Annular BOP

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ANNULAR BOP

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GENERALITY

It is used at the stack top, and it can close around any tubing diameter. In case of emergency it can
perform total well closure.

It is usually the first BOP to be closed when a kick occurs.

It is used in stripping operations because it is the only type of BOP which can maintain sealing
during the tool joints passage.

Closing time (API RP 53 regulations) :

- for 20" diameters or larger: less than 45 seconds

- for diameters smaller than 20" less than 30 seconds

1.1 COMPONENTS

Annular BOPs are equipped with a piston closing device which is hydraulically operated by
applying pressure to closing and opening chambers.

The main BOP components are:

• body

• head

• piston

• closing/opening chambers

• packing unit

• seals

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Body

The body has been designed to stand high pressures and is of forged steel. It undergoes acoustic
tests to check steel homogeneity and then hydraulic tests.

Inside the body are the opening chamber and the closing chamber, and the API type threaded
holes for connection to the lines:
- opening line (top)
- closing line (bottom)

Head

The head gives access to the BOP packing unit during inspection and maintenance operations.
Annular BOPs can be equipped with three different types of head, depending on the removal
procedure:

1. SCREWED HEAD

It is connected to the body through a square

section threading and sealing is ensured by a
gasket. One possible disadvantage is that
unscrewing operations can be difficult.

2. LATCHED HEAD

It is connected to the body through a set of

latches which are controlled by suitable locking
screws. It is generally used in case of large
diameters and high pressure values.

3. BOLTED HEAD

It is connected to the body through a set of

locking screws. It is generally used with pressure
values lower than 5,000 psi.

Note: Some models are equipped with a wear plate in the internal upper part of the head, between the packing
unit and the head itself, to avoid the latter's wear. Plates are worn by horizontal friction of the packing
unit iron parts, and they thus protect the BOP body. Besides, wear plates allow to avoid the head
surface hardening treatment which would make it unsuitable for use in presence of H2S (maximum
hardness < Rockwell C26).

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Piston

Thanks to its inclination, the

piston turns the vertical
movement into radial movement.

During closing operations, its

upwards movement determines
the packer closure around the
pipe.

Hydraulic seal between piston and

body is ensured by appropriate
seals.

Opening and closing chamber

Annular BOPs have two chambers where flows the working fluid that controls the piston stroke
and therefore the BOP opening and closing. Some models have a third chamber to reduce the
effect of the well pressure on the BOP piston.

Packing unit

The packing unit represents the

actual sealing component and is a
rubber structure with steel
reinforcement (segments).
The rubber part is deformable in
order to perform sealing while the
steel segments ensure solidity thus
preventing the rubber from
extruding and reducing friction
with the BOP head.

This component is the most

critical of BOP elements and must
be regularly checked. Adequate
procedures to limit wearing
should be adopted.

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Packing units differ depending on:

 type of rubber (right)

 type of BOP where they are to be installed
 BOP nominal diameter
 BOP working pressure

Rubber components are marked and identified by coloured zones and codes printed during
manufacture.

Identification codes in compliance with API RP 53 regulations are composed of two parts:

1. hardness
2. manufacturer's component code

Note: Neoprene keeps better elasticity than nitrile rubber at low temperatures, but undergoes a worse
deterioration at high temperatures.All packing units are H2s service. Exposure to hydrosulfide can
determine serious degradation of rubber resiliency. Also temperature substantially affects rubber
properties: the longer the exposure to high temperatures, the shorter the rubber life.

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Seals

Usually, there are 7 seals, positioned

between:

 opening chamber and head

 opening chamber and closing

chamber

 closing chamber and well

They are directly energised by closing pressure and can be of two types:

 seals which are used for medium and low

pressure BOPs

 Double "U" seals which are used for High

pressure BOPs

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1.2 OPERATIONAL PRINCIPLES

Closure

When the BOP closing starts, the working fluid enters the closing chamber and pushes the
piston upwards. As a consequence the packing unit tightens more and more around the BOP
centre, sealing it.

Opening

During opening, the working fluid enters the opening chamber and pushes the piston
downwards (the closing chamber has to be discharging). The packing unit returns to its original
position opening the BOP.

Closing pressure

Annular BOPs are characterised by:

 opening/closing pressure
 maximum working pressure (WP)

Adequate opening/closing pressure values inside the chambers allow the piston to move and vary
according to BOP typology. In most cases it ranges between 700 and 1500 psi (50 - 105 kg/cm²).
Maximum working pressure is the maximum well pressure the BOP can bear and control in
working conditions. As regards closing pressure, the following statements are generally valid:

- the larger the tubing diameter, the lower the initial closing pressure;
- in case of closing of an empty well, the BOP shall be closed with the maximum allowable
pressure (1500 psi for all types except Cameron D which in case of emergency can be closed at
3000 psi.)

Annular BOPs closure can be:

- well pressure assisted

Thanks to the piston structure and shape the well pressure exerted on the piston walls produces
a force that adds to the closing pressure. The closing pressure must therefore be reduced when
the BOP is kept closed, to limit rubber wear (following manufacturer's instructions). For this
reason the closing pressure should be kept at the lowest usable value estimated for that
particular well situation.

- non well pressure assisted

The well pressure does not alter the BOP closing pressure which is therefore kept at its
reference value during the preventer closing operations.

Notes: 1 - Sometimes the piston structure determines a force which opposes to closure requiring an increase of
the BOP closing pressure.
2 - Non-assisted-closure BOPs are to be preferred in case of stripping operations.

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1.3 INSPECTION, TEST AND MAINTENANCE

Periodical visual inspection and pressure testing of the hydraulic circuit are necessary to ensure
good functioning of the BOP.

Sight inspection

1. Check upper and lower connections to detect wear, corrosion or damage, especially in the
ring joints seat and in the bolts threaded holes.
2. Check the body to detect damage and/or wear.
3. Inspect the preventer vertical bore to detect any damage due to the tool joint or drilling tools
passage.
4. Check any damage of the internal basket and clear the basket windows from any deposit
which might hamper the piston movement.
5. Inspect the packing unit to check its conditions (wear, cracks, hardening,...)
6. Check damages and wear of the piston, in particular any vertical cuts or corrosions on the
internal and external surface and on the thrust bowl-shaped surface.
7. Check wear in the inside of the head.

Hydraulic circuit pressure test

The test aims at testing the BOP gaskets tightness. After connecting the BOP closing line and
installing the preventer test tool on seat, keep to the following steps.

Test gaskets 2 and 3

- Close the BOP (at closing pressure) and check

closing pressure:

. pressure maintains sealing: gaskets are

sealing;
. pressure does not maintain sealing and no
liquid is leaking out of the opening chamber
hole: gasket 2 is not sealing;
. pressure does not maintain sealing and some
liquid is leaking out of the opening chamber
hole: gasket 3 is not sealing, gasket 2 might
be sealing or not.

If gasket 3 is leaking, close the opening line and

check sealing at gasket 2:

- release closing pressure;

- install a plug on the opening line (or close the
valve on the line);
- close the BOP and check closing pressure:
. the pressure is constant: gasket 2 is sealing;
. the pressure decreases: gasket 2 is not sealing

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Test gasket 1

- release closing pressure

- open the opening line
- apply a 1500 psi closing pressure
- pressurise the well at 1500 psi
- reduce closing pressure to 1000 psi
- close the valve on the closing line and
disconnect the line
- install a gauge on the closing line and open the
valve:

. if the gauge records a 1000 psi pressure value,

gasket 1 is sealing;

. if the gauge records a pressure value higher

than 1000 psi, gasket 1 is not sealing.

Test gaskets 4 and 5

- release well pressure

- release closing pressure
- apply opening pressure and check it:
. pressure maintains sealing: gaskets are sealing;
. pressure does not maintain sealing and no liquid is leaking out of the closing chamber hole:
gasket 5 is not sealing.
. pressure does not maintain sealing and some liquid is leaking out of the closing chamber hole:
gasket 4 is not sealing, gasket 5 might be sealing or not and must be checked.

To test gasket 5:

- release opening pressure

- block the closing line with a plug (or closing the valve on the line, if there is any)
- apply a 1500 psi opening pressure:
. pressure maintains sealing: gasket 5 is not leaking
. pressure decreases: gasket 5 is leaking

Attention: The test does not check sealing of gasket 6 between piston and head.

After carrying out the tests:

- release opening pressure
- open the closing line
- replace gaskets that have been leaking
If a valve has been installed on the closing line make sure it is open at the end of the test.

Maintenance
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To keep the BOP in good working conditions, adequate maintenance procedures and replacement
of the packing unit must be carried out whenever any damage or wear is detected through either
inspections or tests. Wear of the packing unit is mainly caused by: sunlight, high temperature,
ozone and oil. An adequate storage is therefore necessary to ensure lasting of such elements, to
reduce their ageing and deterioration. In case of long-term storage proper tight containers should
be used.
Lasting of the packing unit and of the BOP can be substantially improved by adopting operational
precautions and storage regulations indicated in the following pages.

Operational precautions

1. Limit number of closures

2. Avoid closures with an empty well
3. Apply the indicated closing pressure.
4. Reduce closing pressure for well-pressure assisted models
5. Use the type of rubber which is recommended for the mud being used and for the
environmental conditions.
6. Use the pressure regulating valve correctly during stripping
7. Store rubber parts appropriately (see storage in the next page).
8. Wash and lubricate the BOP if it has to be removed for long periods.
9. Use covers to protect flanges.
10. Avoid moving the drill string with the BOP closed.
11. When the BOP is open, make sure the travelling block lines up with the BOP stack to avoid
eccentric wear of the packing unit.

Stockage of packing units

1. Always use older parts first

2. Keep rubber parts in the darkest possible place
3. Keep rubber parts cool and as far as possible from heat sources
4. Store away from high-tension electric equipment (electric motors, switchboards)
5. Store rubber parts so that they are not subject to rubber stress (pressing, bending...)
6. Keep stockage area dry and clean from oil, grease, liquid...
7. Use tight containers in case of long-term stockage.
8. Before using the parts in stock verify that:
- there are no cracks or galling
- there is no hardening on the surface.
- do not store rubber parts outdoors or in direct sunlight;
- store away from windows or light sources to avoid exposure;
- reduce to a minimum the use of artificial light.

Note 1: Closures with an empty well (no tubing inside the well) must be carried out in case of emergency
only, since they imply great stress on the packing unit.
Note 2: When a reduction of the closing pressure is required, keep to manufacturer's indications.
Note 3: Do not store rubber parts outdoors or in direct sunlight;atore away from windows or light sources to
avoid exposure;
- Reduce to a minimum the use of artificial light.

1.4 HYDRIL BOP

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Types and models

Different models with different operational features and applications are available. The models
most commonly used by SAIPEM are:

GK, GL, MSP

The various models are available with screwed head and wedged head:

- screwed head: models GK and MSP

- wedged head: model GL; models from 11" x 5,000 psi WP; also available for models GK and
MSP.

Note: 1 - Ring Joints seats are finished with stainless steel to ensure sealing and resistance to H2S.
2 - For its annular BOPs Hydril recommends revision and disassembly every 3 years.

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Wear of packing unit

Due to the packing unit shape, front wear of the rubber is compensated by back section which is
pushed forwards by the piston (see animation). The level of rubber wear is strictly connected to
the piston stroke to allow BOP sealing.

In Hydril preventers the degree of the packing unit wear can be checked through a special hole
which allows to measure the piston stroke (and therefore the degree of the rubber stress). Testing
is carried out with the BOP in the closed position, by inserting a dip stick in the hole, reading the
stroke length and comparing it with the maximum allowable stroke, that is the "full piston stroke"
indicated in each model technical specifications:

- stroke is less than full piston stroke: the packing is in good conditions
- stroke is the same as full piston stroke: the packing is nearly worn out
- stroke is longer than full piston stroke: the packing is beyond allowance range

Rubber must be replaced when sealing is not complete and when the piston stroke is longer than
the full piston stroke.

Packing Unit Replacement

Latched head Screwed head

1. Retract jaw operating screws four turns. 1. Remove the head lock screw
This releases the jaws from the head. 2. Unscrew and lift off the BOP head, keeping
2. Remove pulldown bolt assemblies from top it slightly in tension so that it does not weigh
of head. on the thread
3. Lift off BOP head 3. Lift out the packing unit
4. Lift out packing unit 4. Lubricate the piston bowl
5. Lubricate piston bowl 5. Install a new packing unit
6. Install new packing unit 6. Clean and lubricate the head and body
7. Replace head threads
8. Install pulldown bolt assemblies on top of 7. Replace and tighten the head to align the hole
head with the lock screw at stroke end
9. Tighten jaw operating screws four turns to 8. Tighten the lock screw
block the jaws on the head.

Note: If during head assembly operations a standoff

between the BOP head and body occurs, use
pulldown bolts to pull head fully into place.
Note: If the head unscrewing is difficult, apply a high
level of torque while alternately applying and
releasing pressure to the opening chamber.
Pressurising while opening causes a vibration of
the head thus discharging friction between body
thread and head thread. Do not attempt to loosen
the head by applying heat.

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Emergency replacement

In emergency conditions, the rubber can be replaced with the pipes inside the well. In such case
keep to the following procedure:

1. remove the worn packing unit

2. use a sharp knife to cut through the new packing unit between two steel segments

3. insert the new packing unit around the pipe

GL Model

Operational features

 It is designed both for subsea and

land operations; its features make
it particularly suitable for subsea
operations and deep well drilling
which demand drill strings with
different diameters.
 It is available only with a latched
head, equipped with wear plates.
 There are three different
chambers: opening chamber,
closing chamber and secondary
chamber.
 The opening chamber has a
protector plate (opening chamber
head) which prevents
contamination of the hydraulic
system while the packing unit is
replaced.
 Sealing between ring and body is
ensured by a square-section
gasket.
 Sealing between ring and piston
is ensured by a "U" seal for the
13" 5/8 x 5000 psi WP, by a
double "U" seal for larger
diameters.
 Closure is not well pressure
assisted thanks to the third
chamber which reduces the
piston surface that is subject to
well pressure.

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Closing pressure

Maximum closing pressure 1500 psi (105 kg/cm²) which corresponds to recommended pressure
for closure with pipes out of the well (C.S.O. Complete Shut Off). Closing pressure must be
increased as a function of the well pressure, as indicated in the table on the right.

Note: The pressure value given in

the table refers to standard
chambers hook-up (see next
page).

Connection diagrams (land installations)

1- Standard surface hook-up:

secondary chamber - opening chamber

When the BOP is closed, some control

fluid goes into the secondary chamber
causing a lesser pressure loss and
therefore e lesser closure effort.

This type of hook-up requires the least

control fluid to close and thus results in
the fastest closing time.

2- Optional surface hook-up:

secondary chamber - closing chamber

This type of hook-up reduces the

closing pressure (see table) versus
standard hook-up values, because the
thrust surface is larger.

It requires more fluid to close.

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In this table,  represents the factor which, multiplied by closing pressure, gives the new pressure
value to be adopted for closure with this type of hook-up.  is the ratio of the closing chamber
area to the sum of the closing chamber area plus secondary chamber area.

Note: The secondary chamber must never be excluded by putting a plug , because depending on the type of
hook-up, this would determine either a compression of the secondary chamber hampering BOP opening
operations, or a depression, hampering closure operations.

GK Model

Operational features
 Among Hydril annular BOPs, the
GK model is the most common.
 It is mainly used on land rigs but it
can also be used with subsea stacks.
 Two models are available: with
screwed head and with latched head
for the 11" x 5000 psi WP model and
larger.
 Closure is well pressure assisted.
 Most recent models are equipped
with wear plates.

Closing pressure

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To carry out closing procedure apply

the defined initial pressure and then
reduce it as the well pressure
increases to keep pressure to a
minimum value, limiting rubber
stress.

Closing initial pressures can be

determined through operator's
manual (see table on right).

Model MSP 2000 psi

Operational features

 Suitable for both land and subsea rigs.

 It is used with working pressure values
lower than 2000 psi and with large
diameters, in middle-depth drillings.
 Two models available: with a screwed
head and with a latched head.
 Well-pressure assisted closure.

Closing pressure

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Closing initial pressure can be

determined through manufacturer's
tables depending on dimensions of
BOP and of pipes inside the well.

The table on the right shows suitable

closing initial pressure value for model
MSP 2000 in surface installations.

Model MSP 29 1/2" 500 psi

Operational features

 Model MSP 29 1/2" 500 psi is also used as a diverter in land rigs.

 It has closing chamber only. Opening takes place because of piston weight opening the closing
line.

 When increasing pressure inside the well, the closing chamber pressure must be increased
because the well pressure forces rubber to open.

 The head has no wear plate but there is a protector plate in the opening chamber (opening
chamber head).

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1.5 NL SHAFFER BOP

Operational features

 This model is particularly

suitable in case of frequent
closures and stripping
operations.

 Two versions are available:

1. with bolted head in small
size models and with low
working pressure values
2. with latched head in larger
models and with high
working pressure values

 It has a nylon wear gasket

(wear band) to center the
piston movement.

 Closure is partially assisted by

well pressure.

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Packing unit

 The special head spherical cavity requires

a shorter stroke for closing and reduces the
surface in contact with pipes while
substantially reducing also packing unit
wear. It also allows to have more spare
rubber available.

 Segments always return to the initial

opening position even in case of badly
worn rubber.

 No detection system is available to test Packing unit

rubber wear.

 In this type of BOP, the rubber radial

movement is not due to the piston. The
piston only pushes the packing unit
upwards. Thanks to the head internal
cavity and to the rubber particular shape,
when the piston pushes the rubber
upwards, the latter moves towards the
centre sealing off.

Segments

Packing unit replacement

1. Unscrew bolts and lift the head

2. Lift out the packing unit
3. Lubricate bottom and walls of the new packing unit
4. Install a new packing unit
5. Lubricate the head bowl
6. Replace and tighten the head

Note: In cese of emergency the packing unit can be replaced with pipes inside the well by cutting and opening
the new one.

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Closing pressure

With diameters smaller than 7" closure is accomplished

- at 1500 psi if the drill string does not need to be moved,

- at a lower pressure value if stripping operations are necessary.

For diameters larger than 7", keep to the chart below.

Maintenance

Manufacturer's recommended maintenance operations:

1. inspect packing unit once a year; the wear-control hole not being available, it will be
necessary to disassemble the head and inspect the packing unit.

2. carry out complete disassembly once every three years replacing worn parts and any other
packing unit rubber part.

3. after replacing the aforesaid, carry out:

- seals well pressure test

- chambers (opening and closing) sealing hydraulic test
The hydraulic test should be carried out by applying a pressure that is twice as high as
the working pressure.

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1.6 CAMERON "D" TYPE

Operational features

 It is available in different versions with

diameters from 7" 1/16 to 21" 1/4 and
well pressure up to 20.000 psi.
 It is equipped with a special type of
packing unit: when opening or closing,
the segments rotate like a camera
shutter, reducing friction between
segments and rubber.
 Cameron vertical dimensions are small.
The whole stack can be lifted by
provided lifting rings.
 Closure is not well pressure assisted.

Parts

Body

The body lower end can be either flanged or clamp hub. Four pad-eyes for the BOP lifting are
welded on the body.

Head

The head is fixed to the body by a lock ring by an indented ring which perfectly matches the
internal body indentation. The lock ring is expanded by an actuator ring blocked by four
screws positioned in the provided head seats and blocked by four other screws. The locking
unit upper part is protected by a rubber gasket.

Packing unit

The packing unit is made of

"CAMULAR" rubber (Cameron patent)
with steel reinforcement and inserts.
These rotate and are in contact thus
creating a barrier around the body.
Rubber can stand up to 120C°, it is H2S
service and can be used also with oil-
based mud.

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Donut

The Donut is a rubber component which turns the working piston vertical thrust into radial
force applied to the packing unit at closure.

Inner/Outer cylinder

Cylinders allow the seals to work statically on the BOP body internal surface avoiding friction
with parts in motion (such as the working piston). Chambers stay closed and protected during
the packing unit replacement.

Piston

Sealing between piston and body is ensured by lip seals. The piston upper part is connected
through a set of screws to a wear plate which conveys motion to the donut.

Operations

Closure

During closure the control fluid pushes the

piston upwards and the piston, through the
wear plate, deforms the donut. The latter's
expansion causes the packing unit closure.

Opening

The control fluid pushes the piston

downwards allowing the donut to take its
initial position; the packing unit returns to
the opening position.

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Closing pressure

The closing pressure is completely independent

from the well pressure. It is 1500 psi and can reach
3000 psi in particular working conditions.

Without pipes inside the well the closing pressure

value corresponds to the maximum pressure value
(3000 psi)

The closing pressure must never reach a value

lower than 1500 psi, except during stripping
operations.

The table on the side shows volumes, in gallons, of

some Cameron-D models opening and closing
chambers.

Packing unit replacement

1. Remove lock screw upper protection

2. Lubricate screws
3. Unscrew lock screws 1
4. Insert lifting eyes and lift off head 2
5. Remove packing unit. Check donut wear making sure there are no deep cuts, cavities,
deteriorated parts. Replace the donut if necessary.
6. Insert the new packing unit and the new donut, if necessary.
7. Reinstall the head following reverse procedure.

Note 1: Two wrenches are needed to unscrew two opposite screws at a time:

- unscrew for a few turns the lock screws until the screw itself tightens.
- start unscrewing the two other screws
- operate alternately until complete loosening of the four screws (stroke end)

Note 2: The donut might be trapped in the head and it must be loosened.

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1.7 STRIPPING

Generality

Stripping is an emergency procedure to maintain well control running or retrieving any tubing,
such as pipes or casings, with pressure in the well.

Only annular BOP can keep the well sealed during the tool joints stripping. This is the reason why
they are used during stripping operations.

Stripping represents a BOP most critical operation, because the tool-joints passage determines a
serious rubber wear.

In case of low pressure ratings the stripping operation is carried out using an annular BOP alone,
whereas in case of higher pressure ratings, both annular and ram BOPs are used.

Operational recommendations

 To allow the tool joints passage and in order to obtain the longest rubber life, adjust the BOP
closing pressure value low enough to maintain a seal with a small drilling fluid leakage as the
tool joint passes through the packing unit. This leakage indicates the lowest allowable working
pressure and lubricates rubber during pipes stripping through the packing unit.

 For closing pressure values, see the manufacturer's indications:

CAMERON and HYDRIL NL SHAFFER

Reduce closing pressure until a small Reduce closing pressure to a value given in
quantity of fluid starts to leak. tables provided by the manufacturer detecting
any fluid leakage.

 Drill pipes can be rotated during stripping.

 The pressure regulating valve should be set to maintain the proper closing chamber pressure. If
the pressure regulating valve cannot respond fast enough to compensate diameter variations of
the pipes passing through the packing unit, a 10-gallon accumulator should be installed on the
closing line near the BOP.

 The accumulator must be precharged with nitrogen to 50% of the initial closing pressure.

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