IADC/SPE

IADC/SPE 23900

A Field Guide for Surface BOP Equipment lnspections

W.J. Kandel and D.J. Streu, Chevron Services Co.
SPE Members

Copyright 1992, IADC/SPE Drilling Conference.

This papar was prepared for presentalion ar the 1992 IADC/SPE Drllllng Conference held in New Orleans, Louisiana, February 18-21, 1992.

This papar was selected for presentatlon by an IADC/SPE Program Commillee following review of information conlained in an abstract submltted by the author(s). Contents of tns papar,
as presented, have not been reviewed by the Sociely of Petroleum Engineers or ths lnternatlonal Association of Drilling Contractors and are subject lo correctlon by the authorts). The
material, as presentad, does not necessarily reflect any position of ths IADC or SPE, their officers, or members. Papers presentad at IADC/SPE meetings are subject to publication
review by Editorial Commillees of the IADC and SPE. Permission to copy is restricled loan abstrae! of not more than 300 words. !llustralions may not be copiad. The abstrae! should
contain conspicuous acknowledgmenl of where and by whom the paper is presentad. Wrile Librarían, SPE, P.O. Box 833836, Richardson, TX 75083-3836 U.S.A. Telex, 730989 SPEDAL.

Abstract been published. This document details the procedures

required to complete a visual inspection and hydraulic
This document describes a detailed inspection procedure operator test.
used to detect faulty BOP stacks and control systems. It
includes a comprehensive visual inspection and a Equipment addressed in the visual inspection includes the
hydraulic operator test procedure, both of which enhance annular and ram preventers, chokes and valves, and the
a routine pressure test. accumulator unit. A hydraulic operator test sequence is
presented for the annular and ram preventers, which
The goal of the authors is to provide a field guide to assist assesses the pressure integrity of their operating chambers
wellsite personnel in performing thorough BOP equipment and associated seals. The possible leak paths are also
inspections. The ultimate goal is to ensure the BOP stack noted.
and control systems are in proper working condition.
The intent of this document is to assist wellsite personnel in
performing thorough surface BOP equipment inspections.
Introduction These procedures can be implemented on location or prior
to transporting the BOPs to the wellsite. Any equipment
Drilling a well using faulty BOP equipment can prove to deficiencies, noted and corrected pnor to nipple-up
be hazardous and costl y. Although pressure tests are activities, can have a positive impact on the operation's
routinely performed and excepted as a sufficient check, "repair downtime".
damaged components or pending failures often go
undetected. Equipment deterioration can result in less A) Visual Inspection of the Annular Preventer
than desired BOP performance, leading to injury or death,
loss of equipment and environmental disruption. A study For many well control situations, the initial attempt to halt
indicates one in five blowouts is a direct result of BOP fluid flow is made by closing the annular preventer. The
1
equipment malfunction or failure. design of the annular enables it to sea! around differing
pipe and too! diameters. (The various annular components
A successful pressure test, when complimented by a discussed in this section are illustrated in Fig. 1). Before
comprehensive visual inspection and hydraulic operator starting the visual inspection, ensure the control hoses from
test, can greatly enhance the probability of the BOP the accumulator are isolated.
equipment performing as its design intended. Severa!
documents outlining pressure testing techniques have 1) Packer U nits

References and illustrations at end of paper The packer unit consists of a rounded elastomer, reinforced
with flanged steel segments that control rubber flow and

523
2 A FIELD GUIDEFOR SURFACE BOP EQUIPMENT
extrusion (Fig. 2). When closing pressure is transmitted to
the packer, it displaces and deforrns the rubber radially
inwards. This forrns a seal around the pipe or tool in the
BOP bore, providing an effective barrier from wellbore
pressure. Toe packer can also seal off an "open" BOP
bore, but this greatly accelerates packer wear and is
recommended for emergency situations only.
The packer visual inspection can be completed without
removing it from the annular preventer. Begin by looking
for cracked rubber surfaces and excessive wear (sections
of rubber missing or wom away). Remember that thin
cracks or splitting may not be visible until the packer is
closed around pipe. Ensure none of the steel segments
are cracked, protruding, or missing.
Packer unit hardness increases with age. As hardness
increases, it hinders the "flow" of the rubber. If the
packer has problems "relaxing" to its full opemng
diameter, the hardness value can be determined to see if
the packer requires replacement. (Hardness is determined
using a Shore 'A'durometer. Ensure the measured value
meets manufacturer specifications.)
Close inspection of the slots between the packer 's steel
segments (Fig. 2) and the void area above the packer is
necessary on certain models. These are common
locations where cement (and other solids) become lodged,
which can hamper or even prevent the packer from fully
closing. Flushing with a high pressure wash gun will often
cure this problem.
Packer rubber blistering or swelling can be attributed to
previous exposure to CO 2 or oil based mud environments.
Preventer manufacturers provide packer units designed for
specific wellbore fluids. Color and letter codes stamped
on the packer (Fig. 2) distinguish natural rubber, nitrile,
and neoprene for exposure to water based muds, oil
based muds, low temperature and H:¡S conditions.
When not in service, packers should be stored in a cool,
dry, dark location. This will help to maintain the rubber
integrity, as heat, atmosphere, and light can accelerate
deterioration.
Sorne annulars are equipped with a "piston indicator hole"
that permits the measurement of piston travel. Once the
packer is closed, the piston stroke remaining at bore seal-
off is used to indicate remaining packer life.2 Subsequent
measurements will establish a "wear trend". It is important
to note that wear associated with closing the packer
occurs on the outer diameter and wear due to
stripping/snubbing pipe occurs on the inner diameter.
Therefore, routine closing and opening of the packer has
524
INSPECTIONS IADC/SPE 23900
little effect on the stripping life of the packer.
The packer unit can be replaced with pipe in the wellbore.
As this involves splitting the packer, it should only be
performed in an emergency situation. Cut down one side
of the packer, between two of the steel segments, using a
sharp knife. A saw is not recommended because it
removes part of the rubber, possibly effecting the
performance. As the packers are manufactured with the
rubber in compression, placing the cutting surface in
tension, by prying between the steel segments with a bar,
will help to make for an easier knife cut. Once the packer
is split, it can be stretched apart and slipped around the
pipe (Fig. 3). Replace the cut packer with one that has not
been split as soon as possible. Instances have been
recorded where split packers have prevented bits/tools
from entering the wellbore on subsequent trips.
2) Bore
The bore of the annular should be inspected for
"keyseating" and gouging. Keyseating occurs where
rotating or tripping pipe wears away at the bore in a
localized area. This is easily recognized at the top of the
bore, where the varying "wall thickness" of remaining steel
can be observed by using the stainless steel ring groove as
a reference. If wear increases the bore diameter by more
than 3/16 of an inch 3, the BOP manufacturer should be
consulted. Metal burrs and rolled edges resulting from
keyseating or gouging can be carefully removed using an
emery cloth or fine file.
3) Ring Grooves
As tlanged connections are bolted together, the ring gasket
between them yields "plastically", conforming to the
contour of the ring groove. The resulting primary pressure
sealing area (discussion limited to 6B and 6BX tlanges) is
the outer diameter of the ring groove. Minor blemishes and
light rust located here can be removed by polishing with a
4
very fine emery cloth (300 + grit). A more abrasive cloth
can scar the groove, causing the tlange connection to leak.
Pitting, scratches and cracks are more detrimental to the
outer diameter's effective sea!, sometimes requiring the ring
groove to be welded, machined and stress relieved. ·
Since the ring groove's inner and bottom surfaces provide
little or no effective seal, small amounts of pitting or
scratches on these surfaces rarely present a problem.
However, excessive pitting may allow the compressed ring
gasket to flow inward, preventing an effective sea! with the
outer diameter. Any metal burrs should be removed with a
very fine emery cloth.
IADC/SPE 23900 W. J. KANDEL & D. J. STREU
Ring groove inspection should not be limited to the bottom
flange. Toe annular's top ring groove must also provide
an effective seal, as situations arise where equipment
requmng pressure integrity is installed on top of the
annular (additional BOPs, snubbing unit, lubricator). To
help maintain the condition of the top ring groove, ensure
a ring gasket is installed between the annular and bell
nipple.
4) Bolt Roles
The bolt boles surrounding the upper ring groove must be
free of debris and allow studs to be fully tumed into every
bolt hole. Damaged bolt hole threads may prevent proper
equipment make up to the top of the annular preventer,
leading to a faulty sea! between the connections. If
possible, the threads should be checked with a thread
profile template. If one is. not available, a "field method"
is to install a stud in the bolt hole and wiggle it back and
forth to determine if "excessive play" justifies thread
repair. (Remember, these bolt boles may be required to
secure a lubricator or snubbing unit). To help maintain the
integrity of the bolt boles (and the ring groove), ali bolts
should be used when installing a bell nipple.
5) Control Hose Connectors
lnspect the condition of the threads used for the hydraulic
control hose connectors. Ensure there are no galled
threads that could result in a line disconnect (or leak)
when under pressure. Also note the length of the
connecting nipples. A minimized length aids in protecting
these lines from falling objects.
6) Wear Sleeve (ifapplicable)
Sorne annular preventers have a wear sleeve installed to
protect the piston. Ensure this is still firmly attached to the
annular's body and inspect the drainage slots for mud and
cement. Debris trapped in the slots can scar the piston
and restrict piston movement. If the annular's head and
packer unit are removed (discussed in the next section),
the wear sleeve can also be removed to better assess any
wear or damage.
7) With Head and Packer Unit Removed
The authors do not advocate the removal of the annular's
head and packer unit for every visual inspection, as this
can be an involved procedure. However, if the packer
unit is deemed unacceptable or the annular fails either the
Hydraulic Operator or Pressure test, (thus requmng
replacement of the packer unit or seal assemblies), an
excellent opportunity is provided to perform a visual
525
3
inspection of the inner body and associated parts. If the
reason for head removal is a damaged packer unit, first
perform the Hydraulic Operator test. Fluid leaks due to
faulty sea! assemblies are identified by this test, and repair
can coincide with the packer replacement.
a) Piston, Sea) Assemblies, and Cylinder Walls
Check the piston walls for pitting and longitudinal
seores. Minor pitting and gouging can be removed by
polishing with an emery cloth. If the piston has a
tapered bowl, any pits and gouges should be filled with
a permanent type adhesive, like an epoxy. 5 Toe intent
is to produce a relatively smooth surface. Metal burrs
on the inner diameter should be removed to prevent
them from cutting the packer unit. Toe outer diameter
of the piston should also be smooth, to prevent any
damage to the seal assemblies.
Inspect the cylinder walls for pitting and scoring. Pay
particular attention to the open and close chambers,
where burrs could damage the seals. Finally, note any
nicks and cuts on the seal assemblies, to determine
their origin. Replace if the cut covers the surface from
edge to edge. Also look for fraying of lips and general
abrasion.
b) Wear Plate (ifapplicable)
Sorne annulars have a wear plate installed on the
bottom side of the annular's head. This plate protects
the cap from the packer unit's metal fingers, as they
deflect off of it during routine closure. Grooves or
channels etched into the wear plate indicate
considerable wear. For this situation, the manufacturer
recommends the plate be replaced, to prevenl
excessive wear that will damage the annular's head 6•
When re-assernbling "screw type" heads, pipe dope
should not be used as a thread lubricant. Dried pipe
dope makes future head removal very difficult. An anti-
seize cornpound, such as molybdenum disulfide
lubricant, is recommended.
B) Visual lnspection of the Rams
Ram preventers consist of two ram blocks that house
elastomer packers, and are connected to independent
operating pistons that have a common hydraulic supply.
Closing pressure forces the ram blocks across the bore into
one another, providing the seal. Pipe rams are designed to
close around specific pipe diameters, while blind rams close
4 A FIELD GUIDE FOR SURFACE BOP EQUIPMENT INSPECTIONS
on an open BOP bore. (Toe ram components discussed
in this section are illustrated in figs. 4 and 5). Before
starting the visual inspection, ensure the control hoses
from the accumulator are isolated.
1) Bore
Toe inspection procedure for the ram bore is the same as
previously described for the annular preventer. In fact, if
the annular and the rams have been part of the same
stack, the degree of bore wear could be similar.
2) Ring Grooves
All ring grooves should be inspected, including those on
the outlets. As stated in the annular section, the primary
sealing area for 6B and 6BX flanges is the outer surface of
the ring groove, which must be free of pits and scratches.
Minor blemishes and light rust can be removed by
polishing the damaged area using a very fine emery cloth
(300 + grit). Remember that an abrasive cloth can scar
the groove, enabling the connection to leak. Ensure the
ring grooves are clean and free of debris prior to installing
a new ring gasket.
3) Flange Bolts and Nuts
BOP stack movement during drilling operations can
actually stretch flange bolts (more noticeable offshore due
to increased stack motions). These bolts and nuts should
be inspected using a thread profile, replacing the ones
with galled or pulled threads. Ensure the flange bolts are
long enough so at least one full thread extends past the
made-up nut.
4) Bonnet Doors
With the bonnet doors opened, remove the ram blocks
and thoroughly wash the bonnet doors, body face, and
ram cavines. Most rams have an elastomer gasket that
seals between the bonnet door and the BOP body face.
The gasket fits in a groove machined into the bonnet door.
This groove should be clean and free of severe scars or
pitting. Previous inspections have revealed severe pitting
and washing on the back of the groove, requiring repair at
a certi fied facility.
Two types of gaskets are the most common; an elastorner
(o-ring gasket) and an elastomer with a steel reinforced
element. Toe sealing area for the o-ring gasket is the
entire groove. The steel reinforced gasket's sealing area
is primarily the back of the groove (the surface parallel to
the bonnet door face). Minar groove pitting or scratches
can be repaired using a emery cloth. Scarring or pitting
526
IADC/SPE 23900
outside of the groove area will not affect the bonnet door
seal, as is shown in Fig. 6. However, ensure there is no
damage that will prevent the bonnet door from completely
closing. Note that the gaskets should be replaced each
time the door is opened.
5) Body Face
This area is often scarred (or dented) due to debris,
misaligned steel gaskets, or raro block contact during raro
changes or bonnet door closure. Localized pitting is
common, but usually not a problem. Trouble occurs when
there are longitudinal scratches across the sealing area
(Fig. 7) or if pitting extends across the entire sealing area
(Fig. 8). Any evidence of washing is an indication of
previous leakage and the BOP should be sent to a certified
shop for repair. A straight edge (such as a machinist's
ruler) may be used to check the body face for flatness and
the severity of pitting, scratching or washing (Fig. 9). This
should be done both vertically and horizontally, looking at
the base of the straightedge for areas where light is visible.
The surface outside of the gasket sealing area should be
free of anything that may prevent the bonnet door from
closing complete[ y. Raised surfaces can be removed using
a fine, long, flat file. Care should be taken to ensure that
the file remains flat across the face of the body and only the
raised metal is removed.
6) Bonnet Bolts
The condition of the bonnet bolts greatly affects the seal
between the bonnet door and the BOP body. Galled or
pulled threads hinder proper make-up torque. Threads on
the bolts and in the BOP body should be checked with a
thread profile template.
The surface where the bolt head seats against the bonnet
door should be inspected for galling. Galling indicates
much of the bolt rnake-up torque is lost at this surface,
rather than being transferred to the threads. Insufficient
make-up torque may result in leaks between the bonnet
door and body face.
Minor galling may be repaired using a file or emery cloth.
Ram manufacturers can provide hardened washers for the
bolts, to help prevent further problems.
Lubrication of the bonnet bolts will reduce galling and
distribute the proper rnake-up torque throughout the bolt.
The threads and the surface under the bolt's head should
be coated with a molybdenum disulfide (or comparable)
lubricant. Note that applying excessive lubricant can cause
a hydraulic lock within the threaded bolt hole. (Use only
IADC/SPE 23900 W. J. KANDEL & D. J. STREU 5

manufacturer's recommended lubricants, NEVERuse pipe Operating shaft leaks associated with "lipseal" and "0-ring"
or drill collar dope.) failures are often identified by fluid dripping out the weep
hole (tattle tail), located on the bottom half of the bonnet
7) Ram Cavities door. Inspection of the weep hole can not be over
emphasized. (The authors have looked at numerous rarns
Visual inspection of the ram cavity is necessary to ensure where the weep boles were plugged or welded over.) With
the ram block elastomers have a smooth surface to seal the weep hole blocked, lip sea] (see section 10) and 0-ring
upon. As ram BOPs are designed to hold pressure only failures can go undetected. All plugs should be removed.
from below (wellbore assist), the effective sealing area is Ifthe weep hole is permanently sealed, the ram should be
the top half of the ram cavity. Light surface rust is sent to a certified facility for repair. Use of a ram with a
common if the BOP has not been in recent use. It should blocked weep hole could result in a blowout through the
be removed with a fine buffing wheel. Raised surfaces can accumulator.
damage the ram block's top seal, and should be removed.
Longitudinal scarring and gouges across the ram cavity's 10) Emergency Pack Off
sealing area are both concerns, and should be smoothed
with light buffing, filing or an emery cloth. The emergency pack off assembly (Fig. 12 ) is designed to
sea! off well bore pressure, where an operating shaft lip
8) Ram Blocks sea! failure has occurred during a well control situation. A
plastic packing is forced through a small check valve, filling
The condition of the elastomers on the ram block should a machined ring. This is designed as a temporary
be inspected for cracking, blistering, cutting or missing replacement of the failed seals, to prevent the possibility of
rubber. Realize that cuts across the elastomer may wellbore fluids entering the ram's hydraulic chambers and
provide leak paths, requiring elastomer replacement. The running back to the accumulator unit. Most ram preventers
pipe ram block should be inspected for cracking and any with working pressures of 5000 psi (35,000 kPa) and
evidence of hang off damage. greater have emergency pack off assemblies.

Quite often blind rams have deep gouges on the top side,
caused by bit contact while the rarn blocks are still closed.
The gouges will not effect the pressure integrity of the ram
as long as no burrs cause damage to the sealing area
within the ram cavity.
The back of sorne ram blocks are designed to be flat,
which should be confirmed using straightedge (Fig. 10).
Any outward deformation indicates an obstruction prevent-
ing the rams from fully opening, or the ram being opened
with excessive pressure. This could also indicate possible
damage to the ram operating shaft and/or foot.
9) Ram Operating Shaft
The operating shaft should be inspected for scratches or
pitting which could result in a hydraulic fluid leak. Ensure
shaft straightness and that the ram foot is square with the
shaft. Determine ifany cracking has developed where the
foot is welded to the shaft.
The only conclusive way to verify "an energized" emergency
pack off is to disassernble the bonnet door. However, a
good indicator is to determine the amount of plastic
packing still above the check valve. This is done by
removing the top cap and the first hex head screw. If the
emergency pack off has been energized (even slightly), the
packing will have been pushed down further than the
thickness of the hex head screw. The bonnet door should
be disassembled and repaired in this case.
The condition of the packing can be visually inspected by
pulling it out with a "cork screw". lt should be soft enough
to allow easy insertion of a fingernail.
As previously stated, this pack off is an emergency sea!
only and should not be energized during pressure testing
operations. If a leak occurs during testing, the operating
shaft sea! should be replaced.
11) Locking Devices

Hydraulic pressure should never be used to open "hinge" Locking devices are designed to hold the rams in the
type bonnet doors. This action may bend the shaft and/or closed position if accumulator operating pressure is lost or
damage the foot. Inspection of the shaft and foot will removed. Manual devices are more common for surface
indicate this misapplication (Ultrasonic or magnetic particle stacks, but self-locking models are sometimes incorporated.
inspection may be required for detection of very small
cracks). Depending on the manufacturer, the manual locks either
screw inward or unscrew to hold the rams closed. Yerify

527
6 A FIELD GUIDE FOR SURFACE BOP EQUIPMENT INSPECTIONS IADC/SPE 23900

which style is present. In either case, the threads on the ram sections. Individual valve disassembly may be required
locking shafts should be in a condition that allows the if it fails a pressure test, or to confirm the valve has the
locks to easily be closed. Since each manual locking proper components (eg. H:zS trim).
device works independent of the other, both sides must be
locked.
D) Visual Inspection of Accumulators
12) Control Hose Connectors
A rig accumulator unit consists of a reservoir tank,
Inspect the condition of the threads used for the hydraulic accumulators bottles that store pressurized hydraulic fluid,
control hose connectors. Ensure there are no galled a charging system to "energize" the hydraulic fluid, and an
threads that could result in a line disconnect or leak when operating manifold that houses the 4-way valves which
under pressure. Also note the length of the connecting direct the fluid flow. The purpose of the accumulator unit
nipples. A minimized length aids in protecting these lines is to provide pressurized fluid that will promptly function
from falling objects. the blowout preventers. (The components discussed in this
section are illustrated in Fig. 13).

C) Visual Inspection of Valves and Chokes 1) Prior to Energizing the Unit

Most operations utilize a manual and an HCR (high closing a) Charging Systerns
ratio) valve coming off a drilling spool, connected to a
line running to a choke manifold. The authors do not The accumulator unit comes equipped with at leas! one
advocate dismantling the choke manifold for every type of pump, either electric or air. (Many units have
inspection. However, ifthe manifold has not been used for both). lts purpose is to energize the accumulator
an extended period of time, or if cement is found in bottles and assist in the rapid closure of the BOP. In
selected areas, then disassembly may be necessary to colder climates, where the air pumps may be
ensure val ve integrity. If the manifold is enclosed, ali inoperable, a nitrogen system supplements the electric
electrical wiring should be inspected to ensure an pump. This back up system is tied directly into the
intrinsically safe environment. operating manifold, using a check valve to isolate it
from the accumulator bottles.
1) Chokes
Before commencing with the visual inspection, ensure
It is not uncommon to find chokes rigged up backwards. power to the electric pump and the air supply to the air
Circulating through a choke in this manner will erode the pump are both turned "off". Also isolate the pumps
body, possibly causing it to fail during operation. The flow from the reservoir tank by closing the suction valves,
resistant (hardened) material should be located located upstream of the pump suctions.
downstream of the choking mechanism.
Numerous articles are available that detail accumulator
Prior to installation, the condition of the actual choking volume and pump sizing procedures. Therefore, they
mechanism and the downstream diameter should be will not be addressed.
inspected for washing or cutting. Also look for cement
and other solids. i) Electric Pumps

2) Valves As the accumulator unit may be located in a

potentially explosive environment, ensure there are
Gate valves are comrnonly used for stack and manifold no exposed wires. The guard, covering the chain
valves. Ensure the handles for the manual valves are or belt connecting the motor to the pump,
present and that each val ve operates easily. Ali val ves sometimes vibrates loose and should be secured.
should be fully greased. Toe actuator for the HCR valve Ensure routine maintenance includes checking the
will be tested during the hydraulic operator test. oil level in the pump's crankcase and chain guard.

The bore of the valve should be inspected for washing or ii) Air Pumps
plugging. Cement and mud cuttings are often found
embedded in valve bores. Inspection of the ring grooves Check the condition of the air filter and lubricator.
should follow the procedures outlined in the annular and Ensure the lubricator contains a sufficient amount

528
IADC/SPE 23900 W. J. KANDEL & D. J. STREU
of oíl. Inspect the condition of the low pressure arr
line running into the pump(s).
. For both pumping systems, ensure the high
pressure discharge lines are secured to the
accumulator unit. The suction strainers, located
upstream of the pumps, should be removed and
cleaned. This provides an opportunity to assess
the condition of the hydraulic fluid, by exposmg
the types of contaminants present.
iii) Nitrogen Backup System
Although it is not considered to be a charging
system, bottles of nitrogen can be used to operate
desired BOP components. Ensure the nitrogen
bottles are secured in an upright position and note
the individual pressures. (Sizing will depend on
the pressure of the bottles and the components to
be functioned). Inspect the condition of the hoses
and junctions connecting the bottles to the
manifold line.
b) Accumulator Bottles
Accumulator bottles store pressurized hydraulic fluidto
facilitate the quick operation of the BOPs. The bottles
stand together in multiple rows (banks) and vary in
number, depending on the accumulator volume
requirements. Once the appropriate number of bottles
is determined, verify the position of the "bank isolation"
valves. (These valves permit a row of bottles to be
taken "off service" - isolate the row). Accidental
isolation of an entire row could result in a less than
anticipated volume of hydraulic fluid (based on the
sizing calculations). Sorne bottles are fumished with
individual isolation ball valves, whose position should
be checked.
Also note the posmon of the "bank bleeder" valves,
which allow pressure to be bled from a particular row
of bottles. These valves (if present) are normally
closed.
Accumulator bottles contain either a float or bladder
configuration that separates a nitrogen pre-charge
from the pressurized hydraulic fluid. Prior to checking
the pre-charge, ensure the hydraulic fluid has been
drained off. Connect a pressure gauge (Fig. 11) to the
"Schrader valve" (looks like a bicycle stem) located on
the top of the bottle. After the pre-charge pressure is
read, make the appropriate nitrogen additions or
deletions. This procedure should be performed on
every accumulator bottle. Note that subsequent tests
529
7
willindicate ifthere is any communication between the
nitrogen and the hydraulic fluid .
e) Operating Manifold
The common operating manifold consists of severa!
4-way valve control stations, three pressure gauges, two
pressure regulators, and a pressure by-pass valve. Ali
of these iterns should have labels attached, indicating
their respective functions. In addition, the blind ram or
shear/blind ram control station should be guarded by
a "screening device", that has to be lifted or moved
before the blind or shear/blind 4-way valve handle can
be manipulated. The intent of this deterrent is to
confirm "operator assurance" prior to selecting the valve
handle, thereby discouraging accidental use of the blind
rams. Toe deterrent design should not impair
manipulation of this valve handle from an accumulator
remole station (such as a "Forked Finger" design does).
d) Reservoir Tank
The height of the hydraulic fluid in the reservoir tank
must be measured to ensure enough fluid is available.
For tanks not having a fluid view glass, the fluid height
can be determined by removing the tank inspection
plugs on the sides and measuring the leve!. The
corresponding volume is then calculated. API7
recommends the tank be able to hold at least two times
the useable fluid required for the accumulator bottles.
Also, since hydraulic fluid types vary (" 10 weight" oil to
"water soluble/ biodegradable" oils), ensure the fluid in
the reservoir complies with the intended operating
environment (eg. offshore, extreme cold).
e) Additional lterns
i) Pressure Relief Valve
The purpose of the pressure relief valve is to
prevent overcharging of the accumulator. This
valve vents hydraulic fluid back to the reservoir tank
in the event that the pump "pressure switch" fails to
stop the pump. A resetting spring-loaded model
and a replaceable "burst disk" model are both
common. Removal of either model's top cover will
indicate whether the valve needs to be reset (spring
type) or the burst disk replaced.
ii) Control hoses
The control hoses are the high pressure lines that
carry hydraulic fluid from the accumulator to the
BOPs. As accumulators are required to deliver
8 A FIELD GUIDE FOR SURFACE BOP EQUIPMENT INSPECTIONS IADC/SPE 23900

considerable fluid volumes over a short time frame, Note that when the 4-way valve is placed in the "block"
it is vital that the control hoses be free of any posrtion, operating pressure is trapped in the BOP
damage (constrictions) that may slow fluid chamber and line containing hydraulic fluid. Fluid will
delivery. Toe sections of flexible control hoses not drain back to the reservoir tank ("vent" is isolated)
merit a very close visual inspection. Make every unless the 4-way valve is leaking. Toe valve can leak
effort to protect them from falling objects or two ways:
vehicles. Drilling rigs often have steel control
hoses enclosed by "suitcases", or run on top of i) Leak to the "vent", draining the pressured line
buildings, thereby reducing the chance of them and chamber into the tank.
being deformed.
ii) Leak across to the other chamber and line,
The integrity of all of the control hoses will be equalizing the pressure in both chambers. If
tested when the accumulator is pressured up and this happens to a ram preventer in the "open"
the BOPs individually function tested. Color position, fluid will flow from the "open"
coding or other distinguishing marks on each chamber to the ram's "closed" chamber,
control line will help ensure the lines are installed equalizing pressures. Toe design of the ram's
to the proper BOP component. operating piston could result in this ram
closing. Therefore, it is recommended to never
2) System Energized leave an in-service 4-way valve in the "block"
position.
a) Leak Detection
During daily operations, a system leak willbe indicated
A convenient time to determine the integrity of the by an unprompted accumulator pressure drop, with a
accumulator unit is during the BOP hydraulic operator continua! re-starting of the charging pump.
test (a detailed procedure follows this section). Once
test pressure is applied to a specific BOP component, b) Pressure Gauges
a needle valve on the "hot line" assembly is closed,
isolating the accumulator from the stack (Fig .14). The During the Operator test, prior to isolating the
unit is then inspected for leaks, which can occur at the accumulator from the BOPs, a comparison between the
charging units (faulty pump discharge check valve), accumulator pressure gauge reading and chart recorder
the manifold or annular regulators, the manifold reading gives an indication of the accumulator's
bleeder valve and any pressured line connections or pressure gauge accuracy.
control hoses. Leaks are often traced to the 4-way
valves. e) Remote Panel

Acommon "three-position" (open, block close,) 4-way Ensure each control on the remote panel is clearly
valve directs hydraulic fluid to a specified BOP identified and able to function its assigned BOP
component, either to the "open" or "close" chamber. component. Also compare the panel' s pressure gauge
Toe valve consists of two metal plates (one stationary readouts to those on the accumulator's operating
and one rotating) with a series holes in each. When manifold. For electrically operated panels, repair any
the 4-way val ve is shifted to the "close position", one exposed wires.
set of holes line up, sending hydraulic fluid to the
BOP's closed chamber. Another set of holes
simultaneously line up, allowing hydraulic fluid from the E) The Hydraulic Operator Test
BOP's open chamber to vent back into the reservoir
tank. Shifting the valve to the "open" position has the Toe hydraulic operator test determines the integrity of the
reverse effect. It is the seals surrounding the holes hydraulic chambers and associated seals. This test can
that sometimes fail, causing the 4-way valve to leak. identify Jeaks that go undetected during a routine wellsite
Shining a light into the tank inspection port will BOP pressure test. The following procedures are presented
identify any hydraulic fluid leaking out of the 4-way in a generic fashion, designed to encompass most of the
valve. (Prudence must be used when selecting the BOP manufacturers.
source of light. This could be an explosive
environment). To ensure that any leak identified is in the BOPs and not
the accumulator, a "hot line" assembly (Fig. 14) is installed

530
IADC/SPE 23900 W. J. KANDEL & D. J. STREU
to isolate the pressure between the BOPs and the
accumulator. Field application of this assembly has
proven the necessity of double valves. Using the outer
valve to bleed pressure and the inner valve to seal
pressure has greatly improved valve life.
Annular preventer hydraulic operator test
1) The annular should be closed on the pipe size that is
to be used, with 1500 psi (10,500 kPa) closing
pressure.
2) Allow the element to stabilize. Due to the large
amounts of rubber in the element, it will take a few
minutes for the element to stop "creeping".
3) Once "creeping" has ceased, lock the pressure on the
closing chamber using the "hot line" assembly. The
pressure should be monitored using a chart recorder.
4) Carefully remove the opening line and monitor the fluid
draining out. Ensure the fluid is free of sand and other
abrasives and that the fluid is the proper type for the
BOP (i.e. hydraulic fluid).
5) If there is no pressure drop in 10 minutes, the seals
are holding and proceed to step 9.
6) If the pressure drops, there are two possible leak
paths:
a) Closing chamber to the opening chamber
b) Closing chamber to the well bore
7) lf fluid continues to flow out the opening chamber
(Fig. 15), then the seals between the closing and
opening chambers are in need of repair.
8) Ifthe fluid stops running out of the opening chamber,
then the leak is into the well bore and those seals
need repair.
9) The opening line should be reinstalled and the annular
opened with 1500 psi (10,500 kPa). Lock the pressure
on the annular and monitor it using a chart recorder.
10) Carefully remove the closing line and inspect the fluid
as in step 4.
11) lf the pressure remains constant for l O minutes, the
seals are holding and the test is completed.
12) lf the pressure drops there two possible leak paths:
a. Opening chamber to the closing chamber
b. Opening chamber to the well bore
13) If fluid continues to flow out the closing chamber,
then the seals between the opening and closing
chamber need repair.
14) lf the fluid stops flowing out of the closing charnber,
the leak is into the well bore and those seals need
repair.
Two additional leaks are possible involving the hydraulic
chambers are possible:
1) From the well bore to the closing chamber
2) From the well bore to the opening chamber
531
9
Both of these leaks can result in a blowout through the
accurnulator. Identification of these leaks can be
determined by a "shell test".
a) lnstall a blind flange on top of the annular. This will
also test the condition of the ring groove and bolt
holes on the annular head. As previously stated, a
competent seal on top of the annular is needed if a
lubricator or snubbing unit is installed.
b) Rernove the opening and closing lines and pressure
test the annular. As with any pressure test, low
pressure should be done first, followed by high
pressure. Care should be taken to ensure that the
area in front of the hydraulic operating line outlets
is clear of personnel while the annular is
pressurized.
e) Any fluid leaking out of the opening or closing
charnbers indicares a leak in the respective sea!
assemblies.
If a top blind flange is not incorporated, only the bottorn
set of seals will be tested. Toe annular should be closed
around a test mandrel, using the lowest possible closing
pressure required to gel an effective sea!. This closing
pressure should be locked on the annular with the "hot line"
assembly. The annular should then be pressure tested to
a pressure higher than the closing pressure, typicall y 70 %
of the working pressure. Monitor the closing pressure
trapped on the annular (by the "hot line" assembly). If this
pressure increases, then the seals isolating the closing
chamber from the well bore are leaking and require repair.
(It should be noted that ifthe annular is "wellbore assisted",
the pressure trapped by the "hot line" assembly will
decrease when well bore pressure is applied.)
If any leak occurs during the hydraulic operator test, ali
seals, the pistan and cylinder walls should be closely
eval uated, and repaired as necessary.
Ram preventer hydraulic operator test
1) The rams should be closed on the proper pipe size (no
pipe for blind rams) and closing pressure increased to
3000 psi (21,000 kPa).
2) Lock the pressure on the closing chamber and monitor
using a chart recorder.
3) Carefully rernove the opening line and inspect the fluid
draining from the chamber, as is done with the annular.
4) Ifthere is no pressure drop in 10 minutes, the seals are
holding and proceed to step 6.
5) lf the pressure drops, there are severa! possible leak
paths:
10 A FIELD GUIDE FOR SURFACE BOP EQUIPMENT INSPECTIONS IADC/SPE 23900

a) From the closing chamber to the opemng Acknowledgements

"chamber.
• Continuous flow out of the opening chamber The authors would like to thank Chevron's Drilling
indicates the seals between the closing and Technology Center (especially the Mobile Training Section)
opening chambers are in need of repair. for providing the time and resources to prepare this
b) Around the locking mechanism document. Thanks to Hydril, rnh Koomey Inc., Cooper Oil
e) Between the bonnet door and the BOP body. Tools, and Shaffer for their permission to publish pictures
6) The opening line should be reinstalled and opening and for their technical support.
pressure increased to 3000 psi (21,000 kPa). Lock the
pressure and monitor it using a chart recorder. References
7) Carefully remove the closing line and inspect the fluid
as before. l. Hughes, V.M.; Podio, A.L. and Sepehmoori, K.: " A
8) If the pressure remains constant for 10 minutes, the Computer-Assisted Analysis of Trende Among Gulf
seals are holding and the test is completed. Coast Blowouts," paper SPE/IADC 16127 presented at
9) If the pressure drops, there are severa) possible leak the 1987 SPE/IADC DrillingConference, New Orleans,
paths: March 667-670.
a) From the opemng chamber to the closing
chamber. 2. Hydril, Ma11ual-6644A GK 13 5/8" - 5000 psi A1111ular
Continuous flow out of the closing chamber Blowout Preventer , Hydril Mechanical Products
indicates the seals between the opening and Division, Los Angeles, California (1982), p. 4-3.
closing chambers are in need of repair.
b) The weep hole. 3. Cooper Oil Tools (Cameron), Periodic lnspection of
• Flow out the weep hole indicates the seals on Cameron U and Ull Blowout Preventers , Cameron Iron
the operating shaft need repair. Works, Inc, Houston.Texas (1986), p. 10.
e) Between the bonnet door and the BOP body.
d) The hinge, if applicable. 4. lbid, p. 7.

lf any leak occurs during the hydraulic operator test, the 5. Hydril, p. 4-l.
ram bonnet door assembly should be closely evaluated,
and repaired as necessary. 6. lbid, p. 4-1.

HCR valve hydraulic operator test 7. rnh Koorney, Type 80 Surface BOP Control Equipmeni,
rnh Koomey. Houston, Texas (1991), p. 3.
This procedure is very similar to the ram test. The test
pressure should be 3000 psi (21,000 kPa) and the test
should be run from both the opening and closing
chambers. If any pressure drop occurs the leak should
be isolated and repaired in a manner similar to that of the
rams.

CONCLUSION

The inspection procedures outlined are intended to assist

wellsite personnel in completing an "all-encompassing "
BOP equipment inspection. ldentifying and repairing
deficiencies uncovered during the comprehensive visual
inspection, hydraulic operator and pressure test can
reduce the chances of equipment malfunction or failure.
In a well control situation, obtaining the expected BOP
performance is paramount if personnel safety, an
unpolluted environment, and no equipment losses are to
be attained.

532
ANNULARPREVENTER
Figure 1
RING GROOVE
BOLT HOLES BORE

HEAD

PACKER
UNIT

CYLINDER WALLS

SEAL
ASSEMBLIES

WEAR SLEEVE

PACKER UNIT SPLIT PACKER

Figure 2 Figure 3

CHECK SLOTS
FOR CEMENT

LETIERCODE

533
 RING GROOVE

RAM PREVENTOR
Figure 4

EMERGENCY PACK-OFF
(SEE FIGURE 12)

CONTROL
HOSE
LOCKING CONNECTOR
DEVICE

OPERATING SHAFT

RAM PREVENTOR
Figure 5

TOP SEAL

RAM SEALING
AREA

534
 BONNETDOOR
Figure 6

BONNET SEAL
GROOVE

RAM FOOT NOTE BAO SCORE OUTSIDE OF

SEALING AREA.

FACE SEALING AREA:SCRATCHES

Figure 7

NOTE LONGITUDINAL SCRATCHES

ACROSS THE SEALING AREA.

535
 FACE SEALING AREA:PITTING
Figure 8

NOTE SEVERE PITTING

ACROSS THE SEALING
AREA.

CHECKING FACE SEALING FLATNESS

Figure 9

NOTE LOW AREA (POSSIBLE LEAK

PATH).

536
 CHECKING FLATNESS OF RAM BLOCK PRE-CHARGE TEST PRESSURE GAUGE
Figure 10 Figure 11

ENERGIZEO EMERGENCY PACK-OFF ASSEMBLY

Figure 12
PLASTIC INJECTION SCREW

BACK-UP RINGS
(IN 10,000 ANO 15,000 PSI
W.P. PREVENTERS ONLY) CHECK VALVE

LIP SEAL, ENERGIZING RING

RETAINER RING ANO
PLASTIC PACKING RING
LOCKING RING

OPERATING CYLINOER

PREVENTERBODY----- - PREVENTER BONNET

537
ACCUMULATOR UNIT
Figure 13

ACCUMULAT MANIFOLD BLEEDER VALVE

BOTTLE
/
ANNULAR REGULATOR
BANK
BLEEDER
VALVE

BANK
ISOLATION
VALVE
r-···
j
~- <,
---

PRESSURE
RELIEF VALVE

HOT UNE ASSEMBLY HYDRAULIC OPERATOR TEST/

Figure 14 LEAK BETWEEN CHAMBERS
Figure 15
TO CHART
RECORDER

BLEED OFF VALVES

TO ACCUMULATOR

538