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BOP - Pressure Testing

BOP - Pressure Testing

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Published by Chitta Gogoi
BOP Installation & Pressure Testing Procedures
BOP Installation & Pressure Testing Procedures

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Published by: Chitta Gogoi on Jun 24, 2014
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10/29/2014

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 Reference: Drilling Operational Manual/ Institute of Drilling Technology/ONGC/Chapter-15
PRESSURE TESTING OF BOPs & CHOKE MANIFOLD
TEST FLUID
Clean water should be used as test fluid.
TEST FREQUENCY
BOP stack should be pressure tested (1) when installed. (2) after setting each casing string. (3) prior to entry into a transition zone. (4) not less than once a week. (5) following repairs that require breaking a pressure connection.
TEST PRESSURE
Both low pressure and high pressure testing procedure should be followed.
 Low pressure test
A low test pressure in the range of 15-25 kg/cm2 (200 to 350 psi) should be carried out..
 High pressure test
Once the equipment clears the low pressure test, it should be tested to a pressure to be decided as explained  below:
On installation of the BOP stack 
, the test pressure should be minimum of the following: (1) Rated working pressure of the preventer stack. (2) Rated working pressure of the well head.
On subsequent tests as mentioned above,
the BOP stack should be tested to at least 70% of the preventer rated working pressure but limited to the least of the rated working pressure of the wellhead and 90%of the  burst pressure of the upper part of casing string. However, in no case the test pressure should be less than the expected surface pressure. An exception is the annular preventer which should be tested to 50% of its rated pressure to minimize pack-off element wear or damage. TEST PROCEDURE Detailed step wise procedure for pressure testing of BOP stack and other associated equipment is as under
 
 
 Reference: Drilling Operational Manual/ Institute of Drilling Technology/ONGC/Chapter-15
PRESSURE TESTING OF BLIND RAMS (Fig.15.1)
1.
 
Make up appropriate casing head test plug on top of a stand of drill collar and run-in the same on a joint of drill pipe. Set the plug in casing head seat. Back off and remove drill pipe joint.
Note:
 Ensure that test plug size, shape and contour matches with that of casing head where it will seat. If the test plug is of open bore type, make sure that it is run-in with bull plug to isolate casing and open hole from test pressures. 2.
 
Fill preventers with water . 3.
 
Open all the valves and chokes on choke manifold and allow water to flow through each outlet. Flush all the lines and BOP with water. 4.
 
Open both the valves on casing head below test plug seals to recognize leaking seal and pr 
 
event formation or casing damage in case of any leakage through test plug. 5.
 
Close valve no.7& 9 on choke line and 2 & 3 on kill line. 6.
 
Fill and top up BOP stack bore with water . 7.
 
Close blind rams with 105.6 kg/cm2 (1500 psi) closing pressure. 8.
 
Check closing line and preventer for leaks. 9.
 
Apply pressure by cementing unit or test pump through main kill line and pressurize upto 15 to 25 kg/cm2 and hold for 3 minutes. If pressure is holding, increase the pressure upto final test pressure as decided and hold for 5 minutes. 10.
 
Check all the valves, flanges apd seals that are under pressure for leaks and tighten if necessary. Check  blind rams for leak. Check test plug for leaks. Release pressure. 11.
 
Open blind rams with 105.6 kg/cm2 (1500 psi). Check opening line for leaks. 12.
 
Record test results.
Fig. 15.1: Testing of Blind Ram
 
 
 Reference: Drilling Operational Manual/ Institute of Drilling Technology/ONGC/Chapter-15
PRESSURE TESTING OF ANNULAR AND PIPE RAM BOPs (Fig. 15.2)
While testing above elements, it is recommended that test pressure should be applied from the drill pipe to create a situation where all elements can be tested in the direction they would experience pressure during a well kick. Step wise procedure is as under: 1.
 
From the previous test with all the lines and BOP flushed with water and the test plug seated in the casing head with a stand of drill collar, run in appropriate size drill pipe and make up with test plug. Pull out the drill pipe with test plug and tighten the joint if required. Again lower the test
 
 plug and allow it to set in casing head seat.
Note
: Make sure that the test plug has the integral port. If not, a perforated sub should be used with the test  plug. Ensure that the casing head valves are open for the reasons discussed earlier. 2.
 
Make necessary connections at the rig floor to pump through drill pipe with the help of cementing unit or test pump. Purge all air from drill pipe and preventer. Fill the preventer with water, if required. 3.
 
Close valve no.7& 9 on choke line and 3 & 6 on kill line (nearest to the stack). 4.
 
Close annular preventer with appropriate closing pressure as per manufacturer's recommendations. 5.
 
Check closing line and annular preventer for leaks. 6.
 
Apply test pressure through drill pipe and raise pressure to 15 to 25 kg/cm2. Hold for 3 mins. Check for any leakage. If pressure is holding, increase and the pressure upto final test pressure as decided and hold for 5 minutes. 7.
 
Check for leaks and release pressure. 8.
 
Open annular preventer and check opening lines for leakage. 9.
 
 Now close upper pipe ram with 105.6 kg/cm2 ( 1500 psi)
 NOTE:
 Be sure that ram size fits with the drill pipe size 10.
 
Check closing line and preventer for leaks. 11.
 
Again apply test pressure through drill pipe and raise pressure upto 15 to 25 kg/cm2. Hold for 3 mins. Check for any leakage. If the pressure is holding then increase the pressure upto final test  pressure as decided and hold for 5 minutes. Test pressure should be limited to the pressure rating of the weakest member exposed to the test pressures. 12.
 
Check for leaks and release pressure. 13.
 
Open pipe rams with 105.6 kg/cm2 (1500 psi) 14.
 
Check opening lines for leaks. 15.
 
Test all other pipe rams in this manner by repeating step no.9 to 14. Make sure that the pipe rams size fits the drill pipe size in the well. lf not, take corrective measure and then test the rams.

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