ACCUMULATOR (KOOMEY)

Courtesy
IADC

Wathik M. Alhashimi, P.Eng.

• An accumulator or Koomey unit is a unit used to hydraulically operate Rams BOP, Annular BOP, HCR and some
hydraulic equipment.
• There are several of high pressure cylinders that store gas (in bladders) and hydraulic fluid or water under pressure for
hydraulic activated systems.
• An accumulator or Koomey unit is a unit used to hydraulically operate Rams BOP, Annular BOP, HCR and some
hydraulic equipment.
• There are several of high pressure cylinders that store gas (in bladders) and hydraulic fluid or water under pressure
for hydraulic activated systems.
• The primary purpose of this unit is to supply hydraulic power to the BOP stack in order to close/open BOP stack
for both normal operational and emergency situation.
• Stored hydraulic in the system can provide hydraulic power to close BOP’s in well control operation, therefore, kick
volume will be minimized.
• The accumulator should have sufficient volume to close/open all preventers and accumulator pressure must be
maintained all time.
• According to API RP53, your reservoir tank should have a total volume at least 2 times of usable volume to close all
BOP equipment.
• Pressure based on 3,000 psi surface stack system that you should check on BOP remote panel and Koomey unit is
listed below:
o Manifold pressure at +/- 1,500 psi
o Accumulator pressure at +/- 3,000 psi
o Annular preventer at +/- 500 – 1,500 psi
o Rig Air at +/- 100 – 130 psi
• There are 4 main components of the Koomey unit as follows:
o Accumulators
o Pumping system (electric and pneumatic pumps)
o Manifold system
o Reservoir tank
• According to API RP 53, there must be 2 or 3 independent sources of power that will be available for each
closing unit. Typically, you will these following sources:
o Hydraulic with pressure charged in the bottles.
o Pneumatic
o Electric
• The diagram below demonstrates how the accumulator is lined up for the surface stack.
• A: Pressure regulator is used to maintain pressure
at annular side at 500-1500 psi
• B: Pressure regulator is used to maintain the
manifold pressure at 1,500 psi
• Blue line for opening equipment as VBR’s,
Blind/Shear Rams, Annular, HCR.
• Red line for closing equipment as VBR’s,
Blind/Shear Rams, Annular, HCR.
 Mechanism of Accumulator (Koomey Unit)
• This topic describes how an accumulator (Koomey Unit) works.
• First of all, I will start with accumulator bottles. The accumulator bottles are used to store hydraulic pressure for
closing/opening all blow out preventers.
• Each bottle, which has a rubber bladder inside, has a storage volume of 10 gallons.
• The rubber bladder inside is pre-charged to 1,000 psi with Nitrogen (N2).
• Each bottle will be pressured up 200 psi over the pressure charge pressure.
• At this stage, 1.7 gal of hydraulic fluid is used in order to compress N2 to minimum system pressure of 1,200 psi
(200 psi over pre charge pressure), called “minimum operating pressure”.
• Hydraulic oil will be pumped into the bottle until pressure in the bladder reach 3,000 psi, called “Operating
Pressure”.
• Volume of hydraulic fluid used to pressure up from 1200 psi to 3000 ps, which is called “Useable Fluid”, is equal
to 5 gallons,
• Note: Use Bolye’s Law to figure out usable fluid later.
• In an accumulator unit as shown in the figure below as an example, there are one electric pump and two pneumatic
pumps, which will be automatically pumped hydraulic fluid, which is stored in a reservoir tank when pressure in bottles
is below set pressure in order to maintain bottle pressure at 3,000 psi.
• The electric pump is mainly used to maintain pressure. Pneumatic pumps will be use in case of
1) the electric pump failure and
2) helping the electric pump to increase bottle pressure quicker.
 Hydraulic fluid under pressured is divided into two following ways:
• 1. The first way is used for controlling an annular preventer.
• Hydraulic under pressure of 3,000 psi in bottles passes a pressure regulator (in the figure is a regulator “A”) in
order to regulate pressure from 3,000 to 500-1500 psi for operating annular preventer.
• Pressure used to operate the annular preventer must be less than pressure used to operate rams preventer
because high pressure will damage a rubber seal inside of the annular preventer.
• 2. Another way is used to control rams preventers (VBR’s rams, blind/shear rams, pipe rams) and HCR valves.
• Hydraulic under pressure of 3,000 psi in bottles passes a pressure regulator (in the figure is a regulator “B”) in
order to reduce pressure from 3,000 to 1,500 psi for operating rams preventers and HCR valves.
• The regulated hydraulic fluid under pressure of 1,500 goes to a manifold which is used to divide hydraulic
pressure in many ways to operate equipment.
• This is normally called “Manifold Pressure”.
• All pressure activated equipment as annular preventer, VBR’s and HCR valves have two hydraulic fluid ports.
• One is for opening equipment and another one is for closing equipment.
• You can operate the BOP equipment by pushing remote switches or handles at the accumulator unit.
• In case of opening equipment, pressured hydraulic fluid will be transmitted to the open port and hydraulic
power will drive an internal mechanism inside equipment in order to open equipment.
• Fluid in closing side will be pushed out and go back to a reservoir tank. On the contrary, in case of closing
equipment, the process is quite as same as opening process but only fluid flow direction is opposite.
 BOP Control System Components & Recommendations
• A Blowout Preventer (BOP) Control System as one of the drilling rig components, is a high-pressure hydraulic power unit fitted with
directional control valves to safely control well kicks and prevent blowouts during drilling operations.
• A typical system offers a wide variety of equipment to meet the customer’s specific operational and economic criteria.
• The following text gives a brief description of the equipment and some of its major components.
• Control systems for surface-mounted BOP blowout preventers used for well drilling are usually “closed-loop” design hydraulic
systems.
• This means two lines are required for all pressure open/pressure close BOP stack functions, and that fluid in one line is returned to
the control unit reservoir when the other line is pressurized.
• These systems lend themselves to the use of petroleum-based fluids for the control system operating fluid.
• Since there is a possibility of an “ecological incident” in the event of a system leak, many offshore contractors are turning to the use
of water-based control system fluids.
• Water-based fluids have no detrimental effect on operations as long as:
• The environmentally safe lubricating agent is added to the water.
• Freeze protection is provided if the system is to be operated in cold climates.
• The fluid is regularly inspected and bacteria growth is checked either by addition of chemical agents or timely replacement of the
fluid.
• Water base control system fluid can be premixed in proper ratios in accordance with the control system manufacturers’
recommendations.
• The control system manufacturer should specify control system fluid that is compatible with the equipment seals and materials.
NOTE: System designed to meet API RP 16E must have Electric Remote Control Panels if they are used on offshore rigs
1. CUSTOMER AIR SUPPLY: Normal air supply is at 125 psi. Higher air pressure may require an air regulator for No.
88860 air pumps.
2. AIR LUBRICATOR: Located on the air inlet line to the air-operated pumps. Use SAE 10 lubricating oil.
3. BYPASS VALVE: To automatic hydro-pneumatic pressure switch. When pressures higher than the normal 3,000
psi are required, open this valve. Keep closed at all other times.
4. AUTOMATIC HYDRO-PNEUMATIC PRESSURE SWITCH: Pressure switch is set at 2,900 psi cut-out when air and
electric pumps are used. Otherwise set at 3,000 psi for air pumps alone. Adjustable spring tension control.
5. AIR SHUT-OFF VALVES: Manually operated — to open or close the air supply to the air-operated hydraulic
pumpS.
6. AIR OPERATED HYDRAULIC PUMPS: Normal operating air pressure is 125 psi, (For No, 88550 pumps, maximum
air pressure is 200 psi and for No. 88660 pumps maximum air pressure is 125 psi.)
7. SUCTION SHUT-OFF VALVE: Manually operated. Keep normally open. One for each air operated hydraulic pump
suction line.
8. SUCTION STRAINER: One for each air operated hydraulic pump suction line. Has removable screens. for best
performance of BOP control system, it should be cleaned every 30 days.
9. CHECK VALVE: One for each air operated hydraulic pump delivery line.
10. ELECTRIC MOTOR DRIVEN TRIPLEX OR DUPLEX PUMP ASSEMBLY.
11. AUTOMATIC HYDRO-ELECTRIC PRESSURE SWITCH: Pressure switch is set at 3,000 psi cut-out and 250 psi cut-in
differential. Adjustable.
12. ELECTRIC MOTOR STARTER (AUTOMATIC): Automatically starts or stops the electric motor driving the triplex or
duplex pump. Works in conjunction with the automatic hydro-electric pressure switch and has a manual
overriding on-off switch.
13. SUCTION SHUT-OFF VALVE: Manually operated, normally open, Located in the suction line of the triplex pump.
14. SUCTION STRAINER: Located in the suction line of the triplex or duplex pump,
15. CHECK VALVE: Located in the delivery line of the triplex or duplex pump.
16. ACCUMULATOR SHUT-OFF VALVE: Manually operated. Normally in open position when the unit is in
operation. Close when testing or skidding rig or when applying pressure over 3,000 psi to open side of ram
preventers, OPEN WHEN TEST IS COMPLETED.
17. ACCUMULATORS OF BOP CONTROL SYSTEM: Check nitrogen precharge in BOP accumulator system every 30
days, Nitrogen precharge should be 1000 psi +/- 10% CAUTION: Use NITROGEN when adding to precharge.
Other gases and air may cause fire and/or explosion,
18. ACCUMULATOR RELIEF VALVE: Valve set to relieve at 3,500 psi.
19. FLUID STRAINER: Located on the inlet side gl the pressure reducing and regulating valves. Clean strainer every
30 days.
20. PRESSURE REDUCING AND REGULATING VALVE: Manually operated. Adjust to the required continuous
operating pressure of ram-type BOP’s.
21. MAIN VALVE HEADER: 5000 psi W.P., 2ʺ all welded.
22. 4-WAY VALVES: With air cylinder operators for remote operation from the control panels. Keep in the
standard operating mode (open or close), NEVER IN CENTER POSITION.
23. BYPASS VALVE: With air cylinder operator for remote operation from the control panels. In CLOSE position, it
puts regulated pressure on the main valve header (21), and in the OPEN Position it puts full pump pressure
on that header. Keep in a CLOSE position unless 3000 psi (or more) is required on ram-type BOPs.
24. MANIFOLD RELIEF VALVE: Valve set to relieve at 5,500 psi.
25. HYDRAULIC BLEEDER VALVE: Manually operated-normally closed, NOTE: This valve should be kept OPEN
when precharging the accumulator bottles.
26. PANEL-UNIT SELECTOR: Manual 3-way valve. Used in BOP control system to apply pilot air
pressure to the air-operated pressure reducing and regulating valve, either from the air regulator
on the unit or from the air regulator on the remote control panel
27. PRESSURE REDUCING AND REGULATING VALVE — AIR OPERATED: Reduces the accumulator
pressure to the required annular BOP operating pressure. Pressure can be varied tar stripping
operations. Maxi- mum recommended operating pressure ut the annular preventer should not
be exceeded.
28. ACCUMULATOR PRESSURE GAUGE.
29. MANIFOLD PRESSURE GAUGE.
30. ANNULAR PREVENTER PRESSURE GAUGE.
31. PNEUMATIC PRESSURE TRANSMITTER FOR ACCUMULATOR PRESSURE.
32. PNEUMATIC PRESSURE TRANSMITTER FOR MANIFOLD PRESSURE,
33. PNEUMATIC PRESSURE TRANSMITTER FOR ANNULAR PREVENTER PRESSURE,
34. AIR FILTER: Located on the BOP control unit supply line to the air regulators.
35. AIR REGULATOR FOR PRESSURE REDUCING AND REGULATING VALVE — AIR OPERATED,
36. AIR REGULATOR FOR PNEUMATIC TRANSMITTER (33) FOR ANNULAR PRESSURE.
37. AIR REGULATOR FOR PNEUMATIC PRESSURE TRANSMITTER (31) FOR ANNULAR PRESSURE.
38. AIR REGULATOR FOR PNEUMATIC PRESSURE TRANSMITTER (32) FOR MANIFOLD PRES-
SURE. NOTE: Air regulator controls for pneumatic transmitters are normally set at 15 psi. Increase
or decrease air pressure to calibrate panel gauge to hydraulic pressure gauge on the unit.
39. AIR JUNCTION BOX: To connect the air lines on the unit to the air lines coming from the remote
control panels through an air cable.
40. RIG TEST CHECK VALVE.
41. HYDRAULIC FLUID FILL PORT.
42. INSPECTION PLUG PORT.
43. RIG TEST OUTLET ISOLATOR VALVE: High pressure, manually operated. Close when rig testing — open when
test is complete.
44. RIG TEST RELIEF VALVE: Valve set to relieve at 6500 psi.
45. RIG TEST PRESSURE GAUGE.
46. 46A. RIG SKID OUTLET and 46B. VALVE HEADER ISOLATOR VALVES: Manually operated. Close valve header
isolator valve and open rig skid isolator valve when rig skidding. Open valve header isolator valve and close
rig skid isolator valve during normal drilling operations.
47. RIG SKID RELIEF VALVE: Valve set to relieve at 2500 psi.
48. RIG SKID PRESSURE GAUGE.
49. ACCUMULATOR BANK ISOLATOR VALVES: Manually operated, normally open.
50. RIG SKID RETURN. Customer’s connection.
51. RIG SKID OUTLET. Customer’s connection.
52. ELECTRIC POWER. Customer’s connection.
53. RIG TEST OUTLET. Customer’s connection.
 BOP Control System Installation
• The main accumulator with its hydraulic control manifold, separate hydraulic manifold, or hydraulic panel
should be installed in a safe area protected from falling debris or gas accumulations during a blowout.
• All of the control functions should be operable from the drill floor by use of a remote control panel.
• A second remote control panel is recommended.
• This panel is normally located in the tool pushers’ office or in a safe egress area and is intended as a last means
to close in the well as the rig is being abandoned.
• The initial installation, (and each time the rig is moved), should be fully tested according to the
recommended BOP control system acceptance procedures to ensure proper leak-free operation and
correctness of function.
• The hydrostatic test should be to full working pressure and/or ten percent below any relief valves in the line.
• Piping downstream of the pressure reducing and regulating valves should be tested to the maximum (full open)
regulator settings.
• Automatic pump system cut-off devices should be tested to ensure the pump(s) cut off at the maximum system
design working pressure.
• The system design capacities should be verified at the initial installation and interface of the control system to
the BOP stack.
• The contractor must ensure that all oil and gas companies, local statutes, governmental, and other governing
agencies at the drilling venue have been met in the design.
• In particular, the contractor must ensure the following:
• The control system design meets or exceeds the performance requirements of the most stringent of the
regulatory bodies in force.
• Accumulator precharge is maintained within the control system manufacturer’s specification.
• Pump system cut “on” and cut off automatic set points are maintained at the control system manufacturer’s
specification for the system design.
• Closing response times from activation at any control point are within the time limits of the most stringent of
the regulatory bodies in force.
• NOTE: The minimum performance and capacities recommendations for surface BOP well-drilling control
systems are listed in API RP 16E, Section 16E.2.
 Typical Maintenance Items
• While BOP control systems by various manufacturers may vary widely in color, size, configuration, and layout,
they are functionally very similar.
• Figure 1 “Typical Surface BOP Control System” and table 2 “Preventative Maintenance Schedule Check List”
are not intended to promote any manufacturer’s product.
• They are intended to highlight areas that need to be identified and properly maintained to ensure the
capability or the control system to perform to its design intent.
Figure 1
 Operational Recommendations
• Well Control procedures are intended to inform of possible well control practices that have proven practical.
They should not be interpreted to be a solution to all problems.
• BOP Control system manufacturers generally make the following operational recommendations.
• During normal drilling, the blowout preventer control valves are typically in the “open” position, kill and choke
valves are typically in the “closed” position.
• This will hydraulically lock the BOP in position, give visual indication of the annular BOP, ram or valve position
and most importantly, indicate leaks in the valves, lines or BOP which can be detected by the pumps coming on
too frequently.
• Ensure all pump system (air and electric) power is “online” at all times.
• Ensure all accumulator banks are “on tine” at all times.
• Ensure pump system automatic “on”/”off” limits are properly set.
• Setting the pump system cut off too low results in significantly reducing usable fluid capacity o f the
accumulator system.
• Setting the pump system “on” point too low results in accumulator pressure being too low, and the usable fluid
capacity reduced significantly so that the BOP performance is adversely affected.
• Ensure the BOP control system nitrogen precharge in all of the accumulators is properly maintained within the
specified limits. Reduced precharge decreases the recoverable (usable) fluid from the accumulator.
• Zero precharge (probable ruptured bladder) equals nil recoverable fluid.
• The nitrogen precharge must be measured when there is zero hydraulic pressure on the accumulators.
• This means they must be bled back to the reservoir to measure precharge.
• Operate with the fluid reservoir approximately half full. Reservoirs are typically sized to hold at least twice the
recoverable (usable) fluid of the accumulator system.
• This means bleeding down all of the accumulators is possible without overflowing the reservoir. Newer systems
built in accordance with API RP 16E have twenty-five percent (25%) accumulator bank isolation.
• They also have isolation and bleed valves on each bank permitting checking precharge on one bank at a time
without shutting down operations.
• Ensure all components of the BOP control system are in proper working order, clean, and, where required,
lubricated.
 Nitrogen Back-up System Operation
• Nitrogen back-up can, implemented successfully, fill this void if the rig stored air system is not designed to handle
it (used for closing blowout preventers in the event hydraulic capability is lost)
• The nitrogen back-up system of BOP control system should include pressure regulation, relief valve protection,
and either automatic intervention in the event rig air pressure is interrupted, or be selectively available from the
driller’s panel and at least one “safe area” remote panel.
• Set Annular Regulator to highest regulated pressure.
• Place Manifold Regulator Bypass Valve in the “HIGH” position.
• Ensure Nitrogen Bottle Valves are open and place the Nitrogen System Isolator Valve in the “OPEN” position.
• Close appropriate BOPs for Well Control situation.
• NOTE: Leave BOPs closed until they can be opened hydraulically, (Refer to following steps).
• Remove four (4) inch tank inspection plugs at top end of Reservoir.
• Close Nitrogen Isolator Valve (after emergency).
• With BOPs still closed, open the Manifold Bleed Valve and slowly bleed Nitrogen back to the Reservoir.
• If Nitrogen was used to close the Annular, slowly decrease the Annular Regulator setting allowing Nitrogen to
bleed back to the Reservoir.
• Re-establish hydraulic pressure and return the Manifold Regulator Bypass to the “LOW” position.
• Reset the Annular Regulator to the correct operating pressure.
• Open the BOPs hydraulically.
THANK YOU