Well Control Manual

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SAUDI ARAMCO
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Well Control Manual
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4th Edition May, 2010

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WELL CONTROL MANUAL: 4TH EDITION
Drilling & Workover VOLUME I
Table of Contents
INTRODUCTION
CHAPTER A : EQUIPMENT REQUIREMENTS ......................................1-1
CHAÿPTER B: BOP SYSTEMS .....................................................................* 2-1
CHAPTER C : MAINTENANCE, TESTING AND RECERTIFICATION .....3-1
CHAPTER D : WELL CONTROL POLICIES .............................................. 4-1
CHAPTER E : WELL CONTROL DRILLS ................................................... 5-1
CHAPTER F : SUPPLIMENTAL INFORMATION....................................... 6-1
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Current Edition: May 2010 4 Edition
Previous Revision: October 2002
WELL CONTROL MANUAL: 4TH EDITION VOLUME I
Drilling & Workover
INTRODUCTION AND DOCUMENT CONTROL
1.0 INTRODUCTION
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The 4th Edition of Saudi Aramco’s Well Control Manual is different from the previous editions in several
respects. The Manual has been divided into two (2) volumes:
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1. Volume 1 contains Saudi Aramco specific requirements, policies and procedures. This volume is
continually reviewed and updated and copies are controlled to ensure that the latest revision is being
used at any given time. The manual has been divided into two (2) volumes.
2. Volume 2 contains industry information that is subject to only occasional revision.
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Section 2, below, details responsibilities for the review, revision and issuance control of the Well Control
Manual. Variations or deviations of BOPE, specifications, arrangement, pressure rating or requirements
from this manual requires endorsement of the Well Control Committee, and approval by the Vice President of
Drilling and Workover. The enforcement of these equipment standards shall be the responsibility of the
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Drilling or Workover Rig Superintendent. The Rig Foreman shall ensure that the proper equipment is
available and correctly installed. If not specified in these standards, all BOP equipment shall comply with
API Specifications and Recommended Practices.
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2.0 REVISIONS
The Well Control Manual (WCM) will undergo a full review and revision every two (2) years. The WCM will
be reviewed by the Well Control Committee (WCC), endorsed by the General Manager of Drilling and
approved by the Vice President of Drilling and Workover.
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Document Control
The Well Control Manual (WCM) is a controlled document that is subject to constant review, revision and
updates by the Well Control Committee (WCC). The timely implementation of the policies contained in this
document is critical and steps must taken to ensure that the latest revision is available to Drilling and
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Workover Rigs and Management.

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Revisions and Updates will be controlled as follows:

1 The WCM will be fully reviewed and reissued after two (2) years.
2 Interim revisions and updates will be issued as required.
3 The WCM is revisable at the page level. Each page will have a revision date and revision level in the
footer. Revision levels will be proceeded by the page number followed by the edition/rev. level. For
example the rev. level for the initial issue will be 4.0 it will be incremented (e.g.: 4.1) any time a
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revision is issued for a particular page or set of pages (e.g.: for page A-5 the subsequent rev. levels
would be A-5/4.1, A-5/4.2, A-5/4.3 etc).
4 After the first issue of the 4th Edition, any subsequent revisions will be marked with a vertical line to
the right of the revised paragraph. Revised text will be in Bold Italic.
5 A revision log will be maintained at the beginning of the WCM that will list and summarize any
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changes as well as documenting the WCC minutes, reference document and/or letter number for the
revision.
6 At the two (2) year review all revision marks and Bold Italic text will be removed, the revision/update
log will be cleared and the process will start over.
Current Revision: May, 2010 INT - 1 Rev. INT - 1/4.0

Previous Revision: NONE
Drilling & Workover
To ensure that the document is available to all concerned parties there will be three (3) versions of the
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manual available, Electronic, Printed and Uncontrolled.
Electronic Version:
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The Electronic version will reside on the Drilling Information Highway. This document is available for viewing
by all authorized DIH users. If a page or section is printed from DIH, it is considered uncontrolled as of the
print date.
Printed Version:
Printed copies will be issued as follows:
• V.P. D&WO
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• General Manager, Drilling
• All D&WO Managers
• All Drilling and Workover Rig Superintendents
• All Members of the Well Control Committee.
• All rigs operating under Drilling and Workover will have one copy in the Foreman’s Office.
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• Each Drilling or Workover Rig Contractor’s local head office.
• D&WO Contracts Administration Division
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A list of all issued Printed Manuals and corresponding holders will be maintained by the WCC complete with
revision records.
Updates and Revisions to printed copies will be controlled as follows:

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1. Each hard copy will be assigned a serial number.
2. When a revision or update is issued the revised page(s), a current revision/update history form
and a cover letter will be sent to each WCM holder.
3. The cover letter will include a statement with a signature block for the Manual holder that the
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new pages have been received and that the old pages have been removed from the manual and
replaced with the new pages.
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4. The signed cover letter and the removed pages will returned to the Well Control Committee
(WCC).
5. The cover letter and removed pages must be received within two (2) weeks from the transmittal
date.
6. If not received within two (2) weeks a reminder will be sent. If not received within one (1) week
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after the reminder the matter will be elevated to the next level of supervision of the Manual
Holder. If not received within one (1) week after elevation the manual will be declared
uncontrolled, the holder removed from the update list and D&WO Management informed of the
action.
Uncontrolled Version:
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In certain circumstances we need to issue certain chapters of the WCM to Companies who do not have
access to DIH and who do not need the entire Volume I. For instance, our BOPE Manufacturer’s need the
chapters on “Equipment Specifications and Requirements, BOPE Systems and Maintenance, Testing and
Certification Requirements.” These Companies do not have access to DIH and they do not need any of the
other parts of the manual. We also have no way to control any copy we give them to ensure that they are
using the latest revision.

Drilling & Workover
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Uncontrolled copies will be issued subject to the following conditions:
1. A written request/justification for issuing to a Company approved by the Chairman of the WCC.
2. A list will be maintained by the WCC of all recipients of uncontrolled versions.
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3. Only the required chapters will be issued.
4. The chapters will be issued in a password protected electronic format (PDF) file.
5. The copy will be marked “UNCONTROLLED COPY, NOT SUBJECT TO REVISION.”
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CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS
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CHAPTER A: EQUIPMENT SPECIFICATIONS AND REQUIREMENTS
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TABLE OF CONTENTS
1.0 PRIMARY BOP EQUIPMENT REQUIREMENTS

1.1 General Requirements A-3
1.2 Annular Units and Diverters A-5
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1.3 Fixed Ram Preventers and Elastomers A-5
1.4 Variable Bore Ram Preventer Blocks and Elastomers A-6
1.5 Shear Blind Ram (SBR) Blocks and Elastomers A-6
1.6
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Valve Removal Plugs and Blind Flanges on BOP Side Outlets A-8
1.7
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Drilling Spools A-8
2.0 Requirements for Kill, Emergency Kill, Choke Lines and Chokes
2.1 The Minimum Bore Size for Kill, Emergency Kill and Choke Lines Shall Be As Follows: A-9
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2.2 Material and Fabrication A-9
2.3 Requirements for Drilling Chokes A-10
2.4 Requirements for Valves A-11

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2.5 Requirements for Cup Testers A-12

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3.0 ACCESSORY BOP EQUIPMENT REQUIREMENTS

3.1 Pit Volume Totalizers A-12
3.2 Mud Flow Indicators A-12
3.3 Gas Busters A-12

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3.4 Full Opening Safety Valves A-14
3.5 Inside BOP A-15
3.6 Trip Tank A-15

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3.7 Mud-Logging Units A-16
3.8 Bowl Protectors (Wear Bushings) A-16
3.9 Valve Removal Plugs A-16
Current Revision: May, 2010 A-1 Rev.A-1/4.0

Previous Revision: October, 2002
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3.10 Drillpipe Float Valves A-16
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3.11 Weco Connections A-16
3.12 Chiksans A-17
3.13 Accumulator Closing Units A-17
3.14 Stroke Counters A-18
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3.15 Gas Detectors A-19
3.16 Drill Rate Recorders A-19
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1.0 BOP EQUIPMENT SPECIFICATIONS AND REQUIREMENTS
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This Chapter of the Well Control Manual sets forth the specifications and requirements for Blow Out Prevention
Equipment (BOPE) and systems for use in Drilling and Workover Operations. Variations or deviations of BOPE,
specifications, arrangement, pressure rating or requirements from this standard requires endorsement of the
Well Control Committee, and approval by the Vice President of Drilling and Workover. The enforcement of these
equipment standards shall be the responsibility of the Drilling or Workover Rig Superintendent. The Rig
Foreman shall ensure that the proper equipment is available and correctly installed. If not specified in these
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standards all BOP equipment shall comply with API Specifications and Recommended Practices.
1.1 General Requirements

All Drilling and Workover Blow Out Prevention Equipment (BOPE) shall meet the following
requirements:
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1.1.1 All BOPE (Annulars, Rams, Valves, Chokes, Crosses Flexible Lines, Hard Lines and etc.) shall
be Monogrammed to API Specification 6A, 16A, 16C, 17D or other applicable API Specification
as appropriate.
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1) Equipment that was in service in Saudi Aramco operations prior to January 1, 2010 that
did not have a monogram may be 'grandfathered' and may be used until replaced. When
replaced it must be replaced with monogrammed equipment.
2) For equipment to be considered 'grandfathered' it must be accompanied by a waiver from

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the Well Control Committee. Equipment that is 'grandfathered' under this section must
still meet all other requirements for materials, service levels and recertification.
3) All equipment being brought into service in Saudi Aramco D&WO Operations must be
monogrammed. This includes equipment transferred from other regions whether or not it
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is on a rig already.
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4) Any exceptions to this monogram policy (e.g.; 30" 1,000 psi annulars) are noted in the
section detailing that equipment.
1.1.2 All major BOPE components including, but not limited to, ram BOPs annular BOPs, drilling
spools, ram blocks, valves, choke and kill lines, choke manifolds, gas busters etc. will have an
unique serial or asset identification number assigned by the equipment owner. This number
must be permanently marked in the metal of the component body and should be paint stenciled
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in a prominent and clearly visible location on the equipment. This number must be referenced
on all accompanying certification and recertification documents.
1.1.3 Only OEM (Original Equipment Manufacturer) parts are acceptable when repairing or
redressing the BOP, valves, chokes, and closing units. Documentation (e.g.; PO, invoice,
certificate of compliance etc.) must be maintained for all parts verifying that they are OEM.
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1.1.4 Maintenance, testing, certification and recertification requirements may be found in section
1.1.15 and in Chapter C "Maintenance Testing and Certification Requirements” of this manual.
1.1.5 A drilling spool is preferred for primary choke and kill line installation. However in special cases
(such as space limitation), preventer side outlets may be used in lieu of a drilling spool. The
diameter of all preventer side outlets must be at least as large as the choke manifold lines.

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NOTE: The side outlets are used for the installation of the lower choke and kill lines on 10M
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and higher BOPs.
1.1.6 The through-bore size of the preventer stack, tubing head, and any adapters used in the BOP
hook-up shall be large enough for the maximum size bit, scraper, liner hanger, packer, plug, cup
tester, bowl protector or any other large diameter down-hole tools to be run in the well.
1.1.7 The pressure rating of all pressure control equipment (BOP, Valves, Lines etc.) must be greater
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than the MASP (Maximum Anticipated Surface Pressure).
1.1.8 The inboard manual valves on the choke and kill lines are considered master valves and
normally would not, except for pressure testing, be closed unless the outside valve (HCR) has
failed.
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1.1.9 Check valves must be installed on normal kill lines but shall not be used on emergency kill lines.
1.1.10 The kill line, emergency kill line and choke lines should be flushed and washed out frequently to
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prevent mud solids settling.
1.1.11 BOP assemblies will be dismantled between wells to inspect for internal corrosion, erosion and
to check flange bolts. Refer to Chapter C for maintenance procedures and requirements.
1.1.12 All Rigs shall maintain a logbook of BOP schematics detailing the components installed. The
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logbooks shall contain the part number, size, description and installation date of ram blocks, top
seals, ram and annular packers and bonnet or door seals. This is be witnessed and co-signed
by the Toolpusher and the Saudi Aramco Representative (see form #1 in Chapter C) of this
manual).
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1.1.13 All ram preventers must be equipped with manual or automatic locking devices, which must be
locked whenever the rams are used to control the well. Hand crank, wrench or hand wheel
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systems are acceptable manual locking devices.
1.1.14 All preventers and associated equipment must meet NACE MR-0175/ISO 15156, API
Specification 6A or API Specification 16A for sour service.
1.1.15 A full OEM certification or recertification of the BOP, choke manifold (including chokes) and all
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related equipment must be performed at the start of the contract and least once every three
years thereafter. The documentation package shall be kept with the equipment and must be
available for inspection at the rig site by Saudi Aramco personnel. This includes, but is not
limited to:
¾ Ram preventers.
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¾ Annular preventers.
¾ Valves on the kill, emergency kill, choke line and choke manifold.
¾ Drilling chokes.
¾ Kill, emergency kill and choke lines (and line components) including both hard line and
flexible hoses.
¾ Drilling spools.

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NOTE: Recertification can only be performed by the OEM or their licensee. If recertified by a
licensee, the document package shall include a copy of the license issued by the OEM.
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NOTE: New equipment shall be accompanied by the manufacturer's certificate of compliance
and a full documentation package including inspection and test reports.
1.1.16 All BOPE including, but not limited to, annulars, rams, valves, spools, crosses, tees and other
end and outlet connections with working pressures of 3,000 psi and above shall have flanged,
welded, integral, or hubbed connections only. Threaded connections and threaded connections
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that have been seal welded are not permitted.
1.2 Annular Units and Diverters
1.2.1 All annular units must comply with the following in addition to the requirements in Section 1.1.
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1.2.2 The minimum acceptable ratings for H2S and temperature are as follows,
2,000 psi and less 2.5% H2S and 170°F

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3,000 psi equipment 2.5% H2S and 180°F
1.2.3 The acceptable manufacturers are Cameron, Hydril, Shaffer and T-3.
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1.2.4 Gray/Regan diverters are acceptable for 500, 1,000 and 2,000 psi service.
1.2.5 If a rotary diverter system is utilized on an offshore rig, the diverter lines must have the
capability of discharging below the bottom of the hull due to H2S concerns.
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1.2.6 Bolted, latched and screwed top annulars are acceptable.

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1.2.7 30 inch 1,000 psi annulars may not be monogrammed under API specification 16A. These
annulars are exempt from the monogram requirement.
1.3 Fixed Ram Preventers and Elastomers
1.3.1 All fixed ram preventers must comply with the following in addition to the requirements in
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Section 1.1 above.
1.3.2 Only fixed size rams are acceptable as the master pipe ram (bottom ram) on all BOP stacks.
1.3.3 The minimum acceptable ratings for H2S and temperature for ram assemblies are:
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3,000 psi stack 5.0% H2S and 250°F

10,000 psi stack 20.0% H2S and 300°F
15,000 psi stack 20.0% H2S and 300°F

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1.3.4 Cameron, Shaffer, Hydril and T-3 are acceptable manufacturers for ram preventers. All ram
assemblies shall meet NACE Standard MR-0175-2000 for sour service.
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NOTE: Fixed size ram preventers CANNOT CLOSE on TOOL JOINTS
1.3.5 All ram preventers shall be equipped withy manual or automatic locking devices which must be
locked whenever the rams are closed to control the well. A hand crank/wrench or handwheel
system are acceptable manual devices. Automatic devices (e.g.: Shaffer Posi0locks) are also
acceptable.
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1.4 Variable Bore Ram Preventer Blocks and Elastomers
1.4.1 All variable bore ram preventers must comply with the following in addition to the requirements
in Section 1.1 above.
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1.4.2 Variable bore rams (VBR) are optional for tapered drill string applications on Class ‘A’ stacks.
In all cases the master pipe ram (bottom ram) must be a fixed ram.
1.4.3
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The minimum acceptable ratings for H2S and temperature for VBR's are:

10,000 psi stack 20.0% H2S and 300°F
15,000 psi stack 20.0% H2S and 300°F
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1.4.4 The Cameron Extended Range High Temperature VBR-II Packer (3-1/2” to 5-7/8” pipe sizes)
for the Cameron 13-5/8” U Type blowout prevented is acceptable for 3,000 and 5,000 psi
applications ONLY. This VBR was successfully tested to 250 oF with a CAMLAST elastomer
rated for 20% H2S.
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NOTE: The Cameron ER-HT VBR-II, described above, is approved for use in 3M and 5M Class
'A' BOPs. This is the ONLY APPROVED VBR.
1.5 Shear Blind Ram (SBR) Blocks and Elastomers
1.5.1 SBR's are required on:

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¾ Close Proximity Wells (All Wells in Populated Areas)

¾ Gas Cap Wells (Either 3,000 or 5,000 Class ‘A’ Stacks)
¾ Onshore Class ‘A’ 5,000 psi stacks (Expl./Dev. Wells >10 % H2S)
¾ Smart Well Completions and Downhole monitoring systems where more than one (1) line is
run on the OD of the tubing.
¾ ESP Completions in areas where the well can flow naturally
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¾ Offshore Class ‘A’ 5,000 psi stacks (Offshore Wells)

¾ Class ‘A’ 10,000 psi stacks (Deep Gas Exploration and Development Wells)
¾ Class 'A' 15,000 psi stacks (Deep Gas Exploration and Development Wells)
1.5.2 The minimum acceptable ratings for H2S and temperature for SBR's are:

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10,000 psi stack 20.0% H2S and 300°F
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15,000 psi stack 20.0% H2S and 300°F
1.5.3 Approved Shear Blind Rams are as follows:
¾ Cameron Shearing Blind Rams

¾ Shaffer V-Shear, T-72 and LFS (Low Force Shear) Rams
¾ Hydril Blind/Shear Rams
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¾ T-3 Model 6000 Shear Blind Rams
1.5.4 All rigs utilizing SBR in 3,000 and 5,000 psi BOP equipment shall have a 3” emergency kill line.
This will provide additional kill line capacity in case the SBR does not make a proper seal after
cutting the pipe. If the wellhead spool outlet is 2”, then the inboard manual valve shall be 2” with
DSA back to 3”. Rigs with 10,000 psi and higher BOP equipment shall have dual choke and kill
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lines as specified in Chapter B.
1.5.5 Shear Blind Rams are normally installed in Class A BOP stacks. When installed they will be in
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the position immediately above the drilling cross as detailed in the individual stack
configurations shown in this manual. They may be used on Class B BOP stacks on close
proximity wells to allow the utilization of smaller rigs. When installed in Class B stacks, the
configuration must be a fixed pipe ram in the bottom position, a drilling cross above that, the
SBR and then the annular.
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NOTE: Double rams may not be used in conjunction with SBR’s on a Class B stack.
1.5.6 The tables below indicate the shear capability of SBR for different BOP manufacturers, sizes
and pressure applications.
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NOTE: Shear Blind Rams CANNOT BE CLOSED ON TOOL JOINTS.

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SHEAR BLIND RAM CAPABILITY
10,000 - 15,000 PSI SERVICE

BOP BOPE MFG. DRILL PIPE REQUIRED OPERATOR SIDE PACKER
SERVICE SIZE - WP SHEAR SHEAR REQUIRED
CLASS CAPABILITY BLIND RAM SIZE
TYPE
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TEMP H2S,
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( F) (%)
(2)
DEEP GAS 13-5/8" 10M CAMERON ALL SIZES TO 'SBR' YES/ LBT 300 20
(1)
EXPL/ DEV. CLASS 'A' 5-1/2" 24.7# G-105
(1) (3)
SHAFFER ALL SIZES TO 'V' 14"/10" 300 20
5-1/2" 24.7# G-105
T-3 ALL SIZES TO 6000 YES/LBSB 300 20
5-1/2" 24.7# G-105
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(2)
11" 10M CAMERON ALL SIZES TO 'SBR' YES/ LBT 300 20
(1)
CLASS 'A' 5" 19.5# G-105
(1) (3)
SHAFFER ALL SIZES TO 'T-72' 14"/10" 250 20
5" 25.6# G-105
T-3 ALL SIZES TO 6000 YES/LBSB 300 20
5" 25.6# G-105

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3,000 - 5,000 PSI SERVICE
BOP BOPE MFG. DRILL PIPE REQUIRED OPERATO SIDE
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SERVICE SIZE - WP SHEAR SHEAR R PACKER
CLASS CAPABILITY BLIND REQUIRED
RAM TYPE SIZE
TEMP TE
0
( F) MP
0
( F)
(1)
OFFSHORE 13-5/8" 3-5M CAMERON ALL SIZES TO 'SBR' YES/ LBT 250 20
(2)
ONSHORE CLASS 'A' 5-1/2" 24.7# G-105
EXPL/DEV. w/ H2S > DUAL TUBING
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10% STRINGS
(1)
GAS CAP WELL SHAFFER ALL SIZES TO 'V' 250 20
(3)
POPULATED 5-1/2" 24.7# G-105 14"/10"
AREAS
T-3 ALL SIZES TO 6000 Yes/LBSB 250 20
5-1/2" 24.7# G-105
(1)
11" 3-5M CAMERON ALL SIZES TO 'SBR' YES/ LBT 250 20
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(2)
CLASS 'A' 5" 19.5# G-105
(1) (3)
SHAFFER ALL SIZES TO 'T-72' 14"/10" 250 20
5" 25.6# G-105
NOTE: (1) CAMERON, HYDRIL SHAFFER AND T-3 ARE APPROVED MANUFACTURERS.
(2)
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CAMERON - LBT REFERS TO LARGE BORE SHEAR BONNETS WITH TANDEM BOOSTERS.
(3) SHAFFER - 14" OPERATOR WITH 10" BOOSTER IS REQUIRED.
1.6 Side Outlets, Valve Removal Plugs and Blind Flanges
1.6.1 Two side outlets are required below each ram on a BOP. Therefore, a single ram body will
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have two (2) outlets and a double ram body will have four (4).
1.6.2 Valve Removal (VR) plugs are not required on BOP side outlets, however they may be used.
The following conditions apply to the blind flanges installed on side outlets:
¾
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Flanges installed on the side outlets of ram preventers that do not have VR plugs installed shall
be blind with no penetrations.
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¾ Flanges installed on the side outlets of ram preventers that have VR plugs installed shall have a
½ inch NPT or an Autoclave tap (depending on the pressure rating) and have a plug installed.
1.7 Drilling Spools
1.7.1 All Drilling Spools shall comply with the following requirements:
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¾ Monogrammed to API Specification 6A or 16A

¾ PSL-2 (5,000 psi working pressure or lower)
¾ PSL-2 with PSL-3 Gas Test (10,000 psi working pressure or higher)
¾ PR-1 (or better)
¾ MR-DD (or better)
¾ TR-U (5,000 psi working pressure or lower)
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¾ TR-U Suitable for 300 F service (10,000 psi working pressure or higher)
¾ Forged bodies

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2.0 Requirements for Kill, Emergency Kill, Choke Lines and Chokes
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All Kill, Emergency Kill and Choke lines shall comply with the following in addition to Section 1.1.
2.1 The Minimum Bore Size for Kill, Emergency Kill and Choke Lines Shall Be As Follows:
KILL LINE
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Nominal Size (in) Working Pressure (psi) Minimum Bore (in)
2-1/16" 3,000 and 5,000 1.72"
2-1/16" 10,000 2.09"
3-1/16" 15,000 3.09"
EMERGENCY KILL LINE
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2-1/16" 3,000 and 5,000 1.72"
3-1/8" 3,000 2.93"
3-1/8"
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3-1/16" 10,000 and 15,000 3.09"
CHOKE LINE
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3-1/8" 3,000 2.93"
3-1/8" 5,000 2.65"
4-1/16" 10,000 and 15,000 4.09"
2.1.2 The complete piping system, valves, chokes and choke manifold will be the full working
pressure of the BOP through the block valves downstream of the chokes.
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2.2 Material and Fabrication
2.2.1 The lines from the BOP stack to the choke manifold shall have the same working pressure (or
greater) as the BOP stack. All lines shall meet Sour Service requirements for API
Specifications 6A and 16C.
2.2.2 Choke lines for 3M and 5M applications shall be either steel pipe, flexible hose or a combination
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of these.
2.2.3 Choke lines for 10M and higher applications shall be hard line only.
2.2.4 Flexible steel hose or a combination of flexible hose and hard line may be used for kill and, or,
emergency kill lines on 3M, 5M and 10M applications and choke line on 3M and 5M applications
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provided the following requirements are satisfied:
¾ Made by an approved manufacturer as listed in section 2.2.7 below.

¾ All components of the hose and end fittings in possible contact with wellbore fluids meet
Sour Service NACE MR-0175/ISO 15156 (latest revision)

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2.2.5 All lines and end connections shall be pressure tested and Monogrammed as per API
specification 6A, 16C or 17D as appropriate.
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2.2.6 Steel line material shall meet the requirements of API specification 6A or 16C for H2S service.
2.2.7 Flexible choke and kill lines shall be monogrammed to API Specification 16C. The only
approved flexible choke and kill lines are:
¾ Technip/Coflexip (coflon lined)
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¾ Phoenix HNBR (only allowed in 5,000 psi and lower service)
NOTE: The Phoenix HNBR hose has the following limitations in chemical compatibility:
Product compatibility of HNBR lined Phoenix Rubber hoses

(choke and kill hoses acc. to API Spec. 16C 07 C draft &hoses c\w st. st. internal carcass acc. to API Spec. 17K)
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0oF 75oF 150oF 200oF 250oF
Medium Concentration -18oC 24oC 66oC 93oC 121oC
Hydrochloric acid HCl 15% + + - - -
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Hydrofluoric acid HF 0.6% + + - - -
Xylene C6H4 (CH3)2 25% + + + L L
Methanol CH3OH 100% + + L L L
Zinc bromide ZnBr2 Saturated + + L L L
Calcium bromide CaBr2 Saturated + + L L L
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Calcium chloride CaCl2 Saturated + + L L L
Diesel 100% + + + + -
Sea water --- + + + - -
Sodium hydroxide NaOH 50% L L - - -
Hydrogen sulfide H2S 20% + + + + +
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(+) Suitable, (-) Not Suitable, (L) Limited Service

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2.2.8 Field welding is not permitted on choke and kill lines. These must be welded in an API licensed
shop to a qualified welding procedure and must, at a minimum, pass hardness tests (HRC 22 or
less) and radiography of the welds.
2.2.9 All choke and kill lines shall be as straight as possible with targeted, block tees at turns. The
tees will be targeted with renewable target flanges. Welded or threaded tees are not
acceptable.
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NOTE: Threaded tees that are seal welded are NOT ALLOWED in any service.
NOTE: Chiksans are not acceptable for kill line, emergency kill line or choke line.
2.2.10 All kill, emergency kill, choke and choke manifold connections should be flanged, welded,
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integral or hubbed and shall be monogrammed to API Specification 6A.
2.3 Requirements for Drilling Chokes
2.3.1 A remote controlled hydraulic choke(s) shall be installed on each manifold. All chokes used in
Saudi Aramco service must be one of the approved models listed below. Acceptable models
are:
Current Revision: May, 2010 A - 10 Rev.A-10/4.0

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¾ SWACO 'Super Choke'
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¾ Cameron Drilling Choke
¾ Shaffer Drilling Choke
¾ T-3 HXE Drilling Choke With Severe Service Seals
¾ T-3 (EEC) E-S Drilling Choke With Severe Service Seals
NOTE: Other brands of hydraulically controlled chokes will be considered on an individual

basis. Manufacturer's must contact the Well Control Committee for acceptance
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procedures. Choke makes and models not listed above must be accompanied by an
individual waiver issued by the Well Control Committee for each installation.
2.3.2 All Chokes, regardless of make and model, shall comply with the following specifications:
¾ Monogrammed to API Specification 6A or 16C
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¾ PSL-2 (With PSL-3 Gas Test)
¾ PR-1 (or better)
¾
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TR-U (5,000 psi working pressure or lower)
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¾ TR-U Suitable for 300 F service (10,000 psi working pressure or higher)
¾ Forged bodies and bonnets
2.4 Requirements for Valves

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2.4.1 All Gate Valves shall be non-rising stem, single slab, floating gate valves. Split gates or valves
with floating seats that can pressure lock are not acceptable. No specific manufacturers are
specified for contractor owned equipment, however, it should be noted that each valve must be
re-certified by the OEM at contract start-up and every three (3) years thereafter.
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2.4.2 All valves shall comply with the following specifications (in addition to Section 1.1):
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¾ Monogrammed to API Specification 6A

¾ PSL-2 with PSL-3 Gas Test (10,000 psi and higher)
¾ PSL-2 (5,000 psi and lower)
¾ PR-1 (or better)
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¾ TR-U suitable for 300 F service (10,000 psi working pressure or higher)
2.4.3 All Check Valves shall comply with the following specifications (in addition to Section 1.1):
¾ Monogrammed to API Specification 6A

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¾ PSL-2 with PSL-3 Gas Test (10,000 psi and higher)

¾ PSL-2 (5,000 psi and lower)
¾ PR-1 (or better)
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¾ TR-U suitable for 300 F service (10,000 psi working pressure or higher)

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¾ Top entry valves only, no bottom body penetrations.
¾ Metal to metal seal valves only.
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2.5 Requirements for Cup Testers
2.5.1 Cameron Type ‘F’ cup testers are the only approved model. All elastomers and other parts
must be OEM.
3.0 ACCESSORY BOP EQUIPMENT REQUIREMENTS
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3.1 Pit Volume Totalizers
3.1.1 All rigs shall have a pit volume totalizer installed. These should be kept on at all times, even
when out of the hole, changing bits or logging.
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3.1.2 Charts and, or, warning devices (horn, lights etc.) should be installed at the Drill Floor, Mud
Logging unit and the Toolpushers or Drilling Representative's office.
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3.2 Mud Flow Indicators
3.2.1 All rigs shall have a mud flow indicator installed. These should be kept on at all times, even
when out of the hole, changing bits or logging.
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3.2.2 Electrical Differential and the Flow Sensor types are approved.
3.3 Gas Busters
3.3.1 Gas busters (poor boy degassers) shall be installed on every rig.
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3.3.2 The vent lines must meet the following requirements:

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¾ Lines will be 8” minimum OD flanged or clamped steel line (minimum of 240’ in length, from
the gas buster)
¾ Same pressure rating (or greater) than that of the gas buster.
¾ Shall terminate in a flare pit, positioned away from the reserve/waste pits to prevent ignition
of any waste hydrocarbons while circulating gas from the wellbore.
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3.3.3 The gas buster design for ‘deep gas rigs’ is shown in Figure A-3.1 The minimum internal
capacity for Gas Rig gas busters is 35 barrels.
3.3.4 The gas buster design for ‘oil development rigs’ is shown in Figure A-3.2 The minimum internal
capacity for Oil Rig gas busters is 17.5 barrels.
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3.3.5 Gas busters should be cleaned out periodically.
3.3.6 Never circulate cement returns through a gas buster.
3.3.7 Gas busters have a tendency to shake and rattle when they are in use. They should be
securely anchored.

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3.3.8 All gas busters shall be built in compliance to ASME Boiler and Pressure Vessel Code, Section
VIII, Division I, with all materials meeting requirements of NACE Standard MR-0175/ISO15156
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(Latest Revision). All welding on the vessel shall meet ASME requirements. New gas busters
shall be hydrostatically tested to 190 psi to give a maximum working pressure of 150 psi, as per
ASME.
SAUDI ARAMCO
GAS WELL
MUD/GAS SEPARATOR
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DEFLECTOR PLATE
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4” INLET FROM
CHOKE MANIFOLD
GAS VENT
All inlets at OUTLET
elevation above
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baffle plates
10”
8” INLET FROM
FLOW LINE
30 ft
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BAFFLE PLATES
VESSEL HEIGHT = 30 ft min.

VESSEL DIA. = 36” OD min.
MUD RETURN TO SHAKER Capacity = 35.2 bbls
POSSUM BELLY Shell Mat’l. = 0.625” wt x GR-B
GAS VENT = 10” diverted into
2 ea. 400 ft x 8” lines at GL
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CHOKE INLET DIA. = 4” min.

FLOW LINE INLET DIA. = 8” min.
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MUD OUTLET DIA. = 10-12” dia.

7 ft MUD MUD LEG = 7 ft
LEG (Mud Column Height Inside Gas Buster)
DRAINAGE OUTLET = 8-10”
SPHERICAL TOP & BOTTOM
36”
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DGN JUNE, 2001

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FIGURE A-3.1: Mud Gas Separators for Gas Service
3.3.9 There should be a by-pass line upstream of the separator directly to the flare line and a valve on
the separator inlet line to protect the separator from high pressure.

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3.3.10 The mud discharge line from the separator must have a vacuum breaker stacked vent line if the
discharge line outlet is lower than the bottom of the separator. This is to prevent siphoning gas
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from the separator to the mud pits. The vacuum breaker stack must be as high as the separator.
SAUDI ARAMCO
MUD/GAS SEPARATOR
for OIL DEVELOPMENT RIGS
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DEFLECTOR PLATE
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GAS VENT
OUTLET
3” INLET FROM
CHOKE MANIFOLD
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(Inlet elevation
above baffle plates) 8”
15 ft
BAFFLE PLATES
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VESSEL HEIGHT = 15 ft min.
VESSEL DIA. = 36” OD min.
Capacity = 17.6 bbls
MUD RETURN TO Shell Mat’l. = 0.625” wt x GR-B
SHAKER POSSUM BELLY GAS VENT = 8” OD min.
Onshore: 400 ft flare line at GL
Offshore: +175 ft vertical vent line
CHOKE INLET DIA. = 3” min.
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MUD OUTLET DIA. = 8-12” dia.

MUD LEG = 7 ft
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(Mud Column Ht Inside Gas Buster)

7 ft MUD
LEG
DRAINAGE OUTLET = 8”
SPHERICAL TOP & BOTTOM
36”
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DGN JUNE, 2001
FIGURE A-3.2: Mud Gas Separators for Oil Service

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3.4 Full Opening Safety Valves
3.4.1 A full opening safety valve to fit each size of drill pipe and drill collar in use will be kept in the
open position on the rig floor (including a closing/opening wrench).
3.4.2 A safety valve and appropriate cross-over are also required when running casing and tubing.

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3.4.3 Care should be taken to ensure that valves have the proper threads and that they will go
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through the BOP stack and casing. This will allow the valves to be stripped into the hole below
a inside BOP.
NOTE: The term 'full opening' does not mean that the ID of the valve is the same as the pipe, but rather
that the bore through the valve is not restricted.
3.5 Inside BOP
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3.5.1 An inside BOP to fit each size of drill pipe and drill collar in use will be kept in the open position
on the rig floor
3.6 Trip Tank
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3.6.1 A circulating trip tank will be used on all rigs while tripping out of or back into the hole.
3.6.2 The trip tanks shall have two (2) 60 barrel compartments.
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3.6.3 There shall be two (2) independent measuring devices, a mechanical float operated pit level
indicator graduated in inches and an electro-mechanical device.
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FIGURE A-3.3: Typical Trip Tank
3.6.4 Calculated versus actual volumes shall be monitored and recorded in a log book recording the
following data:
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¾ Volume and weight of slug

¾ Number of strokes the slug is pumped.
¾ Time for slug to stabilize and flow to stop in the annulus.
¾ Amount of mud to fill hole:
o 5 Stands for Drill Pipe
o 2 Stands for HWDP
o Every Stand for Dill Collars

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NOTE: If the volume of mud used to fill the hole is not correct for any interval, stop pulling and
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determine the reason the hole is not taking mud properly.
¾ Total volume of mud per trip to fill hole (calculated and measured)
¾ Leave drill pipe wiper rubbers off pipe for the first five (5) stands to observe hole.
3.7 Mud-Logging Units
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Mud Logging companies provide personnel and equipment to analyze well cuttings, mud and cuttings
gas, drilling rate vs. formation and gas type. They also provide detailed mud analysis and predict and
analyze hydrocarbon shows.
3.7.1 Mud Logging Units should be used as per operational requirements in exploration and
development wells.
3.8 Bowl Protectors (Wear Bushings)
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Bowl protectors, or wear bushings, protect the hanger bowl in the casing or tubing head during drilling
operations.
3.8.1 Bowl protectors shall be used in all operations when drilling through the same wellhead for more
than 14 days.
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NOTE: Bowl protectors, just like BOP test plugs have a Manufacturer specific profile. The bowl
protector used must match the Manufacturer and Model of the Wellhead.
3.9 Valve Removal Plugs

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Valve Removal (VR) plugs are one-way check valves that can be installed through an outlet valve on a
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casing head, casing spool or tubing spool into a female thread in the outlet for its repair or replacement.
Once the valve has been repaired or replaced the VR plug can be removed.
3.9.1 VR plugs shall be removed from the wellhead in order to have access to the annulus. This
should be confirmed prior to nippling up the wellhead.
3.9.2 VR plugs are to be installed under the blind flanges on all wellheads prior to the rig move/well
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completion.
3.9.3 Under no circumstances should a VR plug be left in a side outlet that has a valve installed.
3.10 Drillpipe Float Valves

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Drill pipe float valves shall be run in all Saudi Aramco operations except when planned operations
preclude running a float; testing, treating or squeezing. The drillpipe float valve shall be positioned
directly above the bit.
3.11 Weco Connections

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3.11.1 Weco connections (other than the remote connections at the end of the catwalk) are not
acceptable for kill, emergency kill or choke line service.
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3.11.2 Integral or butt welded Figure 1502 connections are acceptable downstream of the choke
manifold buffer tank for land operations.
3.11.3 Weco type connections are not acceptable on well test lines for offshore operations
3.11.4 2 inch Figure 602 connections are not allowed in any Saudi Aramco Drilling and Workover
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Operation.
3.12 Chiksans
3.12.1 Chiksans are sections of pipe with hammer unions and two swivels in each joint. The primary
use of chiksans is to run temporary lines for high pressure pumping and cementing operations.
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3.12.2 Chiksans shall not be used in kill lines, emergency kill lines or choke lines.
3.13
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Accumulator Closing Units
The brand of closing unit used by the Drilling or Workover Contractor is not specified by Saudi Aramco,
however, all closing units shall meet the following requirements.
Fluid Requirements:
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3.13.1 The accumulator shall store enough fluid under pressure to close all preventers, open the choke
HCR valve and retain 50% of the calculated closing volume with a minimum of 200 psi above
pre-charge pressure without assistance from the accumulator pumps.
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Design Requirements:
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3.13.2 The accumulators and all fittings will be 3,000 psi working pressure. Hydraulic lines from the
accumulator to the BOP stack shall be designed and manufactured to API Specification 16D.
They must be steel or an approved armored hose (equivalent to Goodhall No. 660 with 4,000
psi working pressure). Manifold and BOP hydraulic lines should be tested to 3,000 psi at
installation.
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NOTE: All air and hydraulic BOP operating units shall be equipped with regulator valves similar
to the Koomey type TR-5. These will not fail open causing loss of operating pressure.
Bottle Pre-Charge Requirements:
3.13.3 Accumulator bottles will be pre-charged with nitrogen as per manufacturer’s

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specifications/recommendations. The minimum required pre-charge pressure for a 3,000 psi

working pressure accumulator unit is 1,000 psi. The nitrogen pre-charge pressure shall be
checked and adjusted prior to connecting the closing unit to the BOP stack and any other time
the accumulator must be completely de-pressured.

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3.13.4 The accumulator should be capable of closing each ram within 30 seconds. Closing time should
not exceed 30 seconds for annulars smaller than 18-3/4” nominal bore and 45 seconds for
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annular preventers of 18-3/4” and larger.
OPERATING CONTROLS:
3.13.5 All operating controls shall be clearly marked with function and ram sizes. Accumulator controls
must be in open or closed position, but not in neutral position. During normal drilling operations
the HCR valve next to the wellhead will be closed.
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ACCUMULATOR LOCATION:
3.13.6 The accumulator shall be located at a remote location, at least 60 feet distance from the
wellbore for oil wells and 100 feet for gas wells, shielded from the wellhead and protected from
other operations around the rig. There must be at least two (2) sets of remote controls for
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operating the accumulator to activate the BOPs. One remote control shall be on the rig floor,
accessible to and visible by the driller and the other shall be located at least 100’ from the
wellhead and near the Company Representative’s office. Master Controls shall be at the
accumulator.
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PUMP SYSTEM:
3.13.7 Two pump systems are required, one will be electric/hydraulic and the second will be pneumatic
(air)/hydraulic. The primary electric/hydraulic pump system and the secondary
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pneumatic/hydraulic pump system must be independent of each other and fully operational
when the accumulator is in use. The high-pressure set point for both the electric pump and air
pump should be 3,000 psi. The low-pressure set point should be above 2,800 psi for both
systems. Do not bleed off pressure due to ambient temperature rise. Pressure may vary from
3,000 to 3,400 psi in a 24-hour period.
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Each of the two systems shall have the quantity and sizes of pumps such that, with the
accumulators isolated from service, the following steps are completed within two minutes:
¾ The annular BOP closes on the minimum size drill pipe being used
¾ All hydraulically operated valves opened
¾ Provide the pressure recommended by the annular BOP manufacturer to effect a seal on
the annulus
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Pressure Regulator Settings:
3.13.8 The pressure regulators for the annular preventer and ram preventers will be set as per
manufacturer’s specification/recommendation. All BOPs with Shear Blind Rams installed shall
have a bypass to route full system pressure to the SBR's.
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NOTE 1 For non-emergency BOP operation, use of the lowest possible pressure will extend
elastomer life. Upon completion of the daily testing the pressure regulators shall be
returned to the normal operation pressure.
NOTE 2 DO NOT close annular preventers on open hole for complete shut-off except in an
emergency.

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NOTE 3 DO NOT close pipe rams without pipe in the hole. Pipe rams should only be closed
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on the proper size pipe in order to avoid damage to the rubber packer or to the ram
carriers (DO NOT CLOSE on TOOL JOINTS).
3.14 Stroke Counters
Stroke counters provide the Driller a method of measuring fluid volumes when displacing special fluids
or lost circulation pills. It is also used to determine pumped volumes when executing well control
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procedures.
3.14.1 Stroke counters are required on all rigs at both the Driller's station and the choke control
console.
NOTE: The kill line should not be used in conjunction with the rig pumps and a stroke counter
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for hole filling purposes. The kill line is an emergency piece of equipment and should
not be used for routine hole fill-up during trips.
3.15 Gas Detectors

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These devices, usually found in mud logging units, are useful in detecting abnormal pressure sections
as well as shows of hydrocarbons. Rig Supervisors should monitor the trip gas, connection gas, and
background gas for any significant change. The presence of gas in the mud can be one of the more
useful indicators of abnormal pressure. Gas Detector readings can sometimes be misleading, however,
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and the important things to look for are the relative trends and magnitudes, rather than the individual
number of gas units reported.
3.16 Drill Rate Recorders

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These devices come in both analogue and digital styles. They are useful as correlation tools,
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particularly if logs are available from other wells in the area. The records can be used to detect and
correlate formation tops and types, as well as in selecting bits and estimating their useful lives. A
sudden increase in penetration rate can be the first signs of a well kick.
3.16.1 All rigs should have a drill rate recorder.

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Drilling & Workover
CHAPTER B - BOPE SYSTEM CONFIGURATION
CHAPTER B: BOPE SYSTEM CONFIGURATION
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TABLE OF CONTENTS
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1.0 BOP EQUIPMENT SYSTEM CONFIGURATION
1.1 Pressure Rating of BOPE Systems B-1
2.0 CLASS ‘A’ 15,000 psi BOP STACK

2.1 Usage B-1
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2.2 Class ‘A’ 15,000 psi BOP Stack Arrangement (Single Sized Drill Pipe) B-1
2.3 Class ‘A’ 15,000 psi BOP Stack Arrangement (Tapered Drill Pipe String) B-6
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3.1 Usage B-8
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4.1 Usage B-11
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5.1 Usage B-17

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5.2 Class ‘A’ 3,000 psi BOP Stack Arrangement for Large Hole (Single Sized Drill Pipe) B-18
5.3 Class ‘A’ 3,000 psi BOP Stack Arrangement for Smaller Hole (Single Sized Drill Pipe) B-19
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6.0 CLASS ‘B’ 3,000 psi BOP STACK

6.1 Usage B-20
6.2 Class ‘B’ 3,000 psi BOP Stack Arrangement B-21
7.0 CLASS ‘C’ 3,000 psi BOP STACK B-21

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8.0 CLASS ‘D’ DIVERTER STACK B-23
9.0 CLASS ‘I’ 2,000 psi WORKOVER STACK

9.1 Usage B-25
Current Revision: May, 2010 B-1 Rev. B-1/4.0

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9.2 Class ‘I’ 2,000 psi Stack Arrangement B-25
10.0 CLASS ‘II’ 3,000 psi WORKOVER STACK
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10.1 Usage B-26
10.2 Class ‘II’ 3,000 psi Stack Arrangement B-26
11.0 CLASS ‘III’ 5,000 psi WORKOVER STACK

11.1 Usage B-26
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11.2 Class ‘III’ 5,000 psi Stack Arrangement B-27
12.0 CLASS ‘IV’ 10,000 psi WORKOVER STACK

12.1 Usage B-27
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12.2 Class ‘IV’ 10,000 psi Stack Arrangement B-27
13.0 CLASS ‘V’ 15,000 psi WORKOVER STACK

13.1 Usage
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13.2 Class ‘IV’ 10,000 psi Stack Arrangement B-27
14.0 SPECIAL WELL OPERATIONS BOP STACKS

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14.1 BOP Equipment Requirements for Coil Tubing Operations B-27
14.2 BOP Equipment Requirements for Snubbing B-30
14.3 BOP Equipment Requirements for Electric Line Operations B-32

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15.0 CHOKE MANIFOLDS

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15.1 15,000 PSI Working Pressure Choke Manifold B-35

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15.5 Location B-40
15.6 Choke Manifold Pressure Ratings B-40
15.7 Piping Specifications B-40

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15.8 Choke Manifold Discharge B-40
15.9 Gas Buster Lines B-41

Drilling & Workover
1.0 BOP EQUIPMENT SYSTEM CONFIGURATION
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This Chapter of the Well Control Manual sets forth the configurations for BOP equipment systems for use in
Drilling and Workover Operations. All equipment must comply with the other chapters in this manual.
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Variations or deviations of BOP equipment, specifications, arrangement, pressure rating or requirements
from this standard requires endorsement of the Well Control Committee, and approval by the Vice President
of Drilling and Workover. The enforcement of these equipment standards shall be the responsibility of the
Drilling or Workover Rig Superintendent. The Rig Foreman shall ensure that the proper equipment is
available and correctly installed. If not specified in these standards all BOP equipment shall comply with API
Specifications and Recommended Practices. The BOP equipment must be arranged to allow:
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¾ A means of closing the top of the open hole, as well as around drill pipe or collars, and stripping the
drill string to bottom.
¾ A means of pumping into a hole and circulating out a well kick.
¾ A controlled release of the influx.
¾ Redundancy in equipment in the event that any one function fails.
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¾ All preventers shall be installed so that rams can be changed without moving the stack.
¾ The drilling program shall specify the Class BOP stack (not individual components) to be used.
1.1
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Pressure Rating of BOPE Systems
The pressure rating of the BOP system is based on the MASP (Maximum Anticipated Surface
Pressure). The MASP is not to exceed 80% of the rated working pressure of the BOP system as
detailed in the table below:
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MASP (psi) BOP System W.P. (psi)
Onshore Offshore
0 - 800 1,000 1,000
801 – 2,400 3,000 5,000
2,401 – 4,000 5,000 5,000
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4,001 – 8,000 10,000 10,000

8,001 – 12,000 15,000 15,000
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NOTE: BOP’s with higher rated working pressure than shown above may be used at any time.
2.0 Class ‘A’ 15,000 psi BOP Stack

2.1 Usage
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A Class ‘A’ 15,000 psi BOP stack shall be installed on all offshore and onshore wells with a MASP
up to 12,000 psi. If MASP exceeds 12,000 psi contact the Chairman of the Well Control Committee
for instructions on how to proceed.
The through bore of the BOP stack including drilling spools, risers, DSA's and any other equipment
will be at least as large as the wellhead section immediately below it. These BOP stacks are
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available in 7-1/16", 11", 13-5/8" and 18-3/4" 15M
2.2 Class ‘A’ 15,000 psi BOP Stack Arrangement (Single Size Drill Pipe)
When using a single size of drill pipe the stack arrangement (from bottom to top) shall be as
described below and as shown in Figure B-1:

Drilling & Workover
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2.2.1 A wellhead spool or tree with a 18-3/4", 13-5/8", 11” or 7" 15M flange with two (2) 3-1/16"
15M studded side outlets shall be installed. Each outlet shall have two (2) 3-1/16" (minimum)
15M flanged gate valves with a blind flange installed.
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2.2.2 If the top flange of the wellhead is below ground level, a spacer spool spacer is required. If
the BOP Stack is larger than the wellhead a double studded adapter flange is required.
2.2.3 A flanged or studded double gate ram preventer shall be installed on the wellhead or spool.
The BOP shall be above ground level with master drill pipe rams in the bottom position (1)
and blind rams in the top position (2).
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2.2.4 A flanged drilling cross shall be installed on the double ram preventer. The drilling cross shall
have two (2) 4-1/16" 10M flanged side outlets.
2.2.5 Kill Lines
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There shall be two (2) kill lines, an upper and a lower. Both lines shall be 3-1/16" 15M and
configured as below:
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From the drilling cross out on the kill line side, there shall be:
¾ a double studded adapter flange 4-1/16" 15M to 3-1/16" 15M

¾ a 3-1/16" 15M flanged manually operated gate valve
¾ a 3-1/16" 15M flanged hydraulic control (HCR) gate valve
¾
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a 3-1/16" 15M flanged spacer spool
¾ a 3-1/16" 15M studded tee
The bottom outlet of the tee will connect to the lower kill line. The other side of the tee will
have a flanged spacer spool followed by a second studded tee. On each side of the second
tee there shall be a 3-1/16" 15M flanged gate valve and a 3-1/16" 15M flanged check valve.
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On the remote (emergency pump connection) side, the kill line shall be 15M and run at least
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90 feet from the wellbore to the end of the catwalk, with a flange to Weco 3" welded union.
On the primary (mud pump) side, the kill line shall be connected directly to the mud pumps
or to the stand pipe manifold, with a 10M manual isolation valve between the kill line and the
7,500 psi stand pipe.
The lower kill line from the 4-1/16" 15M BOP master pipe ram side outlet out there shall be:
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¾ a 4-1/16" X 3-1/16" 15M DSA

¾ two (2) 3-1/16" 15M flanged manually operated gate valves
¾ 3-1/16" 15M flanged spacer spools and studded (targeted) tees as required
¾ a 3-1/16" 15M flanged manually operated gate valve attached directly to the studded
tee on the upper kill line.
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2.2.5 Choke Lines
There shall be two (2) choke lines, an upper and a lower. Both lines shall be 4-1/16" 15M
and configured as below:
From the drilling cross out on the choke line side there shall be:

Drilling & Workover
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¾ a 4-1/16" 15M flanged spacer spool
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The bottom outlet of the tee will connect to the lower choke line. The other side of the tee
will connect (through flanged line) to the manually operated gate valve at the choke
manifold.
The lower choke line from the 4-1/16" 15M BOP master pipe ram side outlet out there shall
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be:

¾
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a 4-1/16" 15M flanged manually operated gate valve attached directly to the studded
tee on the upper choke line.
NOTE: All steel piping shall be made with 15M flanges, targeted tees, block-tee elbows, and
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factory-made 15M working pressure line. All tees must be targeted with renewable
15M blind flanges (welded tees are not acceptable).
Chiksans and Weco connections (other than the remote connections at end of the
catwalk) are not acceptable for kill line, or choke line. Coflex hose (refer to Chapter
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A Section 2.0) may be used in combination with steel line for the kill line.
2.2.6 A 15M flanged or studded double gate ram preventer shall be installed on the 15M drilling
cross. There shall be shear blind rams in the bottom (3) and drill pipe rams in the top (4) of
the double ram preventer.
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2.2.7 A 10M or 15M annular preventer will be installed on the top of the double ram preventer.
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The annular shall be flanged bottom X studded top.
2.2.8 A flanged rotating head, with a flanged bottom connection to match the top connection of the
annular preventer and a 9" 3M flanged side outlet, may be installed on top of the annular
preventer. A spacer spool may be required if annular studded top is not compatible with the
rotating head flange.
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THIS AREA INTENTIONALLY LEFT BLANK

Drilling & Workover
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Figure B-1: Class 'A' 15,000 psi BOP Stack with Single Sized Drill Pipe
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2.3 Class ‘A’ 15,000 psi BOP Stack Arrangement (Tapered Drill Pipe String)
When using a tapered string of drill pipe the stack arrangement shall be the same as that for the
single string EXCEPT the blind rams in the bottom double (2) shall be changed to pipe rams and

Drilling & Workover
sized for the smaller sized pipe and the master pipe rams (1) and upper pipe rams (4) shall be sized
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for the larger pipe as shown in Figure B-2:
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Figure B-2: Class 'A' 15,000 psi BOP Stack with a Tapered String of Drill Pipe

Drilling & Workover
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3.1 Usage
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A Class ‘A’ 10,000 psi BOP stack shall be installed on all offshore and onshore wells with a MASP of
up to 8,000 psi.
available in 7-1/16", 11", 13-5/8" and 18-3/4" 10M
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3.2 Class ‘A’ 10,000 psi BOP Stack Arrangement (Single Size Drill Pipe)
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3.2.1 A wellhead spool or tree with a 18-3/4", 13-5/8", 11” or 7" 10M flange with two (2) 3-1/16"
(minimum) 10M studded side outlets shall be installed. Each outlet shall have two (2) 3-1/16"
10M flanged gate valves with a 3-1/16” blind flange installed.
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3.2.2 If the top flange of the wellhead is below ground level, a spacer spool spacer is required. If
the BOP Stack is larger than the wellhead a double studded adapter flange is required.
3.2.3 A flanged or studded double gate ram preventer shall be installed on the wellhead or spool.
The BOP shall be above ground level with master drill pipe rams in the bottom position (1)
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and blind rams in the top position (2).
3.2.4 A flanged drilling cross shall be installed on the double ram preventer. The drilling cross shall
have two (2) 4-1/16" 10M flanged side outlets.
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3.2.5 Kill Lines

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There shall be two (2) kill lines, an upper and a lower. Both lines shall be 2-1/16" 10M and
configured as below:
¾ a double studded adapter flange 4-1/16" 10M to 2-1/16" 10M

¾
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a 2-1/16" 10M flanged manually operated gate valve

The bottom outlet of the tee will connect to the lower kill line. The other side of the tee will
have a flanged spacer spool and followed by another studded tee. On each side of this tee
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there shall be a 2-1/16" 10M flanged gate valve and a 2-1/16" 10M flanged check valve. On
the remote (emergency pump connection) side, the kill line shall be 10M and run at least 90
feet from the wellbore to the end of the catwalk, with a flange to Weco 2" welded union. On
the primary (mud pump) side, the kill line shall be connected directly to the mud pumps or to

Drilling & Workover
the stand pipe manifold, with a 5M manual isolation valve between the kill line and the 5,000
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psi stand pipe.
The lower kill line from the 4-1/16" 10M BOP master pipe ram side outlet out there shall be:
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¾ a 4-1/16" X 2-1/16" 10M DSA
¾ two (2) 2-1/16" 10M flanged manually operated gate valves
tee on the upper kill line.
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3.2.5 Choke Lines
There shall be two (2) choke lines, an upper and a lower. Both lines shall be 4-1/16" 10M
and configured as below:
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From the drilling cross out on the choke line side there shall be:

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The bottom outlet of the tee will connect to the lower choke line. The other side of the tee
will connect (through flanged line) to the manually operated gate valve at the choke
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manifold.
The lower choke line from the 4-1/16" 10M BOP master pipe ram side outlet out there shall
be:

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tee on the upper choke line.
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Chiksans and Weco connections (other than the remote connections at end of the
catwalk) are not acceptable for kill line, or choke line. Coflex hose (refer to Chapter
A Section 2.0) may be used in combination with steel line for the kill line.
3.2.6 A 10M flanged or studded double gate ram preventer shall be installed on the 15M drilling
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cross. There shall be shear blind rams in the bottom (3) and drill pipe rams in the top (4) of
the double ram preventer.
3.2.7 A 5M or 10M annular preventer will be installed on the top of the double ram preventer. The
annular shall be flanged bottom X studded top.

Drilling & Workover
3.2.8 A flanged rotating head, with a flanged bottom connection to match the top connection of the
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annular preventer and a 9" 3M flanged side outlet, may be installed on top of the annular
preventer. A spacer spool may be required if annular studded top is not compatible with
rotating head flange.
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Current Revision: May, 2010 B - 10 Rev. B-10/4.0

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Figure B-3: Class 'A' 10,000 psi BOP Stack with Single Sized Drill Pipe
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When using a tapered string of drill pipe the stack arrangement shall be the same as that for the
single string EXCEPT the blind rams in the bottom double (2) shall be sized for the smaller sized
pipe and the master pipe rams (1) and upper pipe rams (4) shall be sized for the larger pipe as
shown in Figure B-4:

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Figure B-4: Class 'A' 10,000 psi BOP Stack with a Tapered String of Drill Pipe
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4.1 Usage
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A Class ‘A’ 5,000 psi BOP stack shall be installed on onshore wells where MASP may become more
than 2,401 psi but not more than 4,000 psi. They will be used on all offshore wells where the surface
pressure will not be more than 4,000 psi. All of the elements of the BOP stack shall be 5,000 psi
rated working pressure. All preventers shall be installed so that rams can be changed without
moving the stack.
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available in 7-1/16", 11", 13-5/8" and 18-3/4" 5M.
All Class 'A' 5,000 psi stacks used offshore shall have shear blind rams installed in the ram cavity
immediately above the drilling cross. Shear blind rams on onshore stacks are required only on wells
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with high H2S, wells in gas cap areas and wells in populated areas (close proximity). Further details
on the use of shear blind rams is provided in Chapter A Section 1.5.
4.2
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Class ‘A’ 5,000 psi BOP Stack Arrangement (Single Size Drill Pipe)
4.2.1 A wellhead spool (casing head) with a 18-3/4", 13-5/8", 11” or 7" 3M or 5M flange with two
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(2) 2-1/16" or 3-1/16" 3M or 5M studded side outlets shall be installed. One outlet shall have
a flanged gate valve with a blind flange installed. The other outlet other outlet shall have a
manually operated flanged gate valve installed next to the wellhead and a hydraulically
operated (HCR) flanged gate valve connecting to the emergency kill line. The emergency
kill line shall be an individual line with flanged steel piping (no chiksan swings or hammer
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unions) and a minimum 2” 5M rated working pressure. Flexible hose (compliant with
Chapter A section 2.0) may be used in combination with steel line.
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For onshore operations, the emergency kill line shall extend from the wellbore to end of the
catwalk (approximately 90 feet), with a 2" 1502 Weco welded union (threaded connections
are not acceptable) for connection to an emergency pump.
NOTE: If shear blind rams are utilized, then the emergency kill line shall be 3” and 5M rated
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working pressure. The manual gate valve shall remain as 2” with double studded
adapter to 3”.
NOTE: If the wellhead spool has a 5M top flange, then the side outlet valves shall be 5M.
NOTE: All BOP equipment with working pressures of 3,000 psi and above shall have
flanged, welded, integral, or hubbed connections only.
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Figure B-5: Class 'A' 5,000 and 3,000 psi BOP Stack with a Single Sized String of Drill Pipe
4.2.2 If the top flange of the wellhead is below ground level, a spacer spool is required. If the BOP
Stack is larger than the wellhead a double studded adapter flange is required.
4.2.3 A 5M flanged single ram preventer shall be installed on the wellhead spool above ground
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level with master drill pipe rams (1).
Variable bore rams are optional (provided the minimum acceptable ratings for H2S and
temperature are met) for use on Class ‘A’ 5M stacks. However, the master pipe ram must be
a fixed ram.

Drilling & Workover
NOTE: Currently, Cameron’s Extended Range High Temperature VBR-II Packer is the only
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variable bore ram that is approved for 5M applications (3-1/2" - 5-7/8" pipe sizes).
Additional information regarding the use of variable bore rams is provided in Chapter
A, Section 1.4.
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4.2.4 A 5M flanged drilling cross shall be installed on the single ram preventer. The drilling cross
shall have two (2) 3-1/8" 5M side outlets.
4.2.5 There shall be a 3-1/8" 5M to 2-1/16" 5M double studded adapter flange installed on the kill
line side.
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4.2.6 Kill Lines
For Land Operations:
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¾ a 2-1/16" 5M flanged hydraulic control gate valve
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¾ a 2-1/16" 5M flanged tee
On each side of the tee there shall be a 2-1/16" 5M flanged gate valve and a 2-1/16" 5M
flanged check valve.
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On the remote side, the kill line shall be 5M and run at least 90 feet from the wellbore to the
end of the catwalk, with a flange to Weco 2" welded union.
On the primary side, the kill line shall be 5M and connected directly to the mud pumps or to
the stand pipe manifold.
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For Offshore Operations:

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¾ a 2-1/16" 5M check valve
¾ a 2-1/16" 5M flanged line or Coflex hose (coflon lined) to the pump/choke manifold
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The emergency kill line shall have the capability of being connected to the cement manifold
through the choke manifold as shown in Figure B-19 or through a dedicated line from the rig
floor cement manifold. A 3” ID, 5M flexible hose (refer to Chapter A Section 2.0) shall be run
between the fixed piping and applicable casing spool.
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NOTE: Due to the length required in offshore operations, it is recommended that a short
connection (between the cement manifold and whatever facility is used) be
removable to reduce the chance of plugging the line with cement during cementing
operations. This connection shall be in place and tested during drilling operations.

Drilling & Workover
4.2.7 Choke Lines
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The choke lines for both onshore and offshore operations are configured the same. On the
choke line, from the drilling cross out, there shall be:
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¾ a 3-1/8" 5M steel flanged line or flexible hose (Chapter A, Section 2.0) to a 3-1/8" 5M
flanged manually operated gate valve at the choke manifold
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Chiksans and Weco connections (other than the remote connection at the end of the
catwalk on land operations) are not acceptable. Flexible hose (refer to Chapter A
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Section 2.0) may be used in combination with steel line for kill, emergency kill line,
or choke line.
4.2.8 Either two (2) flanged single ram preventers or a double ram preventer shall be installed,
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blind rams or shear blind rams, see required applications in Chapter A section 1.5, (2) and
drill pipe rams (3).
4.2.9 A 5M flanged bottom and studded top annular preventer will be installed on the top ram
preventer.
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4.2.10 A rotating head is optional.
4.2.11
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When using a tapered drill string (two sizes of drill pipe) from the bottom to top shall be exactly the
same as the arrangement for the single size drill pipe string EXCEPT the top drill pipe rams (3) shall
be replaced with small sized drill pipe rams, as shown in Figure B-6.
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Figure B-6: Class 'A' 5,000 and 3,000 psi BOP Stack with a Tapered String of Drill Pipe

5.1 Usage
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Large Diameter Hole (as with Deep Gas Wells)
A Class ‘A’ 3,000 psi BOP stack shall be installed on all wells where large diameter hole (as with
deep gas wells) is being drilled, as through 18-5/8" casing, and where hydrocarbon reservoirs with a
MASP of up to 2,400 psi may be drilled. All preventers shall be installed so that rams can be
changed without moving the stack.

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Smaller Diameter Hole (as with Critical Oil Wells)
At the discretion of the Drilling Manager, some wells may require a Class ‘A’ 3,000 psi stack instead
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of a Class ‘B’ 3,000 psi stack.
Shear blind rams on onshore stacks are required only on wells with high H2S, wells in gas cap areas
and wells in populated areas (close proximity). Further details on the use of shear blind rams is
provided in Chapter A section 1.5.
5.2 Class ‘A’ 3,000 psi BOP Stack Arrangement for Large Diameter Hole (Single Size Drill Pipe)
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All elements of Class ‘A’ 3,000 psi stacks shall be at least 3,000 psi rated working pressure. The
through bore of the BOP stack including drilling spools, risers, DSA's and any other equipment will
be at least as large as the wellhead section immediately below it. These BOP stacks are available in
7-1/16", 11", 13-5/8" and 20-1/4 and 26-3/4" 3M. Each ram preventer shall have two (2) 4-1/16" 3M
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side outlets. A double ram preventer will have four side outlets.
described below and as shown in Figure B5:
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5.2.1 A wellhead spool (18-5/8" landing base or casing spool) with 20-3/4" 3,000 psi flange and
two (2) 3-1/16" 3M side outlets for emergency kill operations shall be installed. One outlet
shall have a 3-1/16" 3M gate valve with a 3-1/16" 3M blind flange. The other outlet shall
have a manually operated 3-1/16" 3M flanged gate valve next to the wellhead and a
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hydraulic control 3-1/16" 3M flanged gate valve tied into the emergency kill line. The
emergency kill line shall be an individual line with flanged steel piping (no chiksan swings or
hammer unions) and a minimum 3” 3M rated working pressure. Coflex hose (coflon lined)
may be used in combination with steel line. The emergency kill line shall extend from the
wellbore to end of the catwalk (approximately 90 feet), with a 3" 1502 Weco welded union
(threaded connections are not acceptable) for connection to an emergency pump.
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5.2.2 If the wellhead top flange is below ground level a spacer spool is required. If the BOP Stack
is larger than the wellhead a DSA is required.
5.2.3 A 26-3/4” or 20-3/4” 3M flanged single ram preventer shall be installed on the wellhead spool
above ground level with master drill pipe rams (1).
5.2.4 A 26-3/4” or 20-3/4” 3M flanged drilling cross shall be installed on the single ram preventer.
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A drilling cross shall have two (2) 4-1/16" 3M side outlets.
5.2.5 Either a 26-3/4" or 20-3/4" 3M flanged double ram preventer or two (2) single ram preventers
shall be installed, with blind rams (2) and drill pipe rams (3).
5.2.6 A 26-3/4” or 20-3/4" 3M to 30” 1M or 21-1/4" 2M double studded adapter flange (DSA) will
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be required on top of this preventer. The DSA can be eliminated if a 26-3/4” or 20-3/4" 3M
psi flange is manufactured on the annular preventer.
5.2.7 A 30” 1M or 21-1/4" 2M flanged bottom annular preventer shall complete this stack.

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5.2.8 Kill Lines
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¾ a 2-1/16" 3M minimum flanged manually operated gate valve
¾ a 2-1/16" 3M minimum flanged hydraulic control gate valve
¾ a 2-1/16" 3M minimum flanged spacer spool
¾ a 2-1/16" 3M minimum flanged tee
On each side of the tee there shall be a 2-1/16" 3M minimum flanged gate valve and a 2-
1/16" 3M minimum flanged check valve.
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On the remote side, the kill line shall be 3M minimum and run at least 90 feet from the
wellbore to the end of the catwalk, with a flange to Weco 2" welded union.
On the primary side, the kill line shall be 3M minimum and connected directly to the mud
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pumps or to the stand pipe manifold.
5.2.9 Choke Lines

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On the choke line, from the drilling cross out, there shall be:

¾ a 3-1/8" 3M minimum steel flanged line or flexible hose (Chapter A, Section 2.0) to a 3-
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1/8" 3M minimum flanged manually operated gate valve at the choke manifold
NOTE: All steel piping shall be made with 3M minimum flanges, targeted tees, block-tee
elbows, and factory-made 3M minimum working pressure line. All tees must be
targeted with renewable 3M minimum blind flanges (welded tees are not
acceptable).
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Chiksans and Weco connections (other than the remote connection at the catwalk,
land operation) are not acceptable. Flexible hose (refer to Chapter A Section 2.0)
may be used in combination with steel line for kill, emergency kill line, or choke line.
5.2.10 A 3M minimum flanged bottom and studded top annular preventer will be installed on the top
ram preventer.
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5.2.11 A rotating head is optional.
5.3 Class ‘A’ 3,000 psi BOP Stack Arrangement for Smaller Diameter Hole (Single Size Drill Pipe)
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5.3.1 A wellhead spool (13-3/8" landing base) with 13-5/8" 3,000 psi flange and two (2) 2-1/16" 3M
side outlets for emergency kill operations shall be installed. One outlet shall have a 2-1/16"
3M gate valve with a 2-1/16" 3M blind flange. The other outlet shall have a manually
operated 2-1/16" 3M flanged gate valve next to the wellhead and a hydraulic control 2-1/16"
3M flanged gate valve tied into the emergency kill line. The emergency kill line shall be an

Drilling & Workover
individual line with flanged steel piping (no chiksan swings or hammer unions) and a
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minimum 3” 3M rated working pressure (if SBR used) otherwise 2” 3M. Coflex hose (coflon
lined) may be used in combination with steel line. The emergency kill line shall extend from
the wellbore to end of the catwalk (approximately 90 feet), with a 1502 WECO welded union
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(threaded connections are not acceptable) for connection to an emergency pump.
Note: If shear blind rams are utilized, then the emergency kill line shall be 3” and 3M rated
working pressure. The manual gate valve shall remain as 2” with double studded
adapter to 3”.
5.3.2 If the wellhead top flange is below ground level, a 13-5/8” 3M spacer spool may be required
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to raise the bottom flange of the BOP to (or above) ground level.
5.3.3 A 13-5/8” 3M flanged single ram preventer shall be installed on the wellhead spool above
ground level with master drill pipe rams.
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5.3.4 A 13-5/8” 3M flanged drilling cross shall be installed on the single ram preventer. A drilling
cross shall have two (2) 3-1/16" 3M side outlets. The same arrangement on the kill and
choke lines as for the Class ‘A’ 5,000 psi BOP stack (land operation) shall be used, as
shown in Figure B-6.
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5.3.5 Either two (2) 13-5/8" 3M flanged single ram preventers or a double ram preventer shall be
installed, with blind rams or shear blind rams, see required applications in Section 1.7.4,
(bottom) and drill pipe rams (top).
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5.3.6 A 13-5/8" 3M flanged bottom with studded top annular preventer shall complete this stack.
5.3.7 Choke and kill lines shall be configured as per section 5.2 above.
5.4 Class ‘A’ 3,000 psi BOP Stack Arrangement for Tapered Drill Pipe String
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The Class ‘A’ 3,000 BOP Stack arrangement for tapered drill strings will be the same as it is for
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single sized drillpipe EXCEPT the upper pipe rams (position 3) will be sized for the smaller sized drill
pipe as shown in Figure B-6. Alternatively, the upper pipe rams may be Variable Bore Rams as per
Chapter A Section 1.4. NOTE: Variable Bore Rams are not allowed in the Master Pipe Ram
position (lowermost rams).
6.0 Class ‘B’ 3,000 psi BOP Stack

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6.1 Usage
A Class ‘B’ 3,000 psi BOP stack (Figure B-7) shall be installed, as a minimum, on all development oil
producers, water injectors, observation and water disposal wells and a MASP of up to. All BOP
equipment shall be 13-5/8” 3M (or 26-1/4” when used on deep gas wells), with kill and choke line
requirements as previously described in the Class ‘A’ 3M. The kill line shall be 3M and connected
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directly to the mud pumps or to the stand pipe manifold.
This stack will also be used for deep gas wells on 24” or 18-5/8” casing.

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6.2 Class ‘B’ 3,000 psi BOP Stack Arrangement
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All BOP equipment for these wells shall be arranged as described Below.
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6.2.1 A wellhead spool or casing head with a 3,000 psi flanged top and two (2) 2-1/16" 3M side
outlets for emergency kill operations shall be installed. One outlet shall have a 2-1/16" 3M
gate valve with a 2-1/16" 3M blind flange. The other outlet shall have a manually operated 2-
1/16" 3M flanged gate valve next to the wellhead and a hydraulic control 2-1/16" 3M flanged
gate valve tied into the emergency kill line. The emergency kill line shall be an individual line
with flanged steel piping (no chiksan swings or hammer unions) and a minimum 3” 3M rated
working pressure (if SBR used) otherwise 2” 3M. Coflex hose (coflon lined) may be used in
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combination with steel line. The emergency kill line shall extend from the wellbore to end of
the catwalk (approximately 90 feet), with a 1502 WECO welded union (threaded connections
are not acceptable) for connection to an emergency pump.
Note: If used on deep gas wells with 24” or 18-5/8” casing the side outlets will be 4” and
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kill lines will be 3” 3M.
6.2.2 If the wellhead top flange is below ground level, a 3M spacer spool may be required.
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6.2.3 A 3,000 psi single ram preventer shall be installed on the wellhead spool above ground level
with master drill pipe rams.
6.2.4 A 3,000 psi flanged drilling cross shall be installed on the single ram preventer. The drilling
cross shall have two (2) 3-1/16" 3M side outlets.
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6.2.5 A 3,000 psi flanged bottom with studded top annular preventer shall complete this stack.
6.2.6 Kill Lines
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¾ a 2-1/16" 3M minimum flanged spacer spool
¾ a 2-1/16" 3M minimum flanged tee
On each side of the tee there shall be a 2-1/16" 3M minimum flanged gate valve and a 2-
1/16" 3M minimum flanged check valve.
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On the remote side, the kill line shall be 3M minimum and run at least 90 feet from the
wellbore to the end of the catwalk, with a flange to Weco 2" welded union.
On the primary side, the kill line shall be 3M minimum and connected directly to the mud
pumps or to the stand pipe manifold.
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6.2.7 Choke Lines
On the choke line, from the drilling cross out, there shall be:

Drilling & Workover
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¾ a 3-1/8" 3M minimum steel flanged line or flexible hose (Chapter A, Section 2.0) to a 3-
1/8" 3M minimum flanged manually operated gate valve at the choke manifold
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NOTE: All steel piping shall be made with 3M minimum flanges, targeted tees, block-tee
elbows, and factory-made 3M minimum working pressure line. All tees must be
targeted with renewable 3M minimum blind flanges (welded tees are not
acceptable).
Chiksans and Weco connections (other than the remote connection at the catwalk,
land operation) are not acceptable. Flexible hose (refer to Chapter A Section 2.0)
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may be used in combination with steel line for kill line, emergency kill line, or choke
line.
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Figure B-7: Class 'B' 3,000 psi BOP Stack

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7.0 Class ‘C’ 3,000 psi BOP Stack
A Class ‘C’ 3,000 psi BOP stack (Figure B-10) shall be installed on all power water injector wells
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during the drilling and acidizing operations in the Arab-D hole section. The minimum equipment
required will be an annular type preventer and a hydraulically operated dual ram preventer (or two
single ram preventers) with blind rams located on top and pipe rams on bottom. Two (2) 3-1/16” 3M
side outlets below the pipe rams are required, one for the kill line hook-up and other for the choke
line. The kill line shall be adapted to 2-1/16” 3M and connected directly to the mud pumps or to the
stand pipe manifold. A 10” 3M Ball Valve (with 9” bore) is located below the ram preventers and
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becomes part of the injection tree upon completion of the well.
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Figure B-8: Class 'C' 3,000 psi BOP Stack
8.0 Class ‘D’ Diverter Stack

A Class ‘D’ Diverter stack (Figure B-9) will be installed on the conductor and/or next casing of all
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onshore exploration wells and development wells in the shallow gas area or areas where offset data
indicates possible shallow gas. In addition, this diverter stack will also be required on the conductor
of all offshore exploration wells and wells where offset data indicates possible shallow gas.

Drilling & Workover
The diverter lines shall consist of Schedule 40 steel piping. This line shall be securely anchored and
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terminate in the reserve pit or overboard. Saudi Aramco requires two (2) 6” minimum ID, full bore
valves and 10” lines. All lines must be as straight as possible and all turns targeted to minimize
erosion.
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The emergency pump in connection shall be a 3-1/8” 2M flanged connection, located 90 degrees
offset from the diverter lines (as noted in Figure B-8.1 below). The kill line shall be connected directly
to the mud pumps or to the stand pipe manifold.
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Figure B-9: Class ‘D’ Diverter BOP Stack

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INTENTIONALLY LEFT BLANK

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Workover BOP Stacks
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Maintaining control of a well during the completion and workover phases may be more complicated than well
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control in drilling operations. Additional complications may exist as, a) various types of workover fluids
ranging from low-density diesel to high-density brine fluids may be used; b) interrelated activities may occur
simultaneously, such as workovers on a platform with producing wells.
Saudi Aramco has four (4) classes of BOP arrangements for workover operations. The workover program
shall specify the Class BOP stack (not individual components) to be used.
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9.0 Class ‘I’ 2,000 psi Workover Stack
9.1 Usage
This class of BOP Stack is used on water supply wells and shallow, low-pressure aquifer observation
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wells, where the operation to be performed on the well and/or space below the rig substructure
precludes use of ram-type preventers. NOTE: This class of BOP stack with a working pressure of
2,000 psi is not defined in Table 1.1; any given 21-1/4” Annular is typically rated to 2,000 psi and it
may be used on wells with a MASP of up to 1,600 psi.
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9.2 Class ‘I’ 2,000 psi Workover BOP Stack Arrangement
9.2.1 The minimum equipment required will be a Hydril, Cameron, Shaffer or T-3 annular type
preventer with a working pressure of 2,000 psi or greater. A 2” kill and/or fill-up line shall be
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connected to the landing base side outlet as shown in Figure B-10.
9.2.2 When sufficient space below the rig substructure is available, a Power Water Injection Tree
(ball valve) shall be used below the annular, as shown in Figure B.12.
9.2.3 The annular preventer will be visually inspected and functionally tested prior to installation
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and pressure tested after installation using a cup-type tester set at a depth of approximately
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60’. Test pressures, to be specified in the workover program, shall be greater than the
MASP, but shall not exceed 80% of the rated casing burst.
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Figure B-10: Class 'I' Workover BOP Stack
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10.0 Class ‘II’ 3000 psi Workover Stack
10.1 Usage
This class BOP stack is used on most onshore workovers to be performed on producing, water
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injection and reservoir observation wells. These wells are normally low-pressure and equipped with
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up to 3,000 psi WP wellhead equipment.
10.2 Class ‘II’ 3,000 psi Workover BOP Stack Arrangement
This BOP stack is identical to the Class ‘B’ Drilling stack as described in Section 6 above. Please
note that if SBR’s are not being used, in special circumstances (such as low sub-structure height) it
is permissible to leave out the drilling spool and use the BOP side outlets for line connections instead
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(see Chapter A, 1.7.2).
11.0 Class ‘III’ 5,000 psi Workover Stack

11.1 Usage
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This class BOP is used on all offshore workovers with wellhead equipment rated to 3,000 or 5,000
psi and onshore workovers with wellhead equipment rated to up to 5,000 psi.

Drilling & Workover
11.2 Class ‘III’ 5,000 psi Workover BOP Stack Arrangement
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This BOP stack is identical to the Class ‘A’ 5,000 psi Drilling stack as described in Section 4 and
Figure B-6 above.
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12.0 Class ‘IV’ 10,000 psi Workover Stack
12.1 Usage
This class BOP is used on all workovers with up to 10,000 psi WP wellhead equipment.
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12.2 Class ‘IV’ 10,000 psi Workover BOP Stack Arrangement
The Class IV 10,000 psi workover stack is arranged the same as the Class ‘A’ 10,000 psi drilling
stack. All BOP equipment in this stack shall be 11” (or larger) 10M rated working pressure, including
the annular preventer. NOTE: The annular shall be 10,000 psi working pressure. All other
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equipment requirements are as previously discussed in Section 3.0.
13.0 Class ‘V’ 15,000 psi Workover Stack

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13.1 Usage
This class BOP is used on all workovers with up to 15,000 psi WP wellhead equipment.
13.2 Class ‘V’ 15,000 psi Workover BOP Stack Arrangement

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The Class V 15,000 psi workover stack is arranged the same as the Class ‘A’ 15,000 psi drilling
stack. All BOP equipment in this stack shall be 11” (or larger to provide full opening to the tubing
spool and production casing) 15M rated working pressure, except the annular preventer WHICH
shall be 10,000 psi working pressure. All other equipment requirements are as previously discussed
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in Section 2.0.
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14.0 Special Well Operations BOP Stacks

The following represents Drilling and Workover’s minimum BOP equipment requirements for coil
tubing, snubbing, and wireline operations. In some cases, the service company’s internal policy may
exceed these BOP requirements.
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14.1 BOP Equipment Requirements for Coil Tubing Operations
BOP equipment requirements for low-pressure and high-pressure coil tubing (CT) operations are
shown in Figures B-13 and B-14, respectively. Selecting the BOP arrangement shall be based on the
maximum anticipated operating or shut-in wellhead pressure. These arrangements are for standard
CT operations and should be modified as needed for special or unusual applications.
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14.1.1 Low-Pressure Coiled Tubing BOP Equipment Requirements
The low-pressure or standard arrangement (less than 5,000 psi WHP) includes 4 sets of
rams: tubing rams on the bottom in the #1 position, slip type rams in the #2 position, cutter

Drilling & Workover
rams in the #3 position and blind rams on top in the #4 position. In addition, there is a flow
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cross with a valve installed below the cross. See Figure B-11.
Low-pressure stacks shall comply with the following minimum requirements:
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¾ All equipment shall meet or exceed NACE MR-01-75 and API Standards for well control
¾ Rated WP greater than the maximum anticipated well pressure
¾ Side-door stripper
¾ Minimum BOP configuration of blind, shear, slip, and pipe rams
¾ Kill line with minimum 2-1/16” flanged connection
¾ Flow cross with flanged outlets and double valves
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¾ Ability to monitor wellhead pressure below the pipe rams with isolator
¾ Slip design that will minimize fatigue/deformation damage to the coil
¾ Slip rams capable of holding the pipe up to the yield point with maximum rated WP in a
hang-off mode
¾ Accumulator shall be sized to operate all BOPE (close-open-close) at maximum rated
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Figure B-11: Low Pressure Coil Tubing BOP Stack

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14.1.2 High-Pressure Coiled Tubing BOP Equipment Requirements
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The high-pressure arrangement (greater than 5,000 psi WHP) includes the same equipment
as in the low-pressure arrangement, plus a second set of tubing rams below the flow cross
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when lifting the well. The master pipe rams should be substituted for combination shear/seal
and pipe/slip rams when flowing the well with coil tubing in the hole (i.e. treating or
production logging). A second stripper is also required when treating or production logging.
See Figure B-12.
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Figure B-12: High Pressure Coil Tubing BOP Stack

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High-pressure stacks shall comply with the following minimum requirements:
¾ All equipment comply with or exceed NACE STANDARD MR-01-75 and API Standards
for well control
¾ Rated WP greater than the maximum anticipated well pressure
¾ Side-door stripper

Drilling & Workover
¾ Second side-door or radial stripper is required if flowing well w/CT in hole
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¾ Minimum BOP configuration of blind, shear, slip, pipe rams, and master pipe rams
below flow cross
¾ Master pipe rams should be substituted for combination shear/seal and pipe/slip rams
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when flowing the well with CT in the hole
¾ Kill line with minimum 2-1/16” flanged connection
¾ Flow cross with flanged outlets and double valves
¾ Ability to monitor wellhead pressure below the pipe rams with isolator
¾ Slip design that will minimize fatigue/deformation damage
¾ Slip rams capable of holding the pipe up to the yield point with maximum rated WP in a
hang-off mode
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¾ Accumulator shall be sized to operate all BOPE (close-open-close) at maximum rated
WP
14.2 BOP Equipment Requirements for Snubbing Operations
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The stack arrangements in Figure B-15 and B-16 show basic set-ups for low-pressure and high-
pressure snubbing operations. Selecting the BOP arrangement shall be based on the maximum
anticipated operating or shut-in pressure.
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14.2.1 Low-Pressure Snubbing BOP Equipment Requirements
The low-pressure (less than 5000 psi WHP) or standard arrangement’s basic features are the #1 and
#2 stripping rams, equalizing loop, safety, and blind rams. The primary rams are the #1 and #2
stripping rams. These rams are used in conjunction with the equalizing loop to strip the pipe into or
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out of the hole. The equalizing loop and vent line are used to bleed off the pressure. Note that the
equalizing loop contains a fixed or positive choke to minimize the surge pressure when bleeding off
the pressure. Each set of valves contains one manual and one remotely operated valve. Below the
#2 rams is a set of safety or secondary rams to be used whenever either of the stripper rams begin
to leak or fail. Below the safety rams is a set of blind rams to be used to shut the well in when pipe is
out of the hole or landed in the hangar.
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Figure J.14
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Low-Pressure Snubbing Stack
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Figure B-13, Low Pressure Snubbing Stack
14.2.2 High-Pressure Snubbing BOP Equipment Requirements
The high-pressure arrangement (greater than 5000 psi WHP) includes everything the standard
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arrangement has plus a second spool with dual outlets that contains a remotely operated choke, a
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set of shear blind rams, and a second set of safety rams. The shear blind rams are considered a
third line of defence and are a last resort if primary control of the well is lost. In addition, a positive
choke is added to the vent line to allow a slower bleed-off of pressure from the well.
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Figure J.15
High-Pressure Snubbing Stack
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Outlet Spool with
Dual Hydraulic
Chokes
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Figure B-14 High Pressure Snubbing Stack
14.3 BOP Arrangements for Electric Line Operations

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The required BOP arrangement shall be determined by the electric line application (open-hole or
cased hole) and maximum anticipated surface pressure during the operation. All BOP equipment
shall comply with API 6A and NACE MR-01-75 (Latest Revision).
14.3.1 Open-Hole Electric Line BOP Requirements (Over-Balanced Condition)

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When open-hole logging an oil well, an electric line BOP is not required, provided primary
well control (hydrostatic pressure > formation pressure) can be maintained and confirmed.
However, an electric line BOP is recommended on all gas wells.
14..3.2 Cased-Hole Electric Line BOP Requirements (Under-Balanced Condition)

Drilling & Workover
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When perforating or logging under-balanced, an electric line BOP and lubricator are required
with a wellhead adapter flange connected to the top of the test head or tree. Minimum
electric line BOP requirements for various cased-hole pressure applications are summarized
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below.
Cased-Hole Electric Line Wells with Max. Wells with Max.

BOP Requirements: Expected WHP Expected WHP
(Under-Balanced Condition) < 5,000 psi 5,000 to 10,000
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7/32 –1/4” Line psi
Working Pressure 5,000 psi 10,000 psi
Manual BOP Not Acceptable Not Acceptable
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Hydraulic BOP Required Required
Minimum Number of Rams 2 3

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Minimum Temperature
Rating of Elastomer 2500 F 3000 F
Tool Trap Required Required
Tool Catcher Optional Optional

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Ball Check Valve Required Required
Remote Grease Injection Required Required

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Stuffing Box with Hydraulic

Operated Pack-Off Required Required
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A stuffing box (w/ hydraulic operated pack-off) is required in unperforated cased hole when
running CBL, or similar logs, with + 1000 psi surface pressure while logging. An electric line
BOP is optional in this situation.
A typical electric line rig-up for cased-hole operations is shown in Figure B-17.
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Figure B-15 Electric Line BOP

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15.0 Choke Manifolds
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All choke manifolds and piping shall meet Sour Service NACE MR-01-75 (Latest Revision) and API
Specification 6A. Required specifications and applications for the 10,000 psi, 5,000 psi, and 3,000
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psi choke manifolds are shown below.
15.1 15,000 psi Working Pressure Choke Manifold
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FIGURE B-16: 4-1/16” 15M Choke Manifold

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4-1/16” 15M CHOKE MANIFOLDS ARE ACCEPTABLE FOR THE FOLLOWING APPLICATIONS
CLASS ‘A’ 15,000 PSI DRILLING
CLASS ‘V’ 15,000 PSI WORKOVER
All 15M psi choke and test manifolds shall comply with the following minimum requirements:
• Valves and chokes shall be monogrammed to API Specification 6A and made to the
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following,
¾ PSL-2
¾ PR-1
¾ TR-U
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¾ Forged Bodies and Bonnets

¾ All valves must be of a single gate (slab) design
¾ Telescoping seats are not permitted
• All flanges and other components shall be monogrammed to API Spec-6A

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CLASS ‘A’ 10,000 PSI DRILLING
CLASS ‘IV’ 15,000 PSI WORKOVER

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All 10M psi (& higher) choke manifolds shall comply with the following minimum requirements:
following,
¾ PSL-2 (with PSL-3 gas test)

¾ PR-1
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¾ TR-U (Suitable for 3000 F service)
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Drilling & Workover
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Choke manifold configurations for 5,000 psi onshore and offshore applications are shown
in Figure B-18 and Figure B-19 respectively. Figure B-20 shows the test manifold and
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associated required connections from the choke manifold in offshore applications.
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FIGURE B-18: Onshore 3-1/8” 5M Choke Manifold

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CLASS ‘A’ 5,000 PSI ONSHORE DRILLING

CLASS ‘III’ 5,000 PSI ONSHORE WORKOVER
Note All 3-1/8” lines shall be 5M flanged steel piping or Coflex flexible hose (coflon lined, with a 3”
minimum ID). A combination of flanged steel piping and Coflex hose is acceptable. Weco or
chiksan-type connections are not acceptable. Only targeted or block-tee elbows with renewable
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blind flanges are acceptable.

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FIGURE B-19: Offshore 3-1/8” 5M Choke Manifold

CLASS ‘A’ 5,000 PSI OFFSHORE DRILLING
CLASS ‘III’ 5,000 PSI OFFSHORE WORKOVER
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FIGURE B-20: Offshore 3-1/8” 5M Test Manifold

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All 5M psi choke and test manifolds shall comply with the following minimum requirements:
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following,
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¾ PSL-2
¾ PR-1
¾ TR-U
¾
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All valves must be of a single gate (slab) design
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3-1/8” 3M CHOKE MANIFOLD IS ACCEPTABLE FOR THE FOLLOWING APPLICATIONS:

CLASS ‘A’ 3,000 PSI (DRILLING)
CLASS ‘B’ 3,000 PSI (DRILLING)
CLASS ‘C’ 3,000 PSI (DRILLING)
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CLASS ‘II’ 3,000 PSI (WORKOVER)
All 3M psi choke manifolds shall comply with the following minimum requirements:
following,

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¾ PSL-2
¾ PR-1
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¾ TR-U
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15.5 Location
The choke manifold shall be skid mounted on land rig (rig floor mounted on offshore rigs)
and located in an accessible area.
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15.6 Choke Manifold Pressure Ratings
The complete choke manifold, chokes, valves and piping will be full working pressure of the
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BOP stack through the block valves down-stream of the chokes.
15.7 Piping Specifications
The piping from the BOP stack to the choke manifold shall have the same working pressure
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(or greater) as the BOP stack. All piping shall meet Sour Service NACE MR-01-75 (Latest
Revision) and API Specification 6A.
Choke lines for 3M and 5M applications shall either be steel pipe, Coflex hose (coflon lined
only), or combination of Coflex and steel pipe. All flexible hose shall be monogrammed to
API Specification 16C, and all end connections monogrammed to API Specification 6A.
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Choke lines for 10,000 and higher psi applications shall be flanged pipe only.
All fabricated steel piping shall be as straight as possible, with targeted or block-tee elbows
at turns. All tees must be targeted with renewable blind flanges (welded tees are not
acceptable).
All choke line and manifold connections shall be flanged, welded, integral, or hubbed.
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Chiksans and Weco connections are not acceptable.
15.8 Choke Manifold Discharge
Provisions shall be made for the discharge from the choke manifold to be selectively diverted
to:
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15.8.1 Flare Lines
Two (2) 3-1/2” EUE flare lines, each approximately 400 feet in length, shall be
required for onshore oil wells.

Drilling & Workover
Four (4) 4-1/2” LTC gas flare lines and one (1) 3-1/2” EUE liquid flare line, each
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1000 feet in length, shall be required for onshore gas wells.
Note: Using drill pipe for flare line is not recommended because of the difficulty of
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properly making up the connections on the ground.
Elbows and chiksans on the flare line are susceptible to erosion/washouts and are
not acceptable (because of the potential for high fluid velocities). The flare line, as
with the choke line, shall be as straight as possible, with targeted or block-tee
elbows at turns, as required.
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An alternate flare pit and flare line will be rigged-up on deep gas wells (Figure B-22).
This emergency flare pit will be used in well kill operations if the main flare pit cannot
be utilized due to change in wind direction. Electronic flare ignition sources shall be
positioned in the main flare pit, alternate flare pit, and gas buster flare pit.
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FIGURE B-22: Deep Gas Flare Line Layout

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15.9 Gas Buster Lines
There should be a bypass line up-stream of the gas buster directly to the flare line
and a valve on the gas buster inlet line to protect the separator from high pressure.
The mud discharge line from the gas buster must have a vacuum breaker stacked
vent line if the discharge line outlet is lower than the bottom of the separator. This is
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to prevent siphoning gas from the separator to the mud pits. The vacuum breaker
stack must be as high as the gas buster.
One (1) 8” flanged/clamped steel vent line, minimum of 240 feet in length (from the
gas buster), shall be required for onshore oil wells.

Drilling & Workover
Two (2) 8” flanged/clamped steel vent line, minimum of 240 feet in length (from the
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gas buster), shall be required for onshore gas wells.
The flare pit shall be positioned away from the reserve/waste pits to prevent ignition
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of any waste hydrocarbons while circulating gas from the wellbore.
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CHAPTER C - MAINTENANCE, TESTING AND CERTIFICATION REQUIREMENTS
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CHAPTER C: MAINTENANCE, TESTING AND CERTIFICATION REQUIREMENTS
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TABLE OF CONTENTS
1.0 Maintenance of Blowout Prevention Equipment C–3
2.0 General Maintenance Requirements C–3
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3.0 Testing of Blowout Prevention Equipment
3.1 General Pressure Testing Requirements (Test Frequency) C–5
3.2 Specific Requirements for Class ‘A’ 15,000 psi BOP Stack C–7
3.3
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Specific Requirements for Class ‘A’ 10,000 psi BOP Stack C–9
3.4
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Specific Requirements for Class ‘A’ 5,000 psi BOP Stack C – 10
3.5 Specific Requirements for Class ‘A’ 3,000 psi BOP Stack C – 11
3.6 Specific Requirements for Class ‘B’ 3,000 psi BOP Stack C – 12
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3.7 Specific Requirements for Class ‘C’ or ‘II’ Workover Stack C – 13
3.8 Specific Requirements for Class ‘D’ Diverter Stack C – 14
4.0 Pressure Testing Procedure

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4.1 Function Testing and Flow Testing C – 15
4.2 Fill the Stack with Water C – 15
4.3 Casing Test (if required) C – 15
4.4 Blind Rams (if required) C – 16

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4.5 Annular Preventer C – 17
4.6 Upper Pipe Rams C – 18
4.7 Positive Sealing Chokes C – 19

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4.8 Choke Manifold (continued) C – 20
Current Revision: May, 2010 C-1 Rev. C- 1/4.0

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4.11 Choke Line HCR Valve C – 23
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4.15 Choke and Kill Line Manual Valves C - 24
4.16 Master Pipe Rams C – 25
4.14 Small Pipe Rams C – 26
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4.15 Kelly, Surface Circulating Equipment, and Safety Valves C – 27
4.16 Wellhead Valves C – 28
5.0 Accumulator Testing C – 28
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6.0 Hang-Off Limitations while Testing C – 30
7.0 Test Pressure Requirements for Casing Rams

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8.0 Certification and Re-certification Requirements C - 30

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1.0 MAINTENANCE, TESTING AND CERTIFICATION OF BLOWOUT
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PREVENTION EQUIPMENT
This Chapter of the Well Control Manual sets forth the maintenance, testing and certification requirements
required for Saudi Aramco BOP equipment. These policies (as well as the equipment standards and
procedures throughout this well control manual) are considered mandatory. Variations or deviations from
these requirements requires endorsement of the Well Control Committee, and approval by the Vice
President of Drilling and Workover. The enforcement of these requirements shall be the responsibility of
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the Saudi Aramco Drilling Foreman (or Liaisonman) as directed by the Drilling Superintendent.
2.0 GENERAL MAINTENANCE REQUIREMENTS

Blowout prevention equipment is emergency equipment and must be maintained in its proper working
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condition at all times. The Drilling Foreman can best ensure that Saudi Aramco is provided with
equipment that performs to our specifications by being an active participant in the maintenance
requirements of the BOP equipment.
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Several maintenance items, which the Drilling Foreman should verify on a daily basis, by reviewing the
Driller’s pre-tour checklist or by personal observation, are listed below:
1) Examine the fluid level in the accumulator. Make sure it is at the proper level and proper
pressures are indicated on the accumulator, manifold, and annular pressure gauges.
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2) Verify the control lines are run to prevent damage by trucks or dropped tools.
3) Confirm the preventer controls are either in their proper opened or closed position (not
neutral) and that leaks are not evident.
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4) Assure the preventer stack is well guyed so that vibrations are minimized while drilling.
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5) All preventers must be operated at least each time a trip is made. Alternate trip closures
between the remote stations and the accumulator. The annular preventer does not have to be
operated to complete shut-off. Do not close the pipe rams on open hole.
6) The emergency kill line and choke/kill lines shall be washed out as required to prevent mud
solids settling. Clear water should be used to flush and fill the lines (except in extremely cold
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weather, where diesel or glycol should be used).
7) DO NOT circulate green cement through the preventer stack or choke manifold. Always
thoroughly flush with water any piece of blowout prevention equipment, which has come in
contact with green cement and verify the equipment is clear upon the next nipple-up.
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NOTE: This requirement includes the wellhead annulus valves. If green cement is pumped
through these they must be flushed well with fresh water to ensure that they will be
operable.
8) Ensure the rig is centred over the well to reduce drill string and BOP equipment contact and
abrasion.

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9) Do not use the kill line as a fill-up line during trips.
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10) If possible, install the ram preventers so that the ram doors are positioned above and shield
the valves installed on the casing head below.
11) All rigs shall maintain a logbook of BOP schematics detailing the components installed in
each ram cavity. The logbooks shall contain the part number, description and installation date
of ram blocks, top seals, ram or annular packers and bonnet/door seals. To be witnessed and
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co-signed by the Contract Toolpusher and Saudi Aramco Drilling Foreman (or Liaisonman).
12) Only OEM parts are acceptable when repairing or redressing the BOPE. Furthermore, only
OEM approved high-temperature lubricant is acceptable for valve maintenance.
13) At least one spare set of ram seals (top seals and packer rams) for all rams including packer
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rams for each size of tubing or drill pipe, as well as bonnet seals, must be on the rig site.
14) Ram blocks should not be dressed until ready to use.

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15) All BOP rubber goods shall be kept in a cool place and remain in the original packaging with
expiration dates.
16) Preventer assemblies shall be dismantled between wells to inspect for internal corrosion and
erosion and to check flange bolts.
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17) Manufacturer‘s installation, operation, and maintenance (IOM) manuals should be available
on the rig for all BOP equipment installed on the rig.
18) New ring gaskets shall be installed on each nipple-up at each connection, which has been
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parted. Ring gaskets shall never be reused.

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19) Studs and nuts should be checked for proper size and grade. Using the appropriate lubricant,
torque should be applied in a criss-cross manner to the flange studs. All bolts should then be
re-checked for the proper torque as prescribed in API Specification 6A. Bolt sizes 2-3/4” and
larger require more make-up torque than can be provided with Hammer Wrenches. These
larger sizes must be torqued using hydraulic torque units.
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20) Field welding shall not be performed on any BOP equipment. All repairs to BOP equipment
must be performed at an OEM facility, or their Licensee.
21) A Maintenance Log for each piece of BOP equipment shall be maintained. This log shall
include, at a minimum, records of all service and inspections performed on the BOP, serial
numbers for each BOP and expiration date of all elastomers exposed to wellbore fluid. The
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log will travel with the Contractor-owned equipment and shall be kept in the BOP shop for
Saudi Aramco-owned equipment.
22) All BOP equipment shall be API monogrammed.

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23) A full OEM Certification of the BOP, choke manifold (including chokes), and all related
equipment (i.e. kill line valves, choke line valves, Coflex hoses, etc.) shall be required at
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contract start-up and contract renewal with a maximum period of 3 years between OEM re-
certification.
24) Accumulator bottles must have hydrostatic pressure testing completed every 5 years in
accordance with Department of Transportation (DOT) Cylinder Maintenance, Retest and
Certification Requirements #173.34.
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25) The BOP should be opened, cleaned, and visually inspected after every nipple down,
including servicing the manual tie-down screws.
26) Elastomers exposed to well fluids shall be changed at a maximum of every 12 months,
unless visual inspection requires changing earlier. However, it is acceptable to use seal
elements for 30” annulars up to 36 months (provided inspections are satisfactory, properly
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documented, and the expiration date of the elastomer is not exceeded). Seal elements for all
other annulars (21-3/4” and smaller) shall be replaced no later than every 12 months, as per
policy.
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27) All BOP equipment must have documentation of last inspection and certification.
3.0 Testing of Blowout Prevention Equipment

The objective of BOP equipment testing is to eliminate all leaks and to determine that the
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equipment will perform under unplanned pressure conditions. This is accomplished by verifying:
¾ Specific functions are operationally ready

¾ Pressure integrity of installed BOP equipment
¾ Compatibility between control system and BOP equipment
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3.1 General Pressure Testing Requirements
All BOP equipment pressure tests shall be conducted in accordance with the following
guidelines.
Test Frequency
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1) BOP equipment (including blind rams and shear blind rams) shall be pressure
tested as follows:
¾ When installed
¾ Before drilling out each string of casing
¾ Following the disconnection or repair of any wellbore pressure seal in the
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wellhead/BOP stack (limited to the affected components only)
NOTE: When rams are changed, the casing and/or tubing Rams (and annular
PREVENTOR) shall be pressure tested with a test plug and casing/tubing
joint to 80% of the pipe collapse or the rated working pressure of the BOP
(whichever is less).

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¾ Working Pressure: 5,000 psi and lower; Test a maximum of every 21 days (no
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extensions)
¾ Working Pressure: 10,000 psi and higher; Test every 14 days. A maximum 2 day
extension is allowed with Superintendent written approval.Rig crews must be
alerted when pressure test operations are underway. Only necessary personnel
shall remain in the test area.
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2) All tests shall be performed using clear water.
3) When a gas well is being flow tested, the test equipment (manifolds, lines, etc.) must
be tested with nitrogen.
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4) The low-pressure test of each piece of BOP equipment shall be conducted at a
pressure of 300 psi.
5) The high-pressure test is specified in the following sections, by BOP class.

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6) The low-pressure test shall be performed first. do not test to the high- pressure and
then bleed down to the low pressure. The higher pressure could initiate a seal after the
pressure is lowered and thereby misrepresent the low-pressure test.
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7) All valves located downstream of the valve being tested shall be placed in the OPEN
position.
8) OPEN casing valves to the atmosphere when using a test plug to test the BOP stack to
prevent possible leaks from rupturing the casing.
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9) OPEN annular valves when testing to prevent pack-off leaks from pressuring up outer
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casing strings.
10) Vent the cup tester through the drillpipe when testing the upper 60 feet of casing to
prevent possible leaks from rupturing the casing or applying pressure to the open hole.
11) Test all valves on the wellhead individually to their rated working pressure on
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installation (using a VR plug) and to 80% of casing burst on subsequent pressure tests,
with a cup tester at located + 90’.
12) Casing rams shall be tested to the maximum anticipated surface pressure (refer to
Section C, 6.0 for specific test pressures), with a joint of casing connected to a test plug
with appropriate cross-over.
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13) Variable Bore Rams (VBR) shall be tested with all sizes of pipe in use, excluding drill
collars and bottom-hole tools.

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14) All pressure tests must be held for a minimum duration of ten (10) minutes with no
observable pressure decline.
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15) Only authorized personnel shall go in the test area to inspect for leaks when the
equipment is under pressure.
16) Tightening or repair work shall be done only after pressure has been released and all
parties have agreed that there is no possibility of trapped pressure.
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17) The BOPE flange bolt torque must be checked after every other BOP test. This will
help prevent leaks from the flanged connections in the BOP stack.
18) A pressure test is required after the installation of casing rams or tubing rams. This test
is limited to the components affected by the disconnection of the pressure containment
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seal. The bonnet seals and rams shall be tested using a test joint connected to a test
plug, or cup tester, with appropriate crossover.
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19) The initial pressure test performed on hydraulic chambers of annular preventers should
be at least 1,500 psi. Initial pressure tests on hydraulic chambers of rams and
hydraulically operated valves should be to the maximum operating pressure
recommended by the manufacturer. Test should be run on both the opening and
closing chambers. Subsequent pressure tests on hydraulic chambers should be upon
re-installation.
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20) All pressure tests shall be conducted with a test pump. Avoid the use of rig pumps for
pressure testing. Cement units are acceptable.
21) All test results must be documented on a pressure chart, with the following information,
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¾ Date of Test
¾ Well Name
¾ Driller
¾ Toolpusher
¾ Saudi Aramco Representative
21) Test stumps are an acceptable method for pressure testing the BOP stack at the rig
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site. The bottom connection (and any other connection not tested) must be tested with
a test plug upon installation of the BOP stack.
3.2 Specific Pressure Testing Requirements for Class ‘A’ 15M BOP Stack
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1) The initial high-pressure test of the following equipment shall be conducted upon
installation at the rated working pressure of the weakest component:
¾ Wellhead
¾ Ram-Type Preventers
¾ Kill Line and Valves

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¾ Emergency Kill Line and Valves
¾ Choke Line and Valves
¾
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Choke Manifold
2) Subsequent high-pressure test(s) of the above equipment shall be conducted to a

pressure greater than the *maximum anticipated surface shut-in pressure.
Note: For Khuff development wells (Jilh Dolomite casing point)
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¾ Initial high-pressure test is 15,000 psi (full working pressure)
¾ Subsequent high-pressure test(s) are 12,000 psi
For Pre-Khuff wells (Jilh Dolomite casing point and below)

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For K1/MK1 wells only (where NU occurs above Jilh Dolomite casing point)
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(Prior to drilling into the Jilh Dolomite a high-pressure test(s) must be completed
at 15,000 psi)
3) The high-pressure test (initial and subsequent) of the annular preventer shall be
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conducted at 70% of the rated working pressure.
4) All pressure tests, excluding casing tests, must be done with a test plug, due to the
minimum yield strength (burst rating) of the 13-3/8” 72# and 9-5/8” 53.5# casing. Test
plugs must be checked to insure the test plug is of the same manufacture and model as
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the wellhead where it is to be installed. (i.e. Cameron to Cameron, Gray to Gray, FMC
to FMC and Wood Group to Wood Group.) The test plug Tong Neck must be checked
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to insure that the O.D is smaller than the minimum I.D. of the wellhead.
5) The initial high-pressure test of the upper/lower kelly cocks, inside BOP, and safety
valves shall be conducted to their rated working pressure. Subsequent high-pressure
test(s) shall be conducted at the maximum anticipated surface shut-in pressure.
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6) Rotary hoses, standpipe, vibrator hoses, and piping to pumps shall all be tested to
7500 psi.
7) The initial pressure test on the closing unit valves, manifold, gauges, and BOP
hydraulic lines shall be at the rated working pressure of the closing unit (3,000 psi).
Subsequent pressure shall be performed on each well installation at the same pressure
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or after repairs to the hydraulic circuit.
8) At nipple up, the casing shall be tested to 80% of burst rating.

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9) The casing string in use shall be tested with a cup tester to 80% burst rating every 14
days (along with the scheduled BOP test). This will provide a pressure test of the
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casing valves in addition to verifying casing integrity.
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¾ Wellhead
¾ Choke Manifold
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pressure greater than the *maximum anticipated surface shut-in pressure.
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Note: For Khuff development wells (Jilh Dolomite casing point)
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For Pre-Khuff wells (Jilh Dolomite casing point and below)
For K1/MK1 wells only (where NU occurs above Jilh Dolomite casing point)
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¾ Subsequent high-pressure test(s) are 5,000 psi minimum
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11) All pressure tests, excluding casing tests, must be done with a test plug, due to the
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minimum yield strength (burst rating) of the 13-3/8” 72# and 9-5/8” 53.5# casing. Test
plugs must be checked to insure the test plug is of the same manufacture and model as
the wellhead where it is to be installed. (i.e. Cameron to Cameron, Gray to Gray, FMC
to FMC and Wood Group to Wood Group.) The test plug Tong Neck must be checked
to insure that the O.D is smaller than the minimum I.D. of the wellhead.
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12) The initial high-pressure test of the upper/lower kelly cocks, inside BOP, and safety
valves shall be conducted to their rated working pressure. Subsequent high-pressure
test(s) shall be conducted at the maximum anticipated surface shut-in pressure.
13) Rotary hoses, standpipe, vibrator hoses, and piping to pumps shall all be tested to
5,000 psi.

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14) The initial pressure test on the closing unit valves, manifold, gauges, and BOP
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hydraulic lines shall be at the rated working pressure of the closing unit (3,000 psi).
Subsequent pressure shall be performed on each well installation at the same pressure
or after repairs to the hydraulic circuit.
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¾
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¾ Ram-Type Preventers (including fixed PR, VBR, and SBR)
¾ Choke Manifold
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pressure greater than the maximum anticipated surface shut-in pressure. This test
pressure will be determined by the particular application (i.e. formations exposed,
fracture gradient or estimated fracture gradient, casing burst rating).
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Note A cup tester may be used if the high-pressure test does not exceed 80% of the
casing burst rating.
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4) The casing cup tester must be the appropriate size/weight for the application. When
using this tester, care must be taken that the total load applied to the drill string (cup
area times test pressure, plus the weight of the suspended drill string) does not exceed
the string’s tensile limit.
5) The upper/lower kelly cocks, inside BOP, safety valves, rotary hose, standpipe, vibrator
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hose, and piping to pumps shall be tested to same high-pressure tests (initial and
subsequent), as the BOP equipment, but not to exceed their rated working pressure.
6) The initial pressure test on the manifold and BOP hydraulic lines shall be at the rated
working pressure of the closing unit (3,000 psi). Subsequent pressure shall be
Current Revision: May, 2010 C - 10 Rev. C- 10/4.0

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performed on each well installation at the same pressure or after repairs to the
hydraulic circuit.
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NOTE: BOP equipment may have a higher working pressure than required, due to rig
equipment availability. The high-pressure test requirement in these situations
shall be site-specific (limited by the WP rating of wellhead).
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¾
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¾ Ram-Type Preventers (including fixed PR, VBR, and SBR)
¾ Choke Manifold
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2) Any subsequent high-pressure test(s) of the above equipment shall be conducted at
2,500 psi or maximum anticipated surface shut-in pressure (whichever is greater), as
determined by the particular application (i.e. formations exposed, fracture gradient or
estimated fracture gradient, casing burst rating).
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conducted at 2100 psi (70% of the rated working pressure).
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5) Test plugs must be checked to insure the plug fits the casing head.
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hydraulic circuit.
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3.6 Specific Pressure Testing Requirements for Class ‘B’ 3M BOP Stack
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¾ Wellhead
¾
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¾ Choke Manifold

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2500 psi or maximum anticipated surface shut-in pressure (whichever is greater), as
conducted at 2100 psi (70% of the rated working pressure).
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5) Test plugs must be checked to insure the plug fits the casing head.
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hydraulic circuit.

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3.7 Specific Pressure Testing Requirements for Class ‘C’ or ‘II’ 3M BOP Stack
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installation and at the rated working pressure of the weakest member:
¾ Wellhead
¾ Double Ram Preventer
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¾ Choke Manifold

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2,500 psi or maximum anticipated surface shut-in pressure (whichever is greater), as
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conducted at 2,100 psi (70% of the rated working pressure).
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hydraulic circuit.
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Note: When testing a Class ‘II’ 3M Workover stack on a Power Water Injection well
equipped with a ball master valve, the following must be observed:

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a) Check the ball valve for leaks with wellhead pressure, from below, prior
to nippling-up the BOP stack.
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b) Report any observed leak for decision to spot a cement isolation plug.
c) Test the blind ram on the ground against a blind flange prior to nippling-up
the BOP stack. This will provide a pressure test on the blind ram without
relying on the ball valve, which may leak at higher pressure. The pipe ram
and annular can be tested with a cup tester after nippling up.
3.8 Specific Pressure Testing Requirements for Class ‘D’ Diverter Stack
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1) Activate the ‘close/open sequence’ with drillpipe or test mandrel in the diverter to verify
control functions. DO NOT attempt to close the diverter on open hole except in an
emergency.
2) Pump water through the diverter system at low pressure and high rates. Examine entire
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system for leaks, excessive vibration, and proper tie down.
3) The low-pressure test on the diverter shall be conducted upon installation and at 300
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psi.
4) The high-pressure test shall be based on 80% rated working pressure of the weakest
component in the diverter system.
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5) Function test the diverter daily.
4.0 Pressure Testing Procedure

The recommended pressure testing procedure for a Class ‘A’ 10,000 psi BOP hook-up is given
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below. This test procedure can be easily amended and made applicable for the other classes of
preventer stacks. Although the actual testing sequence may vary somewhat, the ultimate
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objective must be achieved: To test each individual preventer, valve, and all associated lines in
the BOP system from the wellbore direction at a 300 psi low-pressure and then a specified high-
pressure.
The pressure source is shown down the drillpipe and through a perforated sub or ported test plug
(excluding blind ram or casing test); although, a BOP side outlet may be used. The annular and
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pipe rams are tested individually in this manner. The blind rams are tested after removing the
drillpipe and applying pressure through the kill line, between closed rams and test plug.
Note: In the case of the Class ‘A’ 10,000 psi (non-tapered string, where a lower set of blind rams
are positioned below the kill line), the test pressure must be applied through the side outlet
of the BOP.
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In order to test each individual valve on the kill line, choke line, and manifold; proceed after
pressure testing the far outside valves, (all other valves open) by opening these valves and closing
each inside adjacent valve, pressure testing, and working inward to the stack.

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Note: The steps in the following procedure should be performed in numerical sequence. The
instructions assume that at the beginning of each step, the equipment is arranged as in the
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end of the previous step. Therefore, if this particular procedure is not followed in sequence,
erroneous test results may be obtained.
4.1 Function Testing and Flow Testing
Before applying test pressure to the preventers, perform the following:
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1) Close and open all preventers. Do not close pipe rams or annular preventer on open
hole.
2) Pump through the kill line, flow line, mud-gas separator, and choke lines and all flare
lines with water to make sure none are plugged.
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4.2 Fill the Stack with Water
Drain the mud from the BOP stack and fill with clear water.
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4.3 Casing Test
A casing test is generally conducted at nipple-up and when testing DV or float equipment. In
addition, this test is required every 14 days (along with the scheduled BOP test), with the use of a
cup tester, to provide a pressure test on casing head valves and verify casing integrity.
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To conduct a casing test, perform the following:
1) Connect the pressure source to the kill line and open kill line valves #4 and #5.
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Figure C.1 Casing

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Shear Blind Rams

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#3
Note: Very Important - Monitor valves #1, #2, #3 and #3a for leaks/well flow.

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2) Open all valves and chokes on choke manifold. Close valve #7 on choke line.
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3) Close outer casing head valves #1 and #3a.
4) Close the blind/shear blind rams (or upper pipe rams, if pipe in the hole).
5) Pump into the well through the kill line monitoring/recording the test pressure at the test
pump. For all casing strings other than drive pipe or structural casing, conduct the test
to 80% of the minimum internal yield (burst) of the casing.
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6) To test inner casing head valves, close valves #2 and #3 and open outer valves #1 and
#3a. See Figure C.1.
Note: No manufacturer recommends opening rams, which are holding pressure.

Damage to the ram rubbers, ram blocks and ram cavities may occur.
4.4
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Shear Blind Ram Test (or Blind Rams for other BOP Stack Configurations)
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To pressure test the Shear Blind Ram (or Blind Ram), the following is required:
1) Land test plug in the casing head and remove running tool from the wellbore.
2) Connect the pressure source to the kill line and open kill line valves #4 and #5 (see
Figure C.2).
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Figure C.2 Shear Blind Ram Test

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Shear Blind Rams

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#3a
Note: Monitor valves #1, #2, #3 and #3a for well flow.

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3) Open all valves and chokes on the choke manifold.
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4) Open all casing head valves and close the choke line valve #7.
5) Close the shear blind rams.
6) Pump into the well through the kill line. Monitor and record the test pressure at the test
pump. Conduct the low-pressure test first at a pressure of 300 psi. Conduct the high-
pressure test next at the pressure specified in previous requirements (Section K 2.2 for
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Class ‘A’ 10M).
Note: This test will also evaluate the choke line HCR valve and thereby eliminate the
need for Step 3.11.
4.5 Annular Preventer
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Test the annular preventer as follows:
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1) Land the test plug and test joint in the casing head.
2) Connect the pressure source to the test joint at the rig floor.
3) Close the kill line HCR (valve #4) and open all other kill line valves (the kill line check
valve should be crippled).
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3) First, open all choke line and choke manifold valves. Then close the outermost choke
manifold valves #15, #16, #17, and #18 (before buffer tank). See Figure C.3.
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Figure C.3 Annular Test
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C
Shear Blind Rams
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lle #19
#3a
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5) Verify that the casing head valves #2 and #3 are open.
6) Close the annular preventer and pump into the well through the test joint. Conduct the
low-pressure test first at a pressure of 300 psi. Conduct the high-pressure test next at a
pressure equal to 70% of the rated working pressure of the annular preventer. Verify
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the accuracy of the gauge installed downstream of choke manifold valve #19 by
observing the test pressure.
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4.6 Upper Pipe Rams
Without changing the choke manifold or testing arrangement, immediately test the upper
pipe rams as follows.
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1) Close choke manifold valve #19 (see Figure C.4).
2) Close the upper pipe rams and pump into the well through the test joint. Conduct the
low-pressure test first at a pressure of 300 psi. Conduct the high-pressure test next at
the pressure specified in previous requirements. Confirm that choke manifold valve #19
is not leaking by observing a zero pressure indication on the downstream gauge.
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Figure C.4 Upper Pipe Rams
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C
Shear Blind
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#3a
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4.7 Remote Hydraulic Choke Integrity Verification:
Verify as described below; before proceeding to Step 3.8.

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1) Open outermost choke manifold valves #15, #16, and #18.
2) Close Hydraulic Chokes (see Figure C.5).
low-pressure test first at a pressure of 300 psi. Record bleed-off time, if any. Increase
pressure to 2500+ psi (do not exceed 10,000 psi). The purpose of the test is to verify
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the choke is not washed-out and is capable of operating and holding adequate back-
pressure during well kill operations.
Note: API Specification 16C for Choke and Kill Systems states in section 9.9: “Drilling
chokes are not intended to be used as shut off valves.”
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Note: The chokes are being shell tested to both low and high pressure under section
3.6 of this manual as well as the pressure integrity test in this section.

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Figure C.5 Positive-Sealing Choke Test
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C
Shear Blind Rams
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#3a
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4.8 Choke Manifold Valves (continued)
Continue testing the choke manifold valves by performing the following:

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1) Open outermost choke manifold valves #15, #16, #17, and #18.
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2) Open chokes.
3) Close choke manifold valves #11, #12, and #14 (see Figure C.6).
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the pressure specified in previous requirements.
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Continue testing the choke manifold valves by performing the following:
1) Open choke manifold valves #11, #12, and #14.

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2) Close choke manifold valves #9, #10, and #13 (see Figure C.7).
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Figure C.7 Choke Manifold Valves
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C
Shear Blind Rams
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#3a
Note: Monitor valves #1, #2, #3 and 3a for well flow.

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1) Open choke manifold valves, #9, #10, and #13.

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2) Close choke manifold valve #8 (see Figure C.8).

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Figure C.8 Choke Manifold Valves
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Shear Blind Rams
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#3a
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4.11 Choke Line HCR Valve

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Test the choke line HCR valve by performing the following:

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1) Open choke manifold valve #8.
2) Close outer choke line HCR (valve #7). See Figure C.9.
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Figure C.9 Choke Line HCR Valve
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Shear Blind Rams
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#3a
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4.12 Choke and Kill Line Manual Valves
Test the inner choke and kill line valves by performing the following:
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1) Open choke line HCR (valve #7).
2) Close choke line manual valve #6.
3) Open kill line HCR (valve #4).
4) Close kill line manual valve #5 (see Figure C.10).

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Figure C.10 Choke and Kill Line Manual Valves
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C
Shear Blind Rams
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#3a
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Note: No manufacturer recommends opening rams, which are holding pressure. Damage to
the ram rubbers, ram blocks and ram cavities may occur.
4.13 Master Pipe Rams

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Test the master pipe rams by performing the following:
1) Open the upper pipe rams (see Figure C.11).
2) Close the master pipe rams and pump into the well through the test joint. Conduct the
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Figure C.11 Master Pipe Rams
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C
Shear Blind Rams
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#1 #2 #3 #3
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4.14 Small Pipe Rams

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Test the small pipe rams by performing the following:
1) Open the master pipe rams (see Figure C.12).
6) Pull the large test joint and test plug. Run a small test joint and plug.
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3) Close the small pipe rams and pump into the well through the test joint. Conduct the
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Figure C.12 Small Pipe Rams
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C
Shear Blind Rams
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#1 #2 #3 #3a
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4.15 Kelly, Surface Circulating Equipment, and Safety Valves

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1) Pick up kelly and install full-opening safety valve on bottom of lower kelly valve.
2) Using an adaptor, connect to an independent test pump or cement pump.
3) Open appropriate standpipe valves and all kelly valves.

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4) Fill the system with water and close standpipe valve to test the standpipe, rotary hose,
swivel, and kelly.
5) Conduct the low-pressure test first at a pressure of 300 psi.
6) Conduct the high-pressure test next at the pressure specified in previous

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requirements.
7) By alternating closing upstream and opening downstream valves, all the kelly valves
could be tested without pressuring up again, although it may not possible to operate the
upper kelly valve under pressure.

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8) The inside BOP (float type) can be tested similarly by installing below the full- opening
safety valve and opening all valves through the standpipe.
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4.16 Wellhead Valves
Test all valves on the wellhead individually to their rated working pressure on installation
(using a VR plug) and to 80% of casing burst on subsequent pressure tests, with a cup
tester at located + 90’.
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5.0 Accumulator Tests
These tests are for the purpose of determining the operating condition of the accumulator and
BOP system. They shall be performed every 14 days, at the same time the BOP equipment is
pressure tested, and at any other time deemed necessary by the Saudi Aramco Foreman. The
results shall be noted on the Saudi Aramco BOP Pressure Test Report (see Figure C.13, or Form
d
# 2.0 in Section S of this manual). To analyse the performance of the accumulator, the results of
each test should be compared with results of several previous tests. Any increase in closure or
recharge time indicates an immediate need for a thorough examination of the accumulator
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system. The accumulator test shall include the following,
• Record the accumulator capacity and useable volume

• Record the accumulator pressure
• Record the pre-charge pressure and last date checked
• Record the closing and opening times for each component
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Note: Alternate accumulator bi-weekly tests between the main nitrogen unit (with charging
system isolated) and air/electric back-up system (with bottle banks isolated).
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Preventer functions should also be operated remotely to insure proper operation of all
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functions from the remote stations.
The accumulator test shall also comply Saudi Aramco’s general requirements as follows:
• Closing time for ram preventers should not exceed 30 seconds.

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• Closing time for annular preventers (less than 18-3/4”) should not exceed 30 seconds.
• Closing time for annular preventers (18-3/4” and larger) should not exceed 45 seconds.
• The accumulator must have enough stored fluid under pressure to close all preventers,
open the choke hydraulic control gate valve (HCR), and retain 50% of the calculated
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closing volume with a minimum of 200 psi above pre-charge pressure, without assistance
of the accumulator pumps.
• The accumulator-backup system shall be automatic, supplied by a power source

independent from the power source to the primary accumulator-charging system, and
possess sufficient capability to close all blowout components and hold them closed.

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Figure C.13
Saudi Aramco BOP Pressure Test Form
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6.0 Hang-Off Limitations While Testing
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Many times, a portion of the bottom-hole assembly will be hung-off below the test plug while
conducting a BOP test. This is done for a variety of reasons including:
• Leaves pipe in the hole to circulate through in case the well kicks.
• Shortens the trip time by not having to pull completely out of the hole.
IT MUST BE REMEMBERED however, that hanging-off weight below the test plug reduces the
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maximum allowable BOP test pressure. The table below lists the maximum allowable hang-load
for a given BOP test pressure for the wellhead manufacturers used by Saudi Aramco. This chart
should be reviewed before hanging-off and testing BOP equipment.
Bowl 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
Size psi psi psi psi psi psi psi psi psi psi psi
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11” 580,000 580,000 580,000 580,000 580,000 580,000 543,000 466,000 389,000 312,000 235,000
13” 580,000 580,000 580,000 580,000 580,000 515,000 388,000 261,000 134,000 7,000 -
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20” 580,000 580,000 580,000 580,000 580,000 580,000 - - - - -
26” 580,000 580,000 580,000 580,000 580,000 580,000 - - - - -
7.0 Test Pressure Requirements for Casing/Tubing Rams

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Casing rams (and annular preventer) shall be pressure tested with a test plug and casing/tubing joint.
The test pressure shall be 80% of collapse of the pipe of the pipe or the working pressure of the flanges,
whichever is less.
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8.0 Re-Certification Requirements

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A full OEM certification or recertification of the BOP, choke manifold (including chokes) and all related
equipment must be performed at the start of the contract and least once every three years thereafter.
The documentation package shall be kept with the equipment and must be available for inspection at the
rig site by Saudi Aramco personnel. This includes, but is not limited to:
¾ Ram preventers.
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¾ Annular preventers.
¾ Valves on the kill, emergency kill, choke line and choke manifold.
¾ Drilling chokes.
¾ Kill, emergency kill and choke lines (and line components) including both hard line and
flexible hoses.
¾ Drilling spools.
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NOTE: Recertification can only be performed by the OEM or their licensee. If recertified by a
licensee, the document package shall include a copy of the license issued by the
OEM.
NOTE: New equipment shall be accompanied by the manufacturer's certificate of compliance
and a full documentation package including inspection and test reports.

CHAPTER D - WELL CONTROL POLICIES
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CHAPTER D: WELL CONTROL POLICIES
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TABLE OF CONTENTS
1.0 WELL CONTROL POLICIES D-4
2.0 Well Control Certification D-4
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3.0 Use of Diverters
3.1 Onshore Wells D-4
3.2 Offshore Wells D-4
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4.0 Leak in Flange or Ring Gasket between BOP Stack and Casing Head D-4
5.0
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Drill Pipe Float D-5
6.0 Encountering Loss Circulation D-6
7.0 Maintaining Minimum Overbalance

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7.1 General Requirements for Drilling and WO Applications D-6
7.2 Drilling the Arab-C Reservoir with Water D-6
7.3 Reducing Mud Weight to Free Differentially Stuck Pipe D-6

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8.0 Isolating Khuff Reservoir D-7

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9.0 Tapered String D-7
10.0 Space Out D-7
11.0 Slow Pump Rate Data D-7

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12.0 Tripping Pipe

12.1 Pulling Out of Hole D-8
12.2 Running In Hole D-8

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13.0 Performing Flow Checks

13.1 While Drilling D-8
13.2 While Tripping D-9
14.0 Displacing to Brine on Horizontal Wells D-9
Current Revision: May, 2010 D-1 Rev. D-1/4.0

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15.0 Shutting In Well
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15.1 Shutting In Well without Flow Checking D-9
15.2 While Drilling D-9
15.3 While Tripping D-10
15.4 With BHA across BOP Stack
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D-10
15.5 Shutting In On Pre-Perforated Liner with DP and 10,000 psi Class ‘A’ BOP Stack D-10
16.0 Failure of Upper Pipe Rams During a Well Kill Operation D-10
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17.0 BOP Configuration When Running Casing or Liners
17.1 Running Casing or Liner W/ Class ‘B’ 3M Stack D-11
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17.2 Running Casing or Liner W/ Class ‘A’ 3M or 5M Stack D-11
17.3 Running Casing or Liner W/ Class ‘A’ 10M Stack (W/ SBR) D-12
17.4 Running 7” Liner W/ Class ‘A’ 10M Stack (W/ SBR) D-12
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17.5 Running 4-1/2” Liner W/ Class ‘A’ 10M Stack D-12
17.6 Running 4-1/2” Pre-Perforated Liner W/ Class ‘A’ 10M Stack D-12
18.0 Changing Rams or Installing Casing Rams

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18.1 Isolation Policy D-12

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18.2 Pressure Testing Casing Rams D-13
19.0 Installing Casing Slips With Multi Stage Cementing D-13
20.0 BOP Configuration when Running Production Tubing

20.1 Running 5-1/2” or 5-1/2”x 4-1/2” With Class ‘A’ 10M and Higher Stack D-13
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20.2 Running 4-1/2” Tubing With Class ‘A’ 10M and Higher Stack D-14
20.2 Running Dual Strings Simultaneously With Class ‘A’ 5M Stack D-14
21.0 BOP Configuration when Running Production Tubing with Packer

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21.1 Running Tubing/Packer Simultaneously w/ Class ‘A’ 3 or 5M Stack D-14
22.0 Removing BOP Stack or Production Tree

22.1 Isolation Policy for Low GOR Oil Wells D-15
22.2 Isolation Policy for High GOR Oil Wells D-15

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22.3 Isolation Policy for Gas Wells D-15
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22.4 Isolation Policy for WIW Wells D-15
23.0 Rigging Down on High GOR Wells W/ SSSV

23.1 RD Procedure (w/ Little Clearance between Rig and Tree) D-15
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24.0 Platform Well Security Prior to Workover Operations
24.1 Required Number of Mechanical Barriers of Isolation D-16
25.0 Running or Pulling Tubing and ESP Cable

25.1 BOP Configuration D-16
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25.2 Pressure Testing Annulars D-16
25.3 Shut-In Procedure D-16

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26.0 BOP Configuration When Running Test String
26.1 Running 3-1/2” Test String w/ Class ‘A’ 10M Stack (W/ SBR) D-17
26.2 Running 3-1/2” Test String w/ Class ‘A’ 5M Stack D-17

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27.0 Rigging Up Surface Well Test Equipment
27.1 Installing Surface Lines Upstream of Test Manifold D-17
27.2 Installing Surface Lines Downstream of Test Manifold D-17

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28.0 Pressure Testing with Nitrogen

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28.1 Surface Well Test Equipment (Gas Wells) D-17
28.2 Lubricator (Gas Wells) D-18
29.0 Problems While Logging

29.1 Shutting in While Logging With Side Entry Sub (Wireline across BOP) D-18
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29.2 Fishing Procedure for Stuck Logging Tool in Open Hole D-18
30.0 Running PDHMS and/or Smartwell Lines on Tubing or Casing

30.1 Oil Wells D-19
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30.2 Gas Wells D-19

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1.0 WELL CONTROL POLICIES
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This Chapter of the Well Control Manual sets forth the well control policies and specifications that are
routinely referenced. These policies (as well as the equipment standards and procedures throughout this
well control manual) are considered mandatory.. Variations or deviations from these requirements requires
endorsement of the Well Control Committee, and approval by the Vice President of Drilling and Workover.
The enforcement of these requirements shall be the responsibility of the Saudi Aramco Drilling Foreman (or
Liaisonman) as directed by the Drilling Superintendent.
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2.0 WELL CONTROL CERTIFICATION
POLICY All Saudi Aramco Rig Foremen, Liaisonmen, Liaisionmen Consultants Contract
Toolpushers, Drillers, and Assistant Drillers shall have current Supervisor Level
Well Control Certification (Well Cap) from an IADC accredited school.
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NOTE: IWCF Certification is not acceptable for Saudi Aramco D&WO
Operations.
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3.0 USE OF DIVERTERS
3.1 NIPPLING UP DIVERTERS ONSHORE
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POLICY A Class ‘D’ diverter stack shall be installed on the conductor and/or next casing
string for all exploration wells and development wells in the shallow gas area or
areas where offset data indicates shallow gas wells.
All other onshore areas do not need a diverter.

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3.2 NIPPLING UP DIVERTERS OFFSHORE

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POLICY A class ‘D’ diverter stack shall be installed on the conductor of all offshore
exploration wells and wells where offset data indicates possible shallow gas.
The diverter lines must have the capability of discharging below the bottom of
the hull due to H2S.
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4.0 LEAK IN FLANGE OR RING GASKET BETWEEN BOP STACK AND

CASING HEAD (WHILE TESTING BOP STACK)
If a leak is observed in a flange during a BOP test the bolts on the flange should first be tightened to
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recommended torque. If tightening the bolts does not cure the leak the following policies should be
followed.
POLICY FOR LEAK IN 9-5/8” CASING HEAD
1) Set RBP 100’ above casing shoe (gas wells only)

2) Set RTTS/STORM VALVE AT + 200’ (With + 3000’ OF KILL STRING)

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3) Remove BOP stack and repair leak
4) Re-install BOP stack and pressure test
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5) Retrieve RTTS/Storm Valve
6) Retrieve RBP (gas wells only)
POLICY FOR LEAK IN 11” CASING HEAD
1) Set BP 100’ above casing shoe (gas wells only)

2) Set RTTS/Storm Valve at + 200’ (With + 3000’ of kill string)
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6) Drill out BP (gas wells only)
1)
2)
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Set BP 100’ above casing shoe (gas wells only)
Set RTTS/Storm Valve At + 200’ (With + 3000’ of kill string)
3)
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6) Drill out BP (gas wells only)

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1) RIH and set cement plug at 500 – 200’. POH
2) Verify TOC
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5) Drill out cement plug

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1) RIH and set cement plug at 500 – 200’. POH

2) Verify TOC
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5) Drill out cement plug
5.0 DRILL PIPE FLOAT

POLICY A drill pipe float shall be run at all times (except when planned operations preclude running a
float; as testing, treating, or squeezing).
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A ported float is not recommended as these ports can be easily plugged and sometimes
washout.

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6.0 ENCOUNTERING LOSS CIRCULATION
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POLICY If loss circulation is anticipated in a potential hydrocarbon-bearing zone, run large jet nozzles
and BHA without mud motor (if possible).
If loss circulation is encountered, attempt to regain with (2) LCM pills and/or cement plugs
For ARAB-D open-hole producers use acid soluble LCM and no cement plugs (unless
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specifically required)
If unable to regain circulation, continue drilling with mud cap to next casing point
NOTE: The only exception to this policy is experiencing complete loss circulation in the
Arab-D rsvr on a Khuff/Pre-Khuff [K2] well, where circulation must be regained
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before continuing drilling to the Jilh dolomite casing point.
7.0 MAINTAINING MINIMUM OVERBALANCE

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7.1 General Requirements For Overbalance For Drilling & Workover Applications
POLICY A minimum overbalance shall be maintained on all wells as indicated below:
•
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100 PSI overbalance on Water Reservoirs
• 200 PSI overbalance on Oil Wells
• 300 PSI overbalance on Gas Wells
NOTE: Water flows, as in Arab-C, may be drilled with flow if hydrocarbons, H2S, or high
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rates are not encountered.

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7.2 Drilling The Arab-C Reservoir With Water
POLICY Drill Arab-C reservoir with water, if well kicks, shut-in and circulate bottoms-up through
choke using the ‘driller’s’ method.
• If hydrocarbon influx, H2S, or ‘high rate’ saltwater flow, kill well and continue drilling with
mud
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• If ‘low rate’ saltwater flow, continue drilling with the well flowing to casing point and mud
up prior to running casing
7.3 Reducing Mud Weight Less Than Pore Pressure Equivalent When Attempting To Free
Differentially Stuck Pipe
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POLICY Never reduce mud weight less than pore pressure when attempting to free differentially
stuck pipe.
NOTE: Avoid pumping diesel to free stuck pipe in a gas zone as gas solubility in diesel can
mask a kick influx.

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8.0 ISOLATING KHUFF RESERVOIR
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Setting Casing At The Top Of The Khuff Formation
POLICY Set casing at top of Khuff formation only on critical wells with:
• Abnormal Lower Jilh pressure

• High differential pressure between lower Jilh and Khuff reservoirs
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• Highly deviated well profile
• Proximity to facilities or populated areas
9.0 TAPERED STRING

POLICY When working with a tapered drill string always be in a position to have at least one stand of
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either size pipe available to pick up.
10.0 SPACE OUT

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10.1 SPACE OUT DATA
POLICY Space out data shall be clearly visible in the dog house and recorded in the IADC tour book
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each time the rig performs a bop drill.
10.2 SPACE OUT FOR BOP’s WITH SBR’s
POLICY When spacing out in BOP Stacks with SBR’s a tool joint shall be positioned 2–3 feet
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above the lower (Master) pipe rams. In the event that pipe is to be sheared, the following
steps will be taken:
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1) Close lower master rams

2) Lower the tool joint lowered to land out in rams
3) Slack off so that the pipe is relaxed (not in tension)
4) Activate the SBR’s using proper procedures
NOTE: This procedure will negate the recoil effects of shearing free, suspended pipe
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allowing pipe to drop and prevent stored energy in drill string releasing suddenly
causing a recoil and possible damage to top drive main shafts and lodging pipe
across BOP stack.
11.0 SLOW PUMP RATE DATA

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POLICY Slow pump rate shall be recorded in the IADC tour book
1) Tourly
2) After a mud weight change
3) After a bit nozzle or BHA change
4) After each 500’ of depth

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5) After a drilling or completion fluid type change
6) Whenever mud properties significantly change
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NOTE: All flow checks shall be at least 15 minutes.
12.0 TRIPPING PIPE

12.1 Pulling Out Of Hole
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POLICY The following procedure is required when POH
1) Ensure a full opening safety valve, inside BOP, closing wrench, and crossover subs are
on rig floor
2) Record data on trip sheet every 5 stands for DP, 2 stands for HWDP, and every stand
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for DC
3) Compare data to expected displacement values
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NOTE: Avoid pulling a wet string whenever possible.
12.2 RUNNING IN HOLE
POLICY The following procedure is required when RIH

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1) Ensure full opening safety valve, inside bop, closing wrench, and crossover subs are
on rig floor
2) Run in hole approximately one minute per stand
3) Record data on trip sheet every 5 stands for DP, 2 stands for HWDP, and every stand
for DC
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4) Compare data to expected displacement values

5) Fill drill pipe every 10 to 20 stands
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NOTE: Use the trip tank when running casing.
13.0 PERFORMING FLOW CHECKS

13.1 PERFORMING FLOW CHECKS WHILE DRILLING
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POLICY A FLOW CHECK SHALL BE PERFORMED WHENEVER
1) Decrease in pump pressure

2) Increase in pump strokes
3) Decrease in mud weight
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4) Increase in chlorides
5) Gradual increase in drill rate
6) Drilling break

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13.2 PERFORMING FLOW CHECKS WHILE TRIPPING
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POLICY A FLOW CHECK SHALL BE PERFORMED WHENEVER
1) When the hole is not taking the correct amount of fluid

2) Before pumping a slug
3)* Before pulling out of the hole
4)* After pulling 5 to 10 stands
5) When bit enters casing shoe
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6)* Prior to pulling last 5 stands
7) Prior to pulling the BHA
* Indicates additional flow checks required when a hydrocarbon zone is open.
14.0 DISPLACING TO BRINE ON HORIZONTAL WELLS
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POLICY The following SHALL BE required
1) A brine density that will provide the same overbalance (at bottom hole temperature) as
mud weight utilized
2) Measurement of brine density in/out to verify that both are the same at same
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temperature
3) A minimum of one hour to wait/observe well after displacing to brine
4) Pumping out of the hole for minimized swabbing, continued fill-up, and improved gas
displacement in the horizontal open hole
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15.0 SHUTTING IN WELL

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15.1 Shutting In Well Without A Flow Check
POLICY Immediate action should be taken to shut in well whenever there is:
1) An increase in pit gain

2) An increase in flow rate
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15.2 Shutting In Well While Drilling
POLICY Shut-in procedure (HARD SHUT–IN)
1) Space OUT (SPOT TOOL JOINT)

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2) Stop mud pumps

3) Close annular or upper ram preventer
4) Confirm well is shut in and flow has stopped
5) Open HCR

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15.3 Shutting In Well While Tripping
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POLICY Shut-in procedure (HARD SHUT–IN)
1) Stab full open safety valve

2) Close safety valve
3) Space out (spot tool joint)
4) Close annular or upper ram preventer
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6) Open HCR
NOTE: DO NOT attempt to run in hole with the well flowing.
15.4 Shutting In Well With BHA Across Bop Stack
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POLICY SHUT-IN PROCEDURE (hard shut–in)
1) Set slips
2)
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3) Stab full open safety valve
4) Close safety valve
5) Close annular
7) Open HCR
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8) Install inside BOP
9) Open safety valve
10) Reduce closing pressure on annular and strip-in a stand of drill pipe
NOTE: In the event of a failure in the annular (with BHA across bop stack) and
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uncontrolled flow, the BHA should be dropped and well shut in with the blind rams.
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15.5 Shutting In On Pre-Perforated Liner with Drill Pipe
POLICY SHUT-IN PROCEDURE:

1) Set casing slips
2) Install XO's to DP
3) Make up a stand of DP and RIH
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4) Stab full open safety valve and close valve

5) Install inside bop and open safety valve
6) Shut upper pipe rams
7) Open HCR
NOTE: If this procedure can not be accomplished due to the amount of flow (or inner
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string), the liner shall be dropped (by closing pipe rams, hanging off, and opening
pipe ram) and shutting the blind rams.
Current Revision: May, 2010 D - 10 Rev. D-10/4.0

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16.0 FAILURE OF UPPER PIPE RAMS DURING A WELL KILL
OPERATION
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POLICY RECOMMENDED ACTION TO INCLUDE
1) Close master pipe rams

2) Repair upper pipe rams
3) Close upper pipe rams
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4) Equalize pressure between upper and lower pipe rams
5) Open master pipe rams
6) Continue with well kill
17.0 BOP CONFIGURATION WHEN RUNNING CASING OR LINERS
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17.1 RUNNING CASING OR LINER WITH CLASS ‘B’ 3000 PSI BOP STACK
POLICY BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING

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ANNULAR: USED AS CASING RAMS
TOP RAM: BLIND RAMS
MASTER PIPE: DRILL PIPE RAMS
HAVE XO (CASING X DP) ON DRILL FLOOR.

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17.2 RUNNING CASING WITH CLASS ‘A’ 3,000 OR 5,000 PSI BOP STACK (WITH OR WITHOUT
SBR)
POLICY FOR SHORT LINERS (< 2000’)

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BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING

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TOP RAM: PIPE RAMS
MIDDLE RAM: BLIND RAMS (OR SHEAR BLIND RAMS)
MASTER PIPE: PIPE RAMS

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POLICY FOR LONG LINERS (>2000’) LONG STRINGS
BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING

ANNULAR:
TOP RAM: CHANGE PIPE RAMS TO CASING RAMS
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MASTER PIPE: PIPE RAMS

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17.3 RUNNING CASING WITH CLASS ‘A’ 10,000 PSI (and Higher) BOP STACK (with SBR)
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ANNULAR:
TOP RAM: CHANGE PIPE RAMS TO CASING RAMS
MIDDLE RAM: SHEAR BLIND RAMS
TOP MASTER: BLIND RAMS
BTM MASTER: PIPE RAMS
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HAVE XO (CASING X DP) ON DRILL FLOOR
17.4 RUNNING 7” LINER WITH CLASS ‘A’ 10,000 PSI (and Higher) BOP STACK (with SBR)

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TOP RAM: PIPE RAMS
TOP MASTER: BLIND RAMS
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BTM MASTER: PIPE RAMS
17.5 RUNNING LINER WITH DP, 10,000 (and Higher) PSI CLASS ‘A’ STACK (with SBR)
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ANNULAR : USED AS CASING RAMS
TOP RAM: LARGE DP PIPE RAMS
TOP MASTER: SMALL DP PIPE RAMS
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BTM MASTER: LARGE DP PIPE RAMS

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HAVE XO’S (LINER TO DRILL PIPE) ON DRILL FLOOR.
17.6 RUNNING PRE-PERFORATED LINER WITH 10,000 PSI (and Higher) CLASS ‘A’ BOP STACK

ANNULAR:
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TOP RAM: LARGE DP PIPE RAMS

TOP MASTER: SMALL DP PIPE RAMS
BTM MASTER: LARGE DP PIPE RAMS
HAVE XO’S (LINER x DP) ON DRILL FLOOR.

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18.0 CHANGING RAMS OR INSTALLING CASING or TUBING RAMS
18.1 ISOLATION POLICY WHEN CHANGING RAMS OR INSTALLING CASING OR TUBING RAMS
POLICY REQUIRES 2 BARRIERS FOR ISOLATION

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1) Closed pipe or blind ram (mechanical shut-off)
2) Kill fluid (non-mechanical shut-off)
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Monitor annulus using wellhead valves.
If the bottom master ram is to be changed and the well is open to the formation, a packer
and storm valve with kill string is required for a mechanical barrier.
NOTE: Refer to GI 1853.001
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NOTE: A test plug or tubing hanger with installed BPV should not be used as a
mechanical barrier in this application.
18.2 PRESSURE TESTING CASING AND TUBING RAMS
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POLICY Casing and Tubing Rams (and annular PREVENTOR) shall be pressure tested with a test
plug and casing joint to 80% of the pipe collapse or the rated working pressure of the BOP
(whichever is less).
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19.0 INSTALLING CASING SLIPS WITH MULTI STAGE CEMENTING
POLICY SET CASING SLIPS AS FOLLOWS
1) Displace 1st stage cement w/ mud ( 2nd, if 3 stage job)
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2) Open upper most DV
3) Circulate hole clean w/ mud
4) WOC 4 hrs with well static (observing well for flow)
5) Break circulation every Hour to prevent cement from setting up across ports (if packer
failure and Expansion)
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6) Circulate bottoms up
7) Pickup BOP stack (DO NOT DROP CASING SLIPS)
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8) Set casing slips prior to cementing final stage
NOTE: Consider pumping second stage cement before setting slips, if the packer fails and
loss circulation is experienced (especially with a hydrocarbon or H2S zone open).
this situation should be referred to operations management on a case by case
basis.
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20.0 BOP CONFIGURATION WHEN RUNNING PRODUCTION TUBING

20.1 RUNNING 5-1/2” PRODUCTION TUBING (OR 5-1/2” x 4-1/2” TUBING) AND CLASS ‘A’ 10,000
AND HIGHER PSI BOP STACK
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POLICY BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING:

ANNULAR:
TOP RAM: 5-1/2” PIPE RAMS
TOP MASTER: 5-1/2” PIPE RAMS
BTM MASTER: 5-1/2” PIPE RAMS

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HAVE XO (5-1/2” x 4-1/2” TBG) ON DRILL FLOOR.
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20.2 RUNNING 4-1/2” PRODUCTION TUBING CLASS ‘A’ 10,000 AND HIGHER PSI BOP STACK

ANNULAR:
TOP RAM: 5-1/2” PIPE RAMS
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BTM MASTER: 5-1/2” PIPE RAMS
HAVE XO (5-1/2” DP x 4-1/2” TBG) ON DRILL FLOOR.
20.3 RUNNING DUAL STRINGS SIMULTANEOUSLY WITH CLASS ‘A’ 5,000 PSI BOP STACK
POLICY
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BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING:
ANNULAR:
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TOP RAM: DUAL RAMS
MASTER PIPE: DUAL RAMS
21.0 BOP CONFIGURATION WHEN RUNNING PRODUCTION TUBING

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AND PACKER
21.1 RUNNING PRODUCTION TUBING AND PACKER SIMULTANEOUSLY WITH CLASS ‘A’ 3,000
OR 5,000 PSI BOP STACK
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ANNULAR:
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TOP RAM: **TUBING RAMS

MASTER PIPE: *DRILL PIPE RAMS
* Do NOT change the master pipe rams to tubing rams (they should remain drill pipe
rams) this will eliminate the need for running a RBP and/or RTTS and storm valve.
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** If a tapered string is to be run, the upper pipe rams shall be changed to the size of the
major section of tubing in the string.
Have XO’s (tbg x DP) and (large tbg x small tbg, for tapered strings) on the drill floor.
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NOTE: In case of loss circulation, the hole shall be continuously filled (both tubing and
backside) while running the completion string.

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22.0 REMOVING BOP STACK OR PRODUCTION TREE
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22.1 ISOLATION POLICY FOR LOW GOR OIL WELLS
POLICY REQUIRED BARRIERS FOR OIL WELLS (GOR < 850 SCF/BBL)
2 SHUT-OFFS (ONE MECHANICAL)
FOR DETAILS REFER TO G.I. 1853.001
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22.2 ISOLATION POLICY FOR HIGH GOR OIL WELLS
POLICY REQUIRED BARRIERS FOR OIL WELLS (GOR > 850 SCF/BBL)
3 SHUT-OFFS (TWO MECHANICAL)
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22.3 ISOLATION POLICY FOR GAS WELLS
POLICY REQUIRED BARRIERS FOR GAS WELLS

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3 SHUT-OFFS (TWO MECHANICAL)
22.4 ISOLATION POLICY FOR WATER INJECTION WELLS
POLICY REQUIRED BARRIERS FOR WIW WELLS (IF POSITIVE WHP)

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2 SHUT-OFFS (ONE MECHANICAL)
POLICY REQUIRED BARRIERS FOR WIW WELLS (IF NOT POSITIVE WHP)
1 SHUT-OFF
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23.0 RIGGING DOWN ON HIGH GOR WELLS WITH SSSV

23.1 RIG DOWN PROCEDURE (WITH LITTLE CLEARANCE BETWEEN RIG AND TREE)
POLICY PROCEDURE
1) NU and PT tree
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2) Retrieve wireline plug from tail pipe

3) Close crown valve (do not RD wireline unit)
4) Open well for clean-up
5) Close lower master valve (observe negative test)
6) RIH with wireline and set plug
7) Bleed off pressure (observe plug is holding) - barrier 1
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8) Close SSSV - barrier 2

9) Split tree above closed lower master valve - barrier 3
10) Move the rig out
11) Re-install tree above the lower master valve
12) Later, RU wireline unit and retrieve the plug
NOTE: A BPV may be installed instead of setting a wireline plug.

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24.0 PLATFORM WELL SECURITY REQUIREMENTS PRIOR TO
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WORKOVER OPERATIONS
24.1 REQUIRED NUMBER OF MECHANICAL BARRIERS OF ISOLATION
POLICY All wells on the same platform shall be shut-in prior to workover operations using two (2)
mechanical methods of isolation,
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BELOW SURFACE
CLOSED AND TESTED SURFACE CONTROLLED SUB-SURFACE SAFETY VALVE
AT SURFACE
CLOSED MASTER VALVE
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Prior to moving in a workover rig, field services will close the sub-surface safety valves on all
wells and de-pressurize the platform. if a sub-surface safety valve is found leaking, well
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services will replace the valve.
25.0 RUNNING OR PULLING TUBING AND ESP CABLE WITH

WORKOVER RIG
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25.1 BOP CONFIGURATION WHEN RUNNING OR PULLING TUBING AND ESP CABLE

ANNULAR:
ANNULAR:
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BOP STACK: BASED ON BOP CLASS

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NOTE: One annular may be used if there is 0 psi SIWHP whenever the ESP is not running
25.2 PRESSURE TESTING ANNULARS
POLICY PRESSURE TEST ANNULARS TO 1,000 PSI (WITH ESP CABLE).

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NOTE: Testing performed in the shop has shown that an annular can hold 1,000 psi with
3-1/2” tubing and 1” cable. However, it is normal to have small leaks when
annulars are closed on cables. The annular in these instances is to slow the kick
only while performing the procedure in section 25.3.
25.3 SHUT-IN PROCEDURE WHEN RUNNING OR PULLING TUBING AND ESP CABLE
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POLICY SHUT-IN PROCEDURE

1) Shut-in well with annular (upper) using Saudi Aramco shut-in procedure for tripping.
2) Cut ESP cable with mechanical cutter at the rig floor (a wire line mechanical cutter must
be on the floor)
3) Open annular and lower tubing
4) Close annular (upper) around tubing

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26.0 BOP CONFIGURATION WHEN RUNNING TEST STRING
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26.1 RUNNING 3-1/2” TEST STRING WITH TEST HEAD AND CLASS ‘A’ 10,000 PSI BOP STACK
(WITH SBR)

ANNULAR:
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TOP RAM: 5” PIPE RAMS (FOR STIFF JOINT)
BTM MASTER: 5” PIPE RAMS
CHANGE TOP 5” PIPE RAM TO 3-1/2” PRIOR TO POH WITH TEST STRING
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HAVE XO (3-1/2” PH6 x 3-1/2” DP) ON DRILL FLOOR.
26.2
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RUNNING 3-1/2” TEST STRING WITH TEST HEAD AND CLASS ‘A’ 5,000 PSI BOP STACK

ANNULAR:
TOP RAM: 5” PIPE RAMS (FOR STIFF JOINT)
MIDDLE RAM: BLIND RAMS
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MASTER RAM: 3-1/2” PIPE RAMS
HAVE XO (3-1/2” DP x 5” DP) ON DRILL FLOOR.
27.0 RIGGING UP SURFACE WELL TEST EQUIPMENT

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27.1 INSTALLING SURFACE LINES UPSTREAM OF TEST MANIFOLD
POLICY Only connections with metal-to-metal seals are acceptable (API flanged, hubbed, or
Grayloc).
NOTE: Weco connections are not allowed (leaks in the lip seal can occur with gas,
CO2, and HT/HP situations).
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27.2 INSTALLING SURFACE LINES DOWNSTREAM OF TEST MANIFOLD
POLICY Weco Figure 1502 or Grayloc connections are acceptable
NOTE: 2 inch Figure 602 hammer unions are not allowed on any Saudi Aramco Drilling
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and Workover Operations.
28.0 PRESSURE TESTING WITH NITROGEN

28.1 SURFACE WELL TEST EQUIPMENT - GAS WELLS

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POLICY Test procedure on gas wells (with 10M WP surface equipment)
1) Pressure test string to 8,500 psi
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2) Negative test surface safety valve (if run) and lower master valve
3) Pressure test downstream of choke manifold to 1,200 psi with water
4) Pressure test upstream of choke manifold to 10,000 psi with water
5) Pressure test downstream of choke manifold to 1,200 psi with nitrogen
6) Pressure test upstream of choke manifold to 8,000 psi (80% of water pressure test)
with nitrogen
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28.2 LUBRICATORS - GAS WELLS
POLICY If a lubricator is required on a gas well (for well testing, completion, or workover operations),
the lubricator shall also be tested with nitrogen to 80% of water pressure test.
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29.0 PROBLEMS WHILE LOGGING
29.1 SHUTTING IN WHILE LOGGING WITH SIDE-ENTRY SUB (WIRELINE ACROSS BOP STACK)
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POLICY SHUT-IN PROCEDURE
1) Close annular around drill pipe and wireline to restrict flow
2) Install wireline clamp to drill pipe
3) Cut wireline (above clamp) at rotary table with manual cutter
4) Open annular and lower DP until wireline is below bop stack
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5) Close annular or uppermost ram as per approved shut-in procedure
29.2 FISHING PROCEDURE FOR STUCK LOGGING TOOL IN OPEN HOLE
POLICY STUCK NON-RADIOACTIVE TOOL

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1) Pull off electric line at rope socket

2) POH with electric line
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3) RIH and engage tool w/ overshot on drill string
STUCK RADIOACTIVE TOOL

1) Cut and strip over electric line w/ drill string
2) Engage tool with overshot
3) Pull off electric line at rope socket
4) POH with electric line
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NOTE: May consider stripping over the electric line on a non-radioactive tool if:
A) Hole conditions are poor

B) Large hole size compared to tool OD
C) Open hole section is not known to contain hydrocarbons
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Logging companies have a ‘circulating sub’ that can be made up on the drill string
(in the event of a well control situation) to hang off the electric line and enable
circulation; however, this may be difficult to install with a strong flow up the drill
pipe.

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30.0 RUNNING PDHMS AND/OR SMARTWELL LINES ON TUBING OR
CASING
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Pipe rams will not close and seal around lines and flat packs. The only way wells with these lines
installed on the OD of the tubing can be controlled is to close the annular (does not provide a full seal),
cut the line and then strip the pipe into the well until the pipe rams can be closed above the line or to
shear the tubing and the line. 30.1 and 30.2 (below) outlines the requirements
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30.1 OIL WELLS
1) The use Shear Blind Rams on ALL smart well and PDHMS completions is required
when deep set control lines or flat packs are utilized. SSSV’s set at 500 feet or above
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are acceptable.
NOTE: The Shear Blind Rams must be capable of shearing the tubing string being run
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2) Run multiple flat-packs with at least 2 inches of space between them.
NOTE: This may require a redesign of the cable clamps.

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3) It is preferred, but not required, to use two (2) annulars on smart wells and PDHMS that
have more than one line on the O.D. of the tubing. Provided that extra annulars are
available.
4) Break in new annular packers by closing and opening ten (10) times before running the
completion
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NOTE: Annular preventers do not necessarily provide a positive seal in this application.
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They should be used while the lines are cut and the pipe is stripped into the well
deep enough to close the pipe ram above the lines.
5) Use a closing pressure of at least 2,000 psi on the annular.
30.2 GAS WELLS

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1) The use Shear Blind Rams on ALL smart well and PDHMS completions is required
when deep set control lines or flat packs are utilized. SSSV’s set at 1,000 feet or above
are acceptable.
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NOTE: The Shear Blind Rams must be capable of shearing the tubing string being run
with the lines on the OD.
2) Run multiple flat-packs with at least 2 inches of space between them.
NOTE: This may require a redesign of the cable clamps.

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3) It is preferred, but not required, to use two (2) annulars on smart wells and PDHMS that
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have more than one line on the O.D. of the tubing. Provided that extra annulars are
available.
4) Break in new annular packers by closing and opening ten (10) times before running the
completion
NOTE: Annular preventers do not necessarily provide a positive seal in this application.
They should be used while the lines are cut and the pipe is stripped into the well
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deep enough to close the pipe ram above the lines.
5) Use a closing pressure of at least 2,000 psi on the annular.
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CHAPTER E - WELL CONTROL DRILLS
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CHAPTER E: WELL CONTROL DRILLS
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TABLE OF CONTENTS
1.0 Pit Drills

1.1 Equipment E-2
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1.2 Frequency E -2
1.3 Procedure E -3
2.0 Trip Drills

2.1 Frequency E -4
2.2 Procedure
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3.0 Accumulator Drill
3.1 Procedure E -5
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Current Revision: May, 2010 E-1 Rev. E-1/4.0

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INTRODUCTION
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Shutting-in the well quickly to minimize the size of the influx is a major element of successful well
control. Drilling crews can only get proficient in this action through training and practice. The Drilling
Foreman should ensure that the Contract Toolpusher administers training in the areas of kick
detection and shut-in procedures until proficiency is demonstrated. The training must be repetitive
and frequent enough so that shutting-in the well becomes automatic whenever a kick is detected.
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The Drilling Foreman can judge the level of crew shut-in proficiency through the use of pit drills and
trip drills. These drills should always be coordinated with the contract toolpusher. Proper drills and
training can prevent panic and provide for orderly operation if a kick should occur. The following
discussions describe how to conduct the drills and provide a basis for crew evaluation.
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1.0 Pit Drills
The pit drill is designed to simulate an actual kick while drilling ahead and is designed as
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both a teaching and a testing tool. While drilling ahead, it teaches the drilling crews to be
alert for positive indicators of a kick and provides practice in the proper Saudi Aramco shut-
in procedures. It also defines and reinforces the assigned duties of every member of the
drilling crew in well control situations. Pit drills are conducted unannounced so that realism
is created and so the crews can be observed under actual operating conditions.
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Pit drills train the Driller to be constantly aware of the fluid level in the mud pits and the
return mud flow, much as the driver of an automobile subconsciously checks his
speedometer. This training is expected to prepare the driller to detect a kick at the first
surface indication and with a minimum of reservoir fluid influx. He will then be able to take
correct preventive action, lessening chances of disaster. Pit drills should be supervised by
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the Contract Toolpusher and coordinated through the Drilling Foreman.

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1.1 Equipment
All equipment required for pit drills is to be installed prior to drilling and kept in good
operating condition. A multi-float pit level indicator and flow show device must be available.
A pre-arranged horn or siren signal is an essential part of the pit drill. At the signal, each
crewmember must go immediately to his assigned post and execute his assigned duties.
The Drilling Foreman should note the times required (in minutes) for various aspects of the
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pit drills and record them on the tour report. The number and times for these drills should
be relayed to the office.
1.2 Frequency
One or more pit drills should be conducted each day until the crews become proficient;
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then at least twice weekly per crew, or more often if deemed advisable by the Drilling
Foreman. Pit drills should be held at least one each day on offshore wells, wildcats, and
wells where above-normal bottomhole pressure could exist. New drillers should be given
special drills and thorough explanation of this practice. It is one of the most important
safety measures that can be initiated and followed.

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Drills are to be conducted during both routine and special operations. Typical times would
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be while drilling, shut down for equipment repairs, logging, waiting on orders, circulating,
the Driller has gone to eat and is replaced by one of his men, the Driller is talking to
someone, or any other time there is open hole and blowout preventers installed.
1.3 Procedure
1) The Toolpusher simulates the kick by raising a float in the mud pits or by raising the
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arm on the flow show indicator and making a note of the time. The Drilling Foreman
should assist in observing the crew and recording completion times.
2) The Driller must detect the kick and sound the alarm. The time of the alarm should be
noted. Upon hearing the alarm, all members of the drilling crew should immediately
execute their assigned duties.
3)
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The Driller should prepare to shut in the well using the approved Saudi Aramco Shut-
in Procedure While Drilling. The Drilling Foreman should be on the rig floor to
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announce to the driller that the exercise is only a drill and to stop him before he
actually closes the blowout preventers. The time should be noted when the driller is
prepared to shut in the well.
4) Members of the drilling crew should report back to the rig floor having completed their
assigned duties. These duties may include:
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Driller
¾ Shut in the well (simulated)
¾ Record drillpipe pressure and casing pressure
¾ Record time
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¾ Measure pit gain

¾ Check choke manifold for valve positioning and leaks
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Derrickman
¾ Weigh sample of mud from suction pit
¾ Check volumes of barite, gel, and water on location
Floor Hand #1
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¾ Check accumulator pressures and pumps

¾ Check BOP stack for leaks and proper valve positions
¾ Turn on water jets to diesel exhausts
Floor Hand #2
¾ Assist Driller on rig floor
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Floor Hand #3
¾ Assist Derrickman on mud pits

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2.0 Trip Drills
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The trip drill is designed to train the drilling crews to recognize and respond to kick
indications, which occur while tripping pipe. Like the pit drill, the trip drill is useful for both
teaching and testing purposes. The pit drill also proves that essential detection equipment
is installed and in good operating condition.
The trip drill is supervised by the Contract Toolpusher with the knowledge of the Saudi
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Aramco Drilling Foreman. All parts of the well control system must be kept hooked up and
in good condition, ready for drills.
2.1 Frequency
When a new rig is picked-up, trip drills should be conducted during each trip (both while
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pulling out and going into the hole) while the bit is up in the casing. When the crew
becomes proficient, trip drills should be conducted at least twice weekly per crew,
conditions allowing.
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2.2 Procedure
1) The Toolpusher simulates the kick by raising a float in the mud pits and making a note
of the time. The Drilling Foreman should assist in observing the crew and recording
completion times.
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2) The Driller must detect the kick and sound the alarm. The time of the alarm should be
noted. Upon hearing the alarm, all members of the drilling crew should immediately
execute their assigned duties.
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3) The Driller should prepare to shut in the well using the approved Saudi Aramco Shut-
on
in Procedure While Tripping. This will include spacing out and stabbing/closing the full
open safety valve. After the safety valve is installed and the Driller is ready to close
the preventers, the Drilling Foreman should announce to the Driller that the exercise
is only a drill and that it is not necessary to close the preventers. The time should be
noted when the driller is prepared to shut-in the well.
4) Members of the drilling crew should proceed with their assigned duties and report
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back to the rig floor upon completion. These duties may include:
Driller
¾ Shut in the well (simulated)
¾ Record drillpipe and casing pressure
¾ Record time
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¾ Measure pit gain

¾ Check choke manifold for valve positioning and leaks
Derrickman
¾ Weigh sample of mud from suction pit
¾ Check volumes of barite, gel, and water

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Floor Hand #1
¾ Check accumulator pressures and pumps
¾ Check BOP stack for leaks
¾ Turn on water jets to diesel exhausts
Floor Hand #2
¾ Stab safety valve. Close safety valve
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¾ Stab inside BOP. Open safety valve
¾ Assist Driller on rig floor
Floor Hand #3
¾ Assist Derrickman on mud pits
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3.0 Accumulator Drill
Accumulator drills are designed to verify that the accumulator/closing system is in good
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working order and that it is properly sized for the particular blowout preventer stack.
Accumulator performance must be proven with an accumulator drill when the blowout
preventers are first installed (which verifies proper sizing), and every 14 days thereafter in
conjunction with the weekly BOP pressure tests (which checks for hydraulic leaks).
Results of the accumulator drill, including closing times of the rams and annular preventer,
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and initial final accumulator pressures are to be reported on the Blowout Preventer Test
and Equipment Checklist. A notation should also be made on the tour report that an
accumulator drill was conducted.
Accumulator drills must be conducted when the drill pipe is not in open hole, but up in the
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casing. At least one joint of drillpipe must be in the hole for the pipe rams to close on. The
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Saudi Aramco Drilling Foreman and Contract Toolpusher should witness all accumulator
drills, but the Toolpusher is responsible for the actual supervision of the drill. Use the
remote station to close the preventers every other drill.
3.1 Procedure
1) Turn off all accumulator-pressurizing pumps.

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2) Record the initial accumulator, manifold, and annular pressures.
3) Close all of the preventers (except the blind rams). Substitute a re-opening of a pipe
ram to simulate the blind ram closure when applicable. Open the HCR valve.
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4) Measure and record the closing times for each preventer with a stopwatch.
5) Record the final accumulator, manifold, and annular pressures.

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6) To pass the accumulator test, all BOPs must have closed in less than 30 seconds
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with at least:
¾ 1500 psi accumulator pressure remaining (for a 3000 psi accumulator)
Note: Equipment that does not meet these requirements either has insufficient
capacity, insufficient precharge or needs repair. Closing time for annular
preventers 20" and larger should not exceed 45 seconds.
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7) Observe the remaining pressure for at least 5 minutes to detect any possible am
piston seal leaks.
8) Tturn the accumulator pump(s) back on. Record the time required to charge system
back up (re-charge time).
9) Open BOP’s..
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PRESSURE TESTING BLOWOUT PREVENTERS & RELATED EQUIPMENT
RIG: WELL NUMBER: PREVIOUS TEST: THIS TEST:
WELL INFORMATION BLOWOUT PREVENTERS

HOLE LAST CASING STRING SET UNIT SIZE TYPE PRESSURE RATING
BURST SHOE
SIZE DEPTH SIZE WT GRADE RATING DEPTH ANNULAR PSI
PIPE RAMS PSI
TESTER DRILL PIPE DATA BLIND RAMS PSI
CUP PLUG NONE SIZE WT GRADE CONN PIPE RAMS PSI
PIPE RAMS PSI
MUD WEIGHT: PCF
ACCUMULATOR UNIT DATA NOTE: HYDRIL TO BE TESTED @ 70% RATED

WORKING PRESSURE WITH PIPE IN HOLE
SYSTEMS OPERATING USEABLE
CAPACITY PRESSURE VOLUME
GAL PSI GAL
TEST DETAILS
PRECHARGE PRESSURE DATE LAST CHECKED
PSI ACCUMULATOR CUT-IN CUT-OFF
PRESSURE PRESSURE
MANIFOLD PRESSURE AIR PUMPS PSI PSI
ELECTRIC PUMPS PSI PSI
ANNULAR MANIFOLD
PSI PSI
TEST OF AUXILIARY SYSTEMS AS PER SAUDI ARAMCO WELL CONTROL MANUAL

KILL LINE CHOKE LINE KELLY EMERGENCY KILL LINE
MANUAL HCR CHECK KILL MANUAL HCR CHOKE SWACO UPPER LOWER MANUAL HCR KILL
PSI VALVE VALVE VALVE LINE VALVE VALVE LINE LEFT RIGHT COCK COCK VALVE VALVE LINE
LOW
HIGH
TIME
LOW
HIGH
REMARKS:
DRILLER SIGNATURE TOOLPUSHER SIGNATURE COMPANY REPRESENTATIVE SIGNATURE
Revision Date: 10/20/02 Page 1 of 2

Form # 2.0
PRESSURE TESTING BLOWOUT PREVENTERS & RELATED EQUIPMENT
RIG: WELL NUMBER: PREVIOUS TEST: THIS TEST:
ALTERNATE BI-WEEKLY TESTS WITH

BOP TEST IN PSI AND TIME
CHARGING SYSTEM ISOLATED BOTTLE BANKS ISOLATED
TEST PRESSURE DURATION OF TEST

UNIT CLOSE OPEN CLOSE OPEN
LOW HIGH LOW HIGH
ANNULAR PSI PSI MIN MIN SEC SEC SEC SEC

PIPE RAMS PSI PSI MIN MIN SEC SEC SEC SEC
BLIND RAMS PSI PSI MIN MIN SEC SEC SEC SEC
ARE THE BELOW ITEMS ON THE RIG AND IN GOOD WORKING ORDER:
YES NO YES NO
ROTATING HEAD AND STRIPPER (PACK-OFF) ACCUMULATOR BOTTLE AND TEST GAUGE
STRIPPING VALVE (TIW) FILL ADAPTER FOR NITROGEN BOTTLE
DRILL PIPE BACK PRESSURE VALVE (INSIDE BOP) SPARE NITROGEN BOTTLES
X-OVER: DC x DP DRILL PIPE PRESSURE GAUGE
KELLY COCK WRENCH (S) ANNULAR PRESSURE GAUGE
ADJUSTABLE CHOKES STEM AND BONNETS DRILL PIPE FLOAT VALVE
MUD GAS SEPARATOR DE-GASSER
P.V.T. SET TO ALARM AT 10 BBLS ALL BOLTS, STUDS & NUTS INSTALLED
AND TIGHTEN PROPERLY
CHOKE MANIFOLD LINED UP FOR A HARD SHUT-IN ALL RING GASKETS ARE NEW
REMARKS:
Revision Date: 10/20/02 Page 2 of 2

Form # 2.0
DESCRIPTION OF BLOWOUT PREVENTERS AND INTERNAL COMPONENTS
RIG: WELL NUMBER:
BLOWOUT PREVENTERS
ANNULAR PREVENTER
SIZE WORKING PRESSURE MODEL MAKE SERIAL # ELEMENT PART #
RAM PREVENTERS
SIZE WORKING PRESSURE TYPE MAKE SERIAL # SINGLE/DOUBLE
PIPE
BLIND
PIPE
PIPE
INTERNAL COMPONENTS
UNIT RAM RAM RAM TOP BONNET/DOOR CONN. ROD DATE
SIZE BLOCK # PACKER # SEAL # SEAL # SEAL # INSTALLED
ANNULAR
PIPE RAMS
BLIND RAMS
PIPE RAMS
PIPE RAMS
REMARKS:
Form # 1.0 Date: 10/20/02

CAMERON INFORMATION SHEET 01-001
SUBJECT: Cameron High Temperature Shearing Blind Ram (SBR)

Blade and Side Packers for 11” and 13-5/8” Cameron U Type Blowout
Preventers
PURPOSE: To provide information on qualification test results and new

part numbers assigned to qualified blade and side packers
Qualification Requirement: API 16A 2nd Edition, Appendix C plus

additional pressure hold time at elevated temperatures
Test Conditions:
BOP used – Cameron 13-5/8”-10,000 psi U mounted on a special test stump with internal
heating system
Test Fluid – Synthetic hydrocarbon motor oil (to simulate a mineral oil based drilling mud)
Test Temperatures - 250°F, 300°F, and 350°F
Test Pressure – 10,000 psi
Test Durations – API 16A 2nd Edition, Appendix C – One hour pressure hold all test temperatures
- Cameron Requirement – An additional 8 hour pressure hold - 250°F
- An additional 3 hour pressure hold - 300°F and 350°F
Results – Standard Cameron Blade and Side Packers qualify to API 16A, 2nd Edition,
Appendix C high temperature verification test requirements and successfully
complete Cameron required additional 8 hour pressure hold test at 250°F .
- High Temperature Cameron Blade and Side Packers qualify to API 16A,
2nd Edition, Appendix C high temperature verification test requirements and
successfully completed Cameron required additional 3 hour pressure hold test at
300°F and 350°F .
U BOP Shearing Blind Ram U BOP H2S Shearing Blind Ram
CIS 01-001 / 5-24-01 REV / HT SBRs 11 & 13 1

SUBJECT: Cameron High Temperature Shearing Blind Ram (SBR)

Blade and Side Packers for 11” and 13-5/8” Cameron U Type Blowout
Preventers
Applicable Part Numbers

BOP Size - Pressure Rating Description Up to 250°F & 5% H2S Up to 350°F & 35% H2S
11’-10,000 psi Blade Packer 046910-04-00-01 644834-04-00-01

Side Packer 046751-04-00-01 2164284-04
Side Packer 046752-04-00-01 2164285-04
Top Seal 644217-01-00-01 644703-01-00-01
13-5/8”-10,000 psi Blade Packer 644435-01-00-01 644834-01-00-01

Side Packer 046751-01-00-02 645427-01
Side Packer 046752-01-00-02 645428-01
Top Seal 644223-01-00-01 644707-01-00-01
For additional information contact Cameron Elastomer Technology (CET), Katy Texas
or your local Cameron representative.
29501 Katy Freeway, Katy, Texas 77494 Tel: 281-391-4615 Fax: 281-391-4640
CIS 01-001 / 5-24-01 REV / HT SBRs 11 & 13 2

SUBJECT: Cameron Extended Range High Temperature VBR-II Packers

for Cameron 13-5/8” U Type Blowout Preventers
PURPOSE: To provide information on qualification test results and new

part numbers assigned to 250°F - 5000 psi Extended Range HT VBR-II
packers for the 13-5/8" Cameron U BOP.
Qualification Requirement: API 16A 2nd Edition, Appendix C plus

additional pressure hold time at elevated temperature.
Test Conditions:
BOP used – Cameron 13-5/8”-10,000 psi U BOP mounted on a special test stump with internal
heating system.
Test Fluid – Synthetic hydrocarbon oil (to simulate a mineral oil based drilling mud).
Test Temperatures - 250°F
Test Pressure – 5,000 psi
Test Durations – API 16A 2nd Edition, Appendix C – One hour pressure hold at 250°F
- Cameron-Saudi Aramco Requirement – An additional 7-hour pressure hold at 250°F
Results – Extended Range HT VBR-II Packers P/N 2164765-01 successfully completed:

1-API 16A, 2nd Edition, Appendix C high temperature verification test requirements
for one hour on both 5-7/8" and 3-1/2" pipe mandrels at 250°F and 5000 psi.
2-Cameron-Saudi Aramco requirement - an additional 7 hour pressure hold test on
both 5-7/8" and 3-1/2" pipe mandrels at 250°F and 5000 psi.
Total time at 250°F and 5000 psi, 16 hours.
3-API 16A fatigue test (546 closures and 78 pressure tests) at ambient temperature.
Ram Subassembly P/N 2164806-01

Top Seal P/N 2164807-01
Ram P/N 2164404-01 Extended Range HT VBR-II Packer P/N 2164765-01
250°F - 5000 psi Extended Range HT VBR-II Packer & Top Seal
CIS 02-001 / 6-11-02 / Ext Range HT VBR-II 1

SUBJECT: Cameron Extended Range High Temperature VBR-II Packers

for Cameron 13-5/8” U Type Blowout Preventers
Applicable Part Numbers

BOP Size Pressure Rating Description Part Number
13-5/8” 5,000 psi Ram subassembly 2164806-01

Ram 2164404-01
Ext. Range HT VBR-II Packer 2164765-01
HT/SS VBR Top Seal 2164807-01
Note: The Extended Range HT VBR-II packers and HT/SS top seals are molded using CAMLAST(tm)
elastomer, which provides H2S resistance up to 35%.
For additional information contact Cameron Elastomer Technology (CET), Katy Texas
or your local Cameron representative.
29501 Katy Freeway, Katy, Texas 77494 Tel: 281-391-4615 Fax: 281-391-4640
CIS 02-001 / 6-11-02 / Ext Range HT VBR-II 2

Spare Parts List for 11” 10M
Type “U” Large Bore Shear Bonnet and Shear Rams
High Temperature and H2S Service
Item Part Number Description Qty
BONNET ASSEMBLY: LARGE BORE SHEAR, RIGHT HAND, for
11" 10M WP TYPE 'U' BOP WITH TANDEM BOOSTER, MANUAL
1. 2164067-02 LOCKING SCREW AND BONNET BOLTS, API 16A, T-20, 1 EA
OPERATION TEMP RATING 'BF' (0-350 DEGREE SERVICE),
NACE, EST. NET WT. 2,620 LBS.
BONNET ASSEMBLY: LARGE BORE SHEAR, LEFT HAND, for
11" 10M WP TYPE 'U' BOP, WITH TANDEM BOOSTER, MANUAL
2. 2164067-01 LOCKING SCREW AND BONNET BOLTS, API 16A, T-20, 1 EA
OPERATION TEMP RATING 'BF' (0-350 DEGREE SERVICE),
NACE, EST. NET WT. 2,620 LBS.
BONNET BOLT: for LARGE BORE SHEAR RAM, 11" 10M WP
3. 041366-05 8 EA
TYPE 'U' BOP, MODEL II
BONNET REBUILD KIT: for LARGE BORE SHEAR RAM, 11"
4. 2164210-12 3M/5M/10M WP TYPE 'U' BOP (PARTS for ONE BONNET), 2 EA
350 DEGREE SERVICE
BONNET SEAL: 11" 3M/5M/10M WP TYPE 'U' BOP, API 16A,
5. 644573-02-00-01 2 EA
TEMP CLASS "BF" (0-350 DEGREE SERVICE)
SEAL, LIP: CONNECTING ROD; fOR 11" 5M/10M WP TYPE
6. 645077-38-00-01 'U' BOP, - 4.867" OD x 3.383" ID x 0.688" LG, API 2 EA
16A, TEMP CLASS "BF" (0-350 DEGREE SERVICE)
RAM ASSEMBLY: H2S SHEARING BLIND; UPPER, for 11"
7. 645011-01-00-01 5M/10M WP, TYPE 'U' BOP, API 16A, TEMP CLASS 'BF' 1 EA
(0-350 DEGREE SERVICE)
RAM ASSEMBLY: H2S SHEARING BLIND; LOWER, for 11"
8. 645011-02-00-01 5M/10M WP, TYPE 'U' BOP, API 16A, TEMP CLASS 'BF' 1 EA
(0-350 DEGREE SERVICE)
INSERT BLADE: UPPER, H2S SBR, for 11" 5M/10M WP
9. 645010-01-00-01 1 EA
TYPE 'U' BOP, API 16A
INSERT BLADE: LOWER, H2S SBR, for 11" 5M/10M WP
10. 645010-02-00-01 1 EA
TYPE 'U' BOP, API 16A
11. 644834-04-00-01 BLADE PACKER: SBR, for 11" 3M-15M WP TYPE 'U' BOP, 1 EA
API 16A, TEMP CLASS "BF" (0-350 DEGREE SERVICE)
SIDE PACKER: FOLDOVER SHEAR RAM, for 11" 3M-10M WP
12. 2164284-04 TYPE 'U' BOP, API 16A, TEMP CLASS "BF" (0-350 DEGREE 2 EA
SERVICE)
SIDE PACKER: FOLDOVER SHEAR RAM, for 11" 3M-10M WP
13. 2164285-04 TYPE 'U' BOP, API 16A, TEMP CLASS "BF" (0-350 DEGREE 2 EA
SERVICE)
14. 644703-01-00-01 TOP SEAL: for 11" SBR, 3M/5M/10M WP TYPE 'U' BOP, 2 EA
CAMRAM 350 (TM) HIGH TEMP, API 16A, TEMP CLASS "BF"
15. 644582-01 MODIFIED SET SCREW: for 11" 10M TYPE ‘U’ UPPER 2 EA
SHEARING BLIND RAM, .750-10 UN-2
16. 200231 PIN: SPIROL - .250 X 1.000 SST 18-8 2 EA
REPAIR KIT: TANDEM SHEAR BOOSTER, COMPOSITE STYLE OR
17. 2164148-03 ORIGINAL STYLE WITH ST/STL END CAP, for 11" 3/5/10M 1 EA
TYPE 'U' BOP (QUANTITY FOR ONE UNIT)
09/15/02
Spare Parts List for 13-5/8” 10M
Type “U” Large Bore Shear Bonnet and Shear Rams
BONNET ASSEMBLY: LARGE BORE SHEAR, RIGHT HAND, for
13-5/8" 10M WP TYPE 'U' BOP WITH TANDEM BOOSTER,
1. 2011803-01 MANUAL LOCKING SCREW AND BONNET BOLTS, PER API 16A, 1 EA
T-20, OPERATION TEMP RATING 'BF' (0-350 DEG SERVICE),
NACE, EST. NET WT. = 3,850 LBS.
BONNET ASSEMBLY: LARGE BORE SHEAR, LEFT HAND, for 13-
5/8" 10M WP TYPE 'U' BOP WITH TANDEM BOOSTER, MANUAL
2. 2011803-02 LOCKING SCREW AND BONNET BOLTS, PER API 16A, T-20, 1 EA
OPERATION TEMP RATING 'BF' (0-350 DEG SERVICE), NACE,
EST. NET WT. = 3,850 LBS.
BONNET BOLT: for LARGE BORE SHEAR Bonnets, 13-5/8"
3. 041366-12 8 EA
10M WP TYPE 'U' BOP, MODEL II
BONNET REBUILD KIT: for LARGE BORE SHEAR RAM,
4. 2164210-09 13-5/8" 3M/5M/10M WP TYPE 'U' BOP (parts for ONE 2 EA
BONNET), 350 DEG SERVICE
BONNET SEAL: for 13-5/8" 3M/5M/10M 'U' BOP, PER API
5. 644573-03-00-01 2 EA
16A, TEMP CLASS "BF" (0-350 DEG SERVICE)
SEAL, LIP: CONNECTING ROD; for 13-5/8" 3M-15M,
20-3/4" 3M, 21-1/4" 2M and 26-3/4 3M TYPE 'U' BOP,
6. 645077-36-00-01 2 EA
5.505" OD X 4.008" ID X 0.938" LG, PER API 16A, TEMP
CLASS "BF" (0-350 DEG SERVICE)
RAM ASSEMBLY: H2S SHEARING BLIND; UPPER, for 13-5/8"

7. 644781-03 1 EA
3M/5M/10M WP TYPE 'U' BOP, CAMRAM 350 (TM)
RAM ASSEMBLY: H2S SHEARING BLIND; LOWER, for 13-5/8"

8. 644781-04 1 EA
3M/5M/10M WP TYPE 'U' BOP, CAMRAM 350 (TM)
INSERT BLADE: UPPER, H2S SBR, for 13-5/8" 10M WP TYPE
9. 644581-01-00-01 1 EA
'U' AND 'T' BOP, PER QP-10005-01
10. 644581-02-00-01 INSERT BLADE: LOWER, H2S SBR, for 13-5/8" 10M WP TYPE 1 EA
'U' AND 'T' BOP, PER QP-10005-01
BLADE PACKER: SBR, for 13-5/8" 3M-15M WP TYPE 'U'

11. 644834-01-00-01 BOP, PER API 16A, TEMP CLASS "BF" (0-350 DEG SERVICE) 1 EA
SIDE PACKER: SBR, for 13-5/8" 3M-10M WP TYPE 'U' BOP,

12. 645427-01 2 EA
CAMRAM 350 (TM)
SIDE PACKER: SBR, for 13-5/8" 3M-10M WP TYPE 'U' BOP,
13. 645428-01 2 EA
CAMRAM 350 (TM)
TOP SEAL: for 13-5/8" SBR, 3M/5M/10M WP TYPE 'U' BOP,
14. 644707-01-00-01 2 EA
CAMRAM 350 (TM) HIGH TEMP, API 16A, TEMP CLASS "BF"
MODIFIED SET SCREW: for 13-5/8" 10M TYPE ‘U’ UPPER
15. 644582-01 2 EA
SHEARING BLIND RAM, .750-10 UN-2
16. 200231 PIN: SPIROL - .250 X 1.000 SST 18-8 2 EA
REPAIR KIT: TANDEM SHEAR BOOSTER, COMPOSITE STYLE OR
17. 2164148-02 ORIGINAL STYLE, 11" 15M AND 13-5/8" 3M-10M TYPE 'U' 1 EA
BOP (QUANITY for 1 UNIT)
09/15/02
Saudi Aramco 7180 (5/89)
G.I. NUMBER Approved
1850.001
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER OPERATIONS ORGANIZATION 01/20/2009 03/16/1999
SUBJECT: ONSHORE WELLSITE EMERGENCY APPROVAL PAGE NUMBER
RESPONSE OPERATIONS ROLES & ZAH 1 OF 13
RESPONSIBILITIES
CONTENT:
This General Instruction outlines the emergency response operations roles & responsibilities for any onshore
wellsite drilling or workover operations emergency, or when a Producing Organization has turned over
responsibility for well control operations to the Drilling & Workover Operations Organization. This document
specifically addresses the following Onshore Wellsite Emergency Response Operations Management Elements:
1. OBJECTIVE
2. IMPLEMENTATION
3. ORGANIZATION
4. WELL CONTROL
5. RESTORATION OR ABANDONMENT OPERATIONS
6. COST ACCOUNTING
7. SUPPORT SERVICES
8. DOCUMENTING AND CRITIQUE
9. DRILLS / TRAINING EXERCISES
APPENDIX I ROLES AND RESPONSIBILITIES
APPENDIX II ROLES AND RESPONSIBILITIES, SUPPORT ORGANIZATIONS
APPENDIX III ORGANIZATION CHART,WELLS WITH OR WITHOUT RIG ON
LOCATION
1.0 OBJECTIVE:
The objective of this General Instruction (GI) is to define the emergency response operations roles &
responsibilities for any onshore wellsite emergency involving D&WOO activities, or when a Producing
Organization has turned over responsibility for well control operations to D&WOO.
This GI will serve as the basis for the development of a D&WOO Onshore Wellsite Emergency
Response Plan, which complies with the applicable requirements of the Saudi Aramco Safety
Management System Element-8 and the Saudi Aramco Corporate Contingency Plan (SACCP).
2.0 IMPLEMENTATION:
2.1 Well Control Operations Emergency During Production Operations
If a well control operations emergency occurs while the well is the responsibility of one of the
Producing Organizations, notification that a well control operations emergency exists will be made
through the normal chain of command. The Area Producing Vice President or Ex. D irector or
G en. Manager (if the Vice President cannot be reached) may request Drilling and Workover
to take over well control operations by contacting (by priority):
• VP / Executive Director, Drilling & Workover Organization
• General Manager, Drilling Operations
• Manager relevant area Drilling / Workover
* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

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D&WOO’s Wellsite Emergency Response Operations Responsibilities when a Producing

Organization turns over well control operations will be strictly limited to coordinating / conducting
safe & effective well control operations until the well is returned back to Area Producing Organization,
while the respective Producing Organization will retain sole responsibility for all other aspects of a safe
& effective emergency response operation beyond the specific wellsite emergency.
2.2 Well Emergency During Drilling, or Workover Operations
If a wellsite emergency occurs during any drilling or workover operations, the situation will be
reported by dialing the 110 Incident Notification System, utilizing the seven digit local area
emergency number and contacting the relevant Manager of Drilling & Workover Dept. or the
General Manager, Drilling Operations. The D&W Organization will be solely responsible for the
safe & effective management of all aspects of the wellsite emergency.
2.3 Reporting of Emergency During Drilling or Workover Operations
2.3.1 The Saudi Aramco D&WOO Liaison-man or Senior D&WOO representative will report
any emergencies or selected drills by dialing the appropriate ISO Control Center’s 110
Incident Notification System Equivalent Number (seven digit).
2.3.2 The appropriate method for reporting selected drills requires that the person reporting
speaks slowly, calmly, and distinctly in a clear voice and give the following sequential
information:
a. Clearly state: “This is a drill, this is a drill, this is a drill at Rig ____, on Well ___ at
______ area”.
b. Identify yourself by name & badge number.
c. Give your wellsite location
d. Briefly describe the training exercise scenario (i.e. H2S Release, Fire, etc)
e. State the simulated number of injured persons
f. Repeat the above information
g. Request the ISO person receiving the call to repeat the information to ensure it is
clearly understood to be a drill.
2.3.3 The appropriate method for reporting wellsite emergencies requires that the person
reporting speaks slowly, calmly, and distinctly in a clear voice and give the following
sequential information:
a. Clearly state: “There is a wellsite emergency at Rig ____, on Well ___ at ______
area”.

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RESPONSIBILITIES
b. Identify yourself by name & badge number.
c. Give your wellsite location
d. Briefly describe the wellsite emergency (i.e. H2S Release, Fire, etc)
e. State the number of killed or injured persons
f. Repeat the above information
g. Request the ISO person receiving the call to repeat the information to ensure it is
clearly & accurately understood to be a wellsite emergency.
2.3.4 The D&WOO Liaison-man will also contact the respective D&WOO Superintendent or the
respective D&WOO Manager, if the respective superintendent cannot be reached, in order
to inform them of the nature & severity of the wellsite emergency. Also notify any nearby
Oil or Gas Operations facility of any potential associated risk to their facilities.
2.4 Wellsite Emergency Response Operations Priorities

2.4.1.1 D&WOO Incident Commander (initially the Liaison-man) will take all actions
necessary to minimize the loss of life and/or personnel injury. In the event that
there are any injured or dead, the D&WOO Liaison-man or most senior D&WOO
representative or Contractor employee on the rig, will be responsible for obtaining
appropriate emergency medical assistance and EMS transportation. This will be
accomplished by clearly stating the number of injured or fatalities in the 110
Incident Notification Message (Section 2.3.3 Item-e).
2.4.1.2 Security patrols will be dispatched to strictly limit access to the wellsite & any
defined offsite hazard zone to Saudi Aramco authorized personnel.
2.4.1.3 The D&WOO Liaison-man or senior drilling representative will designate a

team to immediately begin monitoring the offsite hazard zone (if any) for
flammable gas and hydrogen sulfide (H2S) or other potential hazards.
2.4.1.4 Persons in any endangered area near the emergency site will be alerted and /or
evacuated by Saudi Aramco Government Affairs / ISO authorized personnel.
2.4.1.5 Fire Protection Department will respond to the wellsite emergency with
appropriate fire fighting & rescue resources. The actual level of assistance
will depend upon the remoteness of the wellsite, in combination with the
nature & severity of the incident.
2.5 Safeguarding of Company Assets
Fire fighting and special well control equipment from the D&W SWAT Unit will be dispatched as
warranted to the wellsite. The D&WOO Incident Commander or the D&WOO Well Control Team
Leader will assess the incident severity and define a prudent & practical asset protection strategy.

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Specialized Fire Fighting & Well Control Operations

2.5.1 Well Control
The D&WOO Well Control Team Site Leader will coordinate & direct all on-site well control
operations. o other leader or site commander, designated by other organization, will have the
authority to interfere or take charge of any D&WOO Well Control Operations activities.
2.5.2 Voluntary Well Ignition
Should uncontrolled hydrocarbon flow from a well occur without being accidentally ignited,
the decision to ignite will be based on the following criteria:
A) If uncontrollable flow from a gas well creates a 30ppm H2S Concentration at the defined
RER (Rupture Exposure Radius) ignite the flow immediately.
B) If uncontrollable flow presents immediate and serious danger to adjacent inhabited areas
or facilities, by creating a minimum 100 ppm H2S Concentration at the wellsite parameter
- ignite the flow immediately.
C) Any flow condition other than that described in item (A) & (B) will be evaluated on a
case-by-case basis. The decision to ignite will be made by the VP / Executive Director
D&WOO and/or General Manager, Drilling, after evaluating all the facts. If there is
no communication with higher levels of Management or time factor becomes critical,
then the decision to voluntarily ignite can be made by a D&WOO Liaison-man,
Well Control Team Site Leader, Superintendent or Manager.
3.0 D&WOO Onshore Wellsite Emergency Response Operations Organization
The D&WOO Onshore Wellsite Emergency Response Operations Organization is defined in Appendix III.
Personnel assigned to the organization will be relieved of their routine responsibilities by other
personnel who will carry on regular Company business.
3.1 In the event that the well has a drilling or workover rig on it, the D&WOO Incident Manager
will be responsible for all wellsite emergency response operations. He will appoint the Incident
Commander & Well Control Team Site Leader. The Well Control Team will consist of
designated D&WOO & contractor personnel as deemed appropriate by the Well Control Team
Site Leader, in consultation with the Incident Commander.
3.2 In the event that a Producing Organization turns over a well to D&WOO, the VP / Exe. Director,
D&WO or General Manager, Drilling will appoint a D&WOO Well Control Team Site Leader. The
Well Control Team Site Leader will be solely responsible for all well control operations.
The D&WOO Well Control Team will consist of designated D&WOO & contractor personnel as
deemed appropriate by the Well Control Team Site Leader, in consultation with the Producing
Organization Incident Commander.
3.3 Prior to any rig move to drill or workover a well, the Drilling Superintendent or
designated representative will contact the respective Producing counterpart and others that may
have interest in the area order to:
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RESPONSIBILITIES
- Ensure that the concerned organizations are familiar with their specific roles & responsibilities described
in the D&WOO Onshore Wellsite Emergency Response Plan.
- Established appropriate contact point(s) in case the D&WOO Onshore Wellsite Emergency Response
Plan
is activated.
4.0 WELL CONTROL OPERATIONS:
The D&WOO Well Control Team Site Leader will define an appropriate well control operations strategy
for the respective Incident Commander. The Incident Commander will assist the D&WOO Well Control
Team Site Leader with the coordination of well control operations support service resources at the
wellsite.
5.0 RESTORATION OR ABANDONMENT OPERATIONS:
As a well is brought under control, safety equipment will be installed. Debris must be removed and
construction plans will be implemented to repair the site and return the well to its previous operating
status. If necessary, the well will be abandoned.
6.0 COST ACCOUNTING:

Drilling and Workover’s, Planning & Accounting Services Group, will obtain a special project
number from the Finance and Insurance Claims Administrator, Treasurers Department,
Dhahran, to accumulate costs related to the disaster. The Treasurers Department will determine
the proper disposition of the costs accumulated in the SP.
The Planning and Accounting Services Group of the Drilling and Workover Department will review the
charges and make corrections or adjustments as necessary and issue a final financial cost report if
required.
7.0 SUPPORT SERVICES:
Support services provided by various departments as well as those performed by service companies
will be coordinated by the Incident Commander and the Manager, Drilling and Workover
Services. Each department providing a support service will be responsible for adequate preparation to
provide prompt and efficient service during the emergency.

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8.0 DOCUMENTING AND CRITIQUE

Complete daily logs of all critical wellsite emergency response operations will be maintained in the
respective ECC and continuously updated on the Emergency Message Board System (EMBS) as
warranted . Designated ECC personnel assigned by the Incident Manager will act as liaison with all
of the various groups to maintain continuous documentation of the wellsite emergency operations
including (but not limited to) any fatalities, injuries and environmental impact. A complete factual
report of each day's activities will be maintained by the ECC as a permanent record. The final report
shall be prepared by the Incident Manager and shall contain a complete record of facilities and wells
involved, planning, decisions, photographs, etc. Upon completion of the final report, a critique will be
held to evaluate all the causes, actions and reactions of the various phases up to the final restoration or
disposition.
9.0 DRILLS / TRAINING EXERCISES

9.1 D&WOO will conduct an annual (1) “Primary” rig emergency drill to better prepare for wellsite
emergencies should they occur. These annual drills will be coordinated with the respective
Producing Organizations and designated Support Service Organizations, in order to validate that
the D&WOO Onshore Emergency Response Plan can be safely & effectively implemented for
any onshore wellsite emergency.
The scope of an appropriate D&WOO Primary Drill will require the full mobilization of the defined
Wellsite Emergency Response Operations resources, along with the respective D&WOO ECC.
Designated Support Service Organizations will also be required to demonstrate their preparedness &
competency to safely & effectively fulfill their defined roles & responsibilities.
9.2 D&WOO will also conduct annual “Secondary” rig emergency drills with each respective
Producing Organization Department. These “Secondary” drills will evaluate wellsite emergency
response preparedness and will require minimal mobilization of the defined emergency response
resources.

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RESPONSIBILITIES
APPENDIX I
ROLES & RESPOSIBILITIES

Selected critical roles and responsibilities of designated participants in the D&WOO Onshore Wellsite Emergency
Response Operations Plan organization are defined in this appendix, in order to clarify the crucial operations
functions. This list is not intended to describe all the actions potentially required to safely & effectively
respond to any specific wellsite emergency.
VP / Exe. Director, Drilling & Workover Organization
1. Initially assume the D&WO Incident Manager role and may join the SACCP Crisis Management Team, depending
upon the nature & severity of the incident
2. Update the SACCP Crisis Management Team on emergency response operations as warranted.
3. Appoint an Incident Commander, Well Control Team Site Leader, and Investigating Committee.
General Manager, Drilling Operations
1. Assume the D&WO Incident Manager role at the discretion of the Executive Director, D&WO
2. Appoint a Well Control Team Site Leader for Producing Organization Well Control Operations
3. Authorize voluntary ignition of well effluent, as warranted.
4. Assist the D&WO Incident Manager as warranted
Manager, Drilling or Workover Department
1. Assume I n c i d e n t C o m m a n d responsibilities for well control operations on wells involving drilling or

workover rigs.
2. Implement the operations segment of the D&WOO Onshore Wellsite Emergency Response Operations Plan
3. Appoint a Well Control Team Site Leader at the discretion of the Incident Manager or General Manager
4. Appoint an Engineering General Supervisor to take charge of engineering support.

5. Provide logistical support and operational assistance to the Well Control Team Site Leader
6. Arrange for on-site inspection by VP / Executive Director & General Manager, Drilling & Workover
as warranted.
7. Notify and update the shift superintendent of any nearby Oil or Gas Operations facility of any potential
Risk to their facility.

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RESPONSIBILITIES
APPENDIX I
Superintendent Drilling or Workover operations
1. Notify respective Department Manager of the wellsite emergency.

2. May initially assume Incident Command or Well Control Team Site Leader role at the discretion
of the Incident Manager .
3. Insure that the SA Liaisonman or senior drilling representative has designated a team to initially monitor
the potential downwind hazard area for flammable gas and hydrogen sulfide or other hazards.
4. Coordinate support service provided by other designated department at the discretion of the
Incident Commander.
Manager, Drilling & Workover Services
1. Notify Government Affairs Representative.

2. If necessary call Boots & Coots (281) 931-8884 Fax No. (281) 931-8302
Or Wild Well Control (281) 784-4700 Fax No. (281) 784-4750
Or Alert Disaster(UAE) (9714) 883-2343 Fax No. (9714) 883-2395
3. Notify Department Managers of designated support services departments.
4. Implement the services segment of the D&WOO Onshore Wellsite Emergency Response Operation Plan .
5. Provide equipment, material, and logistical support to the Well Control Team Site Leader.
6. Coordinate mobilization of Emergency Response Operations or Support Services provided by designated
Contractors.
7. Maintain the SWAT Well Control Operation Equipment & Personnel in a continuous emergency
preparedness mode and arrange deployment to any onshore wellsite emergency location.
Superintendent, Drilling Rig Equipment Maintenance Division
1. Mobilize SWAT Well Control Operation Equipment to any onshore wellsite emergency location.
2. Provide personnel to work in the DREM yard to help assemble, operate and repair equipment .
Superintendent, Water Well Maintenance Division
1. Hook up nearby wells for use during onshore well control operations.
2. Provide competent & trained skilled and semi-skilled personnel to work at the well site.
Well Control Team Site Leader
1. Advise the D&WOO Liaisonman & Incident Commander of any immediate action(s) to be taken.
2. Assist the Incident Commander with any wellsite evacuation and rescue operations as warranted.
3. Continuously update the Incident Commander of the Well Control Team’s activities / operations.

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RESPONSIBILITIES
APPENDIX I
Accounting Services
1. Maintain a record of costs incurred and appropriate documentation as directed.
2. Maintain inventory of all Equipment & Materials delivered to disaster site.
Superintendent, Drilling Rig Support Division
1. Obtains all materials and equipment needed for use at the wellsite.
2. Coordinates with Transportation to ensure prompt delivery of materials & equipment.
Superintendent, Wellsite Division
1. Provides a location for emergency equipment and camp to be set up

2. Provides a road way for movement of material and equipment to reach the wellsite location.
3. Provides stand-by equipment for use during well control operations to construct pits or dikes.
Government Affairs Representative
Notify Government officials of situation. All communications will be cleared through the Executive
Director, Drilling & Workover.
General Supervisor., Drilling or Workover Engineering
1. Inform Manager, Area Reservoir Engineering Department of situation and conditions. Obtain relevant
well data including:
(a) Bottom-hole pressure, productivity index, water cut and oil-water contact.
(b) Preferred relief well drilling locations subject to wind and terrain considerations.
(c) Preferred intercept interval.
(d). Contour dip and strike.
2. Request computer flow rate and pressure profile-calculations to be run (computer) for given conditions.
3. Transmit copies of well configuration sketch, wellhead drawing, Morning Reports, and other pertinent
documentation to the D&WOO ECC and SACCP CMT as warranted.
4. Assemble well data and distribute copies as required. Include drilling program, well cross-sectional
sketch, reports, known information - formation tops, final elevation etc.

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RESPONSIBILITIES
APPENDIX I
5. Have large-scale sketch (flip chart size) of well configuration prepared for use in review meetings.
Denote casing sizes/depths, drill string configuration, formation tops, hole problems encountered and
other relevant information which may be of use.
6. Designate qualified and experienced engineer(s) to go to the wellsite to:
(a) Keep accurate log of wellsite operations and well/environmental/weather conditions.
(b) Assist the Well Control Team Site Leader as warranted.
7. Prepare kill program including fluid type, density and pumping rates.
8. Review available rig(s) to drill relief well(s). Recommend rig(s) from optimum technical viewpoint.
9. Once survey location(s) for relief well(s) are received, prepare directional drilling program.
10. Monitor drilling progress on relief well(s) and provide technical liaison among engineering services
group(s) and operations.
11. Prepare relief well kill program(s).
12. Prepare management reviews of progress as required.

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APPENDIX II
ROLES & RESPOSIBILITIES OF SUPPORT SERVICES DEPARTMETS
Communications
1. Design, Install, Maintain, and Test reliable communication systems in all designated D&WOO ECCs
2. Provide communication system installation, testing, and maintenance services required to ensure reliable
wellsite emergency response operations communications.
3. Provide communication system technician(s) at the designated D&WOO ECC & Wellsite
Aviation
1. Provide emergency transportation services for medical evacuation, personnel evacuation, and Well Control
Team members as warranted.
2. Provide aerial wellsite surveillance to assist with search & rescue, security and well control operations as
warranted.
3. Provide for movement of authorized personnel and materials as warranted
Land Transportation
1. Provide immediate emergency response movement of designated materials and equipment.
Fire Protection
1. Provide competent personnel and equipment to support wellsite emergency operations as
requested. The actual level of emergency assistance will depend on remoteness of the wellsite.
2. Provide SA GIS Wellsite & Rig Location Mapping System link in each fire station to ensure an immediate
110 Incident Notification System response.
Security
1. Provide emergency response units for wellsite access control & offsite personnel alert / evacuation operations
Medical
1. Provide emergency medical services as required on-scene and at clinic(s).
2. Provide SA GIS Wellsite & Rig Location Mapping System link in each fire station to ensure an immediate
110 Incident Notification System response.
Community Services
1. Provide accommodation and food services as needed.
Producing
1. Responsible for all aspects of wellsite emergency response operations, other than well control operations for
any well emergency that is turned over to the D&W Organization.
2. Handle all liaison with dispatchers, plant pipelines and other groups concerned with gas/oil movements.
3. Coordinate with the Well Control Team Site Leader on all activities within the field.
4. Supervise all shut-in and start-up activities of nearby wells when the need arises.

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APPENDIX III
WELLS WITH OR WITHOUT RIG O LOCATIO
.
Drilling & Workover

V.P. / EXE. DIRECTOR
SAFETY & IDUSTRIAL SECURITY GOVT. AFFAIRS
GEERAL MAAGER S.A OR .A OIL PETROLEUM EGIEERIG

DRILLIG OPERATIO CHIEF PET. EGR.
AREA PRODUCTIO AREA RESERVIOR

EGR. DEPT MGMT. DEPT
MAAGER MAAGER
DRILLIG OR WORKOVER DEPT.

DRILLIG & WORKOVER MAAGER
SVCS.DEPT
MAAGER
QS & BP Group
DRLG.RIG EQUIPMET
WELL COTROL TEAM
MAIT.DIV
SITE LEADER DRLG.OR WORKOVER
SUPERITEEDT
EGIEERIG DIV.(S)
GE. SUPERVISOR(S)
DRLG. RIG SUP. DIV.
SUPERITEDET
WELL
SUPPORT DRLG. OR WORKOVER
COTROL
WATER WELL DRLG.OPS DIV SVCS EGIEERS
TEAM
SUPERITEDET
WELLSITES SVCS.DIV
SUPERITEDT SPECIAL WELL
ACTIO TEAM
PLAIG & ACCT.
GROUP
SUPERVISOR

Engineering Standard
SAES-B-062 23 July 2009
Onshore Wellsite Safety
Loss Prevention Standards Committee Members
Ashoor, Esam Ahmed, Chairman
Fadley, Gary Lowell, Vice Chairman
Ageel, Adel Abdulaziz
Churches, David Kenneth
Cole, Anthony Richard
Ghobari, Ali Mahdi
Hassar, Fahad Abdullah
Janaby, Mohammad Taqy
Juraifani, Hatim Hamad
Sayed, Salah Moh'D Al-Housseiny
Seba, Zaki Ahmed
Solomon Jr, Clarence Ray
Sultan, Sultan Abdul Hadi
Utaibi, Abdul Aziz Saud
Zahrani, Mansour Jamman
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Definitions....................................................... 3
5 Determination of Rupture Exposure
Radius (RER).......................................... 8
6 Wellsite Location............................................ 9
7 Well Safety Valves and Wellsite Hardware.. 13
8 Abandoned Wells......................................... 15
9 Drilling Rig Access Routes........................... 16
Appendix 1 – Procedure for Determining RER

of Oil and Gas Wells.................................... 17
Previous Issue: 31 March 2009 Next Planned Update: 31 March 2014

Page 1 of 32
Primary contact: Ashoor, Esam Ahmed on 966-3-8728431
Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Loss Prevention Standards Committee SAES-B-062
Issue Date: 23 July 2009
Next Planned Update: 31 March 2014 Onshore Wellsite Safety
1 Scope
1.1 This Standard covers the minimum mandatory requirements for site layout,
wellhead protection, access, and flow isolation for all wells that are drilled into
or through a geological zone that contains hydrocarbons such as oil and gas
production wells, water injection wells, observation wells, abandoned wells,
suspended wells, and waste disposal wells.
1.2 This standard shall apply in the following circumstances:
1.2.1 All new wellsites.
1.2.2 All new wells drilled at existing wellsites.
1.2.3 Re-activation of previously abandoned or suspended wells or re-drilling

of existing wells such as drilling of new laterals or deepening.
1.2.4 Existing wells located in areas that have become populated per this
Standard shall be upgraded with automated shut-in systems, vehicle
crash protection, fencing, wind socks, and other items only when a
workover is required for other remedial work.
2 Conflicts and Deviations
2.1 Any conflicts between this Standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Saudi Aramco Materials System Specifications
(SAMSSs), Saudi Aramco Standard Drawings (SASDs), or industry standards,
codes, and forms shall be resolved in writing by the Company or Buyer
Representative through the Manager, Loss Prevention Department of Saudi
Aramco, Dhahran.
2.2 Direct all requests to deviate from the Standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Loss Prevention Department of Saudi
Aramco, Dhahran.
3 References
All referenced specifications, standards, codes, forms, drawings, and similar material
shall be of the latest issue (including all revisions, addenda, and supplements) unless
stated otherwise.
3.1 Saudi Aramco References
Safety Management Guides [http://lp.aramco.com.sa/]
Page 2 of 32
Emergency Management Guide

Safety Management Guide for Emergency Preparedness
Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Requirement
Saudi Aramco Engineering Standards

SAES-B-064 Onshore and Nearshore Pipeline Safety
SAES-F-007 System Design Criteria of Flares
SAES-J-505 Combustible Gas and Hydrogen Sulfide in Air
Detection Systems
SAES-L-410 Design of Pipelines
SAES-M-006 Fencing
Saudi Aramco Materials System Specification

34-SAMSS-624 Wellhead Control, Monitoring and Shutdown
Systems
45-SAMSS-005 Wellhead Equipment
Saudi Aramco Standard Drawings

AA-036454 Remote Controls for Onshore Wells
AB-036685 Wellhead Guard Barrier
3.2 Industry Codes and Standards
American Petroleum Institute

API RP 14B Design, Installation, Repair and Operation of
Subsurface Safety Valve Systems
4 Definitions
Absolute Open Flow (AOF): In general terms, the rate of flow that would be produced
by a well if the only back-pressure at the surface is atmospheric pressure.
Choke: An adjustable pressure control valve that is used to control backpressure on the
well. Controlling the backpressure adjusts the production rate of the well.
Page 3 of 32
Drilling Island: A wellsite for drilling one or more wells, normally used in populated
areas to minimize land usage. A drilling island is an exclusive land use area.
Drilling Pad: A compacted area of marl located at the wellsite. The drilling pad is
required to be level for use by drilling and workover rigs.
Gas-Oil Ratio (GOR): The ratio of volume of gas produced from a well in a barrel of
crude oil at standard conditions (14.7 psia, 15°C).
GOSP: A gas-oil separation plant (GOSP) is a plant area where water and gas are
separated from the produced crude oil so that the oil is of suitable quality for shipping
through a pipeline to an oil terminal or to a refinery. The gas is sent to gas plants for
further processing.
High-Population Building: Any building, such as a office building, mosque, cafeteria,

or training building, that can be expected to contain 25 or more people at any time.
H2S: Hydrogen Sulfide, a colorless toxic gas that is sometimes produced with natural
water, crude oil, and natural gas.
High Pressure Well: Wells where the shut-in wellhead pressure is expected to exceed
20,700 kPa (3000 psig).
Kick: A unplanned flow of reservoir gas, oil or water from the formation into the
wellbore during drilling operations.
Low Pressure Well: Wells where the shut-in wellhead pressure is not expected to
exceed 20,700 kPa (3000 psig).
LFL: Lower flammable limit of a fuel vapor in air mixture. If a vapor/air mixture is
above the LFL, a fire is likely in the presence of an ignition source.
Major Facility: The outer-most security fence, property line, or other demarcation of
land-use claim of refineries, gas treatment, NGL plants, gas-oil separating or processing
facilities, and the property line of any third party manufacturing facilities (Refer to
Table 1 below for examples).
Page 4 of 32
Table 1 – Examples of Major Facilities
Refineries Gas Treating NGL Oil Process Terminals Non-Aramco

SCEC Power
Abqaiq Plants
Jeddah Berri Juaymah Juaymah Generation
Complex
(formerly SCECO)
Safaniya
Rabigh Uthmaniyah Yanbu Jeddah SWCC Treatment
Onshore GOSP
Tanajib Ras
Commercial
Ras Onshore Tanura
Shedgum International
Tanura GOSP; (North &
Airports
Khursaniya South)
Jubail or Yanbu
Riyadh Hawiyah Shaybah CPF Yanbu Industrial
Complexes
Haradh Khurais
Non-Associated Gas Fields: Areas that are developed for the primary purpose of
producing natural gas. The produced gas is not a by-product of crude oil production.
Population: Any concentration or grouping of people. Population is normally indicated

by the existence of buildings, but may also be a camp site, a site where construction or
maintenance crews are working. Separation spacing from a well shall be measured from
the nearest fence or other landmark that indicates the boundary. For the purposes of this
standard, a road or highway is not considered population.
Populated Area: For the purposes of this standard, a well is in a “populated area” if
the population exceeds 20 persons residing, working, or otherwise located inside the
30 ppm rupture exposure radius (RER). For the purpose of this Standard, the number of
persons considered does not include personnel residing at the rig camp, on-site workers
in support of the drilling or workover rig, or the occupants of vehicles traveling on
roads or highways.
Rupture Exposure Radius (RER):
1) For toxic effects, the rupture exposure radius refers to the horizontal distance from
a leak source to a specified level of hydrogen sulfide (H2S) concentration in parts
per million (ppm).
2) For a flammable gas hazard, the rupture exposure radius refers to the horizontal
distance from a leak source to the ½ Lower Flammable Limit (LFL).
Surface Safety Valve (SSV): An automated spring-assisted fail-safe valve installed on

a wellhead to automatically shut in flow during an abnormal condition such as high or
low pressure of the flowline. This can be the upper master valve, a wing valve
(upstream of choke), or a production valve (downstream of the choke).
Page 5 of 32
Suspension Procedure: Wireline or workover rig procedures for securing a standing

well from production on a long-term basis.
Subsurface Safety Valve (SSSV): An automated valve installed below ground level in
the tubing string of an oil or gas well. The SSSV is used to shut in flow during an
abnormal condition. SSSVs, when required, shall be installed 60 m or more below
ground level per API RP 14B.
Wellhead: The valve manifold directly at the top of the well bore. The wellhead
consists of several specialized valves including the following:
a) Crown Valve: Topmost valve of the wellhead. This valve is used for wireline
and coil tubing access to the well.
b) Lower Master Valve: The first valve on a wellhead. This is not a surface safety
valve (SSV).
c) Upper Master Valve: A second isolation gate valve just above the Lower Master
Valve on a wellhead. If this is automated, it is considered a surface safety valve
(SSV).
d) Wing Valve: The valve on the side branch of the wellhead, normally located
immediately upstream of the choke.
Page 6 of 32
7-1/16" 3M PSI Onshore Production Tree
7" 3M QUICK UNION TREE CAP

14-7/8"
24-1/8"
7" 3M GATE VALVE
7" 3M FLANGE
16"
7" 3M TEE
24-1/8"
7" 3M HYDRAULIC ACTUATED SSV
7" 3M GATE VALVE 24-1/8"
32-1/4"
Saudi Aramco
3M PSI WP WOG
6M PSI TP
Figure 1 – Example of Wellhead (from 45-SAMSS-005, Figure 6)
Wellsite: A wellsite consists of wellhead(s), associated drilling pad, a well flare/burn

pit area or areas, and flare/burn pit buffer zone(s). The entire wellsite constitutes an
exclusive land use area. No other uses are permitted in this area, except as allowed by
this Standard. Size of the wellsite and distances between wellheads shall be specified
by Drilling and Workover Engineering, Drilling Operations, Production and Facilities
Development (P&FDD), and the Proponent Operating Department, on a case-by-case
basis.
Well Status: Wells that are not flowing oil or gas may be described by the following
terms:
a) Abandoned Well: A well that is permanently plugged with cement. This well
Page 7 of 32
cannot be produced again.

b) Observation Well: A well drilled to monitor reservoir conditions such as bottom-
hole pressure in the reservoir.
c) Suspended Well: A well that has been shut-in on a long term basis with all
productive zones isolated and production shut-off on a long-term basis.
d) Standing Well: A well that is shut-in awaiting action, such as flowline tie-in or
well perforation, before it can be returned to production.
5 Determination of Rupture Exposure Radius (RER)
5.1 Three concentric circles representing the three rupture exposure radii - 30 ppm,
100 ppm hydrogen sulfide (H2S) and ½ lower flammable limit (LFL) shall be
plotted from the well's proposed surface location as shown in Figure 2 below.
Refer to Appendix 1 for procedures to determine the RERs.
5.2 For fields, reservoirs, or service not listed in Appendix 1, the rupture exposure
radius shall be obtained from the Saudi Aramco Loss Prevention Department's
Technical Services Unit. In order to calculate the RER, the following
information should be provided with the request: Well composition of produced
fluid (mole %), temperature (Flowing Wellhead Temperature, FWHT), and AOF
for gas wells or maximum flow rate and GOR for oil wells.
Figure 2 – RERs
A well is considered to be in a “populated area” if the population is above 20 persons living,
working, or otherwise located inside the 30 ppm H2S RER (see 6.3). In populated areas,
requirements in sections 6.5, 7.3, and 7.7, and 8 apply.
Page 8 of 32
6 Wellsite Location
6.1 Wells that are drilled through a hydrocarbon bearing formation shall be located
so that no person(s) unrelated to the drilling activity, no portion of an occupied
building or manned facility is within the well's 100 ppm H2S or ½ LFL RER.
The RER for a well is normally provided by Production and Facilities
Development Department (P&FDD). Minimum spacing shall not be less than
that stated in Table 2. The RER to be used for well spacing shall be based on the
worst case of all hydrocarbon zones that are penetrated during drilling. Where
evacuation is strategically not feasible e.g. electrical power plants, military
defense installations, hospitals, schools, or major facilities, wells shall be located
so that such no portion of these types of establishments or facilities are within
the well’s 30 ppm H2S RER.
Exception:
Mobile rig camps at the rig location and unoccupied lands, such as those used
primarily for agriculture, are not required to meet this spacing requirement.
Emergency response coordination with any on-site workers is required to meet
Section 6.9 below.
6.2 Manifolds, significant aboveground appurtenances for cross-country

transportation pipelines such as junctions containing a several scraper
launcher/receiver facilities, Khuff and Jouf gas distribution facilities, and their
associated utilities, roads, highways, and expressways, are allowed to be within
the 100 ppm H2S circle but not within the ½ LFL RER nor closer than the
minimum spacing stated in Table 2.
Table 2 – Spacing from Oil and Gas Wells (4, 5)

Minimum Spacing
Facility
from the Wellhead
(1, 2)
Pipelines 60 m
Overhead powerlines for site-related CP, etc.
100 m
(<69 kV); site related rectifiers
Main overhead powerlines 200 m
(3)
Saudi Aramco or Government roadways 100 m
(3)
Divided Limited-Access Expressways 150 m
(3)
Railroads 150 m
Major electrical distribution centers
450 m
(use only if 100 ppm H2S RER is <450 m)
Occupied buildings, major facilities 450 m
(use only if 100 ppm H2S RER is < 450 m)
Non-well flares and burn pits 450 m
Hospitals and schools 1000 m
(use only if 100 ppm H2S RER is < 1000 m)
Page 9 of 32
1) The existing elevated marl pad around wellhead(s) on a wellsite shall not be crossed by a
pipeline. Rig access shall not be obstructed by installation of a pipeline. In addition, the
minimum spacing does not apply to flowlines that are associated with a multi-well wellsite.
2) New wells may require additional spacing from existing flowlines for wellsite construction and
drilling operations. Spacing shall be increased as needed at the request of the Drilling
Services or Drilling Operations Departments.
3) Spacing from the well to the closest edge of right-of-way, such as a fence.
4) Minimum spacing applies to wells drilled after March 30, 2001.
5) Wells are to be spaced a minimum of 60 m from the closest edge of a burn pit for an oil well
or LP gas well and 150 m from a flare for a HP gas well. See Table 3 for more details on
flare burn pits.
6.3 Water gravity injector, power injector and supply wells that penetrate
hydrocarbon formations shall be spaced the same as hydrocarbon producing
wells. Injector and supply wells that do not penetrate hydrocarbon bearing
formations shall have a basic 60 m minimum spacing requirement from plant
equipment, buildings, etc. Gas injection wells shall use the same location criteria
as producing gas wells.
6.4 A well is in a “populated area” if the population exceeds 20 persons (unrelated

to drilling activities) residing, working, or otherwise located within the 30 ppm
H2S rupture exposure radius of that well (see Figure 2).
Commentary Notes:
For purposes of this Standard, roads do not generate populated areas.
Where wells are located near areas of potential concern, such as roads, parking
areas, or camp sites, the Proponent Operating/Engineering Department shall
determine whether additional precautionary measures, such as subsurface safety
valves, fencing, etc., are required.
6.5 Wells to be drilled or wells subject to workover in a populated area shall

implement the following additional precautionary measures in addition to the
normal drilling safety program during drilling of hydrocarbon zones. Other
drilling precautionary measures may be added at the request of the Manager,
Loss Prevention or the General Manager of Drilling and Workover.
Precautionary measures during drilling and workover in a populated area:

1. Rig-site H2S monitoring systems with 24-hour coverage by a competent
and qualified safety professional.
2. Placement of remote H2S monitors in the vicinity of populations and
nearby facilities to monitor H2S levels at those locations in an emergency.
Page 10 of 32
3. An additional one-hole volume of kill-weight mud available at the drillsite

for immediate use.
4. Capability of cutting the drill pipe with shear rams.
5. On-site coverage 24 hours a day by on-site foremen (minimum 2-man
coverage on 12-hour shifts) with authority for immediate ignition of the
well without prior approval in the event of loss of well control.
6. Capability of burning gas in a controlled release using a properly designed
separation system and an elevated flare with pilot (Only for wells to
protect population within the 30 ppm H2S RER; the use of this equipment
is not required for drilling near GOSPs, process plants or facilities). The
design, location, and elevation of flare shall take into account the potential
dispersion of flammable or toxic materials from the flare during a flame-
out condition, the toxic products of combustion, such as sulfur dioxide,
during flare operation, and other design considerations as specified in
SAES-F-007. Alternative designs for gas handling shall follow a
management of change (MOC) engineering process. The design shall be
approved by the Manager, Drilling Operations and Manager, Drilling
Technical Department.
Commentary Note:
The intent of the MOC process is to assure compliance with standards,

material specifications, and Codes that apply for gas handling facilities. The
engineering review provides a check on the engineering soundness,
concepts, and calculations used in the design. The dispersion analysis is
required in order to identify alternative design or procedures needed to
protect life safety should the flare extinguish during operation.
7. A wellsite emergency response plan that meets the Saudi Aramco Safety
Management Guide for Emergency Preparedness.
8. Other applicable safeguards as needed.
6.6 Under no circumstances shall population be exposed to over 30 ppm H2S gas
concentration for more than 1 hour.
6.7 Well burn pits shall be subject to the same spacing from population and major
facilities as well spacing. The exceptions to 6.1 shall also apply to burn pits.
Minimum spacing shall meet Table 3.
6.7.1 Oil wells and low-pressure gas wells shall have at least one flare while
being drilled.
6.7.2 High-pressure gas well shall have two flares while being drilled.
Page 11 of 32
6.7.3 Burn pits shall be at predominantly downwind and crosswind locations,

at least 60 meters from the well (300 m for high-pressure gas wells)
ranging from 60 to 270 arc degrees from true North. Burn pits shall be
placed to point away from populations and facilities as much as possible.
6.7.4 If there are two flares, they should be a minimum of 90 degrees and a
maximum of 180 degrees from each other and pointing away from
populations and facilities as much as possible.
Table 3 – Spacing from Well Burn Pits (3)

Minimum Spacing
Facility from Oil & Gas Well Burn
Pits
(1) 60 m (Oil & LP Gas)
Well and Well Burn Pits
300 m (HP Gas Well)
60 m (Oil & LP Gas)
Existing Wellheads
150 m (HP Gas Well)
Pipelines (Above Ground) 60 m
(2)
Pipelines (Buried) 30 m
Main Overhead Powerlines 200 m
Overhead Powerlines for Site-Related CP, etc.,
100 m
(<69 kV); Site Related Rectifiers
(2)
Powerlines (Buried) 30 m
(3) 100 m (Oil Wells and LP Gas)
Saudi Aramco or Government Roadways
200 m (HP Gas Wells)
(3)
Divided Limited-Access Expressways 450 m (Oil and Gas Wells)
(3)
Railroads 200 m
Population (use only if RER <450 m) 450 m
Non-well Flares and Burn Pits 450 m
Hospitals and Schools
1000 m
(use only if RER < 1000 m)
1) Spacing of any well related burn pit from a well being drilled shall be a minimum
distance of 60 m for an oil well and 300 m minimum for a high-pressure gas well.
Wells are to be spaced a minimum of 60 m from the closest edge of a burn pit for an
oil well or LP gas well and 150 m from a flare for a HP gas well. A minimum of 60 m
buffer zone shall be maintained around the outside of each burn pit (not on the
wellsite side). The edges of the burn pits shall have a 2 m high berm (minimum
elevation above flare outlet center).
2) Buried CP powerlines, flowlines, and trunklines related to a wellsite shall have no
other spacing restrictions provided the powerlines do not interfere with rig access or
future production flare operations.
3) Spacing from the closest edge of the burn pit to the edge of the right-of-way.
Page 12 of 32
6.8 For existing wells in populated areas, the special precautions in 6.5 shall be used
for workovers. Precautions appropriate for stimulation and wireline work on
existing wells shall be as requested by the Proponent Operating Department,
Drilling and Workover Services, and Loss Prevention as needed.
6.9 Pre-incident Emergency Response Planning
6.9.1 In areas where drilling will take place, an emergency response plan that
meets the Saudi Aramco Safety Management Guide for Emergency
Preparedness shall be created and used by drilling operations, facility
proponents, responding personnel, Saudi Aramco communities, and
other entities to manage emergency response to a drilling, workover, or
producing related incident.
Commentary Note:
Refer to the Emergency Management Guide (http://lp.aramco.com.sa) for

information on how to develop, implement, and maintain a viable
emergency management program.
6.9.2 The plan shall indicate locations where people may be located within the
30 ppm RER or 5 km of the wellsite, whichever is greater. Such
locations include, but are not limited to, occupied buildings, employee
housing compounds, shopping complexes, office buildings, manned
facilities, factories, camp grounds, schools, hospitals, project
construction sites, and other similar situations. The plan shall include an
effective notification protocol for all locations where people may be
impacted by a drilling, workover, or producing related incident.
6.9.3 Participants in the plan shall receive training to help communicate the
plan’s expectations, especially those entities that do not normally work
together.
6.9.4 A system for using the plan shall be in place so that the plan itself or a
summary of key elements can be accessed by the responders while in
transit to and at the site of the incident.
6.9.5 Facilities that are potentially impacted shall modify their own emergency
response plans to help provide guidance on how to respond to a nearby
wellsite related incident.
7 Well Safety Valves and Wellsite Hardware
7.1 Hydrocarbon Producing and/or Hydrocarbon Injection Wells - General

Requirements
Page 13 of 32
7.1.1 All well installations shall be in accordance with the specifications

prepared by Saudi Aramco Drilling and Workover Engineering. Refer to
34-SAMSS-624 and 45-SAMSS-005 for the minimum requirements for
Saudi Aramco oil and gas production trees, wellheads, valves and
miscellaneous equipment relating to the wellhead. Naturally flowing
hydrocarbon wells shall be completed in a manner that permits flow only
through a tubing string equipped with a downhole packer or polished
bore receptacle.
7.1.2 Requirements for wellhead piping, flowlines, trunklines, and testlines are
covered in SAES-L-410.
7.1.3 All wells shall have a manual lower master valve.
7.1.4 At the discretion of the Proponent Operating Department, oil wells may
be equipped with manual remote operators attached to the master valve
and/or wing valve. If manual remote operators are installed on oil wells,
they shall be in accordance with Standard Drawing AA-036454.
7.1.5 Any lockout device used to temporarily hold a surface safety valve
(SSV) in the open position by restricting movement of the valve stem
shall be constructed of fusible materials with a melting point 30°C above
the higher of the flowing wellhead or maximum design ambient
temperature.
7.2 Safety Valves for HP Gas Producing Wells
7.2.1 All high-pressure gas production wells shall have at least two spring-
assisted failsafe surface safety valves (SSVs).
7.2.2 The two SSVs shall be triggered when an abnormally high or low
pressure is sensed in the piping to the well. Fusible devices, with a set
point 30°C above either the flowing wellhead or the maximum design
ambient temperature, whichever is highest, shall be installed on the
wellhead to close the safety valves.
7.2.3 At the discretion of the Proponent Operating Department, addition of

other automated valves, such as subsurface safety valves, shall be
installed as requested.
7.3 Safety Valves on Oil Wells and Low Pressure Gas Wells
7.3.1 Where an oil well or low pressure gas well is in a populated area or
where the associated flowline has Location Class 3 or 4 populations (as
specified in Tables 1 and 2 of SAES-B-064), the well shall be provided
with an SSV and SSSV.
Page 14 of 32
7.3.2 For all existing oil wells and low pressure gas wells in populated areas or
where areas become populated due to growth of communities, those
wells shall remain active, but shall require installation of a SSV and
SSSV. The upgrade shall be done only when other needs justify the use
of a rig on the well.
7.3.3 The upper wellhead master valve shall be a spring-assisted fail-safe

surface safety valve (SSV), triggered when an abnormally high or low
pressure is sensed.
7.3.4 A subsurface safety valve (SSSV), per API RP 14B specification, shall
be installed more than 60 m below ground level in oil wells. The SSSV
shall be triggered when an abnormally high or low pressure is sensed.
7.3.5 A fusible device with a melting point 30°C above the higher of the
flowing wellhead temperature or maximum design ambient temperature
shall be installed on the wellhead to trigger the SSV and SSSV systems.
Commentary Note:
Values for pipeline associated RERs are found in SAES-B-064, Tables 1

and 2. Location Class 3 is where the pipeline RER includes areas with a
population greater than 30. Location Class 4 is where the pipeline RER
includes 4-story or greater buildings, schools, hospitals, hotels, prisons,
shopping malls or similar retail complexes.
Table 4 – Well Safety Valves

Additional
Automated Automated
Drilling
SSV SSSV
Precautions
Oil/LP Gas Well – (a) (a)
(a) No No No
Unpopulated Area
Oil/LP Gas Well –
Yes Yes Yes
Populated Area
(b)
HP Gas Well No Yes, 2 SSVs
PWI Well –
No No No
Unpopulated Area
PWI Well –
Yes No No
Populated Area
Note a Even if the well is in an unpopulated area, if the flowline passes through a
populated area per 8.3, an SSV and SSSV shall be required.
Note b HP gas production wells shall have at least two spring-assisted failsafe SSVs.
Addition of other automated valves, such as subsurface safety valves, shall be
installed where required by the Proponent Operating Department per Section 8.2.
Page 15 of 32
7.4 Hydrocarbon Injection Wells
Hydrocarbon injection well flowlines shall each be provided with a check valve
in the wellhead piping.
7.5 Observation Wells
Wells shall be equipped with the relevant safety devices equivalent in function
to those that would be required for a producing well unless suspended with a
subsurface plug or other acceptable method.
7.6 Suspended Wells
Wells shall be suspended in accordance with Producing Engineering

requirements. Suspension procedures for wells shall be documented by
Producing Operations and shall be available for review.
7.7 Vehicular Crash Protection and Fencing
7.7.1 All wellheads shall be protected with a guard barrier per Saudi Aramco
Standard Drawing AB-036685.
7.7.2 Wellsites and associated burn pits in populated areas shall be enclosed
by a fence meeting the specifications of SAES-M-006 (Type III). The
fence shall have four lockable vehicle gates, one in each quadrant locked
at all times. Keys shall be kept with the Proponent Operating
Department. Two gates shall be a minimum of 18 m wide rig-access
gates. The locations of these rig-access gates shall permit access to all
wells on the wellsite from either gate.
7.8 A wind sock pole and a wind sock (e.g., SAP Material Number 1000132744) are
to be permanently installed at each hydrocarbon production or injection wellsite
in populated areas.
8 Abandoned Wells
The following requirements apply to a wellsite only if all its wells have been
permanently plugged and if it is located in a populated area:
8.1 The perimeter of the drilling pad shall be provided with a fence (SAES-M-006,
Type III) if there is no fence at the perimeter of the buffer zone.
8.2 The fence shall have one lockable vehicle gate 10 m wide.
8.3 One access route 10 m wide shall be maintained to the wellsite gate.
Page 16 of 32
9 Drilling Rig Access Routes
Two land based access routes shall be available to each wellsite. These shall meet the
following requirements:
9.1 Each access route shall be 18 m wide, terminating at a rig access gate.
9.2 Vertical clearance over the access routes shall be 14 m minimum.
9.3 An access route shall not include grades or transverse slopes of more than 5%.
9.4 No obstruction is allowed on an access route.
9.5 The minimum radius of curvature of access routes shall be 70 m. The center
point of all access route curves shall be outside the wellsite served.
9.6 One of the access routes required by paragraph 10.1 above shall have within it a
prepared roadway consisting of a compacted marl surface 0.3 m thick and 9.0 m
wide with 2.5 m wide shoulders, giving a total clear road width of 14 m.
9.7 The two access roads shall have a separation of from 90 to 270 arc degrees from
each other through the 100 ppm RER.
9.8 In situations where a second land-based route per 9.7 is not feasible (e.g. the
wellsite is near a body of water, in wetlands, located on a peninsula, or on a
causeway-connected drilling island), an alternative second method of emergency
egress shall be planned for all personnel that are at the site, including all drilling
personnel, non-drilling personnel, and visitors. Pre-incident planning shall also
include alternative means for accessing the rig site for search and rescue,
firefighting, well control, and other anticipated emergency response needs. The
alternatives shall be approved by the Manager, Drilling Operations.
Revision Summary
31 March 2009 Major Revision.
23 July 2009 Editorial revision in Section 9.8 to removed approval by Manager, DTD.
Page 17 of 32
Appendix 1 – Procedure for Determining RER of Oil and Gas Wells
Introduction
To allow for more cost-effective well spacing, while at the same time maintaining a safe
distance between wells and exposed populations, SAES-B-062 provides variable
rupture exposure radii (RER) that are based on field and well conditions (i.e., the well
fluid composition and maximum potential release rate).
This appendix is based on a comprehensive analysis of RERs for Saudi Aramco oil and
gas wells. Production and Facilities Development Department (PRED/1-099-99)
provided the data used for the RER calculations. Tables A7 and A8, at the end of this
Appendix, summarize the data provide. The RER calculations were made in
accordance with LPD Guidelines for Determining the Consequences of Well Blowouts.
Note that the information in Tables A7 and A8 are based on the latest LPD gas
dispersion model PHAST (Version 6.0). The RERs may change in future updates of
SAES-B-062 as a result of changes in well data or refinements in the models. If the
information for the well or production zone needed is not in Appendix 1, contact the
Supervisor, Technical Services Unit, Loss Prevention Department.
The following sections illustrate the use of the correlations for predicting RERs for oil
and gas wells. The correlations are of the form RER = aQb, where a and b are field-
specific constants and Q is based on the release rate of gas from the well. Correlations
are provided for the following oil and gas fields:
Non-Associated Gas Fields

North Ghawar Areas-Ain Dar and Shedgum South Ghawar Area-Haradh
Central Ghawar Areas-Uthmaniyah Qatif
South Ghawar Area-Hawiyah Berri
Oil Fields
Abqaiq (Abqaiq Cap Gas) Haradh
Abu Hadriyah Harmaliyah
Abu Jiffan Hawiyah
Ain Dar Khurais
Berri Onshore Khursaniyah
Dammam Mazalij
Fadhili Qatif
Fazran Shedgum
Uthmaniyah
The following sections explain and demonstrate the process of RER calculations.
Worksheets for calculating RERs are provided at the end of this Appendix.
Page 18 of 32
Procedure for Determining RER of Gas Wells
Sour gas wells are considered in this Standard to have three Rupture Exposure Radii
(RER): a 100 ppm H2S RER (RER100 ppm), a 30 ppm H2S RER (RER30 ppm) and a
½ LFL RER (RER½ LFL). Sweet gas wells would only have a RER½ LFL. These radii
are used in SAES-B-062 to determine spacing requirements. Follow these steps when
determining the RER for a gas well.
1. Identify the gas field and reservoir for the well of interest (Contact the General
Supervisor, Northern Area or Southern Area Facilities Div., Production and
Facilities Development Department (P&FDD) and obtain the Absolute Open Flow
(AOF) and mole fraction of hydrogen sulfide (H2S) in the gas stream. Note that
the correlations included in this appendix are based upon the expected upper and
lower range of AOFs and H2S content in the gas stream.
2. Determine release rate of H2S (QH2S) from the following:
QH2S = (QAOF)(xH2S)
Where xH2S = mole fraction of H2S in gas stream
QAOF = Absolute Open Flowrate of gas from the well, MMscfd
QH2S = maximum release rate of H2S, MMscfd
3. Use the constants in Table A6 to calculate RER100 ppm, RER30 ppm and RER½ LFL from
the following
RER100 ppm = e(QH2Sf);
RER30ppm = g(QH2Sh);
RER½ LFL = l(QAOF)m
The AOF or H2S concentration of a gas mixture must fall within the limits
presented in Table A6. If an AOF or the H2S concentration is outside the limits,
then LPD/TSU will calculate RER values specifically for the well of interest
(users need to supply LPD/TSU with well name, AOF, gas composition (mole%),
and flowing wellhead temperature).
Example of RER for Gas Well
As an example, consider a high-pressure gas well in the South Ghawar Area, Hawiyah.
Information available indicates that the anticipated Absolute Open Flow of the well is
100 MMscfd and the H2S concentration is expected to be 3 mole%.
Page 19 of 32
The following steps are necessary to determine the RER:
1. Data Requirements
The AOF and the H2S concentration are within the ranges specified in Table A6.
Table A6 indicates that the appropriate constants for this field are as follows:
Table A1 – RER Constants for South Ghawar Area,

Hawiyah Field (from Table A6)
RER100 ppm RER30 ppm RER½ LFL

e f g h l m
245 0.79 700 0.77 11.7 0.54
2. Calculate maximum H2S release rate
The maximum H2S release rate is given by the following:
QH2S = (QAOF)(xH2S)
= (100 MMscfd)( 3 / 100 )
=3 MMscfd of H2S
3. Calculate RERs
RER100 ppm = 245[(3).79] = 583 m
RER30 ppm = 700[(3).77] = 1,631 m
RER½LFL = 11.7[(100).54] = 141 m
The RER for this example well are in Table A2.
Table A2 – RER for Example Well
Rupture Exposure Radii Distance, m

RER100 ppm 583
RER30 ppm 1,631
RER½LFL 141
Procedure for Determining RER of Oil Wells
Gas is flashed during a large release of crude and is then dispersed downwind. As with
gas wells, oil wells have three Rupture Exposure Radii (RER): a 100 ppm H2S RER
Page 20 of 32
(RER100 ppm), a 30 ppm H2S RER (RER30 ppm) and a ½ LFL RER (RER½LFL).
Sweet oil wells only have a RER½ LFL. These radii are used in SAES-B-062 to
determine spacing requirements and to assist in determining emergency response
planning and notification. Follow these steps when determining the RER for an oil well:
1. Identify the oil field and reservoir for the well of interest (Contact the General
Supervisor, Northern Area or Southern Area Facilities Div. /P&FDD, and obtain
the maximum oil flow rate, Gas-Oil Ratio (GOR) and mole fraction of hydrogen
sulfide (H2S) in the oil. The correlations included in this appendix are based upon
the expected upper and lower range of maximum flow rates, gas-oil ratios, and
H2S content in the oil.
2. Use the following equation to calculate the rate of gas flashed from the crude
released at the maximum flow rate:
Qgas = (Qoil)(GOR) /1,000
Where:
Qgas = Release rate of flashed gas, MMscfd
Qoil = Maximum oil release rate, Mbpd
GOR = Gas-Oil Ratio, scf/stb
3. Calculate the concentration of H2S in the flashed gas from the following
equations:
[xH2S]gas = [xH2S]oil
where:
 = a(GOR)b (Note: a, b are obtained from Table A7)
Determine release rate of H2S (QH2S)
QH2S = (Qgas) ([xH2S]gas) [MMscfd of H2S]
4. Calculate RER100 ppm
RER100 ppm = e(QH2S)f (Note: e, f are obtained from Table A7)
5. Calculate RER30 ppm
RER30 ppm = g(QH2S)h (Note: g, h obtained from Table A7).
Page 21 of 32
6. Calculate RER½ LFL
RER½ LFL = l(Qgas)m (Note: l, m obtained from Table A7)
If the AOF or H2S concentration do not fall within limits of Table A7, then LPD/TSU
will calculate RER values specifically for the well of interest (users need to supply
LPD/TSU with well name, maximum oil flow rate, oil composition (mole%), gas-oil
ratio, and flowing wellhead temperature).
Example of Oil Well RER Determination
As an example, consider an oil well that is producing Arab-D in the Khurais field.
Available information indicates the well will have a maximum flow rate of 30,000 bpd,
the oil will have an H2S concentration of 2.9 mole %, and the GOR is 277. What are
the RER values for this well?
1. Available information
The available information is summarized below. The maximum flow rate and the
H2S concentration are within the limits specified in Table A7.
Maximum Flow Rate, Mbpd 30
GOR, scf/stb 277
Mole percent of H2S in Oil 2.9%
Constants for evaluating this well are summarized in Table A3.
Table A3 – RER Constants for Khurais Field (From Table A7)
H2S in Flashed
RER100 ppm RER30 ppm ½ LFL
Gas
a b e f g h l m
2.2 0 1,285 0.69 2,656 0.64 47.3 0.63
2. Calculate flashed gas release rate
The flow rate of released gas may be estimated by the following:
Qgas = (30 Mbpd) x (277 scf/stb) = 8.31 MMscfd
3. Calculate the H2S concentration in flashed gas
 = a(GOR)b = (2.2) x (277)0 = 2.2
[xH2S]gas = [xH2S]oil = (2.2) x (2.9 %) = 6.4%
Page 22 of 32
4. Calculate H2S release rate
QH2S = (8.31 MMscfd) x (.064) = 0.53 MMscfd H2S
5. Calculate RERs
RER100 ppm = e(QH2S)f
RER100 ppm = (1285)(0.53)0.69 = 829 m
RER30 ppm = g(QH2S)h
RER30 ppm = (2656)(0.53)0.64 = 1,769 m
RER½LFL = l(Qgas)m
RER½LFL = (47.3)(8.3)0.63 = 180 m
Table A4 – RER for Example Oil Well
Rupture Exposure Radii Distance, m

RER100 ppm 829
RER30 ppm 1,769
RER½LFL 180
Method of Using RER Results
Saudi Aramco uses the maximum of the 30 ppm RER (100 ppm RER with additional
drilling precautions) or the ½ LFL RER to establish the minimum distance between
wells and population or major facilities (note that spacing can never be less than the
minimums stated in Table 2 of the Standard – see Section 6 for more details). The
purpose for this RER method of spacing is to minimize the possibility of exposing
people to either potentially lethal or flammable vapor clouds. Table A5 summarizes the
effects of hydrogen sulfide exposure to people.
Once the RER100 ppm, RER30 ppm, and RER½LFL are known, draw the RERs as circles with
the well at the center (see
Figure A1). For sour gas wells, the ½ LFL RER will not dominate, but it should still be
drawn on the map showing RERs.
Page 23 of 32
Figure A1 – RER Circles Superimposed Over Wellsite Map
Table A5 – Effects of Hydrogen Sulfide on People

H2S Concentration
Effect on People
(ppm)
ERPG-1*: The maximum airborne concentration below which it is believed
that nearly all adult males could be exposed for up to 1 hour without
0.10
experiencing other than mild transient adverse health effects or perceiving a
clearly defined objectionable odor.
4 Moderate odor, easily detected.
Time Weighted Average (TWA) exposure limitation, beginning of eye irritation.
Setting for Warning low level H2S alarm for control rooms and other indoor
10
areas protected by air intake sensors. Saudi Aramco work permit procedures
require use of SCBA for work in areas with 10 ppm or greater H 2S.
15 Short Term Exposure Limit (STEL) for 15 minutes.
20 Warning High H2S Level alarm setting at Saudi Aramco plants per SAES-J-505.
that nearly all adult males could be exposed for up to 1 hour without
30
experiencing or developing irreversible or other serious health effects or
symptoms that could impair their abilities to take protective action.
Inhalation limit for 60 minutes, threshold limit of possible eye injury.
50 Setting for Warning High-high Level H2S alarm at Saudi Aramco plants per
SAES-J-505.
70 – 150 Headaches, dizziness, sore throat and increasing stress.
100 that nearly all adult males could be exposed for up to 1 hour without
experiencing or developing life-threatening health effects.
150 Loss of sense of smell.
Page 24 of 32
H2S Concentration
Effect on People
(ppm)
150 – 300 Severe irritation of eyes and lungs.
Immediately Dangerous to Life and Health Concentration: The maximum
airborne concentration to which a healthy male worker can be exposed for as
300
long as 30 min and still be able to escape without loss of life or irreversible
organ system damage.
Loss of sense of reasoning and balance, loss of consciousness and possible
500
death in 30 – 60 minutes.
1,000 Immediate loss of consciousness and death within a few minutes.
* Emergency Response Planning Guideline (ERPG), American Industrial Hygiene Association.
Table A6 – Gas Field Constants for RER Calculations
Properties Constants
H2S AOF or Qgas
100 ppm 30 ppm ½ LFL
(mole%) (MMSCFD)
Field min max min max e f g h l m
Abqaiq Cap Gas 1.0 5.0 50 150 268 0.73 729 0.73 14.8 0.49
Berri 20 20 50 120 789 0.63 1894 0.64 11.7 0.49
North Ghawar
0.72 6.0 50 150 273 0.75 689 0.81 14.0 0.48
(Ain Dar and Shedgum)
South Ghawar (Haradh) 0.50 2.0 50 125 242 0.71 654 0.67 14.6 0.49
South Ghawar (Hawiyah) 0.5 4.5 50 150 245 0.79 700 0.77 11.7 0.54
Qatif 7.23 11.2 50 120 376 0.74 1032 0.72 11.1 0.50
Uthmaniyah 2.28 9.27 50 175 295 0.80 855 0.76 16.1 0.46
Equations for Oil and Gas Wells:
RER100 ppm = e(QH2S)f
RER30 ppm = g(QH2S)h
RER½LFL = l(QAOF)m
Equations for Oil Wells Only:
[xH2S]gas H2S]oil
Note: All RER distances are in meters. QH2S = release rate of H2S, MMSCFD. Qgas = release rate of
gas, MMSCFD
Page 25 of 32
Table A7 – Oil Fields Constants for RER Calculations
Properties Constants
H2S (mole%)
in Oil Qoil (MBD) Flash 100 ppm 30 ppm ½ LFL
Field min max min max a b e f g h l m

Abqaiq 0.93 3.19 2.9 85 11.7 -0.29 815 0.58 1,895 0.58 49.4 0.59
Abu Hadriyah 0.21 2.23 1.9 88 2.2 0 1,024 0.57 2,249 0.55 63.8 0.57
Abu Jiffan 2.58 3.61 10 50 2.5 0 1,182 0.56 2,470 0.55 51.2 0.58
Ain Dar 0.25 2.7 6.9 37 1.7 0 897 0.76 2,251 0.84 45.5 0.42
Berri 1.06 8.92 15 143 33.5 -0.48 1,152 0.53 2,474 0.52 59.1 0.59
Dammam 1.04 2.18 8 52 2.8 0 432 0.48 725 0.49 24.1 0.47
Fadhili 4.13 11.1 5 31 1.5 0 878 0.77 1,949 0.71 51.7 0.54
Fazran 0.66 2.15 4.5 27 1.8 0 273 0.25 911 0.37 38.4 0.29
Haradh 0.02 0.79 5 32 2 0 2,741 0.77 3,825 0.37 50.4 0.52
Harmaliyah 1.69 5.3 6 32 1.6 0 856 0.61 1,980 0.59 45.3 0.44
Hawiyah 0.21 1.05 5 30 2 0 1,173 0.73 2,617 0.71 48.8 0.56
Khurais 0.58 2.94 9 36 2.2 0 1,285 0.69 2,656 0.64 47.3 0.63
Khursaniyah 1.96 4.77 7 43 2 0 1,079 0.59 2,346 0.58 47.9 0.53
Mazalij 1.9 5.47 6.3 37.8 2.2 0 1,232 0.71 2,565 0.67 50.6 0.65
Qatif 3.72 11.95 4 90 1.9 0 1,708 0.34 3,488 0.32 64.6 0.55
Shedgum 0.75 1.57 9 46 1.8 0 630 0.51 1,511 0.49 50.0 0.38
Uthmaniyah 0.23 1.55 9 29 1.8 0 1,438 0.83 3,279 0.83 36.5 0.70
Page 26 of 32
Table A8 – Oil Field Data from Exploration and Producing
Components (mole %)
Well Name Reservoir Range N2 CO2 H2S C1 C2 C3 i-C4 n-C4 i-C5 n-C5 C6 C7+ GOR
Abqaiq Arab-D Min. 0.3 4.9 0.9 27.4 10.7 4.4 1.6 3.7 2.6 1.8 4.2 37.4 860
Abqaiq Arab-D Wt. Avg. 0.1 4.6 1.8 29.6 10.3 6.6 0.6 4.3 1.0 3.0 3.1 35.1 860
Abqaiq Arab-C Max. 0.6 5.1 3.2 6.1 4.7 7.4 1.2 5.1 2.1 3.5 4.6 56.6 135
Abu Hadriyah Arab-A&B Min. 0.2 1.0 0.2 3.5 2.9 6.7 1.4 5.4 2.2 3.9 4.3 68.3 57
Abu Hadriyah Wt. Avg. 0.4 1.2 1.4 14.5 8.1 8.1 1.1 4.9 1.8 3.2 3.4 52.0 260
Abu Hadriyah Arab-C Max. 0.3 1.3 2.2 17.2 8.4 7.8 1.1 4.6 1.6 3.1 2.8 49.6 57
Abu Jiffan Arab-D Min. 0.2 1.7 2.6 9.6 9.6 9.3 1.2 4.9 1.7 3.0 3.9 52.4 253
Abu Jiffan Arab-D Wt. Avg. 0.2 1.9 3.1 9.2 8.9 8.8 1.2 4.7 1.7 3.1 4.4 52.7 253
Abu Jiffan Arab-D Max. 0.3 2.1 3.6 8.9 8.3 8.3 1.2 4.6 1.8 3.1 5.0 53.0 253
Ain Dar L. Fadhili Min. 0.1 3.9 0.3 34.3 13.8 8.5 1.0 4.0 1.1 2.1 1.6 29.3 730
Ain Dar Arab-D Wt. Avg. 0.1 5.9 1.7 25.1 10.4 7.7 1.0 3.8 1.2 2.2 3.0 37.8 550
Ain Dar Arab-D Max. 0.2 6.3 2.7 24.0 10.2 7.0 0.9 3.5 1.2 2.1 3.2 38.7 550
Berri Arab-B Min. 0.1 1.2 1.1 4.3 6.7 9.7 1.7 6.1 2.3 3.6 3.5 59.8 139
Berri Wt. Avg. 0.1 1.5 2.1 4.6 6.4 9.2 1.5 5.7 2.2 3.6 3.7 59.3 145
Berri Hanifa Max. 0.1 6.6 8.9 24.9 10.2 7.2 0.9 3.5 1.2 2.1 2.8 31.6 659
Dammam Arab-D Min. 0.2 2.8 1.0 21.9 2.0 1.5 0.3 1.3 0.4 0.9 4.7 63.1 353
Dammam Wt. Avg. 1.4 4.8 1.7 22.6 2.1 1.6 0.4 1.4 0.8 1.3 3.6 58.4 360
Dammam Arab-D Max. 1.5 5.5 2.2 22.4 1.6 1.1 0.2 0.8 0.4 0.9 3.4 60.0 353
Fadhili Arab-D Min. 0.0 2.9 4.1 33.4 11.1 6.8 0.5 3.9 0.8 2.5 3.2 30.7 955
Fadhili Wt. Avg. 0.1 2.3 5.5 31.8 12.8 8.3 0.9 3.8 1.0 2.0 1.4 30.3 962
Fadhili Arab-D Max. 0.1 9.8 11.1 25.8 9.3 7.1 0.9 3.5 1.2 2.0 1.8 27.4 955
Fazran L. Fadhili Min. 0.3 3.8 0.6 21.0 11.3 9.3 1.2 5.2 1.8 3.4 3.7 38.5 1100
Fazran Wt. Avg. 0.2 4.5 1.5 21.5 11.3 8.5 1.0 4.1 1.3 2.5 4.0 39.5 565
Fazran L. Fadhili Max. 0.1 2.1 2.2 34.0 11.7 6.8 0.8 3.7 1.3 2.2 2.1 33.0 1100
Haradh Arab-D Min. 0.3 1.4 0.0 19.5 10.5 10.0 1.2 5.1 1.6 2.8 2.8 44.7 470
Haradh Arab-D Wt. Avg. 0.2 3.8 0.4 22.2 9.5 8.5 1.1 4.5 1.6 2.8 3.9 41.4 470
Haradh Arab-D Max. 0.2 4.8 0.8 27.4 10.7 8.2 1.0 3.9 1.3 2.3 2.0 37.6 470
Harmaliyah Arab-D Min. 0.1 4.8 1.7 25.5 11.8 8.3 0.9 3.8 1.2 2.3 3.1 36.6 772
Harmaliyah Arab-D Wt. Avg. 0.1 5.1 4.1 27.7 11.4 7.8 0.9 3.7 1.3 2.4 3.0 32.7 772
Harmaliyah Arab-D Max. 0.1 5.3 5.3 24.9 10.6 7.6 0.9 3.8 1.2 2.3 3.2 34.8 772
Hawiyah Arab-D Min. 2.1 4.8 0.2 29.4 6.9 5.8 0.8 3.5 1.2 2.2 3.0 40.2 485
Hawiyah Arab-D Wt. Avg. 1.0 4.8 0.8 22.8 9.1 7.9 1.0 4.1 1.4 2.6 3.5 40.9 485
Hawiyah Arab-D Max. 0.4 4.1 1.1 15.9 8.3 7.6 1.0 4.3 1.7 3.4 6.0 46.1 485
Khurais Arab-D Min. 0.3 1.4 0.0 13.8 9.2 8.9 1.3 4.8 1.7 3.1 4.0 51.4 277
Khurais Arab-D Wt. Avg. 0.5 1.9 0.6 13.7 9.3 9.2 1.2 4.9 1.7 3.0 3.8 50.1 277
Khurais Arab-D Max. 0.8 4.5 2.9 12.8 6.1 8.9 1.4 4.9 1.9 3.0 3.9 48.7 277
Page 27 of 32
Table A8 – Oil Field Data from Exploration and Producing (Cont'd)
Components (mole %)
Well Name Reservoir Range N2 CO2 H2S C1 C2 C3 i-C4 n-C4 i-C5 n-C5 C6 C7+ GOR
Khursaniyah Arab-D Min. 0.1 2.5 2.0 19.4 9.8 8.6 1.1 4.5 1.7 3.1 3.2 44.0 350
Khursaniyah Wt. Avg. 0.2 3.1 2.4 21.5 9.8 8.5 1.1 4.2 1.5 2.6 2.8 42.3 380
Khursaniyah Arab-B Max. 0.1 4.7 4.8 15.8 7.2 6.9 1.0 3.8 1.5 2.7 2.9 48.7 350
Mazalij Arab-D Min. 0.1 3.4 1.9 28.7 5.8 6.4 1.0 3.7 1.4 2.2 3.2 42.1 398
Mazalij Arab-D Wt. Avg. 0.3 2.6 3.2 19.2 8.0 7.5 1.1 4.3 1.7 2.7 4.0 45.4 398
Mazalij Arab-D Max. 0.3 1.6 5.5 5.3 8.7 8.3 1.2 5.0 2.1 3.4 5.6 53.0 398
Qatif Fadhili Min. 0.2 3.5 3.7 38.2 12.3 7.4 0.9 3.6 1.2 2.2 3.0 23.8 1266
Qatif Wt. Avg. 0.9 6.6 7.9 14.4 7.0 7.2 1.0 4.1 1.6 2.7 3.8 43.0 330
Qatif Arab-D Max. 0.3 6.7 11.9 20.8 9.0 7.1 1.0 3.6 1.4 2.2 3.6 32.5 870
Shedgum Arab-D Min. 0.3 5.4 0.8 25.0 10.0 7.7 1.0 3.9 1.3 2.4 3.3 38.9 540
Shedgum Wt. Avg. 0.2 5.3 1.1 24.4 9.9 7.8 1.0 4.0 1.4 2.4 3.2 36.2 540
Shedgum Arab-D Max. 0.2 5.4 1.6 24.3 9.8 7.6 1.0 3.9 1.3 2.4 3.3 39.3 540
Uthmaniyah Arab-D Min. 0.1 3.8 0.2 26.1 9.7 7.7 0.9 4.2 1.6 3.0 3.4 39.4 515
Uthmaniyah Arab-D Wt. Avg. 0.2 4.5 0.8 24.6 10.0 8.1 1.0 4.1 1.4 2.5 3.3 39.3 515
Uthmaniyah Arab-D Max. 0.1 5.2 1.6 23.9 9.2 7.7 1.1 4.4 1.5 2.7 4.1 38.7 515
Page 28 of 32
Table A9 – Gas Field Data from Exploration and Producing
Mol Wt. Component (mole %)

Range
Well Name Reservoir N2 CO2 H2S C1 C2 C3 i-C4 nC4 iC5 nC5 C6 C7 C8 C9 C10+
North Ghawar (Ain Dar and Shedgum)
ANDR-277 Khuff-B 23.1 Min. 14.7 3.8 0.7 70.4 4.9 1.8 0.4 0.6 0.2 0.2 0.2 0.3 0.4 0.3 1.1
SDGM-226 Khuff-C 23.7 Med. 11.8 3.7 3.6 69.4 5.1 2.0 0.5 0.8 0.3 0.3 0.4 0.4 0.4 0.3 1.1
SDGM-212 Khuff-C 24.6 Max. 11.5 3.9 6.0 66.6 5.0 2.1 0.5 0.8 0.4 0.3 0.5 0.6 0.6 0.4 1.0
Central Ghawar Area (Uthmaniyah)
UTMN-622 Khuff-B 25.5 Min. 10.5 1.7 2.3 68.4 6.7 3.0 0.6 1.2 0.5 0.5 0.7 0.8 0.8 0.6 1.8
UTMN-616 Khuff-C 24.9 Med. 11.5 3.3 5.2 66.0 5.8 2.5 0.5 1.0 0.4 0.4 0.6 0.6 0.6 0.5 1.3
UTMN-2000 Khuff-C 26.4 Max. 10.2 3.1 9.3 62.0 6.2 2.7 0.5 1.0 0.3 0.3 0.6 0.9 0.8 0.6 1.5
South Ghawar Area (Hawiyah)
Khuff-C 27 Avg. 9.6 2.2 2.5 68 6.7 2.9 0.5 1.1 0.4 0.4 0.7 1.0 1.0 0.7 2.2
Khuff-C 26.6 Min. 9.8 2.3 0.5 69.4 6.8 3.0 0.5 1.1 0.4 0.4 0.7 1.0 1.0 0.7 2.2
Khuff-C 27.1 Med. 9.6 2.2 3.0 67.7 6.6 2.9 0.5 1.0 0.4 0.4 0.7 1.0 1.0 0.7 2.2
Khuff-C 27.2 Max. 9.4 2.2 4.5 66.6 6.5 2.8 0.5 1.1 0.4 0.4 0.7 1.0 1.0 0.7 2.1
South Ghawar Area (Haradh)
Khuff-C 25 Avg. 9.0 1.5 0.6 71.1 7.4 3.3 0.6 1.4 0.5 0.5 0.6 0.8 0.8 0.6 1.2
Khuff-C 25 Min. 9.0 1.5 0.5 71.2 7.4 3.3 0.6 1.4 0.5 0.5 0.6 0.8 0.8 0.6 1.2
Khuff-C 25 Med. 9 1.5 1.0 70.9 7.4 3.3 0.6 1.4 0.5 0.5 0.6 0.8 0.8 0.6 1.2
Khuff-C 25 Max. 9 1.5 2.0 70.1 7.3 3.3 0.6 1.4 0.5 0.5 0.6 0.8 0.8 0.6 1.2
Qatif
QTIF-51 Khuff-A 20.9 Min. 6.5 9.1 7.2 75.8 1.2 0.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
QTIF-152 Khuff-B 24.7 Max. 42.2 2.0 11.2 42.2 0.9 0.2 0.0 0.2 0.0 0.0 0.1 0.8 0.0 0.0 0.0
Abqaiq
Abq Cap
Gas Abqaiq 0.7 8.6 2.3 64.5 14.1 6.1 2.2 0.9 0.3 0.1 0.1 0.1 0.0 0.0 0.0
Berri
Berri Khuff Berri 23.2 10.0 8.2 19.8 61.4 0.3 0.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
The table below shows examples of the maximum RERs for some fields. The RER values shown
are based on the calculation information above and the maximum open flow and highest sour gas
concentration typically expected the fields listed. The values below are for example only.
RER100ppm RER30ppm RER½LFL

Gas Fields
(meters) (meters) (meters)
Abqaiq Gas Cap 1170 3170 170
North Ghawar (Ain Dar and Shedgum) 1420 4090 160
South Ghawar (Haradh) 460 1210 160
South Ghawar (Hawiyah) 1110 3050 180
Uthmaniyah 2740 7110 170
Page 29 of 32
RER100ppm RER30ppm RER½LFL

Oil Fields
(meters) (meters) (meters)
Abqaiq 1780 4140 620
Abu Jiffan 1270 2660 220
Ain Dar 850 2130 160
Dammam 460 770 100
Fazran 280 960 100
Haradh 910 2250 210
Harmaliyah 1340 3060 190
Hawiyah 490 1130 220
Khurais 950 2010 200
Khursaniyah 1340 2890 200
Mazalij 1880 3820 300
Shedgum 530 1270 170
Uthmaniyah 700 1590 240
Page 30 of 32
Gas Field RER Work Sheet
Information Value
Well Name
Field
Absolute Open Flow, Qgas MMSCFD
Mole % of H2S in Gas, [xH2S]gas
DATA from Table A6
Minimum AOF, MMSCFD, per Table A6
Maximum AOF, MMSCFD, per Table A6
Is AOF for well greater than minimum ( ) Yes (continue)
and less than maximum AOF for field? ( ) No (stop: Contact LPD/TSU)
Minimum mole percent (%) of H2S per Table A6
Maximum mole percent (%) of H2S per Table A6
Is H2S mole % for well greater than minimum ( ) Yes (continue)
and less than maximum flow rate for field? ( ) No (stop: Contact LPD/TSU)
Constants from Table A6
e
f
g
h
l
m
Calculate H2S Release Rate
QH2S = (QAOF)(xH2S) [MMscfd of H2S]
Calculate RERs
f
RER100 ppm = e(QH2S) :
h
RER30 ppm = g(QH2S)
m
RER½ LFL = l(QAOF)
Results
RER100 ppm
RER30 ppm
RER½ LFL
Page 31 of 32
Oil Field RER Work Sheet
Information Value
Well Name
Field
Maximum Flow Rate, Qoil Mbpd
GOR, scf/stb
Mole % of H2S in Oil, [xH2S]oil
DATA from Table A7
Minimum Flow Rate, Mbpd, per Table A7 or Qoil
Maximum Flow Rate, Mbpd, per Table A7 or Qoil
Is flow rate for well greater than minimum ( ) Yes (continue)
Minimum mole percent (%) of H2S per Table A7
Maximum mole percent (%) of H2S per Table A7
Is H2S mole % for well greater than minimum ( ) Yes (continue)
Constants from Table A7
a b
e f
g h
l m
Calculate flashed gas release rate
Qgas = (Qoil)(GOR)/1,000 [MMscfd]
Calculate the H2S concentration in flashed gas
b
[xH2S]gas H2S]oil
QH2S = (([xH2S]gas)/100)Qgas [MMscfd of H2S]
Calculate RERs
f
RER100 ppm = e(QH2S)
h
RER30 ppm = g(QH2S)
m
RER½ LFL = l(Qgas)
Results
RER100 ppm
RER30 ppm
RER½ LFL
Page 32 of 32
Shaffer
A Varco Company
Spare Parts List for 13-5/8” 10M

Model ‘SL’ Large Bore ‘V’ Shear Rams
BOOSTER KIT: 10” BOOSTER ASSEMBLY CONVERSION KIT FOR

1. 124992 13-5/8” 10M WP TYPE ‘SL’ RAM BOP, NACE (COMPLETE WITH 2 EA
22 COMPONENTS).
RAM SHAFT: POSLOCK FOR 13-5/8" 10M WP TYPE 'SL' BOP,

2. 114651 2 EA
NACE.
RAM SHAFT SUB-ASSEMBLY (RSSA): FOR 13-5/8" 10M WP

3. 132492 2 EA
TYPE 'SL' BOP, NACE.
4. 030102 CYLINDER O-RING: 2 EA
5. 030791 CYLINDER O-RING: 2 EA
6. 030105 CYLINDER BACK-UP RING: 2 EA
7. 030061 MANIFOLD O-RING: 8 EA
8. 030065 HINGE BRACKET O-RING: 4 EA
POSLOCK PISTON ASSEMBLY: FOR 13-5/8" 10M WP TYPE 'SL'

9. 134481 2 EA
BOP, NACE.
RAM V-SHEAR: COMPLETE WITH 13-5/8” 10M WP ULTRATEMP ™

10. 1 EA
ELASTOMERS (350 DEGREES F AND 20% H2S)
RAM RUBBER ASSEMBLY: UPPER, V-SHEAR, ULTRATEMP ™

11. 1 EA
(350 DEGREES F AND 20% H2S)
12. RAM RUBBER ASSEMBLY: LOWER, V-SHEAR, ULTRATEMP ™ 1EA

(350 DEGREES F AND 20% H2S)
10/01/02

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Enter table of Contents

4th Edition May, 2010

CHAPTER A : EQUIPMENT REQUIREMENTS ......................................1-1

CHAÿPTER B: BOP SYSTEMS .....................................................................* 2-1

CHAPTER C : MAINTENANCE, TESTING AND RECERTIFICATION .....3-1

CHAPTER D : WELL CONTROL POLICIES .............................................. 4-1

CHAPTER E : WELL CONTROL DRILLS ................................................... 5-1

CHAPTER F : SUPPLIMENTAL INFORMATION....................................... 6-1

INTRODUCTION AND DOCUMENT CONTROL

2. Volume 2 contains industry information that is subject to only occasional revision.

Workover Rigs and Management.

Revisions and Updates will be controlled as follows:

Current Revision: May, 2010 INT - 1 Rev. INT - 1/4.0

INTRODUCTION AND DOCUMENT CONTROL

Updates and Revisions to printed copies will be controlled as follows:

Current Revision: May, 2010 INT - 2 Rev. INT - 2/4.0

INTRODUCTION AND DOCUMENT CONTROL

Current Revision: May, 2010 INT - 3 Rev. INT - 3/4.0

CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

1.0 PRIMARY BOP EQUIPMENT REQUIREMENTS

1.2 Annular Units and Diverters A-5

1.4 Variable Bore Ram Preventer Blocks and Elastomers A-6

1.5 Shear Blind Ram (SBR) Blocks and Elastomers A-6

2.3 Requirements for Drilling Chokes A-10

2.4 Requirements for Valves A-11

2.5 Requirements for Cup Testers A-12

3.0 ACCESSORY BOP EQUIPMENT REQUIREMENTS

3.2 Mud Flow Indicators A-12

3.3 Gas Busters A-12

3.4 Full Opening Safety Valves A-14

3.5 Inside BOP A-15

3.6 Trip Tank A-15

3.7 Mud-Logging Units A-16

3.8 Bowl Protectors (Wear Bushings) A-16

3.9 Valve Removal Plugs A-16

Current Revision: May, 2010 A-1 Rev.A-1/4.0

CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

3.12 Chiksans A-17

3.13 Accumulator Closing Units A-17

3.14 Stroke Counters A-18

3.16 Drill Rate Recorders A-19

Current Revision: May, 2010 A-2 Rev.A-2/4.0

CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

1.1 General Requirements

2) For equipment to be considered 'grandfathered' it must be accompanied by a waiver from

Current Revision: May, 2010 A-3 Rev.A-3/4.0

CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

systems are acceptable manual locking devices.

Current Revision: May, 2010 A-4 Rev.A-4/4.0

CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

1.2 Annular Units and Diverters

2,000 psi and less 2.5% H2S and 170°F

1.2.6 Bolted, latched and screwed top annulars are acceptable.

1.3 Fixed Ram Preventers and Elastomers

Section 1.1 above.

3,000 psi stack 5.0% H2S and 250°F

Current Revision: May, 2010 A-5 Rev.A-5/4.0

CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

3,000 psi stack 5.0% H2S and 250°F

1.5 Shear Blind Ram (SBR) Blocks and Elastomers

1.5.1 SBR's are required on:

¾ Close Proximity Wells (All Wells in Populated Areas)

¾ Offshore Class ‘A’ 5,000 psi stacks (Offshore Wells)