BOP

Pressure
Testing
Subsea Engineer Handbook Section 15
In-Spec Inc. 1999 BOP Pressure Testing
Table of Contents
Section 15
Page
1. API RP-53 Testing Recommendations 1
2. MMS Policy 5
3. General BOP Test Report Guidelines 8
4. BOP, Accumulator & Choke Manifold Test Report 9
5. Subsea BOP Test Procedure 10
6. BOP Test Sequence and Function Times Record 11
7. BOP Schematic 12
8. Choke and Kill Manifold Test Report 13
9. Choke Manifold Schematic 14
10. Surface Equipment Test Report 15
11. BOP Test Charts 16
12. Dowell Tests Reports 19
Subsea Engineer Handbook Section 15
In-Spec Inc. 1999 1 BOP Pressure Testing
1) API RP-53 Testing Recommendations
API provides some guidance to pressure testing BOPs in API Recommended
Practice 53, Blowout Prevention Equipment Systems for Drilling Wells, 3
rd
edition.
The points from Section 18, Testing and Maintenance of Subsea BOP Stacks and
Well Control Equipment, worth noting are :
A) PRESSURE TESTS
18.3.2.1
should be tested first to a low pressure of 200 to 300 psi and then to a high
pressure.
When performing the low pressure test, do not apply a higher pressure and bleed
down to the low test pressure. The higher pressure could initiate a seal that may
continue to seal after the pressure is lowered therefore, misrepresenting a low
pressure condition.
A stable low pressure test pressure should be maintained for at least 5 minutes.
18.3.2.2
The initial high pressure test on components that could be exposed to well
pressure should be to the rated working pressure of the ram BOPs or to the rated
working pressure of the wellhead that the stack is installed on, which ever is
lower. Initial pressure tests are defined as those tests performed before the well
is spudded (stump tests) or before the equipment is put into operational service
(upon landing the stack).
Annular BOPs, with a joint of drill pipe installed, may be tested to the test
pressure applied to the ram BOPs or to a minimum of 70% of the annular
preventer working pressure, which ever is the lesser.
1
There may be instances when the available BOP stack and/or wellhead have
higher working pressures than are required for the specific wellbore conditions.
Special conditions such as these should be covered in the site specific well
control pressure test program.

1
Shaffer state that the annular BOP test pressure should not exceed the BOPs rated working pressure.
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In-Spec Inc. 1999 2 BOP Pressure Testing
18.3.2.3
Subsequent high pressure tests on the well control components should be to a
pressure greater than the maximum anticipated surface pressure, but not to
exceed the working pressure of the ram BOPs. The maximum anticipated
surface pressure should be determined by the operator based on specific well
conditions.
A stable high pressure test should be maintained for at least 5 minutes.
2
18.3.2.4
Initial pressure tests on hydraulic chambers of ram BOPs and hydraulically
operated valves should be to the maximum operating pressure recommended by
the manufacturer.
The initial pressure test on hydraulic chambers of annular BOPs should be to at
least 1,500 psi or higher where a subsea annular BOP requires a higher pressure
for water depth and/or drilling fluid density.
A) PRESSURE TEST FREQUENCY
18.3.3
Pressure tests on the well control equipment should be conducted at least :
a. Prior to running the BOP subsea and upon installation.
b. After disconnection or repair of any pressure containment seal in the BOP
stack, choke manifold, or wellhead assembly, but limited to the affected
component.
c. Not to exceed 21 days,
B) PRESSURE GAUGES
18.3.6
Pressure measurement should be made at not less than 25% nor more than
75% of the full working span of the gauge (or recorder).

2
Annular BOPs may experience packer creep for prolong periods after the preventer has closed. These small
movements of the annular sealing element may require that the test pressure be raised in order to get a stable straight
line for the duration of the test period.
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In-Spec Inc. 1999 3 BOP Pressure Testing
C) STACK TESTING NOTES
18.5.1 The subsea stack equipment includes the subsea weilbore pressure
containing equipment above the welihead and below the ball/flex joint. This
equipment includes the wellhead and LMRP connectors, ram BOPs, spool(s),
annular(s), choke and kill valves, and choke and kill lines.
18.5.2 Unless restricted by height, the entire stack should be pressure tested as
a unit.
18.5.3 Annular BOPs should be tested using the smallest OD pipe to be used.
18.5.4 Fixed bore pipe rams should be tested only on the pipe OD size that
matches the installed pipe ram blocks.
18.5.5 Variable bore rams should be initially pressure tested on the largest and
the smallest OD pipe sizes that may be used during the well operation.
18.5.6 Blind rams and blind shear rams should not be tested when pipe is in the
stack. The capability of the shear ram and ram operator should be verified with
the manufacturer for the planned drill string. The shear ram preventer design
and/or metallurgical differences among drill pipe manufacturers may require high
closing pressures for shear operations.
18.5.7 When drill pipe hangoff is a possibility during well control, hangoff
procedures should be preplanned. The manufacturers recommended hangoff
load capacity for fixed-bore ram blocks should be considered. Example hangoff
procedures are included in API Recommended Practice 59. The original ram
BOP equipment manufacturer should be consulted regarding hanging off drill
pipe on variable bore ram BOPs.
18.5.8 Prior to surface testing each ram BOP, the secondary rod seal
(emergency packoff assembly) should be checked to ensure the seals have not
been energized. Should the ram shaft seal leak during the stump test, the seal
shall be repaired rather than energizing the secondary packing.
18.5.10 The BOP elastomeric components that may be exposed to well
fluids should be verified by the BOP manufacturer as appropriate for the drilling
fluids to be used and for the anticipated temperatures. Consideration should be
given to the temperature and fluid conditions during well testing and completion
operations.
18.5.10.1 Manufacturers markings for BOP elastomeric components should
include the durometer hardness, generic type of compound, date of manufacture,
part number, and operating temperature range of the component.
18.5.10.1 Manufacturers markings for BOP elastomeric components should
include the durometer hardness, generic type of compound, date of manufacture,
part number, and operating temperature range of the component.
Subsea Engineer Handbook Section 15
In-Spec Inc. 1999 4 BOP Pressure Testing
18.5.1 0.2 Consider replacing critical BOP elastomeric components on well
control equipment that has been out of service for 6 months or longer.
18.5.11 flexible choke and kill lines should be tested to the same pressure,
frequency, and duration as the ram BOPs.
18.5.12 A properly precharged surge bottle should be installed adjacent to
the annular BOP if contingency well control procedures include stripping
operations.
18.5.13 The drill pipe test joint and casing ram test sub should be
constructed of pipe that can withstand the tensile, collapse, and internal
pressures that will be placed on them during testing operations.
D) CHOKE MANIFOLD TESTING NOTES
18.6.1 The choke manifold upstream of and including the last high pressure
valves
3
should be tested to the same pressure as the ram BOPs.
18.6.2 The configuration of pipes and valves downstream of the last high
pressure valve varies from installation to installation. Each configuration should
be verified for mechanical integrity.
18.6.3 The valves and adjustable chokes should be operated to verify smooth
operation.
18.6.4 Adjustable chokes are not required to be full sealing devices. Pressure
testing against a closed choke is not required.

3
The valves down stream of the chokes on the buffer chamber are usually lower pressure rated than the valves up
stream of the chokes.
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In-Spec Inc. 1999 5 BOP Pressure Testing
2) MMS Policy
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3) General BOP Test Report Guidelines
a) All testing should be in compliance with MMS regulations and any variances
should be noted.
b) The Test report comment section should include test fluid, size test pipe, and any
testing problems encountered.
c) All test reports should include a copy of the BOP and choke manifold
arrangement drawings.
d) Report must be neat and legible.
e) Original reports to be kept in oil company well records.
f) During surface equipment testing of the inside BOP and TIW valves, the report
should include size and serial numbers of the equipment.
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