FAT Procedure for Subsea BOP 4.06”x 2.

06” – 5M, - H2S

Figure 1: 4.06" x 2.06" Dual Bore BOP

Operator Function and Pressure Testing

Pre Test Checks for Function Tests

1. Ensure that the shear/seal rams are dressed with the correct size of shear/seal
inserts for the workstrings to be used.

Standard set-up: 2-3/8" Dia Workstring

2. Visually inspect all externals of the valve block, checking for any damage to the
indicator pins or pipework, etc.

3. Record all results on Testing Charts

Ram Operators Function Testing

1. Ensure the Dual Bore BOP operators are open

2. Apply pressure on the Close port for the Production Bore, observe the visual
indicator and note the pressure required to close the rams

Production Bore Ram Closing Pressure : _____ psi

 3. Apply pressure on the Close port for the Production Bore, observe the visual
indicator and note the pressure required to close the rams

Annulus Bore Ram Closing Pressure : _____ psi

4. Apply pressure on the Open port for the Production Bore, observe the visual
indicator and note the pressure required to close the rams

Production Bore Ram Opening Pressure : _____ psi

5. Apply pressure on the Open port for the Annulus Bore, observe the visual indicator
and note the pressure required to close the rams

Production Bore Ram Opening Pressure : _____ psi

6. Pump to Close all Operators

7. With all Operators Closed, Close the Wedge lock for Production bore and note the
pressure required to close the lock

Production Bore Lock Closing Pressure : _____ psi

8. Close the Wedge lock for Annulus bore and note the pressure required to close the
lock

Annulus Bore Lock Closing Pressure : _____ psi

9. Open the Wedge Lock for Production bore and note the pressure required to open
the lock

Production Bore Lock Opening Pressure : _____ psi

10. Open the Wedge Lock for Annulus bore and note the pressure required to open the
lock

Annulus Bore Lock Opening Pressure : _____ psi

Ram Operator Pressure Testing

Pressure Test Close side of Production Ram Operator

1. Remove the line on the Production Bore Open Port and connect it to the Production
Bore close port (do not connect a return line to the Open port as we will observe any
leaks through this port)

2. Slowly apply hydraulic pressure through the Close port of the Production Ram
operator and move the rams to the close position
 3. With 300 psi on the operators, pressure test the Production Bore ram operators and
check for leaks for 5 min. No leak to be observed through the Open port

4. Slowly increase the pressure to 3000 psi, pressure test the Production Bore ram
operators and check for leaks for 5 min. No leak to be observed through the Open
port

Pressure Test Open side of Production Ram Operator

5. Remove the line on the Production Bore Close Port and connect it to the Production
Bore open port (do not connect a return line to the Close port as we will observe any
leaks through this port)

6. Slowly apply hydraulic pressure through the Open port of the Production Bore Ram
operator and move the rams to the Open position

7. With 300 psi on the operators, pressure test the Production Bore ram operator and
check for leaks for 5 min. Leak criteria is No leak

8. Slowly increase the pressure to 3000 psi, pressure test the Production Bore ram
Operator and check for leaks for 5 min. Leak criteria is No leak

Pressure Test Close side of Annulus Ram Operator

9. Remove the line on the Production Bore Open Port and connect it to the Annulus
Bore close port (do not connect a return line to the Open port as we will observe any
leaks through this port)

10. Slowly apply hydraulic pressure through the Close port of the Annulus Ram operator
and move the rams to the close position

11. With 300 psi on the operators, pressure test the Annulus Bore ram operators and
check for leaks for 5 min. No leak to be observed through the Open port

12. Slowly increase the pressure to 3000 psi, pressure test the Annulus Bore ram
operators and check for leaks for 5 min. No leak to be observed through the Open
port

Pressure Test Open side of Annulus Ram Operator

13. Remove the line on the Annulus Bore Close Port and connect it to the Annulus Bore
open port (do not connect a return line to the Close port as we will observe any leaks
through this port)

14. Slowly apply hydraulic pressure through the Open port of the Annulus Bore Ram
operator and move the rams to the Open position
 15. With 300 psi on the operators, pressure test the Annulus Bore ram operator and
check for leaks for 5 min. No leak to be observed through the Open port

16. Slowly increase the pressure to 3000 psi, pressure test the Annulus Bore ram
Operator and check for leaks for 5 min. Leak criteria is No leak

Shell Test of Rams

Pre-Test Preparations for Shell Tests

1. Connect Hydraulic lines to Open port and open the rams

2. Connect the Bottom flanges of the BOP with the Test Flange.

3. Fill up the BOP bores with water and close the top flange with a Blind flange.

4. Open the Bleed off port on the top of the flange and pump fluid via the test flange to
remove all air and close the Bleed off port

5. Record all results on Testing Charts

BOP Shell Test

1. Increase Pressure of the Production bore to 350 psi and test for 5 min. Leak Criteria
is No leak to be observed during pressure testing (Low pressure test)

2. Increase Pressure of the Production bore to 5000 psi and test for 15 min. Leak
Criteria is No leak to be observed during pressure testing

3. Release all Pressure in the Production bore and switch to Annulus bore

4. Increase Pressure of the Annulus bore to 350 psi and test for 5 min. Leak Criteria is
No leak to be observed during pressure testing

5. Increase Pressure of the Annulus bore to 5000 psi and test for 15 min. Leak Criteria is
No leak to be observed during pressure

6. Release pressure from Annulus bore and complete shell test

Ram Sealing Test

Pre-Test Preparations for Ram Sealing Test

1. With the above setup. Follow the below steps

a. Remove the Top Flange and Close both Production and Annulus Rams
b. Remove any excess Water on top of the rams
Ram Sealing Test Tests

1. Increase Pressure of the Production bore to 350 psi and test for 5 min. Leak Criteria
is No leak to be observed during pressure testing (Low pressure test)

2. Increase Pressure of the Production bore to 5000 psi and test for 15 min. Leak
Criteria is No leak to be observed during pressure testing

3. Release all Pressure in the Production bore and switch to Annulus bore

4. Increase Pressure of the Annulus bore to 350 psi and test for 5 min. Leak Criteria is
No leak to be observed during pressure testing

5. Increase Pressure of the Annulus bore to 5000 psi and test for 15 min. Leak Criteria is
No leak to be observed during pressure

6. Release pressure from Annulus bore and complete Ram Sealing Test.

Shear Test (This is an Optional Test but verifies the shear capability)

Pre-Test Preparations for Shear Test

1. With the above setup, follow the following tests

a. Prepare a 2-3/8” Coiled Tubing test sample with certificates to be run

through the production bore

b. Prepare a 1-3/4” Coiled Tubing test sample with certificates to be run

through the annulus

Shear Test

1. Run the 2-3/8” Coiled tubing sample through the Production Bore and ensure at the
bottom portion has an approximate gap of 1 in from the test flange

2. Close the Shear and Seal Rams and shear the Coiled tubing.

3. Remove the remainder of the 2-3/8” coiled tubing from top of the ram and test the
ram as follows

a. Increase Pressure of the Production bore to 350 psi and test for 5 min. Leak
Criteria is No leak to be observed during pressure testing (Low pressure test)

b. Increase Pressure of the Production bore to 5000 psi and test for 15 min.
Leak Criteria is No leak to be observed during pressure testing.
 4. Switch to the Annulus Bore and Run the 1-3/4” Coiled tubing sample through the
Production Bore and ensure at the bottom portion has an approximate gap of 1 in
from the test flange

5. Close the Shear and Seal Rams and shear the Coiled tubing.

6. Remove the remainder of the 1-3/4” coiled tubing from top of the ram and test the
ram as follows

a. Increase Pressure of the Annulus bore to 350 psi and test for 5 min. Leak
Criteria is No leak to be observed during pressure testing (Low pressure test)

b. Increase Pressure of the Annulus bore to 5000 psi and test for 15 min. Leak
Criteria is No leak to be observed during pressure testing.

Drift Test

Pre-Test Preparations for Drift Test

1. Required Drifts
a. 4.0625” API Drift for the Production Bore
b. 2.0625” API Drift for the Annulus Bore

Note: The AX gaskets for the running tools .were the subject of an engineering standard
change which opened up the drift ID by 0.030" to allow passage of API drifts

Production Bore Annulus Bore

Bore Size 4.0925” 2.0925”
Drift Size 4.0625” 2.0625”

Drift Testing

1. Run the 4.0625” API Drift through the production bore. Drift is not to stickup at any
place

2. Run the 2.0625” API Drift though the annulus bore. Drift is not to stickup at any
place.