
VS111
VS112
VS113
VS114 VS115
VS116
VS117 VS118
VS119
VS110
VS111
VS112
VS113
VS114
VS115
VS116
VS117
VS118
VS119
VS10x >
VS11x >
System Status
Analog Data
The design of the Portable Electronic Test Unit is based upon a standard laptop computer. 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. The Test Unit also permits changes to the surface software system utilizing the software development package.
Cooper Cameron Corporation, Cameron Division, Printed in USA, 3/97,1CHC, TC1145
PC Specifications:
Processor: 80286 based or higher, 25 MHz minimum
RAM: 1 Mbyte, minimum.
Disk Drive: 5-1/4" or 3-1/2"
Monitor: VGA compatible
Ports: 2 serial, 1 parallel

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