Contents Page References S73 Introduction and objectives 574 Resumé 5imis Topic 1 General 3 1 Working pressure classification 7 2 General considerations 7 3 Minimum requirements a ‘Topic 2. ‘The well killing system Simm 1 Choke manifold u 2 High pressure valves B 21 Gate valves 13 2.2. Hydraulically operated choke line valve 13 2.3. "HICR" pressure operated gate valve 14 2.4 Choke and kill line outlet valves 14 3 Chokes M4 3.1 Manual adjustable choke 15 3.2 Bixed choke 15 3.3 Remote controlled choke 15 4 High pressure lines and hoses 7 Topic 3. BOP stack equipment SIT. 1 Annular prevencers a LL General au 1.2. Closing time 2 13 Hydril GK annular preventer 2 14 NI Shaffer spherical annular preventer 24 1.5. Cameron type D annular preventer 25 1.6 Stripping through closed prevencers 26 1.7 Roracing annular preventer 26 2 Ram-type preventers 28 2.1 General 28 2.2 Pipe rams 28 2.3. Shearing blind rams 29 2.4 Variable rams 29 2.5. Secondary sealing 29 26 Locking 30 2.7 Opening zand closing ratios 30 2.8 Cameron type U ram-type BOP. 30 2.9 Shaffer ram-type BOP. 34 2.10. Hydeil ram-type BOP 37 3 Diverters 40 WOLP - Well control equipment Page 5/7/1 v2.0.0Topic 4 Hydraulic BOP operating units SITIAL 1 Requirements Al 2 Hydraulic conerol units 42 3 Remote control panel B 4 Accumulator capacity 44 5 Lines, couplings and valves 45 5.1 Four-way valves 45 5.2 Pressure regulating valves 45 5.3. Hydraulic lines 46 5.4 Self-closing coupling 47 Topic 5 Additional well control equipment 5/7150 1 Kelly cocks 50 2 Inside BOPs 31 3 Circulating heads 52 4 Mud/gas separator 53 41 Purpose and design 33 42 Size of vessel 34 43° Liquid seal (mud seal) 54 44 Vent line 54 5 Vacuum degasser 55 Topic 6 Testing casing, wellhead and well control equipment 511156 1 Casing tests 56 1.1 Initial pressure cests 56 1.2. Subsequent pressure tests 58 2 Tests of X-bushing and slip & seal assembly or BRX hanger 58 3. Surface wellhead and BOP tests 58 4 Choke manifold & valves, kill 8 choke lines, and valves on the side ourlers 59 5 Accumulator tests 60 6 Evaluation of pressure tests 60 Topic 7 Installation requirements for wellhead and BOP equipment 57161 ‘Appendix 1 : Example of accumulator size calculation 517163 Questions 517167 Page 5/7/2 WDIP - Well control equipment v200References ‘Well Engineers Notebook, Section K. EP 88-1000 _ Shallow gas procedure guidance manual EP 2002-1500 Pressure control manual EP 95-0210 Drilling HSE manual API Spec 16C: Specification for Choke and Kill Systems API Spec 16D: Specification for Control Systems for Drilling Well Control Equipment API RP 16E: Recommended Practice for Design of Control Systems for Drilling Well Conerol Equipment WOIP - Well control equipment Page 5/7/3. v200Introduction and objectives ‘Well control equipment is the second and last line of defence against loss of control over the well. Its function is to close off the well bore and stop a well flow in case of loss of primary control, and to provide the means to keep the bottom hole pressure equal co the formation pressure while preparing for, and restoring, primary control. ‘Well conetol equipment includes: the preventer stack, the last sec casing string, the well headand auxi ah ‘equipment such as the choke and kill manifold and the control unit(s) as well as some drill string components. Selecting the appropriate equipment (capacity, pressure raring, etc.) and maintaining its integrity are prerequisites in preventing a complete loss of control (i.e. a kick turning into a blow-out). Drilling Contractor personnel and Operator personnel alike should be fully familiar with this equipment, with respect to function, limitation, and how to operate it, should there be a kick situation. ‘After scudying this Part, consulting other relevant documents and, if necessary, discussions with your mentor, you will be able to: + List che main items of well control equipment and explain their function. + explain in general the working principles of gate valves and the hydraulically operated choke line valve. * explain the working principle of the Cameron AX choke, and the Swaco super choke, * describe the working principles of bag-type annular preventers * lise the procedures that will help co maximise che life span of the packing elements of annular preventers: + explain che differences between Cameron U, Shaffer and Hydril ram type prevencers with, respect t0 - changing the rams - locking the rams manually (in land operations). ~ locking the rams hydraulically * explain when it may be necessary to lock the rams of BOPs © explain when a diverter must be used and describe the basic requirements of a diverter sys- tem. * list che main elements of a BOP control unit and explain how they operate. * summarise the Shell Group policy on accumulator capacity * lise the well control equipment required on che rig Noor during tripping, * describe the correct use of a Gray valve. + explain when a circulating head may be requited * describe the working principles of mud/gas separators and vacuum degassers and explain when and where they are used. ‘lise che pressure tests required on BOP equipment with the cortesponding, frequencies. ‘+ lise che pressure tests required on wellhead and casing, with their frequency Page 5/7/4 WOLP - Well control equipment v2.0.0Resumé Blowout preventers are che secondary well control system, therefore well control equipment is the last line of defence. Adequare knowledge of chis equipment is of vital importance in blowout prevention. This Part deals with most, if not all, of the equipmenc used in well con- trol operations - on land and offshore. WOIP - Well control equipment : Page 5/775 v2.0.0WOLP - Wall control equipment v2.0.0INTRODUCTION This Topic introduces the Working Pressure classification, and shows how a BOP stack is assembled from che individual items. Ic gives guidelines on how well control equipment should be selected for a given set of (expected) conditions. 1 WORKING PRESSURE CLASSIFICATION ‘Well concrol equipment is divided ino several working pressure (WP) classifications. ‘The choice of equipment depends on the maximum expected surface pressure that could be encountered during drilling and workover operations. ‘The most common pressure ratings are: 13,800 kPa (2,000 psi) WP. 20,700 kPa G,000 psi WP. 34,500 kPa (5,000 psi) WP. 69,000 kPa (10,000 psi) WP. 103,500 kPa (15,000 psi) WP. Although the minimum requirements for each WP classification are well and area specific, some of the general considerations follow belo 2 GENERAL CONSIDERATIONS ‘The following considerations should be taken into account when selecting well control equip- ment: ‘+ The equipment should be selected co withstand the maximum ancicipaced surface pres- sures and meet governmental regulations. * Generally the specifications will fall into the 34,500 kPa (5,000 psi) WP class and higher with a trend to the 69,000 kPa (10,000 psi) WP classification. If required, special high pressure/high temperacure equipment is available + The blow-out preventer stack should consist of remote controlled equipment capable of closing in the well at all cimes, whether there is che pipe in the hole or not. + Welded, flanged or hub connections are mandatory on high pressure systems above 13,800 kPa (2,000 psi ‘© In some areas well control equipment suitable for sour service may be required; in such ‘cases the complete high pressure BOP system should be fabricaced of materials resiscant to sulphide stress cracking. WDIP - Well control equipment Page 5/7/7, v2.00© The response time of surface BOPs should be as specified in API RPS3, i.e. the closing system should be capable of closing each ram preventer within 30 seconds; the closing time should not exceed 30 seconds for annular preventers smaller than 508 mm (20") and 45 seconds for annular preventers of 508 mm (20") and larger. Although pressure rating of che equipment is the first concern, the layout of the stack is also critical. 3 MINIMUM REQUIREMENTS Depending on the working pressure the surface blow-out prevention equipment must also comply with minimum compositional requirements. Figure 5.7.1 shows a schematic set-up of a diverter stack and a BOP stack used on land opera- tions. Figure 5.7.2 shows a typical BOP stack set-up as used for land or jack-up operations. The number and type of BOPs units to be used, apart from size, depends on expected formation pressure and che probability of these pressures (i.e. are we drilling in a known area ot wild-cat~ cing). ‘The higher the expected pressures, the greater the precaution needs to be (i, more BOPS to provide redundancy). Page 5/7/8 WOLP - Wall control equipment v2.0.0riser nope cm ys Eve | Diverter stack set-up ‘WLP - Well control equipment v2.0.0 — hogar preventer U0 | ig so — toe BO ™ ~ A 9) nae — Sentra rote Soon seg -amypa prover (bind ans) _ Faumsype provera (ope ams) | BOP stack set-up Figure 5.7.1 : The setup of a BOP stack Page 5/7/9-Figure 5.7.2 : A parlly assembled BOP slack on a jackyp unit Page 5/7/10 - _ WOLP - Well control equipment v200INTRODUCTION When primary control has been lost and formation fluids enter the well bore, a hydrostatic overbalance is no longer maintained. Instead we have a pressure balance in the annulus between the formation pressure and the sum of: ~ the hydrostatic heads of the fluids in the annulus - viscous friction losses due to the flow of the fluids in che annulus ~ any back pressure applied at che surface If no, or insufficienc, back pressure is applied the rate of flow from che formation into the wellbore will increase uncil the increased friction losses in the annulus have enabled equilibri- um to be reached. The result is a blow out. ‘This pressure balance is maintained in static conditions by closing off the annulus at the sur- face by means of the BOPs. Flow will chen only continue until che well head pressure has increased to the difference between the formation pressure and the hydrostatic pressure of the Auid column in the annulus. Under dynamic conditions (i.e. during well killing operations) the balance is maintained and additional inflow is prevented by applying a calculated back pressure which is equal co che formation pressure minus the hydrostatic head in the annulus minus the friction losses plus a safety factor. Given that the hydrostatic head in the annulus will vary as che initial volume of formation fluid flows up the well, especially if it is gas, and as kill mud is pumped down the drill pipe and enters the annulus, it is necessary to vary the applied back pressure. This is done by passing the flow through a quantifiably adjustable choke. “The well control equipment on a rig normally contains ewo adjustable chokes, situated in what is, logically, called a choke manifold (see Figure 5.7.2). As well as the choke manifold, che well killing system includes some of che mud treating, equipment, and the mud pumps, items already covered elsewhere in this package “This pare deals with * Choke manifold + Valves = Chol = ‘High-pressure (HP) lines and hoses an assembly of valves, as depicted in Figure 5.7.2, through which the recurn { aT Ee the well is routed when the blow-out preventets are closed, with the purpose of applying a calculated back pressure. Choke manifolds may be assembled in a variety of lay- WDIP - Wall control equipment Page 5/7/11 v2.00outs but they will always include at least two adjustable chokes, In some cases this may be ( ‘one manual choke and one remote controlled choke as shown in Figure 5.7.3. The manifold provides alternative flow paths for the fluid so that if necessary chokes can be changed and valves repaited without stopping the flow. sopencot Figure 5.7.3 A choke manifold ynees ov La'i« All che high pressure parts of the manifold should have the same working pressure rating as the BOP stack. The manifold is connected co the hydraulically operated choke Line valve and the BOP stack by /C a high-pressure flexible hose, or alternatively a straight high pressure steel line. ‘The flexible (0, hose isa specially designed steel armoured hose. Ordinary kelly hoses are not considered suit- able. ~ > cor be ( te . The manifold has to be adequately secured because it may be subjected co violent forces and vibration during certain stages of well killing, Valve settings Of the two choke line valves on of adjacent to the stack, che inner manual valve is kept open, and the second (the remotely controlled hydraulically activated gate valve) kept closed during drilling. All other valves and chokes in the line co the mucdl/gas separator, are kept open with the exception of che valve immediately upstream of each of the chokes and the second valve in the bypass line after che cross (the centre flow line, the one without a choke), Wherever two valves ate fitted it is standard practice that che second valve is the one operated aand the first one used as backup, in ease the second one fails. FO Coola le Mee ol wre lore When two manual chokes are installed either one can be used. When a manual choke and a remote controlled choke are installed, the remote controlled choke is the one normally used, keeping the manual choke as a standby choke. Before caking over the shife the driller should make sure that all che valves on the choke manifold are set as described above. Poge 5/7/12 WOL? - Well control equipment v2.0.02 HIGH PRESSURE VALVES 2.1 GATE VALVES Al high pressure valves used on the casing head housing, wellhead spools, drilling spools and in the choke and kill mani- i ee a sliding gate with a metal to metal seal nda hill bore opening. Gate valves such as the one illustrated are commonly used in rig manifolds. Ie is however possible thac in some cases plug valves, e.g. Halliburton Lo-Tore valves, have been installed. Such valves are normally prohibited for this applica- tion. A gate valve may require excessive corque co open. Care must ¢o be caken not to damage internal parts. To avoid wearing the seal faces, it is good prac- tice, if possisble, to equalise the pres- sure actoss the valve prior to openin it. In many situations it is advantageous to use remotely operated valves. Figure 5.7.4 : The Cameron typo FL gate valve 2.2 HYDRAULICALLY OPERATED CHOKE LINE VALVE “This type of valve is usually a modified gate valve, provided — {iw With a double acting hydraulic cylinder mounted on the bonnet cap. Figure 5.7.5 1 Hydrovalically operated or “closed’ gate valve WDIP - Well control equipment v200 ‘The stem of the valve is connected co the piston in the cylin- der, When hydraulic pressure is applied ro the bottom of the cylinder, the piston and gate move upwards and the valve opens. When the hydraulic pressure is on the top of the cylinder the valve will close. A handwheel and locking screw are provided to close che valve manually if required. “The lower stuffing box and rail rod on the stem have a ‘three-fold function: + Toact as a pressure balance for the stem which con- nects che gate co the operating piston. + To keep the grease packed in the gate cavity of the valve body. + To serve as an indicator whether che valve is “open” Page 5/7/13tee Clos. He { 2.3 "HCR” PRESSURE OPERATED GATE VALVE On several rigs an older type of remote control gate valve may be found, the "HCR valve” (see aS Figure 5.7.6). This pressure oper~ ated gate valve is a flow line valve requiring relatively low operating pressures. ‘The closing ratio of well pressure to hydraulic operat- ing pressure is approximately 8 10 10 1. The gate is packed with ele- | t ments similar to the "QRC? ram assembly. These valves are made to hold pressure from one side only. Ic is therefore of crucial importance that they are installed with the cor rect side facing the BOP stack. “The flow direction is usually indi- see ate aires seid cae eis cated by an arrow on the body of Figure B7.6 1 HOR prewre opera! aoe vl the valve. "HR" pressure operated gate valves are available in 4" or 6" sizes, either 3,000 psi or 5,000 psi WP, and have standard APT flanges. 2.4 CHOKE AND KILL LINE OUTLET VALVES Owing to area and contractor specific requirements, ic is not feasible to specify a standatd lay- out, but the following minimum requirements should be adhered to: + ‘The choke line must have a minimum ID of 76-2 mm (3"), the kill line may be as small as 50-8 mm (2"), albeit that this might restrain operational flexibility should mediate substiction of a choke line be required. During normal operation, the inner (usually manual) choke and kill line valves should remain open and the outer (hydraulically operated) valves closed such as to prevent excessive solids build-up in these Lines. + Wellhead outlets should, under normal operating conditions, not be used for a choke and kill line tie-in, If che kill line is not meant to ultimately replace or augment the choke line, it is high- ly desirable to install a check valve upstream of the stack valves, 3 CHOKES ‘The choke is normally an adjustable orifice installed in the return line. Ic is used to restrict the flow area so that the pressure drop of the returns through this line can be regulated while a kick is circulated out. ‘Three types of chokes may be encountered in choke manifolds: ‘+ ‘The manual adjustable choke. + The replaceable fixed choke. + ‘The remote controlled choke. Page 5/7/14 WDLP - Well control equipment v2.003.1 MANUAL ADJUSTABLE CHOKE Figure 5.7.7 shows a typical needle valve type manual adjustable choke. ‘The stem and seat area are of tungsten carbide to make them more weat resistane; it must be understood that a choke is noe meant to be used as a valve. The cool is designed to create a flow restriction and not 10 provide a high-pressure seal. Washed out sealing areas are also com- mon. Therefore the choke must be used for initial closing in only and should immediately be backed up by closing the upstream valve. This type of choke should not be left “closed! for long periods of time. ‘Temperature expansion of the needle can damage the seat and the needle may “freeze” in the seat. 3.2 FIXED CHOKE = Instead of using an adjustable spindle valve, che seat can be replaced by different sizes of "beans". Such chokes are used only if the well returns will have to be produced at a con- stant rate over a considerable period of time, such as is com- mon during production tests. Fixed chokes are sometimes referred co as positive chokes. ‘The choke body in such a set-up is provided with a cap instead of a needle assembly. Figure 5.7.7 : Manvolly operated 3.3 REMOTE CONTROLLED CHOKE ae Remote controlled chokes are operated from a panel, usually on the rig floor (see Figure 5.7.8 overleaf). ‘This operating panel should include: + adrill pipe pressure gauge * an annulus pressure gauge + a pump stroke counter + a choke selection switch + a maximum allowable annulus pressure setting regulator (optional) + a choke control lever * and throttles for the pumps (optional) There are different remote controlled chokes, some of which have specific operating character- istics that may affect the well killing operation. Ir is therefore importanc to check details of the unic inscalled. Some examples are given below. Cameron AX choke ‘The Cameron AX choke (Figure 5.7.9 overleaf) is a choke which uses a sleeve that moves in and out of a tapered seat. Ic is available for pressures from 34,500 kPa (5,000 psi) ro 140,000 kPa (20,000 psi). The movement is controlled by a double acting hydraulic cylinder. ‘The choking action starts when the sleeve approaches and then enters the tapered sea, Here agai the wear areas are of tungsten carbide ‘The choke in this case does not form a positive seal, and thus an upstream valve must be closed after the choke is "closed". WOLF - Well control equipment Poge 5/7 v2.00Swaco super choke ‘The Swaco Super Choke igure 5.7.10) is a ‘hydraulically operated valve available in work- ing pressures of up to 138,000 kPa (20,000 psi). The size of che ori- amp aroerate fice is determined by the Ceong pressure overlapping portions of ‘sage half moon openings in ovo flat, highly polished rok pester tungsten carbide discs Hyer gator which rotate with respect to each other. The down- stream disc is fixed while the upstream disc may be Hydraule mum — roraced up to 180 degrees ond uno by a hydraulically driven rotary actuator, The power required co rocate the plates is minimal. One main advantage of | this choke is thac ic pro- ‘vides metal co mecal shut off and, when closed, it will hold pressure and can cherefore be used to shut the well in. Ie is capable of manual as well as hydraulic operation. ri pipe pressure ge Conta tower Myra Hid Figure 5.7.8 + Choke control console stewe Operating force > pean Figure 5.7.9 : Comeron driling choke ae {5,000-15,000psi WF} ne Poge 5/7/16 WLP - Well control equipment. v2.00To replace the tungsten carbide orifice plates it is necessary to break the line on the down- stream side of the choke to gain access. Wear sleeves Downstream, fixed disc — ' Ipstream, rotating disc Flow out < | 7 = A sot { i il Hi A LL Flow in Figure 5.7.10: ! ‘Swaco Super Choke 4 HIGH-PRESSURE (HP) LINES AND HOSES 4.1 HAMMER UNIONS eae (a) ance female sub The connection between ly a fixed set-up consist~ ing of steel pipes. Only a in temporary hook-ups. wy, are steel swings used. These swings are provid- ed with hammer unions. ey ‘A union mostly consists of four parts + A male sub with convex sealing face. wing nut female sub * A female sub with a concave sealing face, an external square thread and an inner recess for vin easel Figure 5.7.11 : Hammer union + Avhammer nut with square threads and two or three lugs. * A rubber seal ring. ‘The convex shape of the sub serves for self alignment when making up the union; this improves make up speed and ensures proper seating of the sealing surfaces. tee 57777Ic is imporcanc chat rig site personnel should inspect both sealing surfaces as well as the rub- ber seal when making up the connections. Ic is also importane that che individual parts of the union should be checked for the correct pressure rating (type) before making up. Some of the pressure classes have nuts and female subs which differ only slightly in dimensions e.g. a WECO union type 1502 nut fits a type 1002 female sub, but che threads engage over a small atea only, When high pressure is applied che union expands and comes apart. When large volumes are involved this can cause severe accidents. It is a good practice to secure the union connection with a safety chain of properly clamped steel wire. 4.2. CHIKSAN SWIVEL JOINT Relatively short sections of jointed pipe called "swings" ane used to hook up a cempo- rary line, for example. between cementing pump and Figure’ + Swing in folded position cementing head, The flexibility of a swing is achieved by a number of swivel joints installed in between the straight pipe sections. “A swivel joine (Figure 5.7.13) consists of a sealed ball bearing conscruction. ‘The balls act as a retainer and bearing which is packed with grease. In addition the construction is such that it prevents the swivel joint from coming apart at the applied pressure, These swivel joints, often called chicksans, are supplied in long or short sweep bends, Bas Conical moat _/ Pastis seating metal sealing a, Long sweep b. Short sweep Figure 5.7.19 : Chikson swivel joint In confined spaces and for static pressure, e.g. che hydraulic operating Lines for the BOPs, short sweep chicksans are used. Long sweeps are preferred in circulating lines, to reduce the frictional pressure drop. 4.3 HIGH-PRESSURE HOSES Construction High pressure hoses are basically buile up of three main parts: An inner hose, a carcass, and an outer hose. The inner hose is internally flush and its material should be resistant to the fluids it has co convey. Generally braided steel wires are vulcanised in che rubber Page 5/7/18 WDIP - Well control equipment. v200‘The outer layer of the hose or sheath is intended to protect the reinforcement against corrosion and wear. Figure 5.7.14 shows an example of a high pressure hose design used for choke Lines. Figure 5.7.14 : HP hose [Stena-Collexip design) Hose connections ‘The hose connections should at least have the same strength as the hose. The weakest point of a hose is always just behind the connection, as the hose has the tendency co kink at that point. Handling Each hose has a minimum bending radius (MBR) which is specified by its manufacturer ‘This should always be respected in order co avoid damage to the hose. If the manufaccurers specification is unavailable a rule of thumb is that the MBR is twelve times che ID. Bending the hose close to the end fittings should be avoided ~ as a rule of thumb the bend should not commence closer than ewice the OD from che fitting. ‘Twisting the hose should also be avoided - the rule of thumb in this case is that the maximum ewist is 1° per chree feet or metre, ‘These handling rules apply not only co hoses buc also to flexible steel pipes ‘The sketches on the following page show the right and wrong ways of handling hoses in vari- ous situations WOIP- Well control equipment Page 5/7/19. v2.00co 8104: S1°Z'g oanBig Poge 5/7/20 WOLP - Well control equipment v2.0.0INTRODUCTION Blow-our control equipment must be simple and reliable but still sophisticaced enough to suit a broad range of applications. A BOP stack should have a large enough internal diameter to pass the drilling tools. For the shallow part of the hole a large diameter stack or diverter set-up with low working pressure ratings is required, while for the deeper sections smaller inside diameters, but high working pressure rating are needed (see Figure 5.7.1) ‘When all of these qualifications plus che operational characteristics, such as quick operation and reliable sealing, have been incorporated, a blow-out preventer stack has become a heavy, massive piece of equipment Alchough all these items look indestructible, they should be watched carefully and inspec- tions, cests and maintenance executed conscientiously. Not seldom was a blow-out the result of damaged or failing BOP equipment. ‘This topic will deal with annular and ram-type preventers 1 ANNULAR PREVENTERS 1.1 GENERAL ‘The annular preventer (also called bag type, spherical or universal preventer) is the most versa- tile piece of equipment on the BOP sack since i can close around casing, drill pipe, drill col- lars, wireline and even close an open hole, ‘The rubber packing elements of the annular pre- venters, which allow this flexibility, are also subject to wear and abuse. Treated properly, the packing element of the annular preventer has a long, reliable life span, but it can be destroyed a very short time or very few closing cycles by improper use. ‘The following factors influence the life span of annular preventets: + ‘The closing pressure as regulaced chrough che control system should be as low as prac- tically possible in order to maximise the life of the packing unit + Testing the annular prevencer under high test pressures significantly shortens the life of the packing element. * Closing the annular prevencer wichout pipe in the hole will shorten the life of the packing element, especially when high closing pressures are required to achieve this. «Motion reversal is hard on the packing element, so pipe should be moved as far as pos- sible in one direction before reversing the direction (ie. long strokes). * Spare packing units should be stored in a dark, cool (air-conditioned if necessary) room, WDIP - Well control equipment ~ Pogo 5/7/21. v2.001.2 CLOSING TIME ‘The main disadvantage of the annular preventer is the time required to close it, ‘The annular preventer takes three to ten times che volume of fluid to close, compared to a set of rams, and therefore requires a longer closing time. Even though current regulations specify a 38 mm ay) ‘um diameter hydraulic control line, many surface stacks may still have hydraulic lines to che annular preventer that are smaller, or have a restriction in chem which prevents rapid closing. Raising the closing pressure does not help as much as using larger lines and fit- rings. In addition ic increases the wear on the packing element, The small lines and/or restrictions make che packing element movement inflexible when trying to strip, and cause excessive packing element wear during stripping operacions, especially when cool joints ate passing through it. ‘The regulator valve (see Topic 4.5.2), used to regulate the annular preventer closing pressure, should allow fluid passage hack throngh ir if rhe line pressure increases. ‘That way the pack- ing uni can open against the closing pressure while stripping a cool joint. Ie is very impor- tant to see to it chat chis regulator is in good shape, that there are no check valves ahead of ic (often present in che four-way valve), or that it has been replaced by a plain regulator, “The arrangement where a small accumulator bottle (surge bottle) is placed in the closing line of the annular preventer, to allow for hydraulic uid movement when stripping, is very desi able from the viewpoint of reducing packing unit wear. This arrangement is recommended for all surface and subsurface stacks. ‘There are some differences in the operation of the various annular preventers. Therefore the ‘most commonly used types will be discussed. | 1.3 HYDRIL GK ANNULAR PREVENTER ‘The Hydril GK annular preventer (Figure 5.7.16) is che most common annular preventer in use, particularly in surface stack installations, and is unique in its response to well pressures. Like mose other annular preventers, che preventer is closed with about 5,520 kPa (800 psi) pressure. The Hydeil GK annular preventer with a working pressure of less than 69,000 kPa (10,000 psi) is however also energised by the well pressure so that when the well pressure ra 1 Closed preventer Open preventer Svat gneve Figure 5.7.16 Hydrl GK annular preventer Page 5/7/22 WOIP - Well control equipment v200increases, the closing pressure must be reduced to avoid damaging the packing unit. ‘This wellhead pressure assist is derived from its piston configuration and applies also to the GL and MSP types of annular preventers (except the 749.3 mm/29¥", 3,450 kPa/500 psi unit) The manufacturer's instructions on Hydril annular preventers should be consulted for more detailed informacion. Charts, determining, operating, pressures, are also provided in the manu- faccurer's liceracure. ‘The packing element o unit has steel segments, vulcanised into the rubber body, to reinforce it and limit the amount of extrusion of the rubber when it is activated, Figure 5.7.16a shows how the packing unit extrudes due to the vertical movement of the piston, whose taper h squeezes the packing rubber inward. ‘The type of elastomer (natural rubber, synthetic rubber or neoprene) used in the packing element should be che 1 t most suitable for the particular well conditions. Refer co ‘Table 5.7.1. Replacing a worn packing unit is fairly simple: © Bled off operating pressure Hare ee + Unlock and remove preventer cover. Lift one worn packing unit. B ‘Check seals on head and piston. ety + Drop in new packing unit, and replace and lock cover. Should the packing unit have to be replaced while pipe is in the * hole, che packing unit has to be cut with a knife between two steel segments, preferably ac 90° co the lifting eye bole holes. Iris also advisable co use the kelly and a special cover break-out Pa : sub with plate for this job (see Figure 5.7.17). ‘The tools i required are lifting boles with che correct thread for the packing \~Sten! © elemenc and lifting bolts with che correct thread and sufficiently = ~~ long to life the piston out. Figure 5.7.17: Table 5.7.1 + Packing element selection Cover break plate Tentification Operating ar Packing uni eype temperature | Dring ti Colour Code range aeeaie Nacural rubber Black NR | -30°C 10 105%C | Water based Nile rubber] Red bord | NBR | -Cwoasec | Olbwedol Neoprene rubber | Green bond | CR | -30°%C 10 75°C | Oil based WOR Wil aelequem ~~ Page 5/7/23 v2001.4 NL SHAFFER SPHERICAL ANNULAR PREVENTER ‘The NL Shafler spherical annular preventer uses a closing piston chat forces the rubber pack- ing clement up against a concave cover, which in turn forces the packing element to close. NI Shaffer suggests a closing pressure of 10,350 kPa (1,500 psi) in its literarure, but also notes that the pressure should be reduced according to the operating characteristic tables if the pipe is co be moved. | Upper housing | — Elomont | __ Adopter ring Part to ‘opening chamber |— Piston Lower 7 housing Port to Eajeimer Figure 5.7.18 : NI Shaffer spherical ‘onnvlar preventer Figure 5.7.19 illustrates che action of the packing element. Steel segments moulded into the element partially close over the top of the rubber to prevent excessive extrusion when sealing high pressures. ‘These segments always move out of the well bore when the element is ‘opened, even when the element is old and worn fat beyond normal replacement conditions. Only the top portion of the rubber, in the spherical sealing element, contacts the drill string or kelly. Most of the rubber is held in reserve, to be used for sealing once abrasion makes it necessary. ‘This large reservoir of rubbber makes it possible to strip into or out of « hole with- out replacing che element during the trip. Closing acon begins. ‘Seal around dit poe. Shutoff sea-—no di pine ing action Doge Figure 5.7.19 : Action of the packing element of NU Shaffer spherical annular proventors Page 5/7/24 WOIP - Well control equipment v2.0.0Long stripping life is especially valuable in offshore use, because an annular preventer closed around the drill pipe of a floating vessel, is con- stantly exposed 0 stripping movement due to vessel motion, Stripping is claimed to be smooth with a spherical BOP because the ele- ment opens and closes easily, due to the steel segments moulded into the fA & ANN rubber. ‘They make meral-o-metal slicing contact with the sphere of a bh i Sew the housing, providing a low coefficient of friction. 1.5 CAMERON TYPE D ANNULAR PREVENTER ‘0 enfreng cogent ‘The Cameron type D annular preventer, shown in Figure 5.7.20, hasa ‘Figure 5.7.19a different type of packing element and piston design. During closing the Detail ofthe packing hydraulic pressure is admitted below the inverted T-shaped operating _ element piston, moving ic and its pusher place upwards. The upward movement of the pusher place forces a large solid rubber coroid (or doughnur) to move the packing ele- ment into the closed position around pipe or over the open hole. eetng Grooves Bytes Leck down opting Figure 5.7.20 : Cameron type D ‘annular prieventer During opening the process is reversed. Hydraulic pressure above che flange section of the operating piston forces it downwards allowing the preventer to open. ‘When the packing element is closing, its steel reinforcing members rotate inward co maineain a continuous steel support ring around che drill pipe. This prevents packing element extrusion far more effectively than the conventional widely spaced radial fingers (see Figure 5.7.21). Figure 5.7.21 : Packing element of Cameron type D onnular prievenier ‘WOIP- Wal onl equipment Rage 577 PE v2.001.6 STRIPPING THROUGH CLOSED PREVENTERS Stripping using che annular preventer is considered the simplest and preferted technique. In order to ensure a long operating life of che annular packing element it is imporcant to reduce the closing pressure to accom- organ modate the annular pressures ‘Surge dampener | J. wt encountered, Thus low annular (precharged 10 50% of pressures allow the closing required closing pressure) pressures to be as low as 3,450 kPa (500 psi), whereas higher pressures (10,350 kPa/1,500 psi) and above could severely reduce the condition of the ele- ment, in particular when tool joincs pass through To further ensure that the Closing tine annular is not subjected to excessive pressures as the tool joine is stripped through the clement, a surge damper must be placed in the closing line ‘Acura prossne gauges (varus ranges) Figure 5.7.22: Surge damper connected to tho closing line of an anavlar preventor (see Figure 5.7.22). Any check valve installed in che closing line - to ensure that the BOP stays closed if hydraulic supply is lost - should be removed, eae such thae the annular regulator can be preventer oo Fire 8 used effectively. ee To facilitate the accurate recording of bled-off volumes in che trip tank, itis advised to install a stripping tank adja- cent to the trip tank (see Figure 5.7.23). The strip tank should be cali- braced co account for the closed-end Carats + | displacement of the pipe in use. Ape Figure 5.7.23 + Rig layout for combined stripping and stot volumatie method 1.7 ROTATING ANNULAR PREVENTER Although rotating annular preventers have been long in existence they were rarely used. In areas where severe mud losses coinciding with stacked reservoirs could occur, they were ed to maintain well control in an effort to drill ahead. Recently the advantages of drilling in an only-just-balanced or even under-balanced situation have led Well Engineers to reconsider the possibilities of utilising a rotating annular preventer. In principle such a pre- venter allows for rotating and stripping (drilling) of the drill string whilst the annulus is allowed to slowly produce through a choke manifold. ‘The main advantages of under-balanced drilling are: Page 5/7/26 WDIP - Wall contol equipment v200+ Rotation of drill string during kick conerol ‘+ Faster penetration rate + Less potential for differential sticking + Less potential for losses + Less formation impairment ‘+ Higher production rates of the completed well n and considerations ‘The design of the rorating annular preventer is in principle based on the design of earlier annular preventers with a modification to allow for rotation of the packing element. Inside the preventer large thrust bearings take the main load generated by the upward thrust of the well bore pressure against a closed packing element, The hydraulic operating system to control the opening and closing pressure is regulated such that the preventer lene: hows is in a sealing condi- et Tw tion with the mini- 8 mum required pressure to reduce wear. Shaffer eee hhas combined the fea~ [mont cuces of its industry Sbieten accepted annular pre- fe venter with state-of-the swear soove art hydraulic control to create a practical sys- tem for underbalanced drilling. A typical uni Figure 5.7.58 £ A rotating annular BOP is shown in Figure 5.758 ‘The packing element should be replaced if any of the following occur: + Footage of pipe stripped through reaches the set maximum allowed for the type of BOP * Differential pressure required is greater chan manufacturers set limit * Rubber ete ig from the packing element However replacement should be scheduled in such a way thar operations will not have to be interrupted while drilling ehrough che formacion for which this preventer is required. The actual wear limits can vary greatly due co a number of field factors such as * Condition of the drillstring, type shoulders/upsets, cong marks, hard banding and grooved drill string components + Diameter of pipe and stripping speed + Method of lubrication ‘+ Wellbore pressure, temperature and cype of drilling fluid ‘+ Misalignmenc of the BOP or drill string Usually ewo or three non-recurn valves ate placed inside che drill scring to allow for deptes- surisation of the upper section which has to be done prior to making a connection, These valves avoid the necessity to depressurise the entire string at each connection, which is very time consuming! WLP - Well control equipment Page 5/7/27 v2.00‘To operate a rotating BOP a considerable amount of peripheral equipment is required on board or on the location. Offshore operations in particular requite careful planning with regards co timing and space. See Figure 5.7.59 for a typical set-up Figure 5.7.59 : Contol system for a otating annular BOP 2 RAM TYPE PREVENTERS 2.1 GENERAL ‘The ram type blow-out preventer (of which a typical examples are seen in Figures 5.7.25, 5.7.29a and 5.7.34) is che resule of some eighty years of development. It is an extremely rugged and reliable piece of equipment. ‘The normal prevencer consists of a ram head with extrudable packer material for sealing and a pipe centring wedge. ‘The ram head sits on a pis- ton rod, which connects it co the hydraulic chambers and seals Rams can be furnished co fit any size of pipe. Stainless steel rams, offset rams for multiple completions, as well as shear rams for cutting off pipe in case of emergency, are available. Generally the closing pressure is less than 10,350 kPa/1,500 psi. There are however high pressure ram preventers, notably from Hydril, which require pressures in excess of 13,100 KPa/1,900 psi. ‘The manufacturers’ data should be consulted for more details. 2.2. PIPE RAMS. BOP pipe rams must form a seal around che pipe and against each other, to seal off well pres sure. Ram packing elements are self feeding and contain a reserve of material in order to assure seal life under wear conditions. They should however be inspected regularly for wear. Pipe rams are made to close around a certain size pipe. ‘They should not be closed on open hole with full closing pressure (10,350 kPa or 1,500 psi), as the packer will be damaged by extrusion. If pipe rams are to be function tested on an open hole, it would be better to close them with reduced operating pressure (2,950 kPa or 500 psi) to avoid damage to the ram packing and also possible damage co the ram face. ‘When stripping or moving pipe through the rams, there is less wear co the packer clement if the closing pressure is reduced co the minimum value sufficient to effect a seal. This practice is accepted only if sufficient backup rams are available. Stripping through rams is not in the scope of this course Wor Wel contol eaipnent v2.0.0 Page 5/7/282.3 SHEARING BLIND RAMS Shearing blind rams (SBRs) are rams with blades integral to the body. Under normal operat- ing conditions they are used as blind rams. If emergency conditions make it necessary to shear he drill pipe, the closing shear rams will cut the pipe and seal the well bore, regardless of whether the lower section of the cut pipe is suspended on che lower pipe rams or dropped. If the fish is nor dropped, the lower shear ram will bend the cut pipe over a shoulder and away from the front face of the lower shear ram which then seals against the packer in the upper shear ram. ‘The recommended shearing procedure is: + Raise the bit off the bottom and position drill pipe in the preventer so that che cool joint is definirely not located in the shear ram cavity, * To ensure proper alignment for shearing, a see of pipe rams may be closed before che shear rams are activated. Also, if the string is not to fall down the hole after being sheared a stting may first be lancled on a closed and locked pair of pipe rams some 750 mm (30") below che shear rams. The tool joint and upset portion of the drill pipe must be below the lower edge of che shear ram cavity to ensure that the pipe is sheared successfully. * Close the shear blind rams with 20,700 kPa (3,000 psi) operating pressure. “The maximum pipe sizes chat can be cut with shear blind rams are limited by preventer size, blade width and operating system capacity. Typical performances are: + A179-5 mm (71%!) bore BOP can shear up to 101-6 mm (4") OD pipe. + A 279-4 mm (11") bore BOP can shear up to 127 mm (5") OD pipe + A346 mm (13%8"") bore BOP can shear up to 139-7 mm (5%2") OD pipe, BOPs with a larger bore are not as limited in blade wideh or operating system capacity and it is possible to shear larger OD pipes with chem, even chough the SBRs were designed to shear standard drill pipes only, 2.4 VARIABLE RAMS ‘The variable bore ram (VBR) extends the versatility of the BOP. It allows a single set of rams to seal on several different sizes of pipe or even on the hexagonal kelly. For example, the vari- able rams for a 16%" bore BOP can seal on diameters from 88-9 to 177-8 mm (312" to 7"). Variabsle bore rams eliminace che need co change rams when different diameter drill strings are used. This can save a round crip with a subsea BOP stack. One set of variable rams in a stack. can provide backup for two different sizes of standard pipe rams. ‘The string cannoc however be hung off on variable rams. VBRs should not be used in 103,500kPa (15,000 psi) WP or higher rated BOP stacks if max- imum wellhead pressures in excess of 69,000 kPa (10,000 psi) could occur duting a well con- trol situation. 2.5 SECONDARY SEALING Ram preventers (with a rated WP of 34,500 kPa/5,000 psi ot higher) are provided with a sup- ply of secondary rod sealant or packing, and a mechanism to force this sealant into place when the primary rod seal is no longer effective. This secondary sealant should not be used! routinely (and in some cases ic should be removed when testing the primary seal). ‘As an example the Cameron secondary seal is shown in Figure 5.7.24. Similar arrangements can be seen in the NL Shaffer and Hydril BOPs in Figures 5.7.29a and 5.7.34. Page 5/7/29Secondary back-up rings Plastic injection screw (in 5,000 psi or higher WP preventers only) Check valve Primary Hycar lip seal Energising ring retainer ring and locking ring —— Plastic packing ting —— O-ring ‘Operating cylinder Preventer bonnet Weep hole. Vent to atmosphere Preventer body Figure 5.7.24 : Secondary rod seal 2.6 LOCKING When a well has co be closed in for a long period, or when the drill scring is to be landed on the rams, chen these rams have to be locked by a locking mechanism. On surface BOPs this is usually by means of bolts that are manually operated via extension rods co which handwheels can be attached. The handwheels must be well accessible and easy to operate, Should chere be a total power failure or a long period without activity che manual lock bolts can be used to close the rams. In such a case a check should be made that the open- ing pressure has been bled off ‘On subsea BOPs a hydraulic system has to be used to lock the rams. Such hydraulic locks are also becoming more common on surface BOPs in place of the slower manually operated lock- ing bolts, 2.7 OPENING AND CLOSING RATIOS Ram type preventers have specially designed opening and closing ratios (as shown in Table 5.7.2). These are the ratios becween the well pressures and the operating pressures needed to ‘open or close the rams. Closing ratios are generally of the orcler of seven to one. ‘That means chat a BOP having a closing ratio of seven to one would requite a closing pressure of 3,450 kPa/500 psi co close the rams when the well bore pressure is 24,150 kPa/3,500 psi. Opening ratios are much lower because the well bore pressure acts behind the ram to oppose opening Opening ratios of two co one are common. 2.8 CAMERON TYPE U RAM TYPE BOP Cameron type U BOPs are available as single or as double units. A cut-away drawing of a sin- gle type U BOP (i.e. with only one pair of rams), is shown in Figure 5.7.25. Diagcams showing the type in chree operating positions are presented in Figure 5.7.26. Page 5/7/30 WODIP - Well control equipm v2.00Table 5.7.2 : Rom preventor opening and closing rations Sue | WP [Cameron U [Shaffer SC] Tiydeil Ram (psi)_ | Open] Close] Open] Close | Open] Close Tie 3,000 23 69 1s 34 5,000 23 | 69 us | 54 10000 | 23] 69 17 | 82 15000 | 23 | 69 | sa7] ru 66 | 76 ¥ 7000 3,000 26 | 33 5,000 26 | 53 10,000 T2000 a5 | 73 3,000 23 | 73 20 | 6a sooo | 25 | 73 20 | 68 wooo | 25 | 73 | 762] ru) 24] 76 15000 | 22| 99 | 28 | ru] 324] 76 13%" 3,000 23 7.0 3.00 354 21 3.2 so00 | 23] 70] 300] ssa] 2r| 52 wooo | 23 | 70] 429] 71] 38 | 106 15000 | 56 | a4 | 214] 7 | 336] 7.74 Ta" | 2000 3000 | 23| 6a so00 | 23| 68 | 203] 5.4 10,000 23 68 206 | 7.1L 241 10.6 18%," 10,000 36 74 1.83 FAL 19 10.6 15000 | 41 | 97 | 168 | tos] 215 | 7.27 21h 2,000 13 7.0 0.98 32 3,000 13 | 70 ose | 5.2 so00 | 51 | 62 19 | 106 tooo | 41 | 72 | 163] 710 Ter [2000 3,000 10 | 70 WOLF - Wall control equipment v2.00 Comeron type U BOP wih pipe rams Page 5/7/31.©, Replacement of rams ynder to shift the bonnet bonnet closing pision. bonnet opening piston. Fam open’ post ram "leso" port = locking bolt " lb 4 J K L Figure 5.7.26 : Cameron Type U BOP operation Opening and closing of the rams is through che hydraulie pressure ports, marked on the side of the preventer. The hydraulic system is a closed system i.e. the fluid on the opposite side of the operating, piston returns rahe chee equip | €HPOURH the operating line back into the hydraulic Hid stock tank ment, Ic is also not] For ram replacement the bonnet bolts are loosened allowing the ram sorte ee bonnets and give access to the rams. Even though the rams move inward the bonnet stroke is sufficient co bring che rams out of the preventer bore. Applying opening pressure on the open ing pore will now close the bonnets. The hydraulic fluid chen draws the bonnets back against the preventer body. After the rams have been pulled back the bonnet bolts serve to hold the bonnets closed ‘In Cameron rams the material of the packing element is bonded to steel plates, which confine it to the sealing area. A selection of rams for the type U BOP is shown in Figure 5.7.27. Page 5/7/32 WoL? - Well controlcama yen Shoating blind ram ‘Side packer. ‘ _ <7 bale 4 = Pipe ram oe nee fs - ise RK 7 ea S cas ‘ep saa a Py H,6 Shearing blind ram 1 Shearing bind rams coma ata = } inde ‘\ } ex Liye Figure 5.7.27 : A selection of Cameron rams. ry e — ‘The variable bore ram packer contains steel reinforcing inserts similar to those in the type "D" annular BOP packer. ‘The inserts rotare inward when the rams are closed so that the steel pro- les solid support for the rubber which seals against che pipe. ‘The inserts serve the same purpose as the retainer plates in the standard type "U® pipe ram packer. In standard fatigue tests variable bore ram packers have shown excellent performance, comparable to that of standard pipe ram packers. Cameron's locking mechanism ‘The mechanical locking mechanism Figure 5.7.28 : Hysravalic ram lock mechanism used by Cameron is a simple bole engaging che chread in a “locking screw housing" that is flanged onto the bonnet. Like most mechanical systems it can be used to close the rams in the absence of hydraulic power, but cannot re-open them as there is no solid connection with the operating piston. The sub-sea system is called a “wedge lock”, using hydraulic power co force a wedge across the end of an extension rod attached to the operating piston as shown in Figure 5.7.28, WDIP- Well control equipment v2.00 ~ Page 5/7/332.9 SHAFFER RAM TYPE BOP Figure 5.7.29a shows an Shafler triple ram type blow-out preventer. It shows that blow-out preventers are not necessarily manufactured as single units. This specific design is very com- pact, and therefore attractive for sicuations where there is little head room below the substruc- ture, It does, however, have the disadvantage that if one preventer body is damaged the whole stack muse be senc for repair. ‘The special design features of the Shaffer BOP are that each ram and its operator are complete- ly self-contained in the end section, with hydraulic connections built into the hinge (see Figure 5.7.29b). This eliminates drainage problems and the need to break or remake connec- tions when changing or servicing rams. Rams are easily changed by unbolting and swinging FRoundnad ram shatt ‘Ram shalt sal Picton soale Ram opening circuit Figure 5.7.29b : Hydraulic connections Page 5/7/34 WDIP - Well control equipment 2.00( ‘open the doors. The bottom doors swing out from under the upper cylinders so a hoisting line can be attached directly to the rams for easy handling, In Shaffer rams sealing is effected on the top side and che faces of the rams by one single rub- ber, which is held in place by a block bolted to the holder. A selection is shown in Figure 5.7.30. Shear rams Retaining per ater mor boc ere J we Hats upper Holder oo cali X, Pipe rams Weller = Pipe ram for: Pa Eg 9 11%, 139/06", 1694" & 1854" 5,000 and 10,000 psi BOPs Face seal a Retracing crows Holder, — Ram block Pipe ram for 18374" ( 15,000 psi BOPs Figure 5.7.30 + A selection of Shaffer rams L- ‘The shear rams cut pipe and seal the well bore in one operation. These rams also function as CSO (complete shut-off) rams for normal operations. When shearing, the lower blade passes below the sharp lower edge of the upper ram block and shears the pipe as shown in Figure 5.7.31. ‘The lower section of cut pipe is accommodated in the space between the lower blade and che upper holder. ‘The upper section of cut pipe is accommodated in the recess in the top of the lower ram block. The closing motion of the rams continues until the ram block ends meet. Continued closing of che holder squeezes the semicircular seals upward into sealing contact with the seat in the BOP body. These seals have moulded in steel half-rings which limie the squeeze imparted to WOIP - Well contol equipment Page 5/7735. v200them by che holders. ‘The Hotel Sormicreuler tiorizoncal seal is energised seal = at the same time as the semicircular seal. The ‘Support closing motion of the plato | upper holder pushes the horizontal seal forward and downward on top of the lower blade resulting, in a tight sealing contact, ‘The horizontal seal has a moulded-in support place which holds it in place Semiciroular when the rams are open seal : For the size of pipes which can be cut in the several types of preventers refer- ence must be made co che ‘manufacturer's manual Figure 5.7.31 : The operation of NL Shoffer shear rams Shaffer's casing shear rams Conventional shear rams are designed to crush the pipe and then shear the flattened mass. ‘That presents a problem when large diameter pipe has co be cut. Ifan attempt was made to cut 13°" casing, for example,in an 18%4" bore preventer using conventional shear rams, the pipe would not be cut but be crushed and jammed in the bore of the preventer. In addition there may be severe damage to the shear ram blade and the preventer cavity. This is due co the lack of available space between the casing OD and the preventer bore ID. ‘The eype V cams of Shaffer have cucting blades that overcome this problem and prevent excessive flattening of the casing during shear by spreading the cutting stress uniformly over the casing circumference. For instance 13%" casing would not swell mote than up to 15", giving the additional benefic that the lower portion of the sheared casing can be retrieved more easily by conventional fish- 1g tools, Note chat in order to accomplish the above these preventers should be fieced with large sized cylinders plus boosters). Shaffer's locking mechanism ‘The mechanical locking mechanism used by Shaffer is a bolt which screws not into a housing but into the ram shaft itself. Once the rams are closed the locking shaft is backed out of the ram shaft until a collar shoulders against the cylinder head. ‘This can be seen in Figure 5.7.32. Ie too can be used to close the rams in the absence of hydraulic power, but cannot re-open them, An advantage of chis system is that threads on the manual locking shaft are enclosed in the hydraulic fluid and are not exposed to corrosion from mud and sale water or to freezing, Shaffer call their sub-sea system “Poslock”. ‘This is shown in Figure 5.7.33. Poslock operators ‘automatically lock the rams each time they are closed. This eliminates the additional compli- cation and cost of a second hydraulic function for locking the rams. Ic also simplifies the emergency operation, because the rams are both closed and locked just by activating the close function. WOLP - Well control equipment v2.0.0 Poge 5/7/36Figure 5.7.32 + Monval locking system for Nl Shoffer rams ‘When closing hydraulic pressure is applied, the complete piston assembly moves inward and pushes the rams into the well bore. As the piston reaches the fully closed position, the locking, segments slide toward the piston O.D. over the locking shoulder because the locking cone is forced inward by the closing hydraulic pressure. ‘The locking cone holds the locking segments in position and is prevented by a spring from vibrating outward if the hydraulic closing pressure is removed. Actually, the locking cone is a second piston inside che main piston. Ic is forced inward by closing hydraulic pressure and outward by opening hydraulic pressure. Posoce adjustment teat seen Figure 5.7.33 : Hydraulic locking system for NL Shaffer rams ("Poslock” system) 2.10 THE HYDRIL RAM TYPE BOP A Hydril ram type BOP is shown in Pigure 5.7.34. This is again a “single” BOP with a man- ual locking mechanism designed for land operations. Like the Shaffer system the rams are ‘contained in hinged outer sections of the housing so that when the latter is hinged open che rams can be removed from them (by applying the “closing” procedute) and lifted straight up. (One particular feature of the Hydril BOP is that two separate hinges are used ac each joine in order co separate the two functions of the hinge, which are to catty the load and to make a connection for the hydraulic fluid. Hyzdril rams are basically similar to those of Cameron and Shaffer. Both the front packer and the upper seal are bonded to anti-extrusion plates and are easily replaceable in the ram itself See Figure 5.7.37. WOU Wel contol equipment Pope 5/7787 v2.00Hydril's locking mechanism ‘The mechanical locking mechanism used by Hydril is virtually identical co the one used by Shaffer. "Hydril’s hydraulic locking mechanism is called Multiple Position Locking (MPL) and also locks the rams auto- "matically each time thac they are closed. ‘This is shown in Figures 5.7.35 & 5.7.36. It consists of a nut . very coarse pitch chread - chree turns per foot, six start - working in combination with a clutch chac has asymmetric teeth on the engaging faces such thar when they are in con- tact rotation is possible in one direc tion buc not in che other (i.e. a sore of rotating ratchet). The nut is free ro turn but is constrained from moving Page 5/7/38 Hydiil 1356", 10,000 psi Ram BOP (Manual lock), and (let) internal hydraulic system Figure 5.7.35 : Hydils MPL automatic locking mechanism WO? - Well contol equipment v200along the shaft by thrust bearings in the housing, One clutch plate is fixed to the nut and the other rides on splines in the housing so tha¢ it can move to disengage from the other plate (plus nue) bue cannot rotate. Ie is normally kept in contact with the other plate by means of springs. ‘Motion of the piston and tal rod during Closing or opening of the ram causes the lock nut to rotate, The fast thread, six path helical thread rotates the nut three turns per foot of travel Complete assembly igure 5.7.36 : Detail of Hydril’s MPL automatic ram locking mechanism o_o fm Variable roms Figure 8.7.97 + A solection of Hydil pipe cond shear cams WDIP - Well control equipment __ Page 5/7/39 v2.003 > DIVERTERS Ifa kick is taken when the conductor is set in incompetent formation, the well will not be shut- in, but diverted instead. A surface diverter system (see Figure 5.7.38), consisting of an annular preventer and vent lines, allows the flow to be directed to a safe area, preferably down: wind, away from the rig and personnel ‘Vent lines should be as large (304-8 mm/12" minimum) and as straight as practical, so as co minimise back pressure, erosion and the risk of plugging by formation debris. The lines should be adequately braced to absorb severe shock loadings; sections likely co suffer erosion, such as, bends, should be reinforced. There should be no restriction to the bore and any valves in the lines should be full opening ball valves. ‘To prevent the well being inadvercently shut in, any valves in the vent line should be designed to automatically open when the diverter element is closed. The minimum working pressure of a large bore diverter line system should! be 3,450 kPa (500 ps); the hydraulic operating line should have a 38-1 mm (14s") diameter, this allows hydraulic control systems to close diverters smaller than 508 mm (20") within 30 seconds and diverters larger than 508 mm (20") co close within 45 seconds, both of which are API RP requirements. 26" or 30" Stove pipe/marine conductor Figure 5.7.34 Diverter systom for surfoce stock Page 5/7/40INTRODUCTION A large volume of hydraulic operating fluid, scored under high pressure in the accumulator, delivers the hydraulic energy required co close and open the BOPs and the remotely operated valves. 1 REQUIREMENTS ‘The hydraulic BOP operating unit, also called che hydraulic BOP control system) should : * be provided with a control manifold, rated for 20,700 kPa (3,000 psi) WP, which clearly shows "open and "closed" positions for preventer(s) and remote operated choke Line valve. Icis essential that all air and hydraulic BOP operating units be equipped with 0 - 20,700 kPa (0 - 3,000 psi) regulator valves similar to the Koomey type TR-5, which will not fail open causing complete loss of operating pressure. * be provided with electrically and air-driven high pressure pumps which aucomacically charge the accumulator bottles to the pre-set pressure, “The electric pump should be fitted with an electric pressure switch, which automatically stops the electric pump when the accumulator pressure reaches 20,700 kPa (3,000 psi) and starts the pump again when the pressure drops to 18,970 kPa (2,750 psi) or below . The air-driven pump should be fitted with an air pressure switch, which automatically stops the air-driven pump when che manifold pressure reaches 20,700 kPa (3,000 psi) and stares the pump again when the pressure drops ¢o 18,620 kPa (2,700 psi) ot below, ‘The air driven pumps should also be able to operate during a “loss of power" sicuation and be connected to the emergency ait compressor. + be provided with two graphic remote control panels, both clearly showing "open" and "closed" positions for each preventer and the choke line valves. Each of these panels should include a master shutoff valve and controls for regulator valves and for a bypass valve. One panel must be located near the driller's position, the other panel near the exit of the loca- tion or near che toolpusher's office. + preferably use high-pressure control hoses wich a working pressure of 20,700 kPa (3,000 psi), although steel pipe and joints are acceprable. + allow all master and remote operating panel handles to be free to move into either position at all times, ie. the shear ram operating handles should not be locked (but should be pro- tected from inadvertent operation). + have all spare operating lines and connections, which are not used in the system, properly blocked off. WDLP - Well control equipment Poge 5/7/41 v2.002 HYDRAULIC BOP CONTROL UNITS ‘The most common hydraulic BOP control unit is the Koomey unit, although other similar units are available. A general view of a Koomey unit is given in Figure 5.7.45 on page 5/7/48 and described on the page facing it Figure 5.7.39 shows a simplified operating diagram of a 20,700 kPa (3,000 psi) Koomey unic. ee TL R © sano vesare(7) fa eH eeu a fa Tee iam a qa aoe eo | | ese J 7 “check valve { 3 9 sate = Figure 5.7.39 : Simplified diagram | ofa Koray ine WOLF - Well conirol equipment Page 5/7/42 V 20.03 > REMOTE CONTROL PANELS Control panels are provided with the graphic outline design of the blow-out preventer stack, to reduce mistakes made by operating the wrong lever during emergency situations - see Figure 5.7.40. Control panels are connected to the hydraulic BOP operating unit in such a way that, should they be destroyed, all preventers can be controlled from the master hydraulic control manifold by operating the four-way valves manually. a are required to operate the panel. The master control valve must be actuated and eld in place with one hand while the correct function is chosen and operaced with the other hand. This procedure prevents accidental operation due to bumping into the panel control valves. accumulator manifold pressure pressure panel annular pressure omen master air valve regulator for controling prassure to annular preventer g-1) PAT PNY “SHUT MBS "RE (jayun sung.) 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Should there be a kick during trippi prevenc a blow-out through the sti , additional inside pipe shutoff tools are required to ng. The following equipment is required as additional well control tools: ‘Two lower kelly cocks, for each size of drill pipe in use, should be available. One of these is intended for use below the kelly or top drive during drilling operations and the other should be on the drilling floor in the “open” position. ‘The latter should be complete with removable handles for easy stabbing and connecting. Subs, for connecting the kelly cock to the drill collars in use, should be available on the drilling floor. ‘Two drop-in type back-pressure valves, ro match the seating subs fitted in the drill string, must be available, The drop-in valves must be able to pass the smallest bore in the drill string above the seating sub, including the kelly cock. Instead of a drop-in type back-pressure valve (dart valve) a float valve can be installed in che dil sting just abovehe bit / a A "Gray-type" le BOP, wich the appropriate connections for the drill string in use, should be on the drilling floor ready for immediate use at all times. ‘A 69,000 kPa (10,000 psi) WP, 50.8 mm (2") of 76.2 mm (3") rotating type circulating “head with correct bottom subs for the drill string sizes in use should be available on the drilling floor. ‘A left hand threaded upper kelly cock should be installed and in good operating condition at all cimes. A cest sub for testing the kelly and kelly cocks should be available on site ‘This topic will deal with kelly cocks, inside BOPs and circulating heads. 1 KELLY COCKS UPPER KELLY COCK ‘The top valve above a kelly is often an Omsco kelly cock (see Figure 5.7.46) and the bottom valve is often a Hydril or T.LW. kelly cock (see Figure 5.7.47). Both remain open during normal operation. ‘They are manually operated valves and are opened or closed by a key wrench or with a spanner. Regulacions specify that chis key or spanner must always be within the driller's reach. Page 5/7/50 v20.0 WOLP - Well contol equipment‘The Omsco kelly cock at the top of the kelly only maintains pressure from below after it is closed. ‘This kelly cock is used when the kelly is for example almost down, the string stuck and che swivel or hose starts to leak during a well kill. LOWER KELLY COCK igure 5.7.47 shows ewo examples of lower kelly cocks: on the righe is a "standard kelly cock", including cross section, andon the left is a "Hydril kelly guard’ ‘The valve body of the Hydril kelly guard is made of one single piece which means that ic is not necessary to break any tightened con- nections when a seat ot ball has to be renewed. Icis only half che weight of a standard kelly cock and is therefore much easier to handle ‘The simplicity and reduced weight of this type of valve have led to ic being used more Figure 5.7.46 : and more as a stab-in valve. It can be ordered Upper kelly cock (Omsco} with eicher left-hand or right-hand thread, and could in principle also replace the Omsco upper kelly cock. 2 ‘INSIDE BOPS ‘Three types of inside BOPs can be used: + Gray valve ‘+ Drop-in check valve ‘+ Float sub (bit sub) All chese valves are check valves closing with flow from below but free to pump through from above. ‘They are shown in Figures 5.7.48-50 overleaf, ‘The Gray valve is stored on the rig floor and is kept in the open position by a valve rod and a valve release screw. Hyer kelly quere If the well stares owing Mis catass ha tact ak cca while eipping che drill pipe must be closed in firse. When there is alight flow the Gray valve can be installed ditectly on the deill pipe. However, with strong back flow the force of the flowing mud can be so strong thae it is nor possible to insrall che Gray valve due to its obseructed bore. In such a situation a kelly cock, which has full bore passage, has to be installed first. Afeer the kelly cock is made up and closed, the annular preventer is closed. If WIP - Wal contol equipment Page 5/775. ¥200it is decided co strip the string into the hole the Gray valve will be installed. ‘The valve release screw is undone and the spring will close the valve. The locking sub is then removed and the kelly cock opened. Presently there ate alcernative valves on the market which have an unrestricted bore with che (flapper) valve retained by a sleeve. For additional information about drop-in check valves and float subs refer to Se 6 Parr | of this package. soe B AY | 4 Lj Figure 5.7.48: Gray valve/inside BOP — valve valve seal — valve seal 0 ‘sale —eage valve wee vamege | Memacerh Figure 5.7.50 : Dart sub Figure 5.7.49 : Float sub Bit 3° CIRCULATING HEADS ‘Circulating heads are mainly used to circulate through the drillpipe or casing in sicuations where che use of the normal circulating system is not possible/desirable. They are found in different configuration, but should always inclucle a valve. In operations such as setting pack- ers, where ehe pipe must be rotated to activace the setting mechanism, the circulating head may need considerable bearing capacity. ‘The bearings in such heads have sufficient capacity to even withstand prolonged rotation. Page 5/7/52 i WOIP - Well control equipment v2.0.0A circulating head may also have to be used when carrying out wireline bore hole surveying (see Figure 5.7.51) through the drill string. One common characteristic though is that they must be designed to withstand che rated pressure of all other surface equipment and possess the same standards of safety. ya pe ah ion ae ing Bay ter ——T Datppe ater > Hydraulic packeott Figure 5.7.51 : Circulating head with hydraulic packott 4 MUD-GAS SEPARATOR 4.1 PURPOSE AND DESIGN In critical situations, when circulating out a gas kick, a mixture of gas and drilling fluid may be ejected from the well at high rates - as a foam, as gas and as slugs of more-or-less gas free liquid in capid (and chaotic) succession. In the absence of efficient separation of the gas and liquid phases a substantial quantity of drilling fluid may be lost at surface, forcing a suspet sion of well killing activities while fresh supplies of fluid are made up. This is a hazard to be avoided if at all possible. ‘The required separation is provided by the “mud/gas separator” (occasionally known as the atmospheric gas separator), which is designed to provide rapid venting of gas and recovery of the bulk of the drilling fluid.te is standard equipment on drilling units and has the advan- tages of being robust and simple in operation. ‘The main design features are: Adequate height and diamecer. Internal baffling ro aid gas break-out. Fluid seal by U-tube into the trip tank or dip tube. Gas vent outlet of adequate diameter and lengch Liquid outlet co be large diamecer ‘The mud/gas separator is designed to cope with a range of conditions, since drilling fluid propercies may vary widely, as will che characteristics and behaviour of the kick fluids. ‘The type of drilling fluid and the particular conditions existing wichin che well bore will also con- siderably affect the environment within which the separator has to operate. SIF cae eri zvzEATET TELE ags/ 7/8 v2004.2 SIZE OF VESSEL ‘The size of the separator is critical in determining the volume of fuid and gas which can be safely handled, Reasonable minimum size criteria are a diameter of 1,2 m (48") and a vessel height of ac least 5 m (16 fe) co provide sufficient capacity to handle the majority of gas kick tations. Note that the separator inlet oon should have at least the same ID as the largest choke manifold line = pea emrien TARGET PLATE typically 100 mm (4°) i ——™ET ID, though larger sizes 5 ssrecnon are often used. 8 5 een 4 = ‘The inlet should be 3 tata located approximately ac 3 ° SECTION AA if Ps TANGENTIAL LET the tank mid-point. This g permits the top half to 3 iA a act as a gas chamber 154 oo muerzmgenra ro seu. igen ERA EN NEAR while che lower portion | > allows gas to separate out 2 in the retained fluid. As ar one. oxrucs snaanceo LN Sa Socleaaanon the mixcure of drilling ZT owen neroenton fluid and gas enters, the ‘operating pressure will be amo weno annag.e acmospheric plus vent line BRS are ete friction back pressure. ‘The height of the inler above the static fluid level also provides an 2° Nowa UTUOE allowance for fluid levels co rise during the separator operation to overcome liquid Figure 5.7.52 : Mud.gas separator outlet line friction losses. © cLeMouT ewe: 4.3 LIQUID SEAL (MUD SEAL) If gas pressure in the separator overcomes the hydrostatic pressure of the fluidl in the U-tube crap at the separator bottom, gas will blow chrough into the shaker room, ‘The U-tube of liquid out- lec system should be arranged co provide a minimum U-tube height of at least 3 m (10 feet) ‘This, with liquid of say 0-52 psi/fe, will support a back pressure of 5 psi. ‘The liquid outlet line is recommended to be at least 200 mm (8") ID, although 300 mm (12") is advisable co improve the handling of high viscosity contaminated drilling fluid flows. Some combinations of drilling, fluid types and well fluids can produce very high viscosity and significant gellation. 4.4 VENT LINE ‘The derrick gas vent line should be of large diameter, with as few bends as possible, to minimise back pressures. 200 mm (8") ID Lines are strongly recommended. It has been common practice in che pase co use chick walled line pipe for these derrick vents. This seems unnecessary, given che pressures involved, and reduces the internal dimensions, limiting che capacity of the degasser vent line. Poge 5/7/54 control eau v2.0.05 VACUUM DEGASSER Vircually all the gas which is entrained in the drilling Auid can be removed by circulating it through a degasser which is held ac a partial vacuum. In this equipment (see Figure 5.7.53) gas- cut drilling fluid is picked up from the shakers tank and pulled chrough the degasser vessel by a jet pump. The small vacuum pump mounted on top of the vessel removes the freed gas and freely vents these gases co the atmosphere. “The most commonly used degasser, chat of Swaco, has a large contact area with the drilling uid flowing over a corrugated baffle plate. The vent line from the degasser should preferably nor be connected che vent line of che mud/gas separator, bur if connected, a check valve must be insert cad becween these ewo vent lines. Icis good practice ¢o function vest the degasser in conjunction with the regular/weekly BOP test. FB] onscuma ly [ed casos mus sue Figure 5.7.53 : Swaco degosser {WOU - Wal conta equipment Page 57155 v200Topic 6 esting: casing wellhead and INTRODUCTION Casing well head and well control equipment must be function and pressure tested, as appro priate, to ensure proper operation and pressure integrity if pressures reach the highest values that can be expected A functional test on ‘+ all preventers which close atound pipe, + all pressure and manually operated kill- and choke line valves, and + all kelly cocks should be carried out each time they have been installed and each time a new bit has been run to the casing shoe. The blind/shear rams should be opetated at least once a week. Ifany of the above tests indicate faulty equipment, then that equipment must be repaired and re-tested before resuming operations. Given that drilling fluid has sealing properties chat could temporarily seal off small leaks, while one objective of pressure rests is co detect leaks, all pressure tests on well control equip- ment are performed with water, after rhe equipment has first been flushed clean. ‘A pressure test utilising a HP/low volume pump should be made on all blow-our preventers, wellhead components and their connections, the BOP closing unit, the choke manifold, kill- and choke lines, the kelly ot cop drive valves and other deill string shut-off valves in line wich governmental regulations and/or Company policy: + Afver installation of wellhead and BOP assembly and prior to drilling © Bvery week or every fortnight, depending on type of operation, operator's or govern= mental procedures/regulations * Prior to drilling into expected high pressure zones * Prior to production test * Ac any time requested by the Company drilling repre- sentative: ‘This ‘Topic covers the procedures for testing casing, wellheads and well control equipment and the evaluation of the tests. 1 CASING TESTS 1.1 _ INITIAL PRESSURE TESTS ‘The purpose of any casing pressure cest is to verify that che casing string integrity is sufi to concain the maximum anticipated burst loads i.e. the design load case. Integrity for collapse loads is generally only tested, indirectly, when inflow testing liner laps. Exerting a suitable WOIP - Well control equipment v200 tage 5/7/55differential test pressure at any point in the casing string is complicated by the fact chat the fluids inside and outside the casing during the test are unlikely to be those expected to be present for the design load case. This means that the application of a given pressure at surface for a single test may result in insufficient or excessive differential pressures deeper in the well. Ideally, casing pressure tests should thus be designed so thar the differential pressure exerted ac any point is equal to or exceeds the maximum expected load but remains less than 919% of the rated internal yield pressure. For new casing the latter value can be ascertained from data handbooks, Where wear has occurred the following equation may be used : 0.875 x 2%txY D Where the internal yield pressure, without safety factors the specified minimum yield strength for the given casing grade, the actual wall thickness the actual OD all in consistent unies PB Y t o Even when more than one weight and/or grade of casing is not present, it will often require the use of a retrievable packer co test a casing string adequately. ‘The preferted time to test the casing is immediately following cementation prior to the cement setting, a so called "green cement test". This avoids the possibility of creating a micto-annulus, but such a test may not be sufficient as it is further limited to ensure that: * the differential pressure at the casing shoe does not exceed the pressure rating, of the float equipment. This is commonly 21 MPa but equipment can be supplied with ratings of 34,5 MPa and above. + the resultant tensile load does not exceed 77% of the rated pipe body yield strength at the crivical point of he string. (This is consistent with the recommended design factor of 1.3 for casing design ) Note that this resultant tensile load has three components :~ = the load due to the pressure {- Pest xt xa?} ~ the load due to the buoyane weight, and ~ the bending load in doglegs. For the calculation of the tensile load associated with a dogleg refer to the Patt of this package dealing wich Casing Design. In « nominally vercical well the dogleg angle is, taken as 2°/100 fe (0.65°/10m), unless a greacer value has been measured. Notes : + Icis recommended chat a green cement pressure test is restricted to 75% of the casing internal yield pressure. ‘+ When testing with a retrievable packer, it should preferably be set above the top of cement. In any case it should not be placed within 80 m of the shoe or within 80 m of a hydrocarbon bearing zone. + Casing pressure cests should be carried oue for 10 minutes. + Problems may be experienced when trying to set packers in high grade casings due to the problem of getting the slips to bite, WIP - Well control equipment Page 5/7/57 v2001.2 SUBSEQUENT PRESSURE TESTS ‘The surface and incermediace casings may be pressure tested after a maximum period of about 30 days drilling through it and chereafter when it is judged necessary. These casings are also tested after a liner has been installed. ‘The bottom 80 m (250 fe) of the casing is not pressure rested during these subsequent tests “This is to avoid damage co che primary cementation by causing a micro-annulus to form. The same consideration applies if hydrocarbons are present behind che casing, and pressure testing is not carried out within 80 m (250 ft) of the relevane section. 2. ‘TESTS OF X-BUSHING AND SLIP AND SEAL ASSEMBLY OR BRX HANGER Before a casing head spool is installed on the well head the side outlee valves are installed. “These valves are first pressure cesced co their rated pressure using « ces lange. ‘Once the spool is installed on the well head the X-bushing seal is energised by injecting plas- cic (See Section 2, Part | -- Well heads). As soon as the seal is energised it is pressure tested before che complete BOP stack is bolted onto it Ifa BRX hanger has been used the pressure test can be carried out immediately after the spool is installed. 3. SURFACE WELLHEAD AND BOP TESTS ‘After flanging up the BOPs a function test is done to ensure all hydraulic operating Lines are hooked up correctly. The complete well head, stack and manifold connections can then be pressure tested using the cup type tester and the closed annular preventer. ‘The test pressure is the lower value of casing burst pressure and rated pressure of well head and BOP. ‘The preventets are tested to their working pressure using a plug type tester which seats in the landing area of the casing head spool. A bowl type tester or a combination tool for resting and running the wear bushing can also be used (see Figures 5.7.54 to 5.7.56). on When applying test pressure the side outlets of the casing head spool, which are or could be exposed below the test plug, should be open to avoid pres- surising the casing below. cop —-| To test prevencers closing around pipe, Figure 5.7.54: either a test joint or short rest sub with, Plug type tester ahole drilled into the side, or the kill o-Rg, line can be used. ‘The first method has the advantage that the test pressure can be bled off at a choke, installed for this purpose in the standpipe manifold, ‘To test che blind rams, the kill Line must be used, because well pressure (or cest pressure) assists in closing most preventers. Figure 5.7.55 + Cup type testor ‘They should also be tested at a low operating pressure (3,450 kPa or 500 psi). Nore, however, chat some kill lines have a non-return valve installed Page 5/7/58‘The cup type tester is run wich open ended pipe to prevent pressurisation of the casing. ‘The pipe must be strong enough to withstand the censile load caused by che hydraulic pressure on the cup area. F=pxA,where: F = censile load P= pressure A = cup area, The test string is in such a case suspended from the block to monitor the tensile load, When the blind rams are tested, the plug type tester must be converted into a blind plug. Blowout proventor ss f Blowout proventor " Locking flange Housing ot ——[- ceasing head spool Looking fan w a tango | fp Se Used as testing too b.Used as running to! to install ‘or oltieve a wear bushing Figure 5.7.56 + Combination running and testing tool 4 CHOKE MANIFOLD AND VALVES, KILL AND CHOKE LINES, AND THE VALVES ON THE SIDE OUTLETS ‘The choke manifold and valves, the kill and choke lines and che valves on the side outlets are pressure tested with water to the rated working pressure of the ram type preventers. Each part should be tested separately. All lines must be flushed first to ensure they are clean and nor blocked. ‘These tests may not be performed against closed chokes. Notes: + All sizes of plug type and cup cype testers for pressure resting the well head and BOP. equipment on che programmed casing strings must be available. + Kelly and kelly stop cocks must also be pressure tested regularly to their rated work- ing pressure with a test sub. + Should any of the above tests indicate faulty equipment, this must be repaired and retested before drilling is resumed, or before any other operation is allowed to continue. +The tightness of flange bolts and clamps must be inspected frequently, particularly after pressure testing. + Kill and choke lines must be pumped through at regular intervals bearing in mind that weighted drilling fluid must be displaced from the choke manifold and kill lines to prevent the barytes settling in the lines. In freezing conditions the drilling fluid in the Lines must be replaced by fluid which can stand low temperatures. ‘WOU? Wel cont equipment v200 Page 5/7/595 ACCUMULATOR TESTS ‘The accumulator precharge pressure must be checked prior co drilling out cement and chere~ after ac regular intervals. ‘The accumulator unit performance test is made by operating all BOPs on the stored energy in the accumulator, ie. the pressure and the volume available without recharging. The complete test procedure is as follows: Check accumulator fluid pressure. * Check accumulator reservoir level. + Switch off accumulator pumps. © Close and open all preventers and check accumulator fluid pressure; record closing times, Adequate pressure and volume should still be present ro close one annular and cone ram type preventer. + Switch on accumulator pumps. + Record accumulacor recharging time. * Check BOP closing times and accumulator recharge time with manufacturer's data for the system in use, + At the same time that the accumulator performance check is made, it should also be checked that the aic-driven hydraulic pumps have a back-up connection to the emer gency air compressor. 6 EVALUATION OF PRESSURE TESTS ‘To ensure chac even small leaks are detected the applied test pressure should be observed for at least 10 minutes and a record kept of pressure versus time, This record allows an evaluation of the pressure test A constant pressure during the full 10 minutes of test is the ideal result, but a certain drop in pressure is also often acceptable, depending on the way in which this drop occuts (see Figure 5.1.57). 8 3B 10 min Time —> Time — a. Evon a sight test drop in is way ©. tia op o ss than 10 % and then ‘s unacooptable ‘stable for remaining ie i accoptable Figure 5.7.57 + Frossue drop vers ime Page 5/7/60INTRODUCTION ‘The following is a sec of practices and procedures that will enable enable safe well control ‘operations co be carried our. * Adequate well head equipment should be installed to withstand anticipated pressures and allow for fucare remedial operations. + Ram type preventers should be installed the correct way up. + All connections, valves, fittings, piping, erc.which may be subject co well pressure, must have a rated working pressure at least equal co che rated working pressure of the preven- ters, + Welded, flanged or hub connections are mandatory on all pressure systems with a rated working pressure in excess of 13,800 kPa (2,000 psi). + Valves must be of the flush through bore type when in che open position, + When installed, all ring gaskets should be new, checked for cleanliness and coated with light oil. Dry and/or previously used ring gaskets should never be installed. + All bolts and fittings should be in place and tight, and all connections pressure vested, before drilling is resumed. + The ID of che bell nipple to be installed should be large enough for hanger and seal assem- blies to pass through. Slip and seal assemblies should preferably be landed through the BOPs before lifting the BOP stack. * When boll-weevil hangers (BRX) ate used to land the casing string before cementing, well head side outlets should have a bore large enough to avoid excessive annular pressure whilst cementing, ‘+ All manually operated valves should be equipped with handwheels, and be ready for immediate use * Ram cype preventers on surface BOP stacks should be inscalled with extensions and hand- wheels connected, or with a ram lock system, and be ready for use. + The Company drilling representative should inspect and approve every BOP installacion after flanging up and testing. * Well head side outlets should not be used for killing purposes, except in case of serious emergencies. * All pipe lines should be securely anchored, WDIP- Wal contol equipment Fags 5/7781 v200+ Choke lines should be as straight as possible: no more than one choke nected to the choke manifold. © Kill lines should nor be used for routine fill-up operations. Poge 5/7/62 WDIP - Well control equipment v2.0.0Appendix i ENS CHCNE ca ‘The company will be drilling a deep, high pressure land well, and tenders have been received offering a rig having a large bore, low pressure BOP set to drill top hole and a smaller bore high pressure BOP set for drilling che remainder of the well. ‘The BOP closing unit has 50 boreles of 41-64 litres (11 gallon) each (che rubber in the bottle takes up a volume of 3-785 lieees (1 gallon) leaving 37-85 litres (10 gallons) of usable volume). ‘The operating pressure of the accumulator unit is 20,685 kPa (3,000 psi) and che recommended precharge pressure for the bottles is 6,895 kPa (1,000 psi). ‘The large bore, low pressure BOP consists of the following: 2 527 mm (2064) x 20,685 kPa (3,000 psi) Cameron type “U” ram type BOPs 1 540 mm (21%") x 13,790 kPa (2,000 psi) Hydril type "MSP" annular BOP ‘The smaller bore high pressure BOP is made up as follows: 1 double 346 mm (13%) x 68,950 kPa (10,000 psi) Shaffer type LW'S with “poslock” ram lock installed 1346 mm (13%") x 68,950 kPa (10,000 psi) Cameron type “U" ram BOP 1346 mm (13%") x 68,950 kPa (10,000 psi) Shaffer spherical BOP ‘The instruction books for the BOPS give the following information (always check these figures in che manual!): Gallons to: | Operating pressure Unie close open (ws) Cameron: 527 mm (20M) x 20,685 kPa aceon 96 90 Ratio 7.0 346 mm (13%6") x 68,950 kPa (10,000 psi) ype “U" criessttias ft Hyaii 540 mum (214°) x 13,790 KPa {2,000 psi) ype "MSP" eee oe Shaler: 346 men (13%6") x 68,950 kPa 5 + (10,000 psi) type LWS wich “potock” | "7 103 | Ravio7-t 346 mm (13%4") x 68,950 kPa (10,000 psi spherical Prateeee ee eee eee WOIP - Well contol equipment Page 5/7/63 v200Is the accumulator unit acceptable for our operations? First we must find the minimum pressure required to close each type and size of BOP against rated pressure: ‘Cameron Large bore ram is 20,685/7-0 = 2,955 kPa (428-6 psi) Smaller bore ram is 9,860 kPa (1,430 psi) Hydril Large bore annular is 4,758 kPa (690 psi) Shaffer Smaller bore ram is 68,950/7-1 = 9,711 kPa (1,408-5 psi) ‘Smaller bore annular is 68,950/10-5 = 6,567 kPa (952 psi) Minimum pressure for the accumulator unit is therefore 9,711 kPa (1,40855 psi) co be able co close the BOP requiring the highest pressure. ‘Maximum pressure is rated pressure of 20,685 kPa (3,000 psi). ‘When there is no operating fluid in a bottle, the nitrogen occupies the full capacity of 37-85 lieres (10 gallon) under a pressure of 6,895 kPa (1,000 psi). When operating fluid is pumped into the borcle, it will compress the nitrogen. When the nitrogen has a pressute of 20,685 kPa (3,000 psi) ir will have a volume of 8:89.) 97.85 = 12-621 2,000), 10 = 3.38 gals 20,685 3,000 The volume of operating fluid in the bottle is then: 37-85 -12-62 = 25-28 1 10-38-38 = 6-67 gals When the nitrogen has a pressure of 9,711 kPa (1,408-5 psi) (the minimum pressure for clos- ing one of che BOP’s and therefore the minimum pressure to which the accumulator unit is allowed to drop) it will have a volume of: 6,895, 1,000 ) , 37-85 = 26- x10=7-101 (533) b= 25. 71 (sits 5 Volume of operating fuid in che bottle is hen: 37-85-26-87 = 10-981 10-7-10 = 2-90 gals ‘Therefore, with the minimum operating pressures within the accumulator unit, one bottle will provide a volume of usable operating fluid of 25-23-10-98 = 14-251 6-67-2-90 = 3-77 gals ‘With 50 bottles installed the un 50x 14-25 = 712-51 50x3-77 = 188-5 gals Is this enough? To check this we need to find the minimum volume requiced to fulfil che company’s requirement of closing and opening the BOPs. on the rig will provide: For the large bore stack this is: 2x (36-34 +34-07)+36-4=177-161 2x (9-6+9-0)+9-6 = 46-8 gals for the rams, and (117-73-+117-78)+117-73= 353-191 (31-1431-1)+31-1=93-8 gals for the annular preventer. A cotal of 530-35 litres or 140-1 gallons WDIP - Well conirol equipment Page 5/7/64 7 v2.00For the smaller bore stack this is 2x (44-29+39-75)+44-29= 212-371 2x(11-7+10-5)+11-7= 56-1 gals for the double rams, and 26.88 +24-98 = 51-86 1 7-146-6 = 13-7 gals for the type U ram, and (193 81+ 161-64)+193-81=549-261 (61-2+42-7)+51-2= 145-1 gals for the spherical preventer. A total of 813-49 litres or 214.9 gallons Note: The worst case, for closing che ram requiring the highest volume of operating fluid for closing, was chosen. However, this is the recommended practice to ensure the accumulator tunic will comply wich che requirements under all circumstances. Ie can be seen that for the large bore stack the accumulator unit is of sufficient capacity, but for the smaller bore stack an additional number of bottles need to be installed. 813-49-712-5 214-9-188-5 ee aT = = 7-003 14-25 377 An additional 7 bottles would be acceptable, however an additional 8 bottles is to be pre- ferced. WOIP- Wel conta equipment Poge 5/7765 v2.00Poge 5/7/66 WOIP - Well conirol equipment v200