CHAPTER 11

WELL CONTROL EQUIPMENT

11 WELL CONTROL EQUIPMENT

11.1 BOP CONTROL SYSTEMS

The prime function of the BOP control system is to provide a reliable and rapid means of
functioning the BOP`s in the event of a kick and to allow the BOP`s to be operated as
necessary while the kick is being displaced from the hole, or pipe is being stripped into
the hole. In order to provide sufficient reliability and redundancy, the control system
stores energy in the form of compressed nitrogen. This means that in an emergency no
external power supply is needed.

The hydraulic fluid used to operate the BOP functions is stored in accumulators where it
is pressurised by the compressed nitrogen. Commonly an electric power supply pump,
backed up by an air driven pump, is used to charge up the accumulators to operating
pressure. The pump system can also function the BOPs without accumulator assistance.

The hydraulic control systems used on Platforms and Jack-ups follow the same design
principles as those used on land rigs. Each stack function is assigned a dedicated line
along which the hydraulic fluid can be directed from the accumulators, via a regulator, in
order to activate that function. Fluid from the opposite side of the actuated piston is
vented and displaced back to the reservoir from which the accumulators are charged
thus maintaining a closed hydraulic system.

The elements of the BOP control system normally include:

1: Hydraulic fluid and Storage (reservoir) equipment for supplying ample control
fluid to the pumping system.

2: Pumping systems for pressurizing the control fluid.

3: Accumulator bottles for storing pressurized control fluid.

4: Hydraulic control manifold for regulating the control fluid pressure and directing
the power fluid flow to operate the system functions (BOPs, choke and kill valves
etc).

5: Remote control panels for operating the hydraulic control manifold from remote
locations.

6: Hydraulic control fluid.

11.2 Hydraulic Fluid and Storage Equipment

A suitable control fluid should be selected for the system-operating medium based on
the control system operating requirements, environmental requirements and user
preference.

Water-based hydraulic fluids are usually a mixture of potable water and a water-soluble
lubricant additive. When ambient temperatures at or below freezing are expected,

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sufficient volume of ethylene glycol or other additive acceptable to the control system
manufacturer should be mixed with the water-based hydraulic fluid to prevent freezing.

Control fluids used should be in accordance with the control system manufacturers'
recommendations, usually a non-corrosive and non-flammable

The hydraulic fluid reservoir should have a capacity equal to at least twice the usable
hydraulic fluid volume of the accumulator system. Air breather outlets should be
installed of sufficient size to avoid pressurization of the tank during hydraulic fluid
transfers or nitrogen transfers if a nitrogen backup system is installed.

11.3 Pump Requirements

A pump system must include two (primary and secondary) pumps as minimum and
having independently dedicated power source. Each pump must be capable to
satisfactorily perform the following: With the accumulators isolated from service, the
pump must close each annular BOP on the minimum size of drill pipe being used, open
the hydraulically operated choke valve(s) and provide the operating pressure level
recommended by the annular BOP manufacturer to effect a seal on the annulus space
within 2 minutes.

The combined output of all pumps should be capable of charging the entire accumulator
system from pre-charge pressure to the maximum rated control system working
pressure within 15 minutes.

Pumps must automatically start when the closing unit pressure has decreased to less
than 90% of the accumulator operating pressure.

The same pump system(s) may be used to produce power fluid for control of both the
BOP stack and the Diverter system.

Each pump system should provide a discharge pressure at least equivalent to the
system working pressure. Air driven pump systems should require no more than 75 psi
air supply pressure to comply with the charging requirements referred to above.

Each pump system must have as minimum the pump discharge pressure limit and
pressure relief valve installed to prevent the pump system from over-pressurization.

Devices used to prevent pump system over-pressurization should be installed directly in

the control system supply line to the accumulators and should not have isolation valves
or any other means that could defeat their intended purpose.

11.4 ACCUMULATORS

Accumulator types

Accumulators are pressure vessels designed to store power fluid. The purpose of having
stored fluid under pressure in the accumulator bottles is to reduce the closing time of
BOP function and to enable the BOP to be closed in the event of a power failure.

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No accumulator bottle should be operated at a pressure greater than its rated working
pressure.

The two common models of accumulators illustrated on Fig 060 are bladder and float
types. The internal capacities of accumulator excluding the volume of bladder or float are
10 or 15 gallons although 35 gallons accumulators are also available.

The bladder type accumulator contains a rubber bladder that separates the nitrogen
from the stored hydraulic fluid. The gas is injected into the bladder through the pre-
charge valve in the top of the bottle and the hydraulic fluid enters the accumulator at the
bottom. A poppet valve at the base of the bottle prevents extrusion and damage to the
bladder once all the fluid has been expelled.

In the float type accumulator, the gas is introduced at the top of the bottle and is kept
separate from the stored fluid by a buoyant float. Escape of the gas through the fluid port
at the base of the bottle is prevented by the weight of the float actuating a shut-off valve
once all the fluid has been expelled.

Supply pressure isolation and bleed down valves should be provided on each
accumulator bank to facilitate checking the pre-charge pressure or draining the
accumulators back to the control fluid reservoir.

Pre-charging of Accumulators

The pre-charge pressure in the system accumulators serves to propel the hydraulic fluid
stored in the accumulators for operation of the system functions.

The surface accumulators should be pre-charged to 1/3rd of the rated working pressure
of the system.

Accumulators should be pre-charged only with nitrogen due to presence of combustible

components in hydraulic fluid

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Fig 060

The accumulator pre-charge pressure can be checked after bleeding off the control fluid.
In the field, the pre-charge pressure should be checked and adjusted to within 100 psi of
the recommended pressure at installation of the control system and at the start of drilling
each well (intervals not to exceed sixty days).

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Volumetric requirements

The BOP control system should have a minimum stored hydraulic fluid volume, with
pumps inoperative, to satisfy the greater of the two following requirements:

1: Close from a full open position at zero wellbore pressure, all of the BOPs in the
BOP stack, plus 50% (fifty percent) reserve.

2: The pressure of the remaining stored accumulator volume after closing all of the
BOPs should exceed the minimum calculated (using the BOP closing ratio)
operating pressure required to close any ram BOP (excluding the shear rams) at
the maximum rated wellbore pressure of the stack.

Response Time

The closing system for surface stack should be capable of closing all ram and annular
preventers at zero wellbore pressure and keep a remaining accumulator pressure of 200
psi above the recommended pre-charge pressure:
• each ram preventer within 30 seconds or less
• each choke and kill valves within 30 secodns or less
• annular preventer smaller than 18 3/4” within 30 seconds or less
• annular preventer of 18 3/4” or lager within 45 seconds or less

Usable fluid

Usable fluid volume is defined as the volume of fluid recoverable from an accumulator
between the accumulator operating pressure and 200 psi above the pre-charge
pressure.

Ignoring the effects of temperature and nitrogen gas compressibility, the gas law can be
applied in the following way shown below to calculate the usable fluid volume for surface
accumulator bottle.

Pl x Vl = P2 x V2 and also P1 x V1= P3 x V3

Where:

P1: Pre-charge pressure 1000 psi.

P2: Minimum operating pressure 1200 psi.

P3: Maximum operating pressure 3000 psi.

V1: Bladder internal volume at pre-charge pressure 10 gal

V2: Bladder internal volume at minimum operating pressure, P2 (gal)

V3: Bladder internal volume at maximum operating pressure, P3 (gal)

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Note: A factor of 15 psi added to the above converts the gauge pressures to absolute
pressures.

Therefore:

1000 x 10 = 1200 x V2 and 1000 x 10 = 3000 x V3

Giving:

V2 = 8.3 gallons and V3 = 3.3 gallons

The usable volume of hydraulic fluid expelled from the bottle as the nitrogen expanded
from V3 at 3000 psi to V2 at 1200 psi will therefore be:

V2 - V3 = 5 gallons of usable fluid.

Note: Including temperature effects and compressibility in the calculations results in a

figure of 4.95 gallons

FIG 061

Determine the number of accumulator bottles required by dividing the total accumulator
volumetric capacity by the accumulator gas volume capacity. Round off to the next larger
whole number.

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The accumulator gas volume capacity should be determined by consulting the
accumulator manufacturer's gas volume specifications.

The usable hydraulic fluid volume of the accumulator system should be used to
determine pump system sizing and reservoir capacity.

Note: These calculations are for system design only and are not to be used as
performance criteria aboard the rig. The calculations shown here are simplified
examples for estimating minimum, capacity requirements. More rigorous design
calculations, which account for parameters such as adiabatic, gas expansion and
specific volume of gas, may be used.

11.5 HYDRAULIC CONTROL MANIFOLD

The hydraulic control manifold is the assemblage of hydraulic control valves, regulators,
and gauges from which the system functions are directly operated. It allows manual
regulation of the power fluid pressure to within the rating specified by the BOP
manufacturer. The hydraulic control manifold provides direct pressure reading of the
various supplies and regulated pressures. A suitable valve with ports sized at least equal
to the control manifold supply piping size should be provided for supply of control
hydraulic fluid from an alternate source. This valve should be plugged when not in use.

Annular BOP Hydraulic Control Circuit

A dedicated control circuit on the hydraulic control manifold should operate the annular
BOP(s). The components in this circuit should include a pressure regulator to reduce
upstream accumulator pressure to the power fluid pressure level that meets the BOP
manufacturer's recommendations. The regulator should respond to pressure changes on
the downstream side with sensitivity sufficient to maintain the set pressure within plus or
minus 150 psi. The annular BOP pressure regulator should be remotely controllable.
Direct manual valve and regulator operability should permit closing the annular BOP
and/or maintaining the set regulated pressure in the event of loss of the remote control
capability.

Hydraulic Manifold Circuit for Common Pressure Functions

The hydraulic control manifold includes a common power fluid circuit with pressure
regulation and control valves for operation of the ram type BOPs and choke and kill
valves. This circuit may be provided with a manifold regulator, bypass valve or other
means to override the manifold regulator to permit switching from regulated pressure to
direct accumulator pressure for operating functions.

Control Lines

The control lines for a surface BOP stack run from the main control manifold direct to
each individual stack function. They are usually made of 1" seamless steel tubing with a

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working pressure rating of at least 3000 psi and should be routed to minimise the risk of
accidental damage.

Hydraulic Control Manifold Valves ( Manipulator Valves )

Manipulator valves are ¼ inch, 3 position, 4 way valves which are equipped with air
operators for remote control. The four ways are:

1: Power fluid.

2: Vent.

3: Cycle 1, close.

4: Cycle 2, open.

Three positions, Open, Close and Block. When in the Block position the open and close
lines are vented to the accumulator reservoir and power fluid is block to the valve. The
four-way control valves on the manifold lined up for normal drilling operations must be in
either open or close positions and should not be left in the block position.

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MANIPULATOR VALVE

Fig 068

In the BOP stack area, the lines should terminate in non-flammable hoses or steel lines
incorporating swivels and unions to reduce any stress effects.

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11.6 REMOTE CONTROL PANELS

The hydraulic control units must include at least two separately located control panels
clearly indicating close, open and block positions for each function of BOP and having a
master control button installed on each one. One of these panels must be purposed for
Driller`s access and the other one could be located in accumulators control unit or
anywhere if safe to operate.

FIG 062

The Drillers master panel is normally explosion proofed or air-purged since it is located
in a hazardous area. The regulator pressures are controlled by increase/decrease push
buttons and there are gauges for read-back values. A digital readout of the flow meter
located on the control manifold may also be provided.

Many types of Drillers panel also include controls for the operation of the rig Diverter
system, which is controlled in a similar way to a surface BOP system. The mini-panel is
usually not required to be explosion proof. It operates in the same way as the master
panel but does not include the pressure gauges. Both panels include, lamp test facilities

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to check for burnt out lamps. They also contain alarms for low hydraulic fluid level, low
accumulator pressure, low rig air pressure and an alarm to indicate that the emergency
battery pack is in use.

The Electric Remote Panels contain all the necessary electrical switches to operate the
solenoid valves on the hydraulic control manifold, which in turn control the air operators
of the pilot control valves. Lights on the panels (red, amber, green) indicate the position
of the 4-way valve (open, block, close) and there is a memory system so that when a
function is in block with the amber light on, the actual position of the function (the red or
green light) will also be displayed.

The Driller's remote control panel display should be physically arranged as a graphic
representation of the BOP stack. Its capability should include the following:

1: Control all the hydraulic functions, which operate the BOPs, choke, and kill
valves.

2: Display the position of the control valves and indicate when the electric pump is
running (offshore units and electrical units).

3: Provide control of the annular BOP regulator pressure setting.

4: Provide control of the manifold regulator bypass valve or provide direct control of
the manifold regulator pressure setting.

5: The Air Operated (FIG 062) Driller's panel should be equipped with displays for
readout of:

a: Accumulator pressure.

b: Manifold regulated pressure.

c: Annular BOP regulated pressure.

d: Rig air pressure.

6: Offshore rig Driller's panels should have an audible and visible alarm to indicate
the following:

a: Low accumulator pressure.

b: Low rig air pressure.

c: Low hydraulic fluid reservoir level.

d: Panel on standby power (if applicable).

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7: All panel control functions should require two-handed operation. Regulator
control may be excluded from this requirement.

FIG 063

Certain air operated remote panels include indicator lights to observe the BOP status.
These lights indicate the position of the valve handles on the accumulator unit. The
normal pressure, on the panel gauges are:

1: Accumulator Pressure 3000 psi.

2: Air Pressure 100 – 120 psi.

3: Manifold Pressure 1500 psi.

4: Annular Pressure 700 – 1500 psi.

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FIG 064

To operate a BOP function from the Air Operated Remote Panel:

1: Hold down master air valve or enable button, (manufactures recommend the
master valve be depressed for 5 seconds prior to operating a BOP function)

2: With master air valve depressed operate the BOP function (annular) close.

3: The light sequence will change from open to close, this only indicates that the 4-
way valve on the accumulator unit has moved to the closed position.

4: Observe the accumulator and annular pressure gauges, both should indicate a
pressure drop. As soon as the annular element makes contact with the tubular,
the annular pressure gauge will recover to its original preset value.

5: If the accumulator pressure gauge drops by more than 90% of the accumulator
operating pressure the charge pumps should automatically re-charge the system
to its full operating pressure.

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Figures FIG 065a, b & c show the operating sequence for an Electric Remote Panel.

CLOSE FUNCTION ON A SURFACE ELECTRICAL REMOTE PANEL

FIG 065a

OPEN FUNCTION ON A SURFACE ELECTRICAL REMOTE PANEL

Fig 066b

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BLOCK FUNCTION ON A SURFACE ELECTRICAL REMOTE PANEL

Fig 065b

The BOP stack functions should also be operable from the main hydraulic control
manifold. This unit should be installed in a location remote from the drill floor and easily
accessible to rig personnel in an emergency.

Optional Remote Control Methods

Remote control from the remote panels of the hydraulic control manifold valves may be
actuated by pneumatic (air), hydraulic, electro-pneumatic or electro-hydraulic remote
control systems. The remote control system should be designed such that manual
operation of the control valves at the hydraulic control unit will override the position
previously set by the remote controls.

Pneumatic Remote Control

Pneumatic remote controls employ compressed air as the medium to operate actuators
for control of the hydraulic control valves. Response time between the actuation of the
pneumatic valve at the remote panel and the actuation of the control valve is generally a
linear function of the length of the interconnecting hose. Therefore, pneumatic controls
are not recommended where hose lengths exceed 150 feet. Pneumatic remote controls
are not recommended for use in freezing temperatures because condensate in a control
line may solidify and plug the line.

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Hydraulic Remote Control

Hydraulic remote control is a method to interface with the hydraulic control manifold.
This method can be used in the absence of electrical power and can function in sub-
freezing temperatures. Pilot pressure for remote control should be supplied from a
hydraulic power source separate or suitably isolated from the main hydraulic power
source so that failure of the remote control will not affect manual operation of the BOP
control system.

Electro-pneumatic Remote Control

Electro-pneumatic controls employ electric circuits to operate pneumatic solenoid valves

that control the pneumatic actuators, which operate the hydraulic control valves. Electro-
pneumatic controls have the advantage of fast response and ease of running electrical
cables compared to hose bundles of pneumatic remote controls. Electro-pneumatic
controls should not be used in sub-freezing temperatures.

Electro-Hydraulic Remote Control

Electro-hydraulic controls employ electric circuits to operate the hydraulic control valves.
Electro-hydraulic controls have the advantages of fast response, ease of running
electrical cables and are functional in sub-freezing temperatures. The hydraulic power
supply for the remote controls should be isolated from the main hydraulic system so that
a failure in the remote control circuit will not affect the manual operation of the control
valves.

Electric remote control panels and equipment should be designed to meet the
requirements of API RP 14F. All electrical equipment is to be designed so as to be
suitable for use in the atmosphere in which it is installed as defined by API RP 500B.

Required Pressure Rating

According to API RP 16E, all valves, fittings and other components such as pressure
switches, transducers, transmitters, etc., should have a working pressure at least equal
to the working pressure of the control system. BOP control system working pressure
rating is usually 3000 psi. Other working pressure ratings may be preferred based on
function operating requirements.

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Fig 066

Fig 066 shows a basic land configured BOP, Accumulator Unit and Remote Control
panels.

11.7 BLOWOUT PREVENTER STACK ARRANGEMENTS

Configurations of BOP stack may be arranged variously depending on risk assessment

and each main component of stack signed with designation code as shown below:

A - annular preventer
G - rotating head
R - single ram type preventer with one set of rams, blind or pipe
Rd - double ram type preventer with two sets of rams
Rt - triple ram type preventerüith three sets of rams
CH- remotely operated connector attching wellhead or preventers to each other
CL- Lower Marine Riser Package (LMRP) connector
S - drilling spool with side outlet valves for kill and choke lines
M – 1000 psi rated working pressure

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Two different annular and three ram BOP stack configurations shown in Fig 067
(illustration from API RP 53) but not limited. Components are listed reading upward
from the bottom to the top of the BOP stack.

15M, 7 1/6”, RSRRA 10M, 13 5/8”, RSRRAG

Double Ram Type Preventers, Double Ram Type
Preventers,
Rd Optional Rd Optional

Fig 067

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Drilling Spools

While choke and kill lines may be connected to side outlets of the blowout preventers,
many operators prefer that these lines be connected to a drilling spool installed below at
least one preventer capable of closing on pipe. Utilization of the blowout preventer side
outlets reduces the number of stack connections by eliminating the drilling spool and
shortens the overall preventer stack height. The use of a drilling spool is to localize
possible erosion in the less expensive spool and to allow additional space between rams
to facilitate stripping operations.

Drilling spools for blowout preventer stacks should meet the following minimum
specifications:

1: Have side outlets no smaller than 2” nominal diameter and be flanged and
studded. Alternatively, clamped for API Class 2M. 3M. and 5M. API Class 10M
and 15M installations should have a minimum of two side outlets, one 3" and one
2" nominal diameter.

2: Have a vertical bore diameter at least equal to the maximum bore of the
uppermost casing head.

3: Have a working pressure rating equal to the rated working pressure of the
attached blowout preventer.

For drilling operations, wellhead outlets should not be use for choke or kill lines. Such
outlets may be employed for auxiliary or back-up operations but only if there is a failure
of the primary system.

11.8 CHOKE MANIFOLDS

If the well is underbalanced, formation fluids will enter the wellbore. To maintain well
control backpressure is applied by routing the returns through adjustable chokes until the
well flow condition is corrected. The chokes are connected to the blowout preventer
stack through in arrangement of valves fittings and lines, which provide alternative, flow
routes or permit the flow to be halted entirely. This equipment assemblage is designated
the choke manifold
Choke manifold design should consider such factors as anticipated formation and
surface pressures, method of well control to be employed, surrounding environment,
corrosively, volume, toxicity and abrasiveness of fluids.

Installation Guidelines

Recommended practices for planning and installation of choke manifolds for surface
installations include:

1: Manifold equipment subject to well and/or pump pressure (normally upstream of

and including the chokes) should have a working pressure equal to the rated
working pressure of the blowout preventers in use. This equipment should be
tested when installed in accordance with provisions of API RP 53

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2: Components should comply with applicable API specifications to accommodate

anticipated pressure temperature and corrosively of the formation fluids and
drilling fluids.

3: For working pressures of 3M and above flanged, welded or clamped connections

should be employed on components subjected to well pressure.

4: The choke manifold should be placed in a readily accessible location preferably

outside of the rig substructure.

5: The choke line (which connects the blowout preventer stack to the choke
manifold) and lines downstream of the choke should:

a: Be as straight as practicable, turns if required should be targeted.

b: Be firmly anchored to prevent excessive whip or vibration.

c: Have a bore of sufficient size to prevent excessive erosion or fluid friction:

1: Minimum recommended size for choke lines is 3-in. nominal

diameter (2-in. nominal diameter is acceptable for Class 2M
installations).

2: Minimum recommended size for vent lines downstream of the

chokes is 2-in. nominal diameter or at least equal to the choke
line.

3: For high volumes and air or gas drilling operations minimum 4-in.
nominal diameter lines are recommended.

6: Alternate flow and flare routes downstream of the choke line should be provided
so that eroded, plugged or malfunctioning parts can be isolated for repair without
interrupting flow control.

7: Consideration should be given to the low temperature properties of the materials

used in installations to be exposed to unusually low temperatures.

8: The bleed line (the vent line which by-passes the chokes) should be at least
equal in diameter to the choke line. This line allows circulation of the well with the
preventer closed while maintaining a minimum of backpressure. It also permits
high volume bleed-off of well fluids to relieve casing pressure with the preventers
closed.

9: Lines downstream of the choke manifold are not normally required to contain
pressure. However, these lines should be tested during the initial installation.

10: Although not shown in the example equipment illustrations, buffer tanks are
sometimes installed downstream of the choke assemblies for manifolding the
bleed lines together. When buffer tanks are employed, provision should be made
to isolate a failure or malfunction without interrupting flow control.

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11: Pressure gauges suitable for drilling fluid service should be installed so that drill
pipe and annulus pressures may be accurately monitored and readily observed
at the station where well control operations are to be conducted.

12: All choke manifold valves subject to erosion from well flow should be full opening
and designed to operate in high-pressure gas and drilling fluid service. Double
full-opening valves between the blowout preventer stack and the choke line are
recommended for installations with rated working pressures of 5M and above.

13: For installations with rated working pressures of 5M and above the following are
recommended:

a: One of the valves should be remotely actuated.

b: At least one remotely operated choke should be installed.

14: Spare parts for equipment subject to wear or damage should be readily available.

15: Testing, inspection and general maintenance of choke manifold components

should be performed on the same schedule as employed for the blowout
presenter stack in use.

16: All components of the choke manifold system should be protected from freezing
by heating draining or filling with appropriate fluid.

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Fig 067a

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Fig 067b

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11.9 KILL LINES

Kill lines are an integral part of the surface equipment required for drilling well control.
The kill line system provides a means of pumping into the wellbore when the normal
method of circulating down through the Kelly or drill pipe cannot be employed. The kill
line connects the drilling fluid pumps to a side outlet on the blowout preventer stack. The
location of the kill line connection to the stack depends on the particular configuration of
preventers and spools employed: the connection should be below the ram type
preventer most likely to be closed.

On selective high-pressure critical wells, a remote kill line is commonly employed to

permit use of an auxiliary high-pressure pump if the rig pumps become inoperative or
inaccessible. This line normally is tied into the kill line near the blowout preventer stack
and extended to a site suitable for location of a pump or pump truck. This site should be
selected to afford maximum safety and accessibility.

Installation Guidelines

The same guidelines, which govern the installation of choke manifolds, apply to kill line
installations. The more important recommendations include:

1: All lines valves check valves and flow fittings should have a working pressure
rating’s and be tested following installation to pressures equal to or greater than
the rated working pressure of the blowout preventer stack in use.

2: Flanged welded or clamped connections should he employed for fittings or

valves with rated working pressures of 3M or above.

3: Components should be of sufficient diameter to permit reasonable pumping rate

without excessive friction. The minimum recommended size is 2-in. nominal
diameter.

4: Components, which may be exposed to drilling fluids or formation fluids, should

comply with applicable API Specifications with particular consideration given to
pressure, temperature, and corrosion resistance requirements.

5: Double full-opening valves between the stack outlet and the kill line are
recommended for installations with rated working pressure of 5M or above.

6: Periodic operation, inspection, testing, and maintenance should be performed on

the same schedule as employed for the blowout preventer stack in use.

7: All components of the kill line system should be protected from freezing by
heating, draining, or filling with proper fluid.

8: Consideration should be given to the low temperature properties of the materials

used in installations to be exposed to unusually low temperatures.
The kill line should not be used as a fill-up line. Routine use of the kill line could result in
erosion of the lines and valves, thus reducing their usefulness in an emergency.

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11.10 BOP ACCUMULATOR CLOSING UNIT

Fig 069 shows a typical accumulator unit while FIG 070 shows the API schematic of a
basic accumulator system.

1. CUSTOMER AIR SUPPLY: Normal Air supply is at 125 psi. Higher air pressure
may require an air regulator.

2. AIR LUBRICATOR: Located on the air inlet line to the air operated pumps.

3. BYPASS VALVE: To automatic hydro-pneumatic 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, 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.

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 operated hydraulic pump suction line. Have
removable screens.

9. CHECK VALVE: One for each air operated hydraulic pump delivery line.

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Fig 069

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10. ELECTRIC MOTOR DRIVEN TRIPLEX PUMP ASSEMBLY.

11. AUTOMATIC HYDROELECTRIC 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 pump. Works in conjunction with the automatic
hydroelectric 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 line.

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. ACCUMULATOR: Check nitrogen pre-charge in accumulator system every 30

days. Nitrogen pre charge should be 1000-psi +/-10%. ACTION: Use
NITROGEN When adding to pre charge. 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 of the pressure reducing and
regulating valves.

20. PRESSURE REDUCING AND REGULATING VALVES: Manually operated.

Adjust to the required continuous operating pressure of ram type BOPS.

21. MAIN VALVE READER: 5000 psi WP. 2" all welded.

22. 4-WAY VALVES: With air cylinder operators for remote operation from the
control panels. Keep in standard operating mode (open or close). NEVER IN
BLOCK POSITION.

23. BYPASS REDUCING AND REGULATING VALVE: With air cylinder operators for
remote operation from the control panels. Keep close position, it puts regulated
pressure on main valve header (21), and in open position, it puts full pump
pressure on the header. Keep in close position unless 3,000 psi (or more) is
required on ram type BOPS.

24. MANIFOLD RELIEF VALVE: Valve set to relieve at 5,500 psi.

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25. HYDRAULIC BLEEDER VALVE: Manually operated - normally closed. Note:
This valve should be kept OPEN when pre-charging the accumulator bottles.

26. PANEL - UNIT SELECTOR: Manual 3 way valve. This is used 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 for stripping operations. Maximum
recommended operating pressure of the annular preventer should not be
exceeded.

28. ACCUMULATOR 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 supply line to the air regulators.

35. AIR REGULATOR FOR PRESSURE AND REGULATING VALVE-AIR

OPERATED.

36. AIR REGULATOR FOR PNEUMATIC TRANSMITTER (33) FOR ANNULAR

PRESSURE.

37. AIR REGULATOR FOR PNEUMATIC PRESSURE TRANSMITTER (31) FOR

ACCUMULATOR PRESSURE.

38. AIR REGULATOR FOR PNEUMATIC PRESSURE TRANSMITTER (32) FOR

MANIFOLD PRESSURE.

NOTE: Air regulator controls for pneumatic transmitter normally set at 15 psi. Increase or
decrease air pressure to calibrate panel gauge to hydraulic pressure gauge on
unit.

39. AIR JUNCTION BOX: To connect to airlines on the unit to the airlines coming
from the remote control panel through air cable.

40. RIG TEST CHECK VALVE.

41. HYDRAULIC FLUID FILL PORT.

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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(a). RIG SKID OUTLET.

46(b). 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 during normal drilling operations.

47. RIG SKID RELIEF VALVE: Valve set to relieve at 2,500 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.

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Fig 070

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11.11 SHAFFER RAM TYPE BOPs

Fig 074

Shaffer LWS ram type BOP incorporates the following features:

1: Special hard backing on door seals to prevent extrusion and pinching.

2: Standard H2S internal trimming.

3: Poslock™ locks the ram automatically.

4: All rams will support over 600,000 lbs hang-off weight.

5: Shear rams will cut drillpipe and seal the well in one operation.

6: Most grades of drillpipe can be sheared with 1500 psi operating pressure.

7: Manual-lock and Poslock pistons are inter-changeable.

Note: API RP53 and 16E state, ram type preventers should be equipped with extension
hand wheels or hydraulic locks

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Fig 075 shows a NL Shaffer shear ram to fit the SL ram BOP in Fig 074

Fig 076 above shows a NL Shaffer fixed bore ram to fit the SL ram

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Fig 077 - NL Shaffer PosLock System

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Fig 078

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Fig 079 - NL Shaffer Secondary Mud Seal

Fig 079 shows the secondary mud seal on a NL Shaffer ram type BOP. The secondary
seal is a plastic packing injected into an exterior groove around the ram shaft. As more
plastic is injected and seals off between the ram shaft and the interior body off the
preventer. The secondary mud seal should only be used in an emergency and is only
usable once.

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11.12 CAMERON RAM TYPE BOPs

Fig 080

Cameron U ram type BOP incorporates the following features:

1: Well pressure helps to maintain the ram closed.

2: Ram rubbers are self-feeding (extruding)

3: This ram can be fitted with manual or hydraulic locking devices.

4: Shear rams have a thicker intermediate flange.

5: The ram can be used for surface or sub-sea applications.

6: Rams can only hold full wellbore pressure from below.

Fig 081

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Cameron rams are self-feeding, with a large reserve of packer rubber. The packers are
locked in place and are not dislodged by well flow, the packer rubber is bonded to steel
plates which confine it to the sealing area. A set of Variable rams FIG 083 below;
provide a back up for two sizes of standard rams or serves as a primary ram for one size
and a back up for another.

Fig 082

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Fig 083

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1. Body Clamp 22. Protective Cover 40. Retainer Ring, Lip

Seal Tail Rod
2. Intermediate Flange 23. Cap Screw
41. Gland, Bleeder
3a. Bonnet 24. Screw, Plastic
3b. Bonnet Packing 42. Plug, Bleeder

4. Piston, Operating 25. Pipe Plug, Plastic 43. Lifting Eye

Packing
44. Seal Ring,-Ram
5. Piston, Ram Change 26. Check Valve. Plastic Change
Open Packing Piston Head

6. Piston, Ram Change 27. Cap screw 45. Wear Ring

Close to Bonnet Operating Piston

7. Cylinder, Ram 28. Ring, Seal Sec 46. Lip Seal, Operating
Change Con. Rod Piston

8. Stud, Bonnet 29. Stud. Wedgelock 47. 0 Ring

9. Piston, Bonnet 30. Nut, Wedgelock 48. Cylinder, Operating

Stud
31. Retainer Ring, 49. Bearing Retainer
10. Seal, Bonnet Stud Tail Rod Ring, Seal

11. Nut, Bonnet Stud 32. Seal Ring, 50. Plastic Packing
Tail Rod
12. Pin, Ram Guide 51. Ring, Seal
33. Wear Ring Ram Operating Piston
13. Lantern Ring Change Piston Head
52. Ring, Back-Up
14. Ring Retainer 34. O-Ring. Ram Change
Back-Up Ring Piston to Body 53. Check valve,
Weep Hole
15. Ring, Back Up 35. O-Ring Ram
Change 54. Wedgelock w/
16. Seal Ring, Cylinder to Bonnet Pressure Bat Cham
Connecting Rod
36. O-Ring Ram Change 55, O-Ring
17. Retainer Plate Cylinder

18. Retainer Ring 37. Bearing Gland,

Intermediate
19. Bonnet, Seal
38. Seal Ring, Ram
20. Connector, Tbg Change
Piston Rod
21. Quick Disconnect,
Male 39. Connector

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Fig 084

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1. Body 20 Seal Ring, Connecting Rod

2. Intermediate Flange 21. Ring Back-Up

2A. Intermediate Flange/Shear 22. Seal, Bonnet

3. Bonnet 23. Pin, Ram Guide

4. Ram Assembly 24. O-Ring, Operating Cylinder

5. Piston, Operating 25. O-Ring, Operating Piston Rod to Int Flg

5A, Piston. Operating/Shear 26. Lip Seal, Operating Piston

6. Cylinder, Operating 27. Seal Ring, Tail Rod

6A. Cylinder, Operating/Shear 28. O-Ring, Wiping

7. Housing, locking Screw 29. O-Ring, Ram Change Piston To Body

8. Locking Screw 30. O-Ring, Ram Change Piston Rod to Int

Flg
8A. Locking Screw/Shear
31. O-Ring, Ram Charge Cylinder to Int
9. Piston, Ram Change/Open Flg

10. Piston, Ram Change/Close 32. O-Ring, Ram Change Cylinder to

Bonnet
11. Cylinder, Ram Change
33. O-Ring, Ram Change Piston
12. Bolt Bonnet
34. O-Ring Bonnet Bolt Retainer
12A. Bolt Bonnet/Shear
35. Cap Screw, Int Flange to Bonnet
13. Stud, Locking Screw Housing
36. Gland, Bleeder
13A. Stud. Locking Screw
Housing/Shear 37. Plug Bleeder

14. Nut, Locking Screw Housing 38. Lifting Eye

15. Check Valve, Plastic Packing 39. Packing Plastic

16. Screw, Plastic Packing 40. Washer

17. Pipe Plug, Plastic Packing 41. Wear Ring, Operating Piston

18. Ring, Plastic Packing 42. Spacer, Shear

19. Ring, Plastic Energizing

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Fig 085

Fig 086

Steel plates are mounted on the upper and lower surfaces of the ram-packing element
as shown in Fig 086. As the two opposing rams close around the pipe, the leading edges
of the metal plates meet before the rams reach the full closed position. Further
movement of the rams causes the steel plates to move backward. There is reserve
rubber behind the plates and as the rubber is only free to move into the area around the
pipe, it extrudes to provide a seal. If the ram rubber is eroded, in stripping operations,
this self-feeding action causes additional rubber to move toward the pipe to maintain a
seal.

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Fig 087

The Cameron secondary mud seal for ram type BOPs is shown in Fig 087. This type of
seal has no relief mechanism to maintain the correct plastic packing pressure, therefore
care should be take when energising the secondary seal so that only sufficient pressure
is applied to the packing to stop the leak.

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Fig 088

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11.13 HYDRIL RAM TYPE BOPs

Fig 089 - Hydril Ram Type BOP

Fig 090a

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Fig 090b

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Fig 090c

Fig 090d

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Fig 090e

Fig 091

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Fig 091 and Fig 092 show the Hydril Multiple Position Locking, MPL system, which
automatically maintains ram seal-off with the required rubber pressure in the front packer
and upper seal. The MPL will maintain a seal without closing pressure and with opening
forces created by hanging-off on the ram. Locking and unlocking the MPL are controlled
by a unidirectional clutch mechanism and lock nut.

Fig 092

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11.14 SHAFFER ANNULAR BOPs

Fig 093
Fig 095 shows the operation of a Shaffer Spherical BOP closing on drillpipe and on open
hole.

NL Shaffer Bolted Cover Spherical BOP Fig 094

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FIG 095

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11.15 CAMERON ANNULAR BOPs

Fig 096

The Cameron D type annular is of unique design, closing pressure forces the operating
piston and pusher plate upward, displacing the solid rubber donut, forcing the packer to
close inward. As the packer closes steel reinforcing, inserts rotate inward to form a
continuous support ring of steel at the top and bottom of the packer. The inserts remain
in contact with each other whether the packer is open, closed on drillpipe or closed on
open hole. Due to the short piston stroke the Cameron is shorter than comparable
annular preventers.

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Fig 097

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11.16 HYDRIL ANNULAR BOP’s

Fig 098

Fig 99

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Fig 100

Fig 101a and Fig 101b show the Hydril GL annular preventer with both surface and
subsea applications on the secondary or balancing chamber.

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Fig 101a

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Fig 101b

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Fig 102 - shows a Hydril GK annular preventer hooked up for stripping

operations.

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11.17 RING SEALS

To affect a pressure tight seal between each piece of stack and related equipment Seal
Rings are used. The Seal Ring fits into the Ring Grooves on the BOP equipment.

Ring Groove Surface.

All 23-degree surfaces on ring grooves shall have a surface finish no rougher than 32
RMS.

General

Segmented flanges are of the ring joint type and are designed for face-to-face make-up.
The connection make-up bolting force reacts primarily on the flange face. The
segmented flange shall be of the through bolted or studded design. Segmented flanges
shall use Type RX gaskets.

Quick Guide

1: API 6B flange, 2000 to 5000 psi.

2: API 6BX flange, 5000 to 20000 psi

Fig 103a

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Fig 103b

FIG 103c

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11.18 FLANGES AND HUBS

Type 6B Flanges

API Type 6B flanges are of the ring joint type and are not designed for make-up face-to-
face. The connection make-up bolting force reacts on the metallic ring gasket. The Type
6B flange shall be of the through-bolted or studded design. Type 6B flanges shall use
Type R or Type RX gaskets. The torque on the bolts and nuts need be checked at
regular intervals, as it is the torque that maintains the flange tightness.
Type 6BX Flanges

Type 6BX flanges are of the ring joint type and are designed for face-to-face make-up.
The connection make-up bolting force reacts primarily on the raised face of the flange.
Therefore, one of the flanges in a 6BX connection must have a raised face. The Type
6BX flange shall be of the through-bolted or studded design. Type 6BX flanges shall use
type BX pressure energised gaskets. (AX, VX, and CX are types used on Subsea
Stacks).

Rated Working Flange or Hub Minimum Vertical Ring-Joint

Pressure psi Size inches Bore inches Gasket
RX BX
500 (0.5 M) 29½ ” 29½ ” - -
2,000 (2 M) 16 16¾ ” 65 -
20 21 ¼ “ 73 -
26 ¼ 26 ¾” - -
3,000 (3 M) 6 7 1/16” 45 -
8 9” 49 -
10 11” 53 -
12 13 5/8” 57 -
20 20¾” 74 -
26¾” 26¾” - -
5,000 (5 M) 6 7 1/16” 46 -
10” 11” 54 -
13 5/8” 13 5/8” - 160
16¾” 16¾” - 162
18¾” 18¾” - 163
21¼” 21¼” - 165
10,000 (10 M) 7 1/16” 7 1/16” - 156
9” 9” - 157
11” 11” - 158
13 5/8” 13 5/8” - 159
16¾” 16¾” - 162
18¾” 18¾” - 164
21¼” 21¼” - 166
15,000 (15 M) 7 1/16” 7 1/16” - 156
9” 9” - 157
11” 11” - 158
13 5/8” 13 5/8” - 159
20,000 (20 M) 7 1/16” 7 1/16” - 156

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FIG103d

103e

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Fig 104

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11.19 MUD GAS SEPARATOR

The mud/gas separator is used to separate majority of gas from returning drilling
fluid that is gas cut. The separated gas can then be vented to a safe distance from the
rig and re-usable mud is returned to the active system. The most common type is the
atmospheric mud/gas separator, sometimes referred to as a gas buster or poor-boy
degasser FIG 106 .All separators with a liquid level control may be referred to as
pressurized mud gas separators. Of particular importance is the safe handling at
surface of any hydrocarbon influx that has been circulated out of the well and
through the choke. The atmospheric degasser is installed immediately down stream
of the choke manifold.

Fig 105

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The main advantage of this design is its operational simplicity however it does have
limitations as described below, which rig personnel should be aware. Although details
vary from rig to rig, the essential features of the design are:

1: A height of at least 10 ft (preferably 20 ft).

2: A diameter of at least 30".

3: An internal baffle arrangement.

4: A gas vent line of at least 6" diameter

5: A U-tube arrangement sized to maintain a fluid seal inside the separator.

Conventional mud gas separators employ a float-controlled valve to regulate the internal
fluid level and gas pressure. Such designs however risk malfunction due to plugging and
to the relatively complex method of operation. The poor boy degasser uses a much
simpler liquid seal principle.

The volume of the separator determines the maximum amount of gas and fluid that it
can effectively handle. With the inlet point located at the mid-point of the vessel, the top
half of the chamber will contain gas and the lower half will provide the gas separation
and fluid retention.

Therefore size and routing of the vent line is vital in ensuring that large volumes of gas
can be vented with minimum restriction and hence minimum backpressure.

A secondary vent line should be fitted at the highest point in the U-tube pipe work to
avoid siphoning effects and to dispose of any gas carried through with the mud. It does
not have to extend to the top of the derrick but should not be tied in to the primary vent
line.

If the pressure inside the chamber were to overcome the hydrostatic fluid seal in the U-
tube then the gas could be discharged into the mud system causing a hazardous
situation. A gauge installed to register the backpressure of the gas is required and
should be positioned where it can be easily read by the choke operator. The pressure
sensor can be located at the top of the separator body or the bottom of the vent line.

VACUUM DEGASSER

The Vacuum degasser is designed to remove entrained gas bubbles in the drilling fluid
that are too small to be removed by the mud/gas separator. Most degassers make use
of some degree of vacuum to assist in removing this entrained gas. The drilling fluid inlet
line to the degasser should be placed close to the drilling fluid discharge line from the
mud gas separator to reduce the possibility of gas breaking out of the drilling fluid in the
pit. In addition, the drilling fluid throughput capacity of the degasser should exceed the
maximum flow rate from the well to ensure that all drilling fluid is subjected to degassing.

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A design of vacuum degasser in common use is shown in FIG 106. The long horizontal
tank contains down-sloping metal plates over which the mud is spread in thin layers to
enable the gas bubbles to break out. The venturi effect created by the jet pulls the mud
out of the tank. The vacuum pump also helps to pull mud into the tank and aids removal
of the gas and air from the mud.

Another type of mud/gas separator is designed such that it can be operated at moderate
backpressure, usually less than 100 psi
The performance of each of the two pumps has to be set such that they keep the tank
nearly empty of mud so that the plates are not flooded. If insufficient gas is present, a
level control is set to allow air to enter the tank to prevent over-filling. These degassers
are limited as regards their throughput volume.

TESTING OF WELL CONTROL EQUIPMENT

Water or water with anti-freeze additives must be used when pressure test of surface
system equipment is conducted. These tests pressure must not be higher than
anticipated surface pressure.

FIG 106

11.20 FIELD ACCEPTANCE INSPECTION AND TESTING

The field acceptance procedure should be performed each time a new or reworked
blowout preventer or blowout preventer of unknown condition is placed in service.

Ram Type Preventers and Drilling Spools.

Following are recommended inspections and tests for this equipment, FIG 073 shows a
Plug Tester:

1: Visually inspect the body and ring grooves (vertical, horizontal. or ram bore) for
damage wear and pitting.

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2: Check bolting, both studs and nuts for proper type size and condition.

3: Check ring joint gaskets for proper type and condition.

4: Visually inspect ram type preventers for:

a: Wear, pitting and/or damage to the bonnet or door seal area, bonnet or
door seal grooves, ram bores, ram connecting rod and ram operating
rods.

b: Packer wear, cracking and excessive hardness.

c: Measure ram and ram bore to check for maximum vertical clearance
according to manufacturer's specifications. This clearance is dependent
on size, and trim of the preventers.

d: If preventer has secondary seals, inspect secondary seals and remove

the plugs to expose plastic packing injection ports used for secondary
sealing purposes. Remove the plastic injection screw and the cheek
valve in this port. (Some preventers have a release packing regulating
valve that will need to be removed.) Probe the plastic packing to ensure it
is soft and not energizing the seal). Remove and replace packing if
necessary.

5: Hydraulically test with water using the following procedure:

a: Connect closing line(s) to preventer(s).

b: Set preventer test tool on drillpipe below preventers.

c: Check for closing chamber seal leaks by applying closing pressure to

close the rams and check for fluid leaks by observing opening line port(s).
Closing pressure should be equivalent to the manufacturer recommended
operating pressure for the preventer hydraulic system.

d: Release closing pressure remove closing line(s) and connect opening

line(s).

e: Check for opening chamber seal leaks by applying opening pressure to

open rams and check for fluid leaks by observing closing line port(s).
Opening pressure should be equivalent to the manufacturer's
recommended operating pressure for the preventer’s hydraulic system.

f: Release opening pressure and reconnect closing line(s).

g: Check for ram packer leaks at low pressure by closing rams with 1500 psi
operating pressure and apply pressure under rams to 200-300 psi with
blowout preventer test tool installed (when testing preventer containing
pipe rams). Hold for three minutes. Check for leaks. If ram packer leaks
refer to step i. If ram packer does not leak, proceed to step h.

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h: Check for ram packer leaks by increasing pressure slowly to the rated
working pressure of the preventer. Hold for three minutes. Check for
leaks. If ram packer leaks, proceed to step i.

i: If rams leak check for worn packers and replace if necessary. If the
preventer is equipped with an automatic locking device, check it for
proper adjustment in accordance with manufacturer's specifications.
Continue testing until a successful test is obtained.

j: Test the connecting rod for adequate strength by applying opening

pressure as recommended by the manufacturer with rams closed and
blowout preventer rated working pressure under the rams.

k: Release opening pressure and release pressure under rams.

l: Repeat procedure (steps a through i) for each set of pipe rams.

m: Test blind rams in same manner as pipe rams. (step a. and steps c
through i) with test plug installed but test joint removed. FIG 074 below
shows a BOP test plug installed.

Annular Blowout Preventers and Diverters

Following are recommended inspections and tests for this equipment:

1: Visually inspect.

a: Studded face of preventer head for pitting and damage, particularly in ring
groove and stud holes.

b: Body for wear and damage.

c: Vertical bore for wear and damage from drillstring and drill tools.

d: Inner sleeve for pitting and damage. Look through slots in base of inner
liner for cuttings that might be trapped, thereby preventing full movement
of the piston.

e: Packer for wear, cracking, excessive hardness and correct elastomer

composition.

f: Bolting (both studs and nuts) for proper type size and condition.

g: Ring-joint gaskets for proper type and condition.

2: Hydraulic test using the following procedure:

a: Connect closing line to preventer.

b: Set blowout preventer test tool on drill pipe below preventer.

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c: Test the seals between the closing chamber and wellbore and between
the closing chamber and opening chamber by closing preventer and
applying manufacturer's recommended closing pressure. If other
chambers are located between the wellbore and operating chamber, this
seal should also be tested.

d: 1: If pressure holds, refer to step m.

2: If pressure does not hold and no fluid is running out of opening

chamber opening, seal between the closing chamber and the
wellbore or other operating chambers is leaking, refer to step k.

3: If fluid is coming out of the opening chamber opening, indicating the seal
between the closing chamber and opening chamber is leaking proceed to step
e.

a: Release closing pressure.

b: Install a plug in opening chamber opening or if opening line is equipped

with a valve, install opening line and close valve.

c: Test seals between the closing chamber, operating chambers, and

wellbore by applying manufacturer's recommended closing pressure.
Observe to see that pressure holds.

g: Release closing pressure.

h: Remove plug from opening chamber opening and install an open valve in
opening line.

i: Apply 1500 psi closing pressure.

j: Apply 1500 psi wellbore pressure.

k: Bleed closing pressure to 1000 psi.

l: To test the seal between the wellbore and the closing chamber, close
valve on closing line and disconnect closing line from valve on closing
unit side of valve. Install pressure gauge on closing unit side of valve and
open valve. If this seal is leaking. the closing line will have pressure
greater than 1000 psi.

Note: If the closing line does not have a valve installed the closing line should
not be disconnected with pressure trapped in the closing chamber.

m: Release wellbore pressure.

n: Release closing pressure.

4: To test the seals between the opening chamber and the closing chamber and
between the opening chamber and the piston, apply manufacturer's
recommended opening pressure, if pressure holds refer to step u.

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5: If pressure does not hold and no fluid is running out of the closing chamber
opening the seal between the opening chamber and the piston is leaking.
Verify this visually, refer to step u.

6: If fluid is coming out of the closing chamber opening indicating the seal
between the opening chamber and the closing chamber is leaking, proceed to
step q.

q: Release opening pressure.

r: Install closing line and block flow (close valve in closing line if available).

s: Apply 1500-psi opening pressure. If pressure does not hold, seal between
the opening chamber and the preventer head is leaking. Verify this
visually.

t: Release opening pressure and replace necessary seals.

u: Release opening pressure, replace closing line, in addition, and replace

necessary seals.

v: If closing line has a valve installed, make certain that valve is open at the
end of the test.

Note: This procedure tests all seals except the seal between the wellbore and the
opening chamber. This seal should be tested in the bottom annular preventer if
two annular preventers are being used or if a stack is nippled up on another
preventer (for snubbing, etc.). It can be tested as follows:

1: To rated working pressure by running a test joint and plug, closing an upper
preventer, removing the opening line and pressuring the preventer stack.

2: To 1500 psi maximum, or by closing an upper preventer and the annular

preventer, removing the opening line, and pressuring up between preventers.

Closing Unit Pump Capability Test

Prior to conducting any tests, the closing unit reservoir should be inspected to be sure it
does not contain any drilling fluid, foreign fluid, rocks, or other debris. The closing unit
pump capability test should be conducted on each well before pressure testing the
blowout preventer stack. This test can be conveniently scheduled either immediately
before or after the accumulator closing time test. Test should be conducted according to
the following procedure:

1: Position a joint of drill pipe in the blowout preventer stack.

2: Isolate the accumulators from the closing unit manifold by closing the required
valves.

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3: If the accumulator pumps are powered by air isolate the rig air system from the
pumps. A separate closing unit air storage tank or a bank of nitrogen bottles
should be used to power the pumps during this test. When a dual power source
system is used both power supplies should be tested separately.

4: Simultaneously turn the control valve for the annular preventer to the closing
position and turn the control valve for the hydraulically operated valve to the
opening position.

5: Record the time (in seconds) required for the closing unit pumps to close the
annular preventer plus open the hydraulically operated valve and obtain 200 psi
above the pre-charge pressure on the closing unit manifold. It is recommended
that the time required for the closing unit pumps to accomplish these operations
not exceed two minutes.

6: Close the hydraulically operated valve and open the annular preventer. Open the
accumulator system to the closing unit and charge the accumulator system to its
designed operating pressure using the pumps.

Accumulator Tests

Accumulator Pre-charge Pressure Test, this test should be conducted on each well prior
to connecting the closing unit to the blowout preventer stack. Test should be conducted
as follows:

1: Open the bottom valve on each accumulator bottle and drain the hydraulic fluid
into the closing unit fluid reservoir.

2: Measure the nitrogen pre-charge pressure on each accumulator bottle using an

accurate pressure gauge attached to the pre-charge measuring port, and adjust if
necessary.

Accumulator Closing Test

Alarms for for low fluid level must be tested on a weekly basis.

This test should be conducted on each well prior to pressure testing the blowout
preventer stack. Test should be conducted as follows:

1: Position a joint of drill pipe in the blowout preventer stack.

2: Close off the power supply to the accumulator pumps.

3: Record the initial accumulator pressure. This pressure should be the designed
operating pressure of the accumulators. Adjust the regulator to provide 1500 psi
operating pressure to the annular preventer.

4: Simultaneously turn the control valves for the annular preventer and for one pipe
ram (having the same size ram as the pipe used for testing) to the closing
position and turn the control valve for the hydraulically operated valve to the
opening position.

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5: Record the time required for the accumulators to close the preventers and open
the hydraulically operated valve. Record the final accumulator pressure (closing
unit pressure). This final pressure should be at least 200 psi above the pre-
charge pressure.

6: After the preventers have been opened recharge the accumulator system to its
designed operating pressure using the accumulator pumps.

11.21 TEST PLUGS AND TEST JOINTS

There are several makes of test plugs are available for testing BOP stacks. The testing
tool arrangement should provide for testing the bottom blowout preventer flange. Test
plugs generally fall into two types, cup type Fig 107 and hanger type Fig 108

Fig 072

Fig 107

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Fig 074

Test Plugs and Test Joints

Fig 108

1: The hanger type test plug Fig 108, has a steel body with outer dimensions to fit
the hanger recess of corresponding types of casing heads. An “0” ring pressure
seal is provided between the tester and the hanger recess. The tester is available
in various sizes depending on wellhead type and size and is equipped with tool
joint connections. These plugs should be constructed with an upper bevel and/or
bevelled groove to facilitate the use of locking screws. The “0” ring groove if used
should be machined to permit a pressure seal from above or below the plug.
Other types of seals should also be capable of holding pressure from above or
below the plug. A weep hole may be drilled in the pin end of the test joint or may
be installed in the test plug. These testers can be provided with a plug to test
blind rams with the drill string removed. The tester can be retrieved with the drill
string. Side outlet valves below the plug should always be open during BOP tests
for the following reasons:

a: To observe for flow from the annulus.

b: To check for a leaking test plug.

c: To prevent damage to the casing and open hole.

2: The cup type test plug, FIG 107 consists of a mandrel threaded with a box on top
and a pin on bottom for a tool joint connection. A cup type pressure element
holds pressure from above. Some models contain a backpressure valve to
bypass fluid when going in the hole. Also, a set of snap plugs (usually 4) can be
provided integral to the mandrel so that the snap plugs can be broken off by
dropping a bar inside the pipe. This allows the annulus to be connected with the
inside of the drill pipe and permits the tool to be pulled without swabbing the hole.

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Test Joints

The test joint should be made of pipe of sufficient weight and grade to safely withstand
tensile yield, collapse or internal pressures that will be placed on it during testing
operations.

11.22 PERIODIC FIELD TESTING

Blowout Preventer Operating Test

A preventer operating test should be performed on each round trip but not more than
once per day.

The test should be conducted as follows while tripping the drill pipe with the bit just
inside casing:

1: Install drill pipe safety valve.

2: Operate the choke line valves.

3: Operate adjustable chokes, (certain chokes can be damaged if full closure is

affected).

4: Position blowout preventer equipment to check choke manifold. Open adjustable

chokes and pump through each choke manifold to ensure that it is not plugged. If
choke manifold contains brine, diesel, or other fluid to prevent freeze-up in cold
weather some other method should be devised to ensure manifold lines and
assembly are not plugged.

5: Close each preventer until all pipe rams in the stack have been operated. Do not
close pipe rams an open hole. If blind rams are in the stack, operate them when
out of the hole.

6: Return all valves and preventers to their original position and continue normal
operations and record the test results.

7: Annular preventers need not be operated on each round trip. They should
however be operated at an interval not to exceed 7 days.

Blowout Preventer Hydraulic Tests

The following items should be checked each time a preventer is to be hydraulically

tested:

1: Verify wellhead type and rated working pressure.

2: Check for wellhead bowl protector, wear bushing.

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3: Verify preventer type and rated working pressure.

4: Verify drilling spool, spacer spool, in addition, valve types and rated working
pressures.

5: Verify ram placement in preventers and pipe ram size.

6: Verify drill pipe connection size and type in use.

7: Open casing valve during test, unless pressure on the casing or hole is intended.

8: Test pressure should not exceed the manufacturer's rated working pressure for
the body or the seals of the assembly being tested.

9: Test pressure should not exceed the values for tensile yield, collapse and
internal pressure tabulated for the appropriate drill pipe as listed in API RP 7G.
Recommended Practice for Drill Stem Design and Operating Limits.

10: Verify the type and pressure rating of the preventer tester to be used.

Test Pressure Recommendations. Preventer Equipment Tested.

Blowout preventer stack 1: Entire blowout preventer stack
rated working pressure 2: All choke manifold components upstream of
chokes.
3: All Kelly valves, drill pipe, and tubing safety
valves.
4: Drilling spools, intermediate casing-heads, in
addition, side outlet valves.
Rated working pressure of 1: Closing unit valves and manifold
preventers, or 3000 psi, whichever is 2: All operating lines
less
Casing test pressure 1: Any blind rams below drilling spool
2: Primary casing head and side outlet valves
3: Casing string
Fifty percent(50%) of rated working 1: Choke manifold components downstream of
pressure of components chokes
200 - 300 psi 1: All ram type preventers.
2: Annular preventer.
3: Hydraulically operated valves

Note 1: Initial test pressure for the blowout preventer stack, manifold, valves, etc.
should be the lesser of the rated working pressure of the preventer stack,
wellhead, or upper part of the casing string.

Note 2: Optional test, rated working pressures test on the top flange of the
annular preventer. A companion test flange will be required.

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An initial pressure test should be conducted on all preventer installations prior to drilling
the casing shoe. Conduct each component pressure test for at least three minutes.
Monitor secondary seal ports and operating lines on each presenter while testing to
detect internal seal leaks.

Subsequent pressure tests of blowout preventer equipment should be performed after

setting a casing, prior to entering a known pressure transition zone, and after a
preventer ram and/or any preventer stack or choke manifold component change, but no
less than once every 21 days. Equipment should be tested to at least 70% of the
preventer rated working pressure, but limited to the lesser of the rated working pressure
of the wellhead or 70% of the minimum internal yield pressure of the upper part of the
casing string. However, in no case should these or subsequent test pressures be less
than the expected surface pressure. An exception is the annular preventers, which may
be tested to 50 % of its rated working pressure to minimise pack-off element wear or
damage.

Auxiliary Equipment Testing

The lower Kelly valve, Kelly, Kelly cock, in addition, the inside blowout preventer should
be tested to the same pressure as the blowout preventer stack at the same time the
preventer assembly tests are made. This equipment should be tested with pressure
applied from below.

11.23 MAINTENANCE PROCEDURES

Field welding on blowout preventer or related equipment is not recommended.

The service life of annular preventer packing units can be extended by:

1: Closing on pipe rather than open hole.

2: Closing using manufacturer recommended pressures.

3: Utilizing the type of elastomer packing unit that best suits the drilling fluid
conditions and environment expected.

4: Proper use of a regulator or accumulator when stripping tool joints. Rapid

movement of a tool joint through the preventer packing unit may cause severe
damage and early failure of the packing unit.

If elastomer parts are to be stored for a long time, sealed containers will help extend
their useful life.

When a blowout preventer is taken out of service, it should be completely washed,

steamed and oiled. The rams’ sealing element should be removed and the ram bore
washed, inspected and coated with a rust inhibitor. Flanged faces should be protected
with wooden covers. Any burrs or galled spots should be smoothed.

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