OIL INDUSTRY SAFETY DIRECTORATE

तेल कुं आ नियुंत्रण

ओआईएसडी - एसटीडी - 174
WELL CONTROL
OISD-STD-174

Inception October 1998

1st Revision 2008

2nd Revision 2016

3rd Revision XXXX 2023

FOR RESTRICTED CIRULATION ONLY

OIL INDUSTRY SAFETY DIRECTORATE

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: https://www.oisd.gov.in Tele: 0120-2593833,
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 Page No I

PREFACE

Indian petroleum industry is the energy lifeline of the nation and its continuous performance
is essential for sovereignty and prosperity of the country. As the industry essentially deals
with inherently inflammable substances throughout its value chain – upstream, midstream
and downstream – Safety is of paramount importance to this industry as only safe
performance at all times can ensure optimum return of these national assets and resources
including sustainability.
To ensure proper implementation of the various aspects of safety in the oil & gas industry,
the Government of India, vide Resolution No. R-13013/4/84-OR-1 dated 10th January,
1986 set up a Safety Council at the apex, under the administrative control of the Ministry of
Petroleum & Natural Gas (MoP&NG). To assist the Safety Council, a technical directorate,
namely the Oil Industry Safety Directorate (OISD) under the aegis of MoP&NG, has been
entrusted with the responsibility of formulating standards, overseeing its implementation
through safety audits to enhance safety level in the oil & gas industry.
OISD has developed a rigorous, multi-layer, iterative and participative approach for
development of standards. OISD develops and revises Standards, Guidelines &
Recommended Practices for the oil and gas sector through a participative process involving
all the stakeholders (including the public at large), drawing inputs from international
standards and adapting them to Indian conditions by leveraging the experience of the
constituents. These standards cover inbuilt design safety, asset integrity and best operating
practices in the field of production, processing, storage and transport of petroleum.
The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry. It also goes to prove the old adage that self-regulation is the
best regulation. The quality and relevance of OISD standards had been further endorsed
by their adoption/ reference in various statutory rules and regulations of the land.
OISD and industry together strive to achieve nil incident in the entire hydrocarbon value
chain. We at OISD, are confident that the provisions of this standard, when implemented in
totality, would go a long way in ensuring safe operation in the oil and gas industry.

Executive Director
Oil Industry Safety Directorate
 Page No II

NOTE

Oil Industry Safety Directorate (OISD) publications are prepared by the Oil and Gas industry
under the Ministry of Petroleum & Natural Gas. This standard is a property of Oil Industry
Safety Directorate (OISD) and shall not be reproduced or copied and loaned or exhibited to
others without written consent from OISD.
OISD standards are published to facilitate sound engineering, operating practices and aimed
to supplement the information to the oil and gas industry, however this may be used by anyone
desiring to do so and are not intended to obviate the need for applying sound engineering
judgement regarding when and where these standards should be utilized. The formulation and
publication of OISD standard is not intended in any way to inhibit anyone from using any other
practices and not to replace the prevailing statutory requirements, which must be followed as
applicable.
Wherever Acts/ Rules/ Regulation and National/ International Standards are mentioned in the
standard, the same relates to in-vogue version of such documents. Whenever there is any
difference between the statutory norm and OISD standard, more stringent requirement should
be followed. However, in case of any difference in the requirement between OISD standards,
the requirement as specified in the standard released at a later stage shall prevail.
The industry has to carry out gap analysis and make necessary changes in their system in line
with the revised standard and the requirement should be implemented within a time frame of 1
year (from the date of release of revised standard).
Though every effort has been made to assure the accuracy and reliability of the information
contained in these documents, OISD hereby expressly disclaims any liability or responsibility
for loss or damage resulting from the use of OISD standard.
The standards would be reviewed periodically based on the decision in the Steering
Committee/ Safety Council, industry request, technological development, recommendations of
high level committee and accident investigation reports. Generally, OISD standards are
reviewed and revised, reaffirmed or withdrawn at least every ten years.
Suggestions for revision are invited from the oil and gas industry and should be submitted to
OISD at ps-ed.oisd@gov.in.
 Page No III

CURRENT FUNCTIONAL COMMITTEE

NAME DESIGNATION ORGANISATION

LEADER

Ajay Dixit ED Oil and Natural Gas Corporation Ltd.

MEMBERS
Chitrapu Srinivas GGM (P) Oil and Natural Gas Corporation Ltd.
Satyabrata Bhattacharjee CGM (D) Oil and Natural Gas Corporation Ltd.
A.R. Shrivastava CGM (D) Oil and Natural Gas Corporation Ltd.
Jagannath Chetia CGM (D) Oil India Limited.
Jaya Raman Gupta Unit Lead-Well RIL, Planning & Engineering
Vivek Dixit DGM (D) Oil and Natural Gas Corporation Ltd.
Rohit Patil In-charge Workover/ Cairn Vedanta WCT
Rajnish Baruah Additional Director Oil Industry Safety Directorate

MEMBER COORDINATOR
N.J. Vijay Prasad Consultant Oil Industry Safety Directorate

OISD sincerely acknowledge the valuable contributions made by industry veteran Sh. V P Mahawar by
providing their technical & professional guidance for revision of this standard. OISD also recognize the
support & cooperation of several other experts from industry, who contributed to the preparation, review
and finalization of this document.
 Page No IV

WELL CONTROL

INDEX

Section Description Page

1.0 Introduction 1

2.0 Scope 1

3.0 Definitions 1

4.0 Planning for Well Control 5

4.1 Well Planning 5

5.0 Diverter Equipment and Control System 6

5.1 Recommended practices for diverter system 7

6.0 Well Control Equipment & Control System 8

6.1 Equipment Selection 8

6.2 Periodic Inspection and Maintenance 9

6.3 Surface Blow out Prevention Equipment 11

6.4 Subsea Blow out Prevention Equipment 15

6.5 Choke Manifold And Kill Manifold And Co-Flex Hoses 21

6.6 Wellhead, BOP Equipment and Choke & Kill Lines Installation 23

6.7 Blow out Preventer Testing 24

Minimum Requirements for Well Control Equipment for Workover Operations

6.8 28
(on land)

7.0 Procedures and Techniques for Well Control (Prevention and Control of Kick) 28

7.1 Cause of Kick 28

7.2 Cause of Reduction in Hydrostatic Head 28

7.3 Kick Indication 29

7.4 Prevention and Control of Kick 29

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7.5 Kick Control Procedure 31

8.0 Drills and Training 36

8.1 Drills 36

8.2 Well Control Training 40

9.0 Monitoring System 41

9.1 Instrumentation Systems 41

9.2 Trip Tank System 41

9.3 Mud Gas Separator (MGS) 41

9.4 Degasser 41

10.0 Under Balanced Drilling 41

10.1 Procedures for UBD 42

11.0 Well Control Equipment Arrangement for HTHP Wells 44

12.0 References 45

13.0 Abbreviations 46

Annexure – A to H 48-66
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1.0 INTRODUCTION
Primary well control is maintained by hydrostatic pressure in the wellbore at least equal to (preferably
more than) the formation pressure to prevent the flow of formation fluids. During drilling and workover
operations flow of formation fluids into the wellbore is considered as kick. If not controlled, a kick
may result in a blowout. For safety of personnel, equipment and environment, it is of utmost
importance to safely prevent or handle kick.
This document provides standard guidelines on selection, installation and testing of well control
equipment. This document also include procedure for preventing occurrence of well kick while drilling
and tripping, safe closure of well on detection of kick, procedures for well control drills, during drilling
and workover operations.
Recommendations for the surface installations are applicable to sub-sea installations also unless
stated otherwise and wherever applicable.
All the sections/ sub-sections of this document mentioning ‘drilling’ are relevant to ‘workover
operations’ also, wherever applicable. Terms like ‘drilling fluid’ would also mean ‘workover fluid’ in
the context of workover operations.

2.0 SCOPE
This document covers selection, installation, testing and maintenance of well control equipment both
surface and sub-sea, standard practices for well kick prevention and well control procedures,
competence requirement) for personnel (training and drills), in drilling and workover operations.

3.0 DEFINITIONS
3.1 Annular Blowout Preventer:
A device, which can seal around different sizes & shapes of object in the wellbore or seal an
open hole.
3.2 Accumulator:
A device having pressure vessel charged with nitrogen or other inert gas and used to store
hydraulic fluid under pressure for operation of blowout preventers, subsea failsafe valves (for
offshore) and/ or diverter system.
3.3 BOP Control Unit:
Provides energy in form of hydraulic pressure to operate the BOP stack.
3.4 Blowout:
An uncontrolled flow of well fluids and/ or formation fluids at surface or sub-surface from the
wellbore.
3.5 Blow-Out Preventer (BOP):
A device attached to the casing head that allows the well to be sealed to confine the well fluids
to the wellbore.
3.6 Blowout Preventer Stack:
The assembly of well control equipment (including preventers, spools, valves, and nipples
installed on top of the well head.
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3.7 Bottom-Hole Pressure (BHP):

Sum of all pressures that are being exerted at the bottom of the hole and can be written as:
BHP = Hydrostatic pressure + Dynamic pressures + Surface pressure
Hydrostatic pressure in a wellbore is due to fluid column density acting at the bottom of the well.
Dynamic pressures are exerted either due to fluid movement or any pipe/ tool movement in the
wellbore.
Surface pressure can be defined as any pressure measured at the surface while circulating
through choke or the back pressure exerted at the surface during well shut-in condition.
The details of various kinds of Bottom Hole Pressure (BHP) are placed at Annexure-A
3.8 Choke Manifold:
The assembly of valves, chokes, gauges, and piping to control flow from the annulus/ tubulars
while maintaining back pressures at the surface, keeping the BOPs closed.
3.9 Connection gas:
A distinct increase in gas quantity above a normal background gas quantity when bottoms-up
circulation occurs after a pipe connection.
3.10 Control Pod:
The assemblage of valves and pressure regulators, which respond to control, signals to direct
hydraulic power fluid through assigned porting to operate functions.
3.11 Degasser:
A fluid/ gas separator vessel which utilizes a vacuum pump to separate dissolved gas from the
wellbore fluid during drilling/ circulation.
3.12 Diverter:
A device attached to the wellhead or marine riser to close the vertical access and divert the flow
safely away from the rig.
3.13 Down-hole Isolation valve (DIV):
A full-opening drill through valve, installed down-hole as an integral part of a casing / liner string,
at a depth either below the maximum pipe light depth for the work string being tripped in the
underbalanced operation (drill string, casing, completion string, etc.) or at a depth that allows the
maximum length of BHA, slotted liner or sand screen etc. required to be safely deployed, without
having to snub-in or kill the well prior to deployment.
3.14 Equivalent Circulating Density (ECD):
Equivalent Circulating Density is equal to original drilling or completion fluid density + Annular
pressure losses in terms of equivalent fluid density.
3.15 Equivalent Mud Weight (EMW):
Equivalent Mud Weight is equal to original Mud weight + Annular pressure losses in EMW +
Weight of drilled cuttings existing in the annulus.

3.16 Fracture Pressure:

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The pressure required to induce a fracture in a sub- surface formation (geologic strata).
Fracture pressure can be estimated by Geo-physical methods; During drilling, fracture pressure
can be determined by conducting a leak off test.
3.17 Full Opening Safety Valve (FOSV):
Full Opening Safety Valve is a ball valve having ID equal to that of ID of tubulars in use and
designed for high pressure condition which can hold pressure from both directions. It is installed
in open condition on the top joint of any tubulars at the rig floor and closed quickly when well kick
occurs.
3.18 Gate Valve:
A valve that employs a sliding gate to open or close the flow passage. The valve may or may not
be full opening.
3.19 Hydrostatic Pressure:
Hydrostatic pressure in a wellbore is due to fluid density acting at the depth of interest.
The magnitude of hydrostatic pressure depends upon the density and vertical height of fluid
column. Hydrostatic pressure can be calculated by the following formula:
Hyd. pressure (psi) = 0.052 x mud wt.(ppg) x TVD (feet) Hyd. pressure (kg/cm 2)
= Mud wt. (gm/cc) x TVD (mts.)/10
Where,
TVD – True vertical depth
3.20 Influx:
The Volume of formation fluid taken during a kick into the wellbore.
3.21 Internal Blow out Preventer (IBOP):
Internal Blow out Preventer is a device that can be installed in the string to prevent back flow &
allows during stripping in hole which acts as a check valve, and it allows drilling fluid circulation
down the string.
3.22 Kick:
A kick is an influx of unwanted formation fluids into wellbore, when BHP becomes less than the
formation pressure. Kick can lead to blowout, if timely corrective measures are not taken.
3.23 Kill Rate:
Kill rate (Reduced circulating rate) is required when circulating kicks so that well kill operations
can be managed without exceeding mud pump liner rating and excessive back pressure in the
wellbore. In case of subsea operation, lower circulating rate is maintained to avoid excessive
choke line friction.
3.24 Kill Rate Pressure:
The circulating pressure measured at remote choke panel when the mud pumps are operating
at the kill rate.
3.25 Kill Manifold:
Kill manifold is an arrangement of high-pressure gate valves, pipelines and check valves which
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provide a means of pumping fluid into the wellbore when normal circulation down the drill string
through Kelly or drill pipe cannot be established.
3.26 Kelly Cock:
A high-pressure valve installed immediately below and above the Kelly that can be closed to
confine pressures inside the drill string.
3.27 Leak Off Test (LOT):
Leak off test is a procedure used to determine the pressure required to induce a fracture in the
exposed formation. Generally, LOT is conducted in exploratory/ appraisal well after opening up
the casing shoe and drilling few meters into the fresh formation.
3.28 Lower Marine Riser Package (LMRP):
Lower Marine Riser Package is the upper section of Subsea BOP stack consisting of a hydraulic
connector, annular BOP, ball / flex joint, riser adapter, jumper hoses for choke, kill and auxiliary
lines and subsea control pods. This interfaces with lower BOP stack.
3.29 Marine Riser System:
The extension of the wellbore from the subsea BOP stack which provides for fluid returns to the
floating drilling vessel and supports the choke, kill, and control lines, guides tools into the well,
and serves as a running string for the BOP stack.
3.30 Maximum Allowable Annular Surface Pressure (MAASP):
It is maximum allowable annular surface pressure which can be applied at the annular surface
over and above the hydrostatic pressure before fracturing the formation. MAASP value should
not exceed the surface equipment rating.
3.31 Mud Gas Separator (MGS):
A device that removes gas from the drilling fluid returns by gravity, when a kick is being circulated
out. Mud gas separator is also known as gas buster or poor-boy degasser.
3.32 Pipe-light:
‘Pipe-light’ occurs at the point where the formation pressure across the pipe cross-section
creates an upward force sufficient to overcome the downward force created by the pipe’s weight.
3.33 Pore Pressure:
Pressure exerted by fluids trapped in the pore spaces of the formation rock is termed as formation
pressure or pore pressure. It can be expressed in various ways like:
In terms of pressure - psi or kg/cm2
In terms of pressure gradient - psi /ft or kg/cm2 /meter.
In terms of equivalent mud wt. - ppg or gm/cc.

3.34 Riser Margin:

Riser Margin is the mud weight increase below the mud line to compensate bottom-hole pressure
in case of a planned / accidental disconnect of the marine riser / LMRP.

3.35 Shall:
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The term “shall” denote a minimum requirement in order to conform to the standard.
3.36 Should:
The term “should” denote a recommendation to be followed as a standard well control practices.
3.37 Trip Gas:
Trip gas is the accumulated gas which enters the wellbore when the mud pumps are shut, and
trip is being made.
3.38 Trip Margin:
Trip margin is the small amount of drilling fluid weight carried over that is needed to balance
formation pressure to overcome the pressure reduction effects caused by swabbing during
tripping operations.
3.39 Umbilical:
A bundle of helically wound small diameter flexible hoses, steel tubes, optical fibre cables or
electrical cables. These provide interface between surface installations and subsea installations
for controls viz hydraulic/ electrical power, medium for fluid injection and/ or communication
services.
3.40 Under-Balanced Drilling (UBD):
A drilling operation, when the hydrostatic head of a drilling fluid is intentionally (naturally or
induced by adding natural gas, nitrogen, or air to the drilling fluid) kept lower than the pressure
of the formation being drilled.
3.41 Drill through Equipment
The equipment that used for drilling oil & gas well.

4.0 PLANNING FOR WELL CONTROL

4.1 Well Planning
Well planning should form the foundation for the provision of primary well control in the form of calculated
mud weight based on predicted pore pressure.
I. Well planning should include any condition anticipated to be encountered during drilling/
completion, work over of the well, the well control equipment to be used, and the well control
procedures that are to be followed. Well integrity should be ensured throughout the life of well.
II. For effective well control, the following elements of well planning should be considered:
a) Use offset well data and drilling experiences to correlate with the planned well.
b) Casing design, kick tolerance, pore pressure, formation fracture pressure, ECD margin, down-
hole temperature prediction, temperature effect on the drilling fluid.
c) Cementation details including density of the fluids planned to be pumped and ECD expected
during the job and hydrostatic expected at the end of the job and surface pressure requirement to
maintain BHP during cement setting.
d) Drilling fluid type, density and other parameters.
e) Drilling fluid monitoring equipment.
Blowout prevention and other surface equipment selection.
f) Contingency plans with actions to be taken to mitigate the abnormalities.
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g) Contingency plan should be in place in case Hydrogen sulphide gas is expected. Gas detection
system also to be in-place.
h) Use of ported/ non-ported float in the drill string, as applicable.
i) Requirement of at least two independents, tested and verified barriers (tested at the RWP/
maximum surface pressure) at all times must be considered.
j) Carryout risk assessment for riser less drilling operations in deep-water wells and take necessary
preventive measure.
k) Ensure that barrier envelops are defined and maintained at every stage of operation.
l) Gas Detection system, kick circulation and safe disposal of hydrocarbon at surface.
III.During well planning shallow gas hazard should also be considered. Operator should carry out
risk assessment of shallow gas hazard and if required, keep in readiness sufficient amount of
fluid & enough Barite at location. ROV to be deployed at seabed for sub-sea wells for continuous
close monitoring of any flow from shallow depth.
IV. Well plan should include mitigating measures considering the following:
a) Pilot hole drilling,
b) Use of diverter.
c) Riser less drilling (with floater)

5.0 DIVERTER EQUIPMENT AND CONTROL SYSTEM

A diverter system is used during top-hole drilling; it allows routing of the annulus flow away from the rig
to protect persons and equipment. Components of diverter system include: –
➢ Annular sealing device,
➢ Vent outlet(s),
➢ Vent line(s),
➢ Valve(s),
➢ Control system.
For surface/ onshore application, large diameter Annular BOP with minimum rated working pressure of
500 psi shall be used.
Operator shall carryout proper risk assessment for shallow gas hazard and accordingly a diverter system
should be used for drilling of:
a) Subsea wells with riser system.
b) Exploratory wells where shallow gas pockets are expected.
c) Development wells where shallow gas pockets are expected.

5.1 Recommended practices for diverter system:

I. The friction loss should not exceed the diverter system rated working pressure induce undue
pressure on the wellbore and /or exceed other equipment’s design pressure, etc., e.g., marine
riser. The diverter system should be accordingly designed.
II. To minimize back pressure (as much as practical) on the wellbore while diverting well fluids,
diverter piping should be adequately sized.
III. Vent lines should be minimum 12” for offshore and minimum 8” for onshore. All the gaskets shall
be fire retardant/ fire safe material.
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IV. The diverter and Mud return (flow line) lines should be separate lines.
V. Diverter lines should be straight as far as possible, properly anchored and sloping down to avoid
blockage of the lines with cuttings etc.
VI. Diverter valves should be operated from the remote panel/ accumulator control unit. It should be
full opening type either pneumatic or hydraulic with automatic sequencing/ manual sequencing.
VII. The diverter control system may be self-contained or an integral part of the blowout preventer
control system. It should be located in safe area.
VIII. The diverter control system should be capable of operating the diverter system from two or more
locations - one to be located near the driller's console and the other one at DIC/ tool pusher office.
IX. When a surface diverter system and a sub-sea BOP stack are used, two separate control /
accumulator systems are required.
X. Size of the hydraulic control lines should be as per manufacturer’s recommendations. All the
control lines should be fire-resistant.
XI. Control systems of diverter should be capable of closing the diverter within maximum 45 seconds
and simultaneously opening the valves in the diverter lines.
XII. Telescopic/ slip joints (in case of floater/ semisubmersible rigs) should be incorporated with
double seals, to improve the sealing capability when gas has to be circulated out of the marine
riser.
XIII. Alternate means to operate diverter system (in case primary control system fails) should be
provided.
5.2 Procedures for Diverter Operations
Following procedure is recommended for use of diverter in case of shallow gas flow:
I. Open both the vent line valves.
II. Close diverter packer.
III. Close upwind side vent line valve.
IV. Open vent line towards downward wind direction, close diverter packer and close shale shaker
inlet valve.
V. In Offshore installation vent line selector valve is to be kept in downward wind direction, close
diverter packer and close shale shaker inlet valve.
VI. Continue pumping water or drilling fluid at maximum possible pump rate.
VII. Monitor and adjust diverter-closing pressure as and when required.
VIII. Take all precautions to prevent fire by isolating all potential fire hazards.
Note: Alert the personnel on the rig and evacuate non-essential personnel from the rig.
IX. In case of subsea wells, Monitor and adjust slip joint packer pressure as and when required.
5.3 Field Testing
5.3.1 Packer Integrity Test:
Diverter Closing/ Packer Integrity Test of Diverter shall be pressure tested as follows:
I. Install a mandrel (within the operating range).
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II. Close diverter using manufacturer’s recommended hydraulic operating pressure.

III. The diverter packer shall have at least 250 psi applied for a minimum of 5 minutes. Acceptance
criteria shall be no visible leakage at packer and flow line seals.
IV. Reduce pressure to zero.
V. Open diverter.
5.3.1.1 Packer Integrity Test Frequency:
The Packer Integrity Test shall be carried out under following condition:
i. Upon installation & commissioning
ii. Replacement of Packer element
iii. After Divert event
iv. Minimum once in a year.
5.3.2 Function Test
Diverter system’s function test shall be carried out to ascertain efficacy of the components under intended
operation. The Function shall be done as under:
I. At least once in a week as drilling operation allows.
II. Function tests shall be alternated weekly from the control stations where all diverter functions are
included. (Remote Panel and Local Panel).
III. Shall be carried out following the disconnection or repair, limited to the affected component.
IV. Shall be carried out after any Divert event.
V. Response times shall be documented for evaluating trends and shall be in accordance with:
a) 30 Seconds for Packing Element ID 20 inch or Less (The primary diverter closing system
shall be capable of operating the overboard line, flow line valves, auxiliary valves, and closing
the annular packing element on the pipe within 30 seconds of actuation).
b) 45 Seconds for Packing Element ID Greater than 20 in. (The primary diverter closing system
shall be capable of operating the overboard line, flow line valves, auxiliary valves, and closing
the annular packing element on the pipe within 45 seconds of actuation).
5.3.3 Flow Test
The Flow Test shall be performed at the beginning of each well upon installation. The test shall be
performed as:
I. Pump water or drilling fluid through the Diverter System.
II. Check overboard line (s) for return.
III. Check the entire system, valves, connections etc. for leaks, excessive vibration and proper tie
down.

5.3.4 Test Documentation

The results of all diverter equipment pressure and function tests shall be documented.

6.0 WELL CONTROL EQUIPMENT & CONTROL SYSTEM

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6.1 Equipment Selection

I. All the equipment including ram preventers, lines, valves and flow fittings shall be selected to
withstand the maximum anticipated surface pressure. Annular preventer can have one step lower
rating than ram BOP. (Maximum anticipated surface pressure = Maximum anticipated formation
pressure - Hydrostatic pressure of gas column in wellbore).
II. Welded, flanged or hub end connections are only recommended on all pressure systems above
3000 psi.
III. In sour gas environment H2S trim (Refer latest NACE MR0175 / ISO 15156) equipment shall be
used.
IV. Kill lines shall be of minimum 2” nominal size and choke line shall be of minimum 3” nominal size
for drilling operations and for work over/ well testing operations nominal size of kill & choke line
shall be 2” minimum.
V. Size of choke line and choke manifold shall be same. Minimum nominal inside diameter (ID) for
downstream of chokes shall be equal to or greater than the nominal connection size of the choke
inlet and outlet.
VI. The BOP control system shall be capable of,
a) Closing each Ram BOP in less than 30 seconds.
b) Closing annular preventers smaller than 18 ¾” in less than 30 seconds and for annular
preventer of 18 ¾” and larger size, in less than 45 seconds.
c) Closing and opening of HCR valves in choke & kill line shall not exceed the minimum observed
ram close response time.
VII. Closing system of sub-sea BOPs shall be capable of closing each ram preventer within 45
seconds and annular preventer within 60 seconds.
VIII. Ram type subsea preventers shall be equipped with an integral or remotely operated locking
system. Surface ram preventer shall be equipped with mechanical/ hydraulic ram locks.

6.2 Periodic Inspection and Maintenance

I. The organization shall establish inspection and maintenance procedures for well control
equipment. Inspection and maintenance procedure shall take into consideration the OEM
recommendations, relevant API and OISD standards.
II. Inspection recommendations, where applicable, include:

i) Verification of instrument accuracy

ii) Relief valve setting
iii) Pressure control switch setting
iv) Nitrogen pre-charge pressure in accumulator
v) Pump system
vi) Fluid Level
vii) Lubrication Points.
General condition of
a) Piping system
b) Hoses
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c) Electric conduit/ Cords

d) Mechanical components
e) Structural components
f) Filters/ Strainers
g) Safety covers/ devices
h) Control system adequacy
i) Battery condition.

III. Inspection between wells: After conclusion of operation at each well, the well control equipment
shall be cleaned, visually inspected, preventive maintenance performed before installation at the
next well. The inspection shall include the seal area of the connectors (Choke and kill lines) for
any damage.
IV. Major inspection of Well Control Equipment shall be carried out every 5 years. The BOP stack
including ram assemblies, Choke and Kill manifold, Well Control Choke Console, Control unit,
Control Pods of subsea BOP, Marine Riser system, Diverter assembly shall be disassembled,
and inspected in accordance with the OEM’s guidelines and /or applicable latest API
specifications and guidelines.
V. Spare parts requirement as per OEM recommendations shall be considered. However, minimum
spare parts as listed below shall be readily available:
a) A complete set of ram seals for each size and type of ram BOP in use.
b) A complete set of bonnet or door seals for each size and type of ram BOP in use.
c) Ring gaskets to fit end connections.
d) A spare annular BOP packing element and a complete set of seals.
VI. During storage of BOP metal parts and related equipment, they shall be coated with a protective
coating to prevent rust.
VII. Storage of elastomer parts shall be in accordance with manufacturer’s recommendation Rubber/
elastomer parts, having limited shelf life shall be stored temperature-controlled Environment.
Elastomers exposed to drilling/ completion fluid shall be compatible to fluid in use while drilling
and completion operations.
VIII. Separate maintenance history / logbook of each of the BOPs, Choke manifold and Control unit
shall be maintained as per the OEM format.
IX. All pressure gauges and relief valves on the BOP control unit and remote panel shall be
calibrated at least once in a year or after any repair/ replacement.
X. Bolting requirement of BOP stack shall be as per latest API 20E.

6.2.1 Inspection and Maintenance

6.2.2 Periodic Maintenance and Inspection

BOP stacks and choke and kill equipment shall be inspected at least every five years in accordance
with the equipment owner’s maintenance system. Individual components and subassemblies may be
inspected on a staggered schedule. The inspection results shall be verified against one of the following:
a) The manufacturer’s acceptance criteria, or
b) The equipment owner’s acceptance criteria if the equipment owner collects and analyzes
condition-based data and performance data to justify their criteria.
6.2.2 Repair/ Remanufacture, Re-certification of well control equipment
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The repair/ remanufacture, re-certification of well control equipment after five yearly major inspections
shall be carried out by OEM or OEM authorized repair facility and if the OEM facility is not available, the
repair/ remanufacture, re-certification shall be carried out by:
A) Facility holding an active API 16A license for specific type of BOP or API SPEC Q1/ Q2 certificate
referring API 16AR duly certified by API with specific scope including design of BOP and applicable
‘Drill Through Equipment’. Facility shall have design verification, design validation for the relevant
OEM equipment to be recertified.
Recertification for BOP and associated ram assemblies shall be as per API 16A latest edition which
refers to API 16AR. Recertification of Flange/ Hub connection shall be as per latest API 6A latest
Edition which refers to API 6AR.
Operator shall ensure each OEM/ remanufacturing agency shall have written specifications for all
elastomeric materials used in the repair and remanufacture of drill-through equipment.
These specifications shall include the following physical tests and limits for acceptance and control:
I. Acceptance and/ or rejection criteria.
II. Physical property requirements and temperature ratings.
III. Material qualification, which shall meet the equipment temperature and pressure class
requirement.
For repair & recertification, operator shall specify the temperature, class of elements, elastomers and
material of the same shall be mentioned in the certificate by OEM/ remanufacturing agency.
B) Facility holding an active API 16C & API 6AR license and API SPEC Q1/ Q2 certificate with specific
scope including design of Choke and Kill Equipment and Wellhead Equipment. Facility shall have
design verification, design validation for the equipment to be recertified. Recertification for the
manifold shall be as per API 16C latest edition.
C) Facility holding an active API 16D license and API SPEC Q1/ Q2 certificate with specific scope
including design of Control Systems. Facility shall have design verification, design validation for
the equipment to be recertified. Recertification for the control system shall be as per API 16D latest
edition.
6.3 Surface Blow out Prevention Equipment
Surface blow out prevention equipment is used at on land operations and offshore operations where the
wellhead is above the water level.
Well control equipment can be classified under the following categories based on pressure rating:
a. 2000 psi WP
b. 3000 psi WP
c. 5000 psi WP
d. 10000 psi WP
e. 15000 psi WP
f. 20000 psi WP
6.3.1 For on land Workover operations, BOP stack for all configurations
I. PRESSURE RATING UPTO 3000 PSI for all wells: BOP Stack shall consist of,
(a) One Blind Ram (Minimum 3000 / 5000 psi)
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(b) One Pipe Ram of correct size (Mini. 3000 / 5000 psi

II. PRESSURE RATING UPTO 5000 PSI:

A. For all wells except Gas Wells: BOP Stack shall consist of,
(a) One Blind Ram (Minimum 5000 psi)
(b) One Pipe Ram of correct size (Minimum 5000 psi)

B. For Gas Wells: BOP Stack shall consist of,

(a) One Blind Shear Ram (Min 5000 psi)

(b) One Pipe Ram of correct size / Variable ram of required range (Min 5000 psi).

When using BSR (Blind shear ram), space between Shear Blind ram and pipe ram/ variable
should be sufficient to accommodate tool joint/ coupling of tubular being used in well so that pipe
portion is cut by SBR when tool joint/ coupling is resting on pipe ram. In case space is not
sufficient, extra pipe ram BOP/ spacer spool of sufficient height is to be used.

III. PRESSURE RATING MORE THAN 5000 PSI & UPTO 10000 PSI:
A. For all wells except Gas Wells: BOP Stack shall consist of,

(a) One Blind Ram (Minimum 10000 psi)

(b) One Pipe Ram of correct size (Minimum 10000 psi)
B. For Gas Wells: BOP Stack shall consist of,

(a) One Blind Shear Ram (Min 10000 psi)

(b) One Pipe Ram of correct size / Variable ram of required range (Min 10000 psi)

IV. PRESSURE RATING MORE THAN 10000 PSI & UPTO 15000 PSI:
(a) One Annular Preventer (Minimum 10000 psi)
(b) One Blind Shear Ram (Minimum 15000 psi)
(c) One Pipe Ram of correct size (Minimum 15000 psi)
Notes to above BOP Stacks brought out above:
i. In case of wells with Electrical submersible pump, Annular BOP is to be used, in addition to
the recommended BOP stack when Annular BOP is not part of original BOP stack.
ii. The recommended stack of BOP for different pressure ratings may be considered as
minimum requirement. Higher size, higher pressure rating, more BOP rams including Annular
BOP can also be used considering the situation in a particular well. Therefore, a documented
risk assessment shall be performed by the respective Assets/ Basins for all classes of BOP
arrangements to identify ram placements and configurations to be installed. Accordingly,
Asset/ Basin should select the rig wherein substructure height is sufficient for installation of
required BOP Stack.

V. Two single ram BOPs can also be used in place of one double ram BOP and vice versa.

VI. Wherever tapered/ combination string is used, Annular BOP/ Variable ram should be used.
Annular BOP can also be used in place of variable ram provided one pipe ram is available.
However, it should be ensured that no load condition is achieved & tool joint/ tubing coupling
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does not come against the shear blind ram. It means there should be enough gap between
the BSR (Blind Shear Ram) & pipe ram/ variable ram to accommodate the tool joint/ tubing
coupling to ensure that only the tubular body is cut.

VII. One independent automatic accumulator unit with a control manifold clearly showing open
and closed positions for preventer(s) to be provided. The accumulator capacity should be
adequate for closing all the preventers without recharging accumulators.
A documented risk assessment shall be performed by the operator for all classes of BOP
arrangements to identify ram placements and configurations to be installed. This assessment shall
include tapered strings, casings completion equipment, test tools.
6.3.2 For on land Drilling Rig operations:
I. Refer Annexure-I for recommended 2000 psi BOP stack.
For on land installation, one single ram type preventer with blind or blind cum shear ram and one
annular BOP or one double ram BOP of which one ram shall be equipped with correct size pipe
ram and the other with blind or blind shear ram.
For Offshore rig one annular BOP and one double ram BOP of which one ram shall be equipped
with correct size pipe rams and the other with blind or blind shear ram shall be used. The Blind
cum shear ram shall be capable of shearing drill pipe of maximum size and highest grade to be
used in the well bore and seal it under maximum anticipated surface pressure. Preferably one
annular preventer shall be considered for the following advantages,
a. It can close on any shape or size of tubular or non-cylindrical objects with minimum response
time.
b. Drill pipe/ tool joint can be stripped through it by means of careful control of the hydraulic
closing pressure.
A minimum of one set of blind ram or blind shear ram (BSR) shall be installed when ram type
preventers are to be installed. This requirement shall also apply to 2K or lesser rated working
pressure system and a minimum two ram type BOP stack arrangement.
II. Refer Annexure-II for recommended 3000/ 5000 psi BOP stack. The stack comprises of besides
annular BOP, one double, or two single ram type preventers - one of which shall be equipped with
correct size pipe ram and the other with blind or blind-shear ram.
III. Refer Annexure-III for recommended 10000/ 15000/ 20000 psi BOP stack. The stack comprises of
besides annular BOP, three single, or one double and one single ram type preventers one of which
shall be equipped with blind or blind-shear rams (For Offshore and Onshore gas wells. Blind shear
ram is mandatory in 10 K and above rated BOP stack) and the other two to be fitted with correct
size of pipe ram and variable ram to close against pipe if multiple size of string is in use.
IV. When the bottom ram preventer is equipped with proper size side outlets, the kill and choke lines
may be connected to the side outlets of the bottom preventer. In that case the drilling spool may
be dispensed with.

V. In spite of the above, a drilling spool use may be considered for the following two advantages:
a) Stack outlets at drilling spool localizes possible erosion in less expensive drilling spool.
b) It allows additional space between preventers to facilitate stripping, hang off, and/ or shear
operations.
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VI. A fill up line should be provided above the uppermost preventer.

VII. Prior to commencing operations with tapered drill string, the BOP stack shall be provided with one
set of variable pipe ram capable of sealing around both the sizes of drill pipes.
VIII. Full opening safety valve (FOSV) of drill string/ tubing string size with matching thread connection/
cross over of tubular being handled and of rated working pressure shall always be available at
derrick floor. It shall be kept ready in 'open' position. Operating wrench to operate FOSV is to be
kept in designated place.
IX. A non-return valve known as check valve (IBOP) of drill string/ tubing string size and matching
thread connection/ cross over of tubular being handled and of rated working pressure also is to be
kept on rig floor in open position.

6.3.3 Control System for Surface BOP Stacks (Onshore and Bottom-supported Offshore
Installations)
I. Control systems are typically simple closed hydraulic control systems consisting of a reservoir
for storing hydraulic fluid, pump equipment for pressurizing the hydraulic fluid, accumulator banks
for storing power fluid, manifold, piping and control valves for transmission of control fluid for the
BOP stack functions.
II. A suitable control fluid shall be selected as the system operating medium based on the control
system operating requirements, environmental requirements and user preference.
III. Control unit shall possess two independent power sources at all times to keep the hydraulic fluid
under required accumulator pressure. The pumps will automatically start when the system
pressure is reduced to approximately ninety percent of the system working pressure and
automatically stop within plus zero or minus 100 psi of the system design working pressure.
IV. With the accumulators isolated, the pump system shall be capable of closing annular BOP on the
minimum size of the drill string being used, open HCR valve on choke line and achieve the
operating pressure level of annular BOP to affect a seal on the annular space within 2 minutes.
V. Each pump system shall be protected from over pressurization by a minimum of two devices.
One device shall limit the pump discharge pressure so that it will not exceed the design working
pressure of a BOP Control System. The second device normally a relief valve, shall be sized to
relieve at a flow rate of at least equal to the design flow rate of the pump systems, and shall be
set to relieve at not more than ten percent over the design pressure.
VI. The combined output of all pumps shall be capable of charging the entire accumulator system
from pre-charge pressure to the maximum rated working pressure within 15 minutes.
VII. The hydraulic fluid reservoir shall have a capacity equal to at least twice the useable hydraulic
fluid capacity of the accumulator system.
VIII. In the field, the pre-charge pressure of accumulator bottles shall be adjusted within 100 psi of the
recommended pre-charge pressure during installation and at start of drilling (interval not to
exceed 60 days).
IX. BOP control system shall have a minimum stored hydraulic fluid volume, with pumps inoperative,
to satisfy the greater of the following two requirements:
a) Close from a fully open position at zero wellbore pressure, all of the BOPs in the BOP stack,
HCR valves plus 50 % reserve.
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b) The pressure of the remaining stored accumulator volume after closing all of the BOPs shall
exceed the minimum calculated (using the BOP closing ratio) operating pressure required to
close any ram BOP (excluding the shear rams) at the maximum rated wellbore pressure of the
stack.
X. All rigid or flexible lines between the control system and BOP stack shall be fire resistant including
end connections and shall have a working pressure equal to the design working pressure of the
BOP control system. Manufacturers guidelines shall be followed on working minimum bend radius
for safe working.
All control system interconnect piping, tubing hose, linkages etc. shall be protected from damage
from drilling operations, drilling equipment movement and day to day operations.
XI. The control unit shall be installed in a location at a safe distance from the wellbore and easily
accessible to the persons during an emergency. Operator shall carry out risk assessment for
defining the safe distance. Preferably for workover rigs, minimum distance should be 16m & for
drilling rigs it should be placed in front of catwalk.
XII. A minimum of two remote control panel accessible at the derrick floor and one at ground floor at
safe distance shall be installed at onshore rigs. In offshore, one remote control panel shall be
available at a non- hazardous area at tool pusher’s office and the second remote panel at the rig
floor as Driller’s panel.
XIII. Remote control panels shall have light indicators to show open/ close/ functions of each BOPS
and HCR valves in choke and kill line.
XIV. A) The hydraulic lines system (from control unit to BOP stack) to be pressure tested at rated
working pressure of the control line/ hose once in six months. (Procedure to be included as per
API)
B) Accumulator relief valve and manifold relief valve to be calibrated once in six months.

6.4 Subsea Blow out Prevention Equipment

Subsea BOP stack arrangements shall provide means to:
I. Close in on the drill string and on the casing or liner and allow circulation.
II. Close and seal on open hole and allow volumetric well control operations.
III. Strip the drill string using the annular BOP(s).
IV. Hang off the drill pipe on a ram BOP and seal the annulus.
V. Shear logging cable or the drill pipe and seal the wellbore.
VI. Disconnect the riser from the BOP stack.
VII. Circulate the riser volume after removal of drill pipe.
VIII. Circulate across the BOP stack to remove trapped gas.

6.4.1 Subsea BOP Stack

Subsea blow out prevention equipment is used on subsea wellhead.
I. Well control equipment can be classified in following categories based on pressure rating.
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a) 5000 psi WP
b) 10000 psi WP
c) 15000 psi WP
d) 20000 psi WP and Above

II. BOP Stack Capabilities

a) Close and seal on the drill pipe, tubing, casing, or liner and allow circulation
b) Close and seal on open hole and allow volumetric well control operations
c) Strip the drill string
d) Hang-off the drill pipe on a ram BOP and control the wellbore
e) Shear the drill pipe, tubing, or wireline in use
f) Disconnect the riser from the BOP stack
g) Circulate across the BOP stack to a choke manifold.

III. Subsea BOP Stack Arrangements

a) The lowermost line connected to the BOP stack shall be designated as the kill line.
b) For BOPs that have lines installed on each side of the outlet below the lowermost well control
ram, either may be designated as a choke line or kill line. Either line can serve the choke or
kill function.
c) A minimum of one choke line and one additional kill line connection shall be located above
the lowest well control ram BOP.
d) Annular bleed valves may be connected to either the choke or kill line.
e) Rig-specific stack identifying nomenclature (choke line, kill line, rams, annular, etc.) shall be
included in the drilling program.
f) A documented risk assessment shall be performed by the equipment user and the equipment
owner for all classes of BOP stack arrangements to identify ram configuration, outlet
placements, and choke and kill valve configurations. This assessment shall include tapered
strings, casings, completion equipment, test tools, etc.
g) See Annexure- IV for a subsea BOP configuration example.
h) Subsea BOP stacks shall be Class 5 or greater and consisting of the following:
i) A minimum of one annular preventer
ii) A minimum two pipe rams (excluding the test rams)
iii) A minimum of two sets of shear rams for shearing the drill pipe and tubing in use, of which
at least one shall be capable of sealing.
i) For moored rigs, a minimum of one set of BSRs (capable of sealing) for shearing the drill pipe
and tubing in use may be used after conducting a risk assessment.
j) All sealing ram-type preventers shall be equipped with remotely operated locking devices.
IV. Some differences as compared to surface BOP systems are:
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a) Choke and kill lines are normally connected to ram preventer body outlets to reduce stack
height and weight, and to reduce the number of stack connections.
b) Spools may be used to space preventers for shearing tubulars, hanging off drill pipe, or
stripping operations.
c) Blind-shear rams are used in place of blind rams. The blind shear ram shell shall be capable
of shearing drill pipe of any size and grade in the hole and seal the well bore under Maximum
Anticipated Surface pressure.
d) Ram preventers shall be equipped with an integral or remotely operated locking system.
6.4.2 Control System for Subsea BOP Stack
For subsea operations, BOP operating, and control equipment shall include:
I. As floating drilling rigs experience vessel motion, this necessitates placement of the BOP stack on
the sea floor. The control systems used on floating rigs are usually open-ended hydraulic systems
(spent hydraulic fluid vents to sea) and therefore employ water-based hydraulic control fluids.
II. An independent automatic accumulator unit for subsea BOP control system complete with an
automatic mixing system to maintain mixed fluid ratios and levels of mixed hydraulic fluids.
III. The accumulator capacity shall be sufficient for closing, and opening all ram type preventers,
annular preventers and fail-safe-close valves without recharging accumulator bottles, and the
remaining pressure shall be either 200 psi above recommended pre-charge pressure or value
based on the closing ratio of ram preventer in use, whichever is more.
IV. The unit shall be equipped with two or more pump system driven by independent power source.
Capacity of the pumps shall meet following:
a) With accumulator isolated, each pump system shall be capable of closing annular preventer
against minimum size of the tubular and opening fail-safe-close valve of choke within 2 minutes
time.
b) Combined output of all the pumps shall be capable of charging accumulator to the rated
pressure within 15 minutes.
V. Accumulators shall be installed on the BOP stack for quicker response of the functions, and its pre-
charge pressure shall be compensated for water gradient.
VI. Two fully functional remote-control panels to operate BOP stack functions shall be available, out of
which one shall be accessible to driller on the rig floor. A flow meter for indicating control fluid flow
shall be located on each remote-control panel.
VII. The remote panels shall be connected to the control manifold in such a way that all functions can
be operated independently from each panel.
VIII. The Subsea BOP stack shall have two fully redundant control pods. Each control pod shall contain
all necessary valves and regulators to operate BOP stack and LMRP functions. The control pods
may be retrievable or non-retrievable. To isolate the pods from one another, each control pod shall
be connected to a shuttle valve that is connected to each operable function.
IX. If one of the two PODS fails, the operations shall be stopped, well secured and the faulty POD shall
be made operational prior to resume the further operations.
Umbilical and Reels,
a) There shall be two or more means of surface to subsea power fluid supply. The rigid conduit(s)
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are attached to the riser and provide the primary hydraulic supply to the subsea control pods.
b) The hot line hose supplies power fluid from the surface to subsea control pods mounted on
the LMRP. The hot line is run, retrieved and stored on the hose reel.
c) The hot line(s) and MUX cable(s) shall be secured to the riser by clamps to prevent corrosion
and damage. The outer sheath of the hot line and MUX cable shall be inspected visually for
damage on retrieval.
d) The hot lines shall be tested at Rated Working Pressure of the system once a year.
e) Re-termination, repair of Hot line and MUX cable shall be tested at the RWP of the hose.
f) The MUX electrical cables supply power and communication for control of the subsea pod
functions. The MUX cable shall be run, retrieved and stored on a cable reel.
g) All underwater electrical umbilical cable terminations shall be sealed to prevent water
migration into the cable in the event of connector failure or leakage and also to prevent water
migration from the cable into the subsea connector termination in the event of water intrusion
into the cable.
h) Individual connector terminations shall be physically isolated so that sea water intrusion does
not cause electrical short circuiting.
i) The hose / MUX cable reel shall be equipped with a brake, mechanical lock and guard.
X. The BOP control system shall be capable of closing each ram BOPs and opening or closing fail-
safe-close valves within 45 seconds. For annular preventer, closing time shall not exceed 60
seconds. Time to unlatch the LMRP shall be less than 45 seconds.
XI. Secondary control system:
ROV (Remotely operated vehicle) intervention:
a) The BOP stack shall be equipped with ROV intervention equipment that allows the operation
of minimum critical functions i.e. shear ram, one pipe ram, ram locks and unlatching of
LMRP connector.
b) The Hydraulic fluid can be supplied to ROV, through accumulators mounted on BOP stack or
an external hydraulic power source maintained at the well site.
c) All critical functions shall be fitted with single port docking receptacle designed in line with
the requirements of API - 17H. If a multiple receptacle type is used, the receptacle and the
functions shall have positive identification.
Acoustic control system:
a) The acoustic control system is an optional control system designed to operate designated
BOP stack and LMRP functions. It may be used when the primary control system fails to
operate.
b) The hydraulic accumulator system may be used for both the acoustic system as well as
emergency control system.
c) The acoustic accumulators shall be capable of being completely discharged subsea prior to
recovering the BOP to surface.
XII. Pre-charge pressure of accumulator bottle in case of 3000 psi WP unit shall be 1000 +/- 100 psi
and in case 5000 psi WP unit shall be 1500+/- 100 psi. Only Nitrogen shall be used for pre-charge.
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XIII. Separate diverter control panel shall be available at rig floor to operate all diverter control
functions. A second control panel shall be provided a t a safe and approachable area away from
rig floor.
XIV. If diverter control system is not self- contained, hydraulic power may be supplied from BOP control
system.
XV. The diverter control system shall be designed to prohibit closing the diverter packer unless diverting
lines have been opened.
XVI. Air storage backup system shall be provided with capability to operate all the pneumatic functions
at least twice in the event of loss of rig air pressure.
XVII. The drilling BOP shall have two annular preventers. One or both of the annular preventers
shall be part of the LMRP. It shall be capable to bleed off gas trapped between the preventers in
a controlled way.
6.4.3 Deep Water Drilling Operations
For Deep water drilling operations following additional requirements shall be met:
I. If two or more different size strings are run, blind-shear ram shall be able to shear all sizes and
grade of strings to be used in the well.
II. Use of two blind-shear rams is preferred for ensuring the backup seal in case of unplanned
disconnect.
III. In addition to choke and kill lines, a dedicated boost line shall be provided for riser cleaning with
necessary boost line valves above the BOP stack.
IV. In the event of full or partial evacuation of mud from the riser, to combat riser collapse, an anti-
collapse valve shall be provided in the riser system allowing automatic entry of seawater.
V. ROV shall be able to perform following functions:
a) LMRP and wellhead connector unlatch.
b) LMRP and wellhead ring gasket release.
c) Methanol / Glycol injection.
d) Opening and closing of pipe rams and blind-shear rams.
e) LMRP and Accumulator Dump.
VI. Preferably a multiplex (MUX) BOP control system to meet the closing time requirements shall be
used.
VII. The kill/ choke line ID shall be verified vis-à-vis acceptable pressure loss, to allow killing of the well
at predefined kill rates. The kill/ choke line shall not be less than 88.9 mm (3½ inches).
VIII. Provision shall be there to monitor the shut-in casing pressure through the kill line when circulating
out an influx by means of the work string/ test tubing string/ tubing.
IX. Provision shall be there to monitor BOP pressure and temperature at surface, through appropriate
means.
X. Provision shall be there to flush wellhead connector with antifreeze liquid solution by using the BOP
accumulator bottles or with a ROV system or other methods.
XI. Detailed riser (mooring analysis) verification analysis shall be performed with actual environment
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and well data (i.e., weather data, current profiles, rig characteristics etc.) and shall be verified by a
3rd party.
XII. A simulated riser disconnect test shall be conducted considering manageable emergency weather
/ operational scenarios.
XIII. The riser shall have the following:
➢ Current meter
➢ Riser inclination measurement devices along the riser
➢ Riser tensioning system with an anti-recoil system to prevent riser damage during disconnection.
➢ Flex joint wear bushing to reduce excessive flex joint wear.
➢ Riser fill-up valve
XIV. Parameters that affect the stress situation of the riser shall be systematically and frequently
collected and assessed to provide an optimum rig position that minimizes the effects of static and
dynamic loads.
XV. Wellhead and riser connector shall be equipped with hydrate seal.
XVI. During drilling operations, to avoid any damage to drilling equipment in the event of station keeping
failure, there shall be prescribed emergency disconnect procedures, clearly indicating the point at
which disconnect action is to be started.
XVII. In general, preparation for disconnect shall begin at a distance with reference to well mouth, when
it is 2.5 % of water depth and disconnect shall be initiated at 5.5 % of water depth.
XVIII. An Emergency Disconnect Sequence (EDS) shall be available on all subsea stacks of dynamically
positioned drilling rigs. It is optional for moored drilling rigs.
a) The EDS is a programmed sequence of events that operates the functions to leave the stack
and control the desired state and disconnect the LMRP from the lower stack.
b) The number of sequences, timing and functions of EDS are specific to the rig, equipment and
location.
c) There shall be a minimum of two separate locations (away from each other and a remote
location) from where the EDS can be activated.
XIX. Emergency disconnect system shall include the following:
a) Hang up of the drill pipes on pipe rams.
b) Shearing the drill pipe.
c) Effective seal on the wellbore.
d) Disconnect the LMRP.
e) Pick up the LMRP above BOP wellhead mandrel.
f) Safely secure the riser.
XX. For monitoring riser angles, flex joint angle reading shall be available at the driller console on a real
time basis and connected to an alarm on derrick floor.
XXI. In variance to 0.5 ppg kick margin normally considered, for deep water a variance of up to 0.2 ppg
for conductor casing interval and 0.3 ppg for surface casing interval can be considered.
XXII. When using tapered drill pipe string there shall be pipe rams to fit each pipe size. Variable bore
rams shall have sufficient hang off load capacity.
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XXIII. Bending loads on the BOP flanges and connector shall be verified to withstand maximum bending
loads (e.g., highest allowable riser angle and highest expected drilling fluid density).
XXIV. The Dynamically positioned all offshore Deep-water drillings shall be provided with emergency BOP
control system i.e., “Auto shear” and “Deadman.
a) The ‘Auto shear’ is a safety system designed to automatically shut in the well bore in the event
of an unintended disconnect of LMRP. The ‘Auto shear’ system shall be armed while latching the
BOP stack on to the wellhead.
b) The ‘Deadman’ is a safety system designed to automatically shut in the wellbore in the event of
a simultaneous failure of hydraulic supply and electrical supply of the drilling rig. The ‘Deadman’
system shall be armed while latching the BOP stack on to well head.
c) The dedicated emergency accumulator system shall be used for both the ‘Auto shear’ and
‘Deadman’ systems.

6.5.0 CHOKE MANIFOLD AND KILL MANIFOLD AND CO-FLEX HOSES

6.5.1 Choke Lines and Choke Manifold Installation with Surface BOP
I. The choke manifold consists of high-pressure pipe, fittings, flanges, valves, and manual and/ or
hydraulic operated adjustable chokes. This manifold shall be designed to bleed off wellbore
pressure at a controlled rate and to stop fluid flow from the wellbore completely, as required
during operations.
II. For working pressure of 3000 psi and above, flanged, welded or clamped connections in
accordance with latest API-6A shall be used for the components subjected to well pressure.
III. Choke line from BOP to choke manifold and bl e ed - of f li n e shall be of minimum 3 inches
nominal diameter (or at least equal to diameter of choke line) for drilling rigs.
IV. In downstream of choke line alternate flow and flare routes configuration shall be provided so
that eroded/ plugged or malfunctioning parts can be isolated for repair without interrupting flow
control.
V. When buffer tanks are employed in downstream of chokes, provision shall be made to isolate a
failure or malfunctioning without interrupting flow.
VI. The choke manifold shall be placed in an easily accessible location, preferably outside of the
rig structure at a safe distance from wellhead for onshore rigs.
VII. All the choke manifold valves shall be full bore opening and designed to operate in high pressure
gas and drilling fluid service. During operations, all valves shall be either fully open or fully closed.
VIII. All the connections and valves in the upstream of choke shall have a working pressure equal to
or greater than the rated working pressure of ram preventer in use.
IX. Choke manifold and Manifold hoses shall be pressure tested as per fixed frequency as followed
for the blowout preventer stack in use.
X. Pressure gauges and sensors compatible to drilling fluid shall be installed so that drill pipe and
annular pressures may be accurately monitored and readily observed at the station where well
control operations are to be conducted. These shall be tested/ calibrated.
XI. Preventive maintenance of the choke assembly and BOP remote choke control panels shall be
performed regularly, with specific checks for corrosion, wear and tear, plugged or damaged lines.
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XII. Spare parts requirement as per OEM recommendations shall be considered. However, minimum
spare parts as listed below shall be readily available:
a) One complete valve for each size installed.
b) Two repair kits for each valve size installed.
c) Parts for manually adjustable chokes, such as flow tips, seat and gate, inserts, packing,
gaskets, O-rings, disc assemblies, and wear sleeves.
d) Parts for remotely controlled choke(s).
e) Miscellaneous items such as hose, flexible tubing, electrical cable, pressure gauges, small
control line valves, fittings and electrical components.
The spare parts for equipment’s which are subject to wear or damage shall be readily available
f)
for replacement.
XIII. The following are the recommendations for choke installation up to 5000 psi WP rating:
a) Use two manually operated adjustable chokes (out of two chokes, use of one remotely
operated choke is optional).
b) At least one valve shall be installed in upstream of each choke in the manifold.
XIV. The following are the recommendations for choke installation of 10000 psi WP and above rating:
a) One manually operated adjustable choke and at least one remotely operated choke shall
be installed. If prolonged use of this choke is anticipated, additionally, a second remotely
operated choke shall be used.
b) Two valves shall be installed in upstream of each choke in the manifold.
c) The remotely operated choke shall be equipped with an emergency backup system such
as a manual pump or nitrogen back up pump for use in the event rig pneumatic air becomes
unavailable.
6.5.2 Kill Lines and Kill Manifold Installation with Surface BOP Stack
I. The kill line system provides a means of pumping into the wellbore when the normal method of
circulating down through the Kelly or drill pipe cannot be employed. The kill line connects the
drilling fluid pumps to a side outlet on the BOP stack.
II. All lines valves, check valves and flow fittings shall have a working pressure at least equal to the
rated working pressure of the BOP stack in use. The equipment shall be tested on installation
and periodic operation, inspection; testing and maintenance shall be performed as per the
schedule fixed for the BOP stack in use, as per OEM’s recommendations.
III. The Kill line size shall be minimum 2 inches nominal diameter and all other components shall also
be minimum 2 inches nominal diameter.
IV. Two full bore valves (manual/ HCR) shall be installed for up to 3000 psi manifold. Use of check
valve is optional.
V. Two full bore manual valves and a check valve or one full bore manual and one HCR valve shall
be used in kill line in 5000 psi and above pressure rating manifold.
VI. Spare parts requirement as per OEM recommendations shall be considered. However, minimum
spare parts as listed below shall be readily available:
a) One complete valve for each size installed.
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b) Two repair kits for each valve size in use.

c) Miscellaneous items such as hose, flexible tubing, electrical cable, pressure gauges etc.
6.5.3 Choke and Kill Lines Installation with Subsea BOP Stack
I. Subsea BOP choke and kill lines are connected through choke manifold to permit pumping or
flowing through either line.
II. Choke and kill line shall be of minimum three inches nominal diameter.
III. One kill/ choke line shall be connected to lower most side outlet of BOP.
IV. There shall be minimum one choke line and one kill line connection above lower ram BOP.
V. The ram BOP outlet connected to choke or kill line shall have two full opening hydraulically
operated fail-safe-close valves adjacent to preventer.
VI. Connector pressure sealing elements shall be inspected, changed as required, and tested before
being put in service. Pressure rating of all lines and sealing elements shall be at least equal to
the rating of ram BOP.
VII. Periodic flushing of choke and kill line shall be carried out to avoid plugging since they are
normally closed.
VIII. Flexible connections required for choke and kill lines shall have pressure rating at least equal to
the rated working pressure of ram BOP.
IX. Spare parts as per OEM recommendation shall be readily available to cater any repair/
replacement requirement. However, minimum spare parts as listed below shall be readily
available:

i. One complete valve of each size installed.

ii. Two repair kits for each valve size in use.

iii. Sealing elements for choke and kill lines.

6.6 Wellhead, BOP Equipment and Choke & Kill Lines Installation

I. Wellhead equipment shall withstand maximum anticipated surface pressures and allow for future
remedial operations. Wellhead shall be tested on installation at rated working pressure.
II. Prior to drilling out the casing shoe, the casing shall be pressure tested. Pressure test of all casing
strings including production casing / liner shall be done to ensure integrity of casing.
III. When the well head and BOP stack used are of higher working pressure, then the equipment shall
be tested at its maximum anticipated surface pressure.
IV. All connections, valves, fittings, piping etc. exposed to well pressure, shall be flanged or clamped
or welded and must have a minimum working pressure equal to the rated working pressure of the
preventers.
V. Always clean the groove and install new API ring gasket. Check for any damage in the ring as well
as groove before use. Gasket should not be re-used, and no grease should be applied.
VI. Correct size studs and fittings shall be used and tightened to the recommended torque. All
connections shall be pressure tested before drilling operations is resumed.
VII. All manually operated valves shall be equipped with hand wheels and braced, and always be kept
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ready for use.

VIII. Ram type preventers shall have locking arrangement manual or auto lock.
IX. Wellhead side-outlets shall not be used for killing purpose, except in case of emergencies.
X. Kill lines shall not be used for routine fill up operations.
XI. All sharp bends, tees etc. in high pressure lines shall be of targeted type to minimize erosion.
XII. All choke and kill lines shall be as straight as practicable and firmly anchored to prevent excessive
whip or vibration. Choke and Kill manifolds shall also be anchored.
XIII. All control valves of BOP control unit be either in the fully close or open position as required and
shall not be left in block or neutral position during operations.
XIV. Control valve of blind / blind–shear ram shall be protected to avoid unintentional operation from the
main unit/ remote panel.
XV. Recommended oil level shall be maintained in the control unit reservoir.
XVI. Outlets of all sections of well head shall have at least one gate valve.

6.7 Blowout Preventer Testing

6.7.1 Purpose
The purpose for various field test programs on drilling well control equipment is to verify:
a) That specific functions are operationally ready,
b) Pressure integrity of the installed equipment,
c) Compatibility of the control system and BOP stack(s).
6.7.2 General
Site-specific procedures for testing of well control equipment shall be incorporated into acceptance tests;
installation; and subsequent tests, drills, periodic operating tests, maintenance practices, and drilling
and/or completion operation.
6.7.3 Function Test
I. Pressure test shall qualify as function test.
II. A function test shall be performed following the disconnection or repair and limited to the
affected component(s).
III. Remote panels where all BOP stack functions are not included shall be function tested in
accordance with the equipment owner's procedures.
IV. Initial function testing, Subsequent operational function testing and Scheduled function
testing shall be performed in accordance with API STD 53 latest edition.
V. Actuation times (and volumes, if applicable) shall be recorded.
6.7.3.1 Procedure for Function Test
I. All operational components of the BOP equipment systems and diverter (if in use) should be function
tested at least once a week to verify the components’ intended operations.
II. BOP stack should be function tested for “CLOSE’ and “OPEN” functions separately.
III. The test should be preferably conducted when the drill string is inside casing except blind shear ram.
IV. Both pneumatic and electric pump of accumulator unit should be turned off after recording initial
Accumulator pressure.
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V. All the blowout preventers and hydraulically operated remote valve (HCR) in choke/ kill line should
be function tested. Closing time of rams and opening time of HCR should be recorded.
VI. For sub-sea BOP stack closing time should not exceed 45 seconds for all ram preventers and 60
seconds for annular preventers.
VII. Function test should be carried out alternately from main control unit/ rig floor panel/ auxiliary panel.
VIII. Record the accumulator pressures drop after each “Close” or “Open” function (with charging pump
shut). The final accumulator pressures after all the functions should not be less than 200 psi above
the recommended pre-charge pressure of accumulator bottles.
IX. All the gate valves and blow out preventers should be returned to their original position before
resuming operations.
X. All the results should be recorded in the prescribed format (Annexure-VII).
6.7.3.2 Control System Response Time
The measurement of the closing response time shall begin when the close function is activated at any
control panel and shall end when the BOP or valve is closed.
a) Close each ram BOP in less than 30 seconds.
b) Close annular BOPs of <18¾" nominal size in less than 30 seconds.
c) Close annular BOPs of ≥18¾" nominal size in less than 45 seconds.
d) Closing time shall be less than 30 seconds for non-sealing shear rams.
e) Response time for choke and kill valves (either open or close) shall not exceed the minimum
observed ram close response time.

6.7.4 Pressure Test

I. All BOP components that can be exposed to well pressure shall be tested first to a low pressure
between 250 psi to 350 psi (1.72 MPa to 2.41 MPa), and then to a high pressure.
II. A pressure test of the pressure containing component shall be performed following the
disconnection or repair, limited to the affected component.
III. Initial pressure testing and subsequent operational pressure testing shall be performed in
accordance with API STD 53 latest edition.
IV. Well control equipment should be pressure tested:
a) When installed.
b) After setting each casing string.
c) Following repairs that require breaking a pressure connection.
d) But not less than once every 21 days.

6.7.4.1 Pressure Test Procedure

I. All blowout prevention components that may be exposed to well pressure should be tested first to a
low pressure and then to a high pressure. These include blowout preventer stack, all choke manifold
components upstream of choke, kill manifold/ valves, Kelly valves, Top-drive safety valves drill pipe
and tubing safety valves and drilling spools (if in use). Pressure test (both low and high) on each
component should be of minimum 5 minutes duration, each. All the results should be recorded in the
format. (Annexure - VIII)
II. Test BOP using cup tester or test plug (Preferably).
III. Before pressure testing of BOP stack, choke and kill manifold should be flushed with clean water.
IV. Clean water should be used as test fluid. However, for high pressure gas wells, use of inert gas such
as N2 (nitrogen) as test fluid is desirable.
V. High pressure testing unit with pressure chart recorder be used for pressure testing.
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VI. Use test stump for sub-sea BOP stack pressure testing.
VII. Once the equipment passes the low-pressure test, it should be tested to high pressure.
VIII. Initial pressure test of blowout preventer stack, manifold, valves etc., should be carried out at the
rated working pressure of the preventer stack or well- head whichever is lower. Initial pressure test
is defined as those tests that should be performed on location before the well is spudded or before
the equipment is put into operational service.
IX. Subsequent high-pressure tests should be carried out at a pressure greater than maximum
anticipated surface pressure. Exception is the annular preventer which should be tested to 70% of
its rated pressure or maximum anticipated surface pressure whichever is lower.
X. The pipe used for testing should be of sufficient weight and grade to safely withstand tensile, yield,
collapse, or internal pressures.
XI. Precaution should be taken not to expose the casing to pressures in excess of its rated strength. A
means should be provided to prevent pressure build up on the casing in the event the test tool leaks
(wellhead valve should be kept open when pressure testing with test plug).
XII. Pressure should be applied from the direction in which all the BOPs choke and kill manifold, FOSV /
Kelly cock, Top drive safety valve etc. would experience pressure during kick.
XIII. FOSV, IBOP, Upper & Lower Kelly cock, Top drive safety Valves, HCR and Manual Valves, Choke
& Kill line manifold shall also be pressure tested along with the BOP Stack at the same pressure.
6.7.5 Hydraulic Chamber Tests
A hydraulic chamber test shall be included in the equipment owner’s maintenance system for operators on
hydraulic connectors, BOPs, and outlet valves attached to the BOPs.
Chamber pressure tests shall be performed and charted as follows:
a) When equipment operator is replaced, repaired, or remanufactured.
b) In accordance with Annexure/ Table-C-6.
6.7.6 Test Fluids
I. The initial installation pressure tests shall be conducted with water or water with preservation, anti-
freeze, and colorant additives.
II. During operations, the drilling fluid in use is acceptable to perform subsequent tests of the BOP
stack.
III. Control systems and hydraulic chambers shall be tested using clean control system fluids with
lubricity and corrosion additives for the intended service and operating temperatures.

6.7.7 Test Documentation

I. The results of BOP stack and choke manifold pressure and function tests shall be documented as
per Annexure G.
II. BOP stack and choke manifold pressure tests shall be documented with a pressure chart recorder
or equivalent data acquisition system.
III. Test documentation shall be signed by the pump operator, contractor’s representative, and
operator’s representative.
IV. BOP function & pressure test should be reported in IADC DPR.
6.7.8 General Testing Requirements
a) Personnel should be alerted when pressure test operations are to be conducted, when testing
operations are underway, and when pressure testing has concluded.
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b) Only designated personnel shall enter the test area to inspect for leaks when the equipment involved
is under pressure.
c) Tightening, repair, or any other work shall be done only after verification that the pressure has been
released.
d) Pressure shall be released only through pressure release lines.
e) When pressure testing, a procedural method shall be used to confirm pressure has been bled off.
f) Lines and connections that are used in the test procedures shall be secured.
g) Fittings, connections, and piping used in pressure-testing operations shall have an RWP equal to
or greater than the maximum test pressure.
h) The drill pipe test joint should be capable of withstanding the tensile, collapse, and internal
pressures that will be placed on it during the test operation.
i) A procedure shall be developed to identify test plug leaks.
6.7.9 Surface BOP Stack Equipment
a) The entire stack shall be pressure tested as a unit.
b) Shearing of drill pipe is not required with function and pressure testing.
c) Prior to testing each ram BOP, the secondary rod seals (emergency pack-off assemblies) shall be
checked to ensure the packing has not been energized.
d) Should the ram shaft seal leak during the initial test, the seal shall be repaired rather than energizing
the secondary packing.
e) Manual ram locks shall be lubricated and inspected annually, at a minimum.
f) Manual lock operators (e.g., hand wheels) shall be available at the rig site, ready and capable for
operation.
6.7.10 Chokes, Choke/ Kill Manifolds and Console
a) All choke, choke/ kill manifold shall be tested.
b) The adjustable choke and backup control system shall be tested to ensure operation in the event
of a loss of the primary power supply in accordance with the equipment owner's maintenance
system.
6.7.11 Main Accumulator Drawdown Test
a) Tests shall be completed at zero wellbore pressure.
b) Manifold, and annular regulators shall be set at the manufacturer’s recommended operating
pressure for the BOP stack.
6.7.11.1 The test shall be performed as follows:

a) Position a properly sized joint of drill pipe or a test mandrel in the BOP, if required.
b) Turn off the power supply to all accumulator charging pumps (air, electric, etc.).
c) Record the initial accumulator pressure.
d) Close the largest-volume annular BOP or any combination of operators with an equivalent or larger
volume. Time each actuation. Response times shall be recorded.
e) Close a maximum of four BOP rams with the smallest cumulative operating volume or any
combination of operators with an equivalent or larger volume. Time each actuation. Response times
shall be recorded.
f) Open the hydraulic-operated valve(s) and record the time.
g) Record the final accumulator pressure; verify against acceptance criteria as per API STD 53 latest
edition.
NOTE: As it takes time for the gas in the accumulator to warm up after performing all of the drawdown test
functions.
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a) It is acceptable to wait 15 minutes after recording the pressure, if the pressure was less than the
MOP (minimum operating pressure). If there is an increase in pressure, indications are that the
gases are warming and there is still sufficient volume in the accumulators.
b) If the MOP has not been reached after 15 minutes, an additional 15-minute wait may be required
due to ambient temperatures negatively affecting the gas properties. After 30 minutes from the time
the final pressure was recorded, if the MOP has not been reached, then it may be necessary to
bleed down the system and verify pre-charge pressures and volume requirements for the system.
6.8 Minimum Requirements for Well Control Equipment for Workover operations (on land)

For workover operations:

I. Stack arrangement for workover rigs shall be same as per clause number 6.3.1
II. Kill line shall be of minimum 2-inch size.
III. An accumulator unit, clearly showing open and closed positions, for preventer(s) to be provided.
The accumulator capacity shall be adequate for closing all the preventers without recharging
accumulators. Control unit shall be installed in a location at a safe distance from the wellbore and
easily accessible to the persons during an emergency. Operator shall carry out risk assessment for
defining the safe distance. All BOP/ valves operating lines and connections which are not used in
the system shall be properly blocked off with blind plugs at the BOP control unit (Accumulator).
IV. The BOP stack shall have remote control panel clearly showing open and closed positions for each
preventer. This Control Panel shall be located near to the driller’s position. All 4-way valves at BOP
control unit shall be either in the fully closed or open position as required and they shall not be left in
the block/neutral position. These shall have provision to be operated from remote panel.
V. Trip tank shall be installed on workover rig deployed for servicing of wells. (It is must for the wells
having gas in the formation fluid and oil wells where formation pressure is hydrostatic or more) for
continuous fill up and monitoring the hole during round trips. Indicator to monitor tank level can be
either mechanical or digital and clearly visible to driller.
VI. Full opening safety valve of drill string / tubing size and matching thread connection shall always be
available at derrick floor during well servicing. It shall be kept ready in 'open' position for use with
operating wrench. Operating wrench(s) shall be kept at a designated place.
VII. Sufficient volume of the workover fluid shall be available in reserve during workover operations.
VIII. During conventional production testing, well shall be perforated with adequate overbalance.

IX. After release of the packer the string shall be reciprocated, to ensure complete retraction of packer
elements, prior to pull out of string. It shall be ensured that there is no swabbing action.

7.0 PROCEDURES AND TECHNIQUES FOR WELL CONTROL (Prevention and Control of kick)
7.1 Cause of Kick
Kick may be caused due to

I. Encountering higher than anticipated pore pressure

II. Reduction in hydrostatic pressure in the well bore.

7.2 Cause of Reduction in Hydrostatic Head

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I Failure to keep the hole full of drilling fluid

II. Swabbing
III. Loss of circulation
IV. Insufficient drilling fluid density
V. Gas cut drilling fluid
VI. Loss of riser drilling fluid column (in case of subsea operation)
7.3 Kick Indications
Primary Indications of kick:

I. Increase in drilling fluid return rate

II. Pit gain or loss

III. Self-flow with pump off

Secondary Indication of kick:

I. Changes in flow line temperature

II. Drilling breaks

III. Pump pressure decease and pump stroke increase

IV. Drilling fluid density reduction

V. Oil & Gas show

VI. Change in shape & size of drilled cuttings

VII. Change in out-coming mud parameters.

7.4 Prevention and Control of Kick
In case of overbalance drilling:

I. The planned drilling safety margin is difference between planned drilling fluid weight and
estimated pore pressure.

II. To maintain primary well control, drilling personnel should ensure that the hydrostatic pressure in
the wellbore is always greater than the formation pressure by safety margin.

III. The use of trip margin (which is in addition to safety margin) is encouraged to offset the effects
of swabbing and equivalent circulating density (ECD). The additional hydrostatic pressure will
permit some degree of swabbing without losing primary well control.

IV. Successful well control (Blowout prevention programme) includes following elements:
a. Training of personnel and drills.
b. Monitoring and maintaining drilling fluid system.
c. Selection of appropriate well control equipment.
d. Installation, maintenance and testing of well control equipment.
e. Adoption of established well control procedures.
7.4.1 Precautions before Tripping Out
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I. Conditioning of drilling fluid prior to tripping out should be ensured. This should include:

a. No indication of influx of formation fluid.

b. The in / out drilling fluid density be homogenous.
II. A trip tank shall be lined up and function tested. Trip sheet shall be ready to be filled during tripping
out to monitor the well behavior during pulling out operation (Annexure-VI). The Trip sheet should
be compared with the previous trip sheet data recorded in the previous trip.
III. Full opening safety valve(s) with suitable working pressure and with proper connections and size,
to fit all drill string connections, must be available on the rig floor. They should be kept ready in
'open' position for use with operating wrench. Operating wrench(s) should be kept at a designated
place.
IV. IBOP, drill pipe float valve or drop in check valve should be available for use whenever
stripping is required to be done.
V. As far as possible tripping out should be dry. If tripping out is wet, proper mud bucket should be
used enabling mud to flow back to the return channel.
Precautions during Tripping Out
VI. Well should be checked for swabbing during pulling out. If positive, suitable corrective measures
such as change in tripping speed, tripping out with pump on, change in drilling fluid properties like
yield point, gel strength should be taken.
VII. Trip tank volume should be monitored and same should be recorded in the trip sheet.
(Annexure -VI).
VIII. If hole is not taking proper amount of mud (as per trip sheet), stop tripping and conduct flow check
to ensure whether the well is self-flowing. If positive, shut the well, record the pressures and circulate
out the kick by suitable well control method. If no self-flow is observed, run back to the bottom and
circulate and condition the drilling fluid.
IX. Flow checks should be carried out:
a) Prior to all trips out of the hole.
b) During first 10 stands.
c) At the casing shoes.
d) Prior to tripping out of drill collars through BOP stack.
X. Any time a trip is interrupted; safety valve should be installed on the drill string and should be kept
in open condition for monitoring the well. The drill string should be on elevators during waiting.
7.4.2 Precautions during Tripping In
I. Regular flow checks and monitoring of level in annulus should be done. Where situation
requires trip tank may be used to monitor drilling fluid loss/ gain.
II. Circulation should be given to break gelation of mud as per requirement especially in deep wells
and where heavy mud is used.
III. With a float valve in the string, drill pipe should be filled up intermittently.
7.4.3 Precautions during Casing Lowering

I. Regular flow checks and monitoring of level in annulus should be done and fill up schedule of casing
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pipe/ liner should be followed through calibrated t a n k as per the plan and use clean mud for
casing/ liner filling.

II. Running in speed of casing/liner should be maintained considering allowable surge pressure.
7.4.4 Pre-kick Planning
I. A plan detailing what actions are to be taken should a kick occur must be available. Plan should
consider equipment limitation, casing setting depth, maximum fluid density, pressures that may
be encountered, fracture gradient and expected hazards.
II. This should also include roles responsibilities of the personnel during kick.
III. The following information should be pre-recorded for use in kill sheet preparation: casing data, safe
working pressure limit for surface BOP equipment, wellhead, casing string. maximum allowable
casing pressure, contingency plan, pump rate (SCR), system pressure losses, capacities-
displacement, mud pump data, drilling fluid mixing capability, trip margin, water depth (offshore),
well profile and shut-in method to be used (soft / hard shut in).
IV. Record slow circulating rates at 1/3 and 1/2 the pump speed of drilling SPM at:
a) the beginning of every shift
b) any time the mud weight is changed
c) after drilling 500 feet/150 mts. of new hole
d) after bit change
e) after pump repair
f) after each trip due to change in BHA, bit nozzle.
V. LOT/ PIT after each casing should be known. Whenever LOT/ PIT is to be carried out, 2-3 meters
of fresh formation should be drilled.
VI. Distance from rotary table to blowout preventer (s) be noted and sketch displayed in doghouse
and Tool pusher's office.
VII. Based on the risk assessment of the well and depending upon the situation, well control
method to be used should be selected. Plan and procedures for special situations such as casing
pressure reaching maximum allowable annular surface pressure (MAASP) should be available at
the installation (contingency plan).
VIII. Shut in method to be used should also be pre-selected in the kill sheet.
IX. Sufficient quantity of drilling fluid weighting materials and chemicals must be stored to meet any
kick situation.

7.5 Kick Control Procedures

Following are recommended well control procedures for surface stack and sub-sea.
7.5.1 Surface Stack
For onshore and bottom-supported offshore installations:
A. During Drilling
I. Stop drilling
II. Pick up Kelly to position tool joint
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III. Stop mud pump.

IV. Check for self-flow.
V. If positive, proceed further to close the well by any one of the following procedures (Refer Table-
1).
• Soft shut in
• Hard shut in
VI. Ensure the integrity of the well is secured and line up the flow line to the trip tank and check the
flange connections for any leakage.
VII. Monitor the casing pressure during the kill plan and kill sheet preparation. If the casing pressure is
about to exceed MAASP, follow the contingency plan.
VIII. Calculate the drilling fluid density required to kill the kick.
IX. Initiate the approved / selected well kill method.
X. Check rig crew duties and stations.
XI. Review and update the well control worksheet.
XII. Check pressures of all annuli of the well.

TABLE - 1

Sl. No. Soft Shut – in Hard Shut – in

1. Open hydraulic control valve (HCR valve)/ manual Close Blow out Preventer (Preferably
valve on choke line. Annular Preventer)

2. Close Blowout Preventer. Open HCR/ Manual valve on choke line when
choke is in fully closed position.
3. Gradually close adjustable/ remotely operated choke, Allow pressure to stabilise and record
monitoring casing SIDPP, SICP and Pit Gain.

4. Allow the pressure to stabilize and record SIDPP, -------------

pressure.
SICP and Pit gain.

B. During Tripping
During tripping whenever flow is observed:
I. Position tool joint above rotary table and set pipe on slips.
II. Install Full Opening Safety Valve (FOSV) in open position on the drill pipe and close it.
III. Close the well following any one of the procedures as per above table. (Table - 1)
IV. Monitor the casing pressure. If the casing pressure is about to exceed MAASP, follow the
contingency plan.
V. Calculate the drilling fluid density required to kill the kick.
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VI. Initiate the approved / selected well kill method.

VII. Check rig crew duties and stations.
VIII. Review and update the well control worksheet.
IX. Check pressures of all annuli of the well.
C. When String is out of Hole
I. Close blind / blind-shear ram.
II. Record shut in pressure.
III. Monitor the casing pressure. If the casing pressure is about to exceed maximum allowed
(MAASP), follow the contingency plan.
IV. Calculate the drilling fluid density to kill the kick.
V. Initiate the approved / selected well kill method.
VI. Check rig crew duties and stations.
VII. Review and update the well control worksheet.
VIII. Check pressures on all annuli of the well.
7.5.2 Floating Installations (Sub Sea)
A. During Drilling
I. Stop drilling.
II. Position the tool joint for the BOP’s operation.
III. Shut down the drilling fluid pump(s).
IV. Check the well for flow – if it is flowing, follow shut in procedure.
V. If the soft shut-in procedure has been selected: open the choke line, close Annular BOP and close
the choke.
VI. If the hard shut-in procedure has been selected: close Annular BOP and open the choke line with
the choke in closed position.
VII. Observe the casing pressure, if it exceeds MAASP, follow the contingency plan.
VIII. Check for trapped gas pressure.
IX. For release of trapped gas, close the uppermost rams below the choke line and close the
diverter, open the annular preventer to allow trapped gas to rise, displace riser with kill fluid and
close the annular preventer, reopen the ram preventer.
X. Adjust the closing pressure on the annular preventer to allow stripping of tool joints.
XI. Hang off the drill pipe as follows:
With a motion compensator:

I. Position a tool joint above the hang-off rams leaving the lower Kelly cock high enough
above the floor to be accessible during the maximum expected heave and tide when the
selected tool joint rests on the hang-off rams.

II. Close the hang-off rams.

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III. Carefully lower the drill string until the tool joint rests on the hang-off rams.
IV. Reduce support pressure on the motion compensator to support about half of the weight of
drill string above the BOPs plus some overpull to provide drill string tension to assist shearing,
if required.
Without a motion compensator:
I. Set the slips on the top joint of drill pipe.
II. Close the lower Kelly cock.
III. Break the Kelly/ top drive connection above the lower Kelly cock and put it in the rat hole.
IV. Pick up the assembled space-out joint, safety valve, and circulating head with the safety valve
closed. Make up the space-out joint on the closed lower Kelly cock.
V. Open the lower Kelly cock, remove the slips, and position tool joint above the hang-off rams
leaving the safety valve high enough above the floor to be accessible during the maximum
expected heave and tide when the selected joint rests on the hang-off rams.
VI. Close the hang-off rams.
VII. Carefully lower the drill string until the tool joint lands on the closed hang-off Rams. Slack off the
entire weight of drill string while holding tension on the circulating head with a tension device.
VIII. Connect the circulating head to the standpipe, open the safety valve.
IX. Allow the shut-in pressure to stabilize and record pressures.
X. Determine the volume of the kick.
XI. Calculate the drilling fluid density required to kill the kick.
XII. Select a kill method.
XIII. Check rig crew duties and stations.
XIV. Review and update well control worksheet.
XV. Inspect the BOP stack with television, if feasible.

B. During Tripping

I. Install safety valve.

II. Position the tool joint for the BOP’s operation.
III. Check the well for flow – if it is flowing, follow shut in procedure.
IV. If the soft shut-in procedure has been selected: open the choke line, close Annular BOP and close
the choke.
V. If the hard shut-in procedure has been selected: close Annular BOP and open the choke line with
the choke in closed position.
VI. Observe the casing pressure, if it exceeds MAASP, follow the contingency plan.
VII. Check for trapped gas pressure.
VIII. For release of trapped gas, close the uppermost rams below the choke line and close the diverter,
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open the annular preventer to allow trapped gas to rise, displace riser with kill fluid and close the
annular preventer, reopen the ram preventer.
IX. Adjust the closing pressure on the annular preventer to allow stripping of tool joints.
X. Hang off the drill pipe as follows:

With a motion compensator:

I. Position a tool joint above the hang-off rams leaving the safety valve high enough above the floor
to be accessible during the maximum expected heave and tide when the selected tool joint rests
on the hang-off rams.
II. Close the hang-off rams.
III. Carefully lower the drill string until the tool joint rests on the hang-off rams.
IV. Reduce support pressure on the motion compensator to support about half of the weight of drill
string above the BOPs plus some over pull to provide drill string tension to assist shearing, if
required.
Without a motion compensator:
I. Pick up the assembled space-out joint, safety valve, and circulating head with the safety valve
closed. Make up the space-out joint on the string.
II. Open the safety valve, remove the slips, and position tool joint above the hang-off rams leaving
the safety valve high enough above the floor to be accessible during the maximum expected
heave and tide when the selected joint rests on the hang-off rams.
III. Close the hang-off rams.
IV. Carefully lower the drill string until the tool joint lands on the closed hang-off rams. Slack off the
entire weight of drill string while holding tension on the circulating head with a tension device.
V. Connect the circulating head to the standpipe, open the safety valve.
VI. Allow the shut-in pressure to stablise and record pressures.
VII. Determine the volume of the kick.

VIII. Calculate the drilling fluid density required to kill the kick.

IX. Select a kill method.

X. Check rig crew duties and stations.
XI. Review and update well control worksheet.
XII. Inspect the BOP stack with television, if feasible

C. When String is Out of Hole:

I. At the first indication of the well flowing, close the blind / blind-shear rams.
II. Open the gate valve on the subsea BOP stack to open the choke line, close the choke line at the
surface.
III. Record shut-in pressures. Wt. (specific gravity) of fluid in the choke line should be considered for
calculating shut-in casing pressure.
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IV. Record the kick volume.

V. Run the drill string in the hole to the top of the BOPs with NRV.
VI. Add the hydrostatic pressure of the fluid in the choke line to the surface pressure to determine the
pressure below the blind rams.
VII. Determine if the pressure below the blind rams can be overbalanced by hydrostatic pressure of the
drilling fluid that can be safely contained by the riser. If so, adjust the riser tensioners to support the
additional drilling fluid weight and displace the drilling fluid in the riser with drilling fluid of the required
density.
VIII. Close the diverter. Open the BOPs and watch for flow. If the well does not flow, open the diverter
and trip in the hole.
IX. If the well starts to flow, close the blind ram preventer, displace the choke and kill lines with heavy
drilling fluid, and circulate until the riser contains drilling fluid of the desired density.
X. Continue going in the hole. Stop periodically, close the pipe rams, and circulate the riser by
pumping down the kill line to maintain the required drilling fluid density in the riser.
After well killing and before resuming normal operations, density of drilling fluid should be reviewed to
include trip margin above kill mud weight.

8.0 DRILLS AND TRAINING

8.1 Drills
I. The competence with which drilling personnel respond to well control situations and follow correct
procedures can be improved by carrying out emergency drills. All the key operational personnel
should have valid well control training certificate from IWCF/ IADC accredited well control training
centre.

II. While drilling in H2S/ sour gas prone area, detectors shall be installed and breathing apparatus in
sufficient quantity and cascade system shall be made available. Crew shall be trained to handle
situations in this environment.
III. Organization should assign specific responsibilities to the identified/ designated persons, for actions
required during an emergency related to well control, which would be part of rig ERP.
IV. All the drills are to be conducted based on risk assessment by the operator by ensuring the
elimination of potential hazards.
V. Drills should be documented, executed, repetitive, and followed-up to correct identified problems.
Drills should be clearly announced so all concerned know that a drill, not an actual event, is taking
place.
a) To conduct a drill, a kick should be simulated by manipulating primary kick indicator such as
the pit level indicator or the flow line indicator by raising its float gradually and checking for the
alarm.
b) The reaction time from float raising to the designated crew member's readiness to start the
closing procedure should be recorded and response time should not be more than 60 seconds.
c) Total time taken to complete the drill should be recorded and it should not be more than 2
minutes.
d) Drill should be initiated without prior warning during routine operation.
e) Drill should be conducted once a week with each crew.
f) Drill should be initiated at unscheduled times when operations and hole condition permits.
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CREW DRILLS
Shallow gas flows generally develop quickly; can be difficult to detect early; and will flow high volumes of gas
from abnormally pressured, highly permeable formations. Likewise, inadvertent gas entry in a marine riser
or a gas bubble migrating up the annulus can be difficult to detect. All concerned personnel should be familiar
with the well control system components and installation and capable of reacting quickly and efficiently to
potential situations requiring their use.
Drills generally enhance the crew proficiency in well control situations. When the desired proficiency is
attained, periodic drills should be continued to maintain performance. The following drills, frequency, and
proficiency levels are considered desirable for drilling operations.

8.1.1 Pit Drill

During a routine operation, the rig supervisor should simulate a gain in pit drilling fluid volume by raising a
float sufficiently to cause an alarm to be activated. If automatic equipment is not available, the drills may be
signalled by word of mouth. The drilling crew should immediately initiate one of the four procedures discussed
below, depending on the operation at the time of the drill. A pit drill is terminated when the crew has
completed the steps up to, but not including, closing the BOPs. The supervisor initiating the drill should
record response time, which should be one minute or less.

8.1.1.1 on-Bottom Drill

This drill should be carried only to the point of driller recognition, signalled by raising the Kelly/ top drive and
pump shutdown. This is to avoid the danger of stuck pipe.
a. Signal given.
b. Stop drilling or other operation.
c. Position the drill pipe for the BOPs while sounding the alarm.
d. Stop pump.
e. Check for well flow.
8.1.2 BOP Drill
This drill includes all steps of the pit drill in 8.1.1 but is continued through all the steps of closing-in the well.
The drill should be repeated on a daily basis until each crew closes-in the well within a span of two minutes.
Thereafter, the drill should be repeated weekly to maintain proficiency.
Following are simplified drill outlines that should be modified for the specifics of the particular rig, equipment,
and operation.
8.1.2.1 Drill pipe in BOP drill
I. Give signal by raising alarm.
II. Position tool joint above rotary and set the pipe on slips.
III. Install full opening safety valve in open position.
IV. Close FOSV after installation.
V. Designated crew members should move to assigned position, during/ after the above steps, as applicable.
VI. Close BOP.
VII. Record response time.
Note: Trip drill should be carried out preferably when bit is inside the casing. A full opening safety valve for
each size and type of connection in the string shall be available on derrick floor, in open position. Safety
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valves may be clearly marked for size and connection.

8.1.2.2 Drill Collars or Tool Joints in the BOP Drill
Preparation for this operation must be made in advance. Prior to reaching the drill collars or bottom-hole
assembly when pulling out of the hole, the appropriate crossover sub must be placed on a single joint of
pipe. A full open safety valve is then made-up on the top of the joint of pipe. Flows that occur with drill collars
or the bottom-hole assembly in the BOPs are generally quite rapid since they are usually the result of
expansion of a gas bubble close to the surface. A joint of pipe picked up with the elevators is usually easier
to stab and make-up than a safety valve alone. Under actual kick conditions (other than drill) if only one stand
of drill collars or the bottom-hole assembly remained in the hole it is probably faster to simply pull that last
stand and close the blind ram.
I. Give Signal.
II. Position the upper drill collar or tool joint and set the slips.
III. Stab the full open safety valve made up on one joint of pipe with the appropriate crossover sub onto the
drill collars or tool joint.
IV. Lower the collars with joint of pipe into the hole.
V. Close the drill pipe safety valve.
VI. Close the pipe ram above the pipe tool joint.
VII. Record response time
8.1.2.3 String out of the hole Drill
I. Give Signal.
II. Close the blind ram.
III. Record Response time.
8.1.3 Stripping Drill
The purpose of this drill is to give drill crews the most realistic type of well control training and a feel for the
equipment and procedures they shall use during stripping into a well. This drill should be carried out prior to
drilling out the casing shoe. It shall never be carried out when open hole sections are exposed and shall be
carried out in a safe distance above cement. Drill is to be practiced considering no gas migration occurring.
Circulate to verify flow path is OK.
A stripping drill by at least one crew on each well should be considered. This drill can be conveniently
performed after casing is set and before drilling out cement. With drill pipe in the hole, the BOP is closed,
and the desired pressure trapped.
Each member of the crew should be assigned a specific position. Strip sufficient pipe into the hole to establish
the workability of the equipment and allow the crew an opportunity to perform their assignments. In addition
to establishing equipment reliability, at least one crew on each well is trained. All crews should become
proficient in stripping operations. Stripping drills are not recommended for operations involving subsea BOP
stacks.
The following procedure is recommended:

Shut-in the well using the FOSV and the annular preventer (as per the rig specific shut-in procedure).
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a. Install the IBOP and open the FOSV used to shut-in the well. Ensure the choke is closed and open
the HCR.
b. Apply 300 psi pressure on the annulus using the kill line (Ensure that the net upward force acting on
the string (cross sectional area of tool joint) by the well pressure must be sufficiently less than the
buoyant weight of the string). Check to ensure the IBOP is not leaking.
c. Reduce the closing pressure on the annular preventer as low as possible and still maintain a seal.
d. Open valve to surge bottle on annular closing line if one exists.
e. Line up choke manifold to trip/ strip tank (tank should be ~ 1/3 full).
f. Make-up drill pipe stand. Use a file to remove any tong/ slip marks on the pipe and apply mud or
suitable lubricant to the bottom upset of the tool joints prior to passing through the rotary table
(surface stack only).
g. Slowly strip the first stand into the hole with choke closed (i.e. without bleeding mud) until the casing
pressure reaches 400 psi (300 psi SICP + 100 psi Safety Factor).
h. Continue stripping the first stand into the hole maintaining the casing pressure at 400 psi while
stripping by bleeding off through the choke. Measure volume bled to ensure it is equal to the closed
end volume stripped (use closed end volume stripped after reaching the 400psi pressure).
i. Install second stand and slowly strip in while maintain pressure at 400 psi. Measure volume bled to
ensure it is equal to the closed end volume stripped.
j. Fill the inside of the two stripped stands with mud.
k. Strip additional stands using same procedure if required to ensure the crew is comfortable with the
operation.
l. When the stripping operation is finished – bleed off casing pressure through the choke; close valve
to annular surge bottle if used; increase annular regulator to normal operation pressure; open
annular; close HCR; align choke manifold for normal drilling operations; pull stripped stands to FOSV;
close FOSV; remove IBOP (check for trapped pressure); open FOSV (to bleed any trapped
pressure); remove FOSV.
m. Debrief and address any gaps. Consider pressure testing the annular prior to commencing the
tripping operation.

Drill Specific Caution Guidance:

1. Ensure pressure is bled off and the BOP and choke manifold are correctly lined up for normal
operations upon conclusion of the exercise.
2. Check for trapped pressure below the IBOP and FOSV prior to breaking out.

8.1.4 Choke Drill

The purpose of this drill is to give drill crews the most realistic type of well control training and a feel for the
equipment and procedures they shall use during killing a well. Choke drill to be performed before drilling out
shoe track to verify crew competence in controlling Bottom hole pressure during killing.
Choke drills should be performed before drilling out surface casing and each subsequent casing string. With
pressure trapped below a closed preventer, use the choke to control casing pressure while pumping down
the drill pipe at a prescribed rate. This drill establishes equipment performance and allows the crew to gain
proficiency in choke operation.
Discharge into a trip tank to accurately monitor flow rates for correlation with choke opening, pump rates,
and pressure drops in the circulating system and across the choke. This is particularly important for subsea
BOP stacks in deepwater, which may have significant circulating pressure losses in the choke lines.
The following procedure is recommended:
a) Run in hole and tag the top of cement.
b) Pull back one stand and install top drive/Kelly.
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c) Break circulation to ensure the string is filled and well is filled with homogeneous mud with no sticking
tendency. Establish slow circulation rate pressures with at least two different rates. Line up the choke
line through remote /manual choke.
d) Close BOP. Open choke line valves. Choke closed. Line up returns through MGS.
e) Pressure up the well with mud pump to around 400- 500 psi in well. Record the pressure in the
remote choke panel.
f) Bring the pump up to kill speed controlling the bottom hole pressure by maintaining the casing
pressure constant. Casing pressure should be controlled (held constant) while circulation started and
stopped several times (by accurate manipulation of choke). Drill also to include maintaining BHP
while changing kill rate (i.e. high to low).
Record the crack opening response of the choke(s).
Note: The standpipe pressure (SPP) gauge and local pressure gauge on the manual choke should be
calibrated to the gauge on the choke panel.
g) At kill rate, maintain the drill pipe pressure constant. It is important that the choke operator
develops a feel for the lag time between manipulation of the choke and its subsequent effect on the
drill pipe pressure. The lag time shall be recorded, so that it can be used for reference should a
kick be taken in the next hole section.
h) Slowly stop circulation maintaining casing pressure constant.
i) Record any important findings/observations. Debrief and take feedback with all involved personnel.
j) Upon completion of drill, bleed off pressure from well and line up the choke manifold, choke(s) and
BOP as per the next operation.

8.1.5 Hang-off Drill (Subsea BOPs Only)

Following prescribed procedures, the crew should place the drill string in position for hang-off. One hang-off
should be made before drilling out of surface pipe to ensure that all necessary equipment is on hand and in
working condition. Actual hang-off is not normally performed on subsequent drills. This drill can be
conveniently performed in conjunction with the pit drill.

8.2 WELL CONTROL TRAINING:

All the key operational personnel1 at the field and base office involved in the operation shall hold valid well
control training certificate (of appropriate level2) from IWCF/ IADC accredited well control training centre.

At least one such trained person shall always be present on derrick floor to observe well for any activity even
during shutdown period.
All the crew members (Other than the key operational personnel) directly involved in the drilling/ workover
operations shall be trained in well control equipment, principles and procedures, once in every two years and
record to be maintained.
Key operational personnel1:
The following field personnel representing Contractor/ Operator/ Service provider should be considered as
key person during drilling/ workover operation:
I. Company Man/ OIM/ Rig Manager/ Installation manager/ Supervisor/ DIC/ Tool pusher/ Tour pusher/
Sub- Sea Engineer.
II. Shift in charge/ Driller.
III. Asst. Shift in charge/ Asst. driller.
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IV. Any other designated personnel involved in well control operation as identified by the competent
authority.
Appropriate level2:
I. IWCF Level 4/ IADC Well sharp supervisor level: Company Man/ OIM/ Rig Manager/ Installation
manager/ Supervisor/ DIC/ Tool pusher/ Tour pusher/ Sub- Sea Supervisor or Subsea In-charge.

II. IWCF Level 3/ IADC Well sharp Driller level: Shift in charge/ Driller/ Sub- Sea Engineer.

III. IWCF Level 2/ IADC Well sharp introductory level: Asst. Shift in charge/ Asst. driller/ Headman.

9.0 MONITORING SYSTEM

9.1 Instrumentation systems
I. Driller's console system shall have provision for monitoring and recording of drilling parameters
(weight, SPM, pump pressure, rotary torque, rate of penetration). Driller’s console shall be positioned
in such a way that driller can see all the gauges without any obstruction.
II. Flow rate sensor should be installed for monitoring return mud flow with high/ low alarms (visual or
audible setting).
III. Mud/ pit volume monitoring system should be installed for all the reserve and active mud tanks to
detect mud tank level's deviation and it should have high/ low alarm (visual and audible setting).
IV. Gas detector shall always be available. Gas measurement should be carried out near the point where
the mud from the well mouth surfaces (Shale shaker and rig sub structure).

9.2 Trip Tank System

I. On a drilling rig, the trip tank shall always be in operation during tripping operation, particularly during
pulling out operation, for early detection of a kick.
II. The primary purpose of the trip tank is to measure the amount of drilling fluid required to fill the hole
while pulling pipe to determine if the drilling fluid volume matches pipe displacement.
III. A trip tank is a low-volume calibrated tank which can be isolated from the remainder of the surface
drilling fluid system and used to accurately monitor the amount of fluid going into or coming out from
the well. A trip tank should be calibrated accurately and should have means for reading the volume
contained in the tank at any liquid level. The readout may be direct or remote, preferably both. The
size of the tank and readout arrangement should be such that volume changes can be easily
monitored from derrick floor.
9.3 Mud Gas Separator (MGS)
MGS shall be used to remove gas bubbles from the contaminated fluid during well killing operation and
installed downstream of the choke manifold. Sufficient hydrostatic head to be maintained in the liquid seal to
prevent gas blow through to shale shaker. Vent line should be away from derrick floor at a safe distance.
The rig maintenance and inspection schedule should provide for periodic non-destructive examination of the
mud gas separator to verify pressure integrity.
9.4 Degasser
A degasser shall be used to remove entrained gas bubbles in the drilling fluid. All degassers use vacuum
pump to remove dissolved gas from the drilling fluid.
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All flare lines should be as long as practical with provision of flaring during varying wind directions. Flare
lines should be straight as far as possible and should be securely anchored. Degasser should be function
tested at least once a week.

10.0 UNDER BALANCED DRILLING

Primary well control during Under Balanced Drilling (UBD) is maintained by flow and pressure control using
specialized surface equipment and procedures. The bottom hole pressure and the reservoir influx is
monitored and controlled by means of a closed loop surface system. This system includes rotating control
device (RCD), flow line, emergency shutdown valve (ESDV), choke manifold and surface separation system.
The primary functions of these systems are to contain well fluids and pressures within a design envelope in a
closed flow control system, provide means to add fluid to the wellbore, and allow controlled volumes to be
withdrawn from the wellbore.
The following are the recommended equipment for UBD operations:
I. The RCD shall be installed above the drilling BOP and shall be capable of sealing the maximum
expected wellhead circulating pressure against the rotating work string and containing the maximum
expected shut-in wellhead pressure against a stationary work string. The RCD is a drill through device
with a rotating seal that is designed to contact and seal against the work string (drill string, casing,
completion string, etc.) for the purpose of controlling the pressure and fluid flow to surface. Its function
is to contain fluids in the wellbore and divert flow from the wellbore to the surface fluids handling
equipment during underbalanced operations (drilling, tripping and running completion equipment).
II. The return flow line shall have two valves, one of which shall be remotely operated and fail- safe-close
(ESDV). The flow line and the valves shall have a working pressure equal to or greater than the
anticipated shut-in wellhead pressure. At least one valve shall be installed in the diverter/ flow line
immediately adjacent to the BOP stack.
III. A dedicated UBD choke manifold shall be used to control the flow rate and wellbore pressure and reduce
the pressure at surface to acceptable levels before entering the separation equipment. The choke
manifold shall have a working pressure equal to or greater than the anticipated shut-in wellhead
pressure. The choke manifold shall have two chokes and isolation valves for each choke and flow path.
Applied surface backpressure should be kept to a minimum to reduce erosion of chokes and other
surface equipment.

IV. A surface separation system shall be selected and dimensioned to handle the anticipated fluid/
solids in the return flow based on the maximum potential production at maximum drawdown.
Plugging, erosion or washouts of surface equipment should not impact the ability to maintain primary
well control.
V. The drill pipe and casing should be designed for exposure to Hydrogen Sulphide (H2S) gas.
VI. The BOP stack, flow/ diverter line, and bleed off and kill lines should be designed for exposure to H 2S
in accordance with NACE (MR 0175) / ISO 15156 specifications.
VII. Blind-shear rams should be considered for underbalanced drilling of wells with high Hydrogen Sulphide
(H2S) potential.
VIII. A stab-in safety valve for the string in use should be available on the rig floor. The stab-in safety valve
shall have a pressure rating equal to or greater than the BOP pressure rating and should be equipped to
screw into any drill string element in use.
10.1 Procedures for UBD
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I. Procedures for UBD operations should be developed based on risk analysis and risk assessments.
These procedures should include:
a) Activity in the wellbore
b) Making connections
c) Live well tripping
d) Trapped pressure in equipment
e) Failure of equipment
f) H2S contingency.
II. When running a work string in under balanced condition, two NRVs shall be installed in the string
directly above to the bit or motor. Installation of additional NRVs should be considered depending
on the nature of the operation (i.e., high-pressure gas). The NRV should have a minimum working
pressure rating equal to the maximum expected BHP.
III. Snubbing facilities should be used, or the well should be killed with a kill weight fluid prior to tripping
pipe, if the shut-in or flowing wellhead pressure can produce a pipe light condition and in case of a
down hole isolation valve (DIV), a retrievable packer system or similar shut-in device, is not in use
or is not functioning as designed.
DIV should have working pressure rating of more than maximum expected differential pressure
after closure.
If DIV is installed, risk assessment and modelling should be conducted to investigate the effects of
a dropped object (including drill string) on the closed valve and to ensure adequate dropped object
risk mitigation is included in the procedures. For example, a 100-bbl fluid cushion or equivalent
surface backpressure is held above the DIV.
IV. Sufficient kill fluid minimum quantity of 1.5 hole volumes of required density should be available on
site at any time to enable killing of the well in an emergency.
V. While still in the design stage, a meeting including all key personnel should be held to discuss the
proposed operation so that everyone clearly understands their responsibilities with respect to
safety. A key element in planning a safe operation is the site layout. The following considerations
should be made when designing the well-site layout:
a) Prevailing winds
b) Access to fluids handling equipment
c) Equipment placement
d) High pressure line placement.
VI. At no time the well should be left open to the rig floor when the well is live.
VII. Trapped gas below the float should be removed safely before removing the float from the drill string
during pulling out.
VIII. If a well is killed prior to tripping, traditional tripping procedures including the completion of trip
sheets should be followed.
IX. Round the clock supervision by competent persons should be ensured. All personnel involved in
operations should be trained in UBD operations, and training should be documented.
X. The Well Site Supervisor should have valid accredited well control certificate for underbalanced
drilling and well intervention operations.
XI. Appropriate PPE should be used by all personnel on the site.
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XII. A site-specific emergency contingency plan should be prepared to a level of complexity that the
operation warrants, prior to any underbalanced drilling taking place.
XIII. The following points describes incident scenarios for which well control action procedures should
be available (as applicable) to deal with the incidents should they occur (This list is not exhaustive;
additional scenarios may be applied based on the actual planned activity):
a. Bottom hole or surface pressure and/ or flow rates detected which could lead to the
pressure rating of the rotating control device (static or dynamic) or the capacity of the surface
separation equipment being exceeded.
b. NRV failure, influx into work string during making connection or tripping in live well.
c. Leaking connection below drilling BOP.
d. Leaking rotating control device or flow line before ESDV, seal elements, connection to flow
line, drilling BOP or high-pressure riser.
e. Erosion or wash out of choke. Consider the case where isolation for repair of the choke cannot
be achieved.
f. Failure of surface equipment after RCD. This can be leaks or plugged equipment and lines.
g. Work string failure.
h. Emergency shut in.
i. Emergency well kill.
j. Lost circulation.
k. H2S in the well.
XIV. When hydrocarbons are being produced or when they are used in the drilling fluid, supplementary
firefighting equipment should be considered. This may require as little as additional hand-held fire
extinguishers to as much as having a fire fighting vehicle on-site.
XV. Regardless of the concentration of H2S, no sour gas may be released to atmosphere at any time.
XVI. Produced fluids containing H2S or drilling fluids contaminated with H2S should not be stored in
open tanks.
XVII. The flare stack shall be as per regulatory requirements.
XVIII. If H2S is expected to be encountered in the well, a monitoring program shall be in place. As a
minimum, monitoring stations should include the rig floor, inside the rig substructure adjacent to the
BOPs, and near separation vessels and storage or circulating tanks.
XIX. A pressurized tank or a tank truck equipped with a functional H2S scrubber should be used for the
transportation of sour fluids off location.
XX. Adequate provision should be made for the safe storage and/ or disposal of produced fluids and
drill cuttings. Consideration should be given to providing additional storage capacity in the event of
unforeseen circumstances, such as inclement weather conditions, which may compromise proper
fluid handling abilities. Reservoir liquids should not be stored in an earthen pit. Refer to MOEF
guidelines for handling of drilling fluids and drill cuttings (OISD-RP-201).
XXI. Explosive potential monitoring should be conducted at all the points where there is a potential of
release of combustible vapours to atmosphere.
XXII. For wells which contain H2S, drill cuttings should be held in tanks equipped with vapour control.
Vapour shall either be vented to a flare stack or through an H2S scrubbing system.
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XXIII. Surface equipment exposed to high pressures and/or high flow velocities shall be inspected on a
regular basis using industry-accepted practices to monitor for materials erosion.

11.0 WELL CONTROL EQUIPMENT ARRANGEMENT FOR HIGH PRESSURE HIGH

TEMPERATURE (HPHT) WELLS:

For HPHT wells, BOP Stack Configuration and Well Control Accessories/ Equipment, Refer OISD-RP-
242.

12.0 REFERENCES

1. Alberta Energy and Utilities Board- ID 94-3: Under Balanced Drilling

2. API-RP 16E: Recommended Practices for Design of Control Systems for Drilling Well Control
Equipment API-STD 53 (latest edition): Recommended Practices for Blowout Prevention

3. Equipment Systems for Drilling Wells

4. API-RP 59 (latest edition): Recommended Practices for Well Control Operations

5. API-RP 64 (latest edition): Recommended Practices for Diverter Systems Equipment and Operations

6. API-SPEC 16C (latest edition): Specifications for Choke and Kill Systems

7. API-SPEC 16D (latest edition): Specifications for Control Systems for Drilling Well Control Equipment

8. API-SPEC 16R (latest edition): Specification for Marine Drilling Riser Couplings

9. IADC: IADC Deepwater Well Control Guidelines

10. IADC: UBD and MPD Operations - HSE Planning Guidelines

11. API-RP-92U (latest edition): Underbalance drilling operations

12. API-16A (latest edition): Drill through equipment

13. API-16AR (latest edition): Standard for repair & remanufacture of drill through equipment

14. API-6A (latest edition): Specification for wellhead & Christmas tree equipment

15. API-6AR (latest edition): Repair & remanufacture of wellhead & tree equipment

16. OISD-GDN-182

17. OISD-RP-242
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13.0 ABBREVIATIONS
API - American petroleum institute
BHA - Bottom hole assembly
BHP - Bottom hole pressure
BOP - Blow out preventer
BSR - Blind shear rams
DIC - Drilling in-charge
DIV - Downhole isolation valve
ECD - Equivalent circulating density
EDS - Emergency disconnect system
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ERP - Emergency response plan

ESD - Emergency shut down
EMW - Equivalent mud weight
ESDV - Emergency shut down valve
FOSV - Full opening safety valve
HCRV - Hydraulically Controlled Remote Valve
HPHT - High pressure high temperature
IADC - International association of drilling contractors
IBOP - Internal blowout preventer
ID - Internal diameter
IM - Installation Manager
ISO - International Organization for Standardization
IWCF - International well control forum
LOT - Leak-off Test
LMRP - Lower marine riser package
MASP - Maximum anticipated surface pressure
MAASP - Maximum allowable annular surface pressure
MGS - Mud gas separator
MOEF - Ministry of environment and forests
MWP - Maximum working pressure
NRV - Non return valve
NACE - National association of corrosion engineers
OEM - Original equipment manufacturer
OIM - Offshore installation manager
OISD - Oil Industry Safety Directorate
PIT - Pressure integrity test
PPG - Pounds per gallon
RCD - Rotating circulation valve
ROV - Remote operated vehicle
RWP - Rated working pressure
SCR - Slow circulating rate
SICP - Shut-in casing pressure
SIDPP - Shut-in drill pipe pressure
SPM - Strokes per minute
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TDS - Top drive system

TVD - True vertical depth
UBD - Underbalanced drilling
WP - Working pressure

ANNEXURES
Annexure-A
BHP under various operating situations is:
When not circulating (static condition):
BHP = Hydrostatic pressure due to fluid column.
While drilling (over balance):
BHP = Hydrostatic pressure of fluid + Annular pressure losses.
While drilling (MPD/UBD):
BHP = Hydrostatic pressure of fluid + Annular pressure losses + Surface applied pressure.
While shut-in after kick:
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BHP = Hydrostatic pressure of fluid + Surface pressure.

While killing operation in well:
BHP = Hydrostatic pressure of annular fluid + Annular pressure losses + Surface pressure
While Running pipe in the hole (Tripping in):
BHP = Hydrostatic pressure + Surge pressure.
While Pulling pipe out of hole (Tripping out):
BHP = Hydrostatic pressure - Swab pressure.

Annexure-B
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OISD-STD-174
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Annexure-C

Name: Name:

Signature (Driller/ SIC) Signature (Tool pusher/ DIC/IM)

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Annexure-D

Procedure of Drawdown Test for Land and Surface Offshore

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1. A drawdown test shall be conducted by actuating the specified BOP operators or any combination of
available operators that draw the same or larger volume as the specified BOP operators.
2. Tests shall be completed at zero wellbore pressure.
3. Manifold and annular regulators shall be set at the manufacturer’s recommended operating pressure
for the BOP stack.
4. The test shall be performed as follows:
a) Position a properly sized joint of drill pipe or a test mandrel in the BOP, if required.
b) Turn off the power supply to all accumulator charging pumps (air, electric, etc.).
c) Record the initial accumulator pressure.
d) Close the largest-volume annular BOP or any combination of operators with an equivalent or
larger volume.
Time each actuation. Response times shall be recorded.
e) Close a maximum of four BOP rams with the smallest cumulative operating volume or any
combination of
operators with an equivalent or larger volume. Time each actuation. Response times shall be
recorded.
f) Open the hydraulic-operated valve(s) and record the time.
g) Record the final accumulator pressure; check whether the value is more than MOP.

5. The frequency of drawdown test should not exceed 180 days.

Note 1: The results of the test can be used to determine whether:

a) Inadequate bottle pre-charge pressure exists
b) A failed bladder, piston, or float exists in the system
c) A temperature change has reduced effectiveness of the pre-charge gas
d) Other leakage from within the system has occurred
e) Improper alignment of valves has isolated some of the accumulator bottles.

Annexure-E
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Operating Chamber Pressure Testing, Surface BOP Stacks

Component to be Pressure Test—Low

Pressure Tested Pressure
Pressure Test—High Pressurea Frequency
psig (MPa)

Annular preventer
open and closing
Not required RWP as specified by equipment Every 12
operating chambers
manufacturer months

BOP choke and kill valve

open and closing
Not required RWP as specified by equipment Every 12
operating chambers
manufacturer months

Ram preventer open

and closing operating
Not required RWP as specified by equipment Every 12
chambers
manufacturer months

Casing shear ram

open and closing
Not required RWP as specified by equipment Every 12
operating chambers
manufacturer months

a Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.
The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the
intended test pressure.
b If the BOP is in operation, the test is to be conducted during the BOP next planned maintenance.
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Annexure-F
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Annexure-G

Name Name

Signature Signature
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Annexure-H

Test Documentation
1. The results of BOP stack and choke manifold pressure and function tests shall be documented.
2. BOP stack and choke manifold pressure tests shall be documented with a pressure chart recorder or
equivalent data acquisition system.
3. Test documentation shall be signed by the pump operator, contractor’s representative, and operator’s
representative.
4. Problems with the BOP system that results in an unsuccessful pressure test and actions to remedy the
problems shall be documented as per the equipment owner's procedures.

Initial Pressure Testing, Surface BOP Stacks

Pressure Test—Low Pressure Test—High Pressureac

Pressureac
Component to be Pressure Change Out of No Change Out of
Tested psig (MPa)
Component, Elastomer,or Component, Elastomer,or
Ring Gasket Ring Gasket

MASP or 70% annular

RWP, whichever is lower.
Annular preventerb 250 to 350 (1.72 to 2.41) RWP of annular preventer

Fixed pipe, variable bore, RWP of ram preventer or

blind, and BSR preventersbd wellhead system,
250 to 350 (1.72 to 2.41) whichever is lower ITP (Initial test pressure)

Choke and kill line and BOP RWP of side outlet valve or
side outlet valves below ram wellhead system, whichever
preventers (both sides) 250 to 350 (1.72 to 2.41) is lower ITP

Choke manifold—upstream of RWP of ram preventers or

chokese wellhead system,
250 to 350 (1.72 to 2.41) whichever is lower ITP

Choke manifold—downstream 250 to 350 (1.72 to 2.41) RWP of valve(s), line(s), or MASP for the well program,
of chokese whichever is lower

Kelly, kelly valves, drill pipe 250 to 350 (1.72 to 2.41) MASP for the well program
safety valves, IBOPs

a
Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.

The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the intended test pressure.

b
Annular(s) and VBR(s) shall be pressure tested on the largest and smallest OD drill pipe to be used in well program.

c
For pad drilling operations, moving from one wellhead to another within the 21 days, pressure testing is required for pressure-containing and
pressure-controlling connections when the integrity of a pressure seal is broken.
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d
For surface offshore operations, the ram BOPs shall be pressure tested with the ram locks engaged and the closing and locking pressure
vented during the initial test. For land operations, the ram BOPs shall be pressure tested with the ram locks engaged and the closing and

locking pressure vented at commissioning and annually.

e
Adjustable chokes are not required to be full sealing devices. Pressure testing against a closed choke is not required.

• ITP - API pressure designation that is equal to or above well program MASP for a land or surface offshore BOP
system.

Subsequent Operational Pressure Testing, Surface BOP Stacks

Component to be Pressure Test—Low

Pressure Tested Pressurea
Pressure Test—High Pressurea Frequency
psig (MPa)

Annular preventerb 250–350 (1.72–2.41) MASP for the hole section or 70 % Not to exceed
annular RWP, whichever is lower 21 days

BOP side outlet valves MASP for the hole section or 70 % Not to exceed
above pipe ram annular RWP, whichever is lower 21 days
250–350 (1.72–2.41)
preventers (wellbore side)

BOP side outlet valves Not to exceed

above pipe ram 21 days
250–350 (1.72–2.41) MASP for the hole section
preventers (non-wellbore
side)

Fixed and variable 250–350 (1.72–2.41) MASP for the hole section Not to exceed
bore pipe ram 21 days
preventersb

Choke and kill line and

BOP side outlet valves
250–350 (1.72–2.41) MASP for the hole section Not to exceed
below pipe ram
21 days
preventers (both sides)

Choke manifold— 250–350 (1.72–2.41) MASP for the hole section Not to exceed
upstream of chokesc 21 days

Choke manifold— 250–350 (1.72–2.41) RWP of valve(s), line(s), or MASP for Not to exceed
downstream of the hole section, whichever is lower 21 days
chokesc

Kelly, kelly valves, drill 250–350 (1.72–2.41) MASP for the hole section Not to exceed
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pipe safety valves, IBOPs 21 days

Blind and BSR preventers 250–350 (1.72–2.41) Casing test pressure At casing points

a Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.
The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the intended
test pressure.

bAnnular(s) and VBR(s) shall be pressure tested on the smallest OD drill pipe expected to be used in the next 21
days.

c Adjustable chokes are not required to be full sealing devices. Pressure testing against a closed choke is not required.

Pre-deployment Pressure Testing, Subsea BOP Stacks

Pressure Test—High Pressurea

Change-out of No Change-out of
Component to be Pressure Pressure Test—Low Component, Component,
Tested Pressurea psig (MPa) Elastomer, or Ring Elastomer, or Ring
Gasket Gasket

RWP of MAWHP or 70 %
annular
Annular preventerb 250–350 (1.72–2.41)
preventer
annular RWP,
whichever is
lower

BOP side outlet valves below RWP of MAWHP or 70 %

annular and above ram annular
250–350 (1.72–2.41) annular RWP,
preventers (wellbore side) preventer
whichever is
lower

BOP side outlet valves below PDTP or 5000

annular and above ram psig, whichever is
250–350 (1.72–2.41) RWP of ram preventers
preventers (non-wellbore side) higher

Fixed pipe, variable bore, 250–350 (1.72–2.41) RWP of ram preventer PDTP or 5000
and BSR preventersbc psig, whichever is
higher

LMRP and wellhead connectors 250–350 (1.72–2.41) Same as BOP Same as BOP
above connector above connector
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Choke and kill line and BOP PDTP or 5000

side outlet valves below ram psig, whichever is
250–350 (1.72–2.41) RWP of ram preventers
preventers (both sides) higher

a Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.
The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the intended
test pressure.

b Annular(s) and VBR(s) shall be pressure tested on the largest and smallest OD drill pipe to be used in well program.

c Ram-type BOPs shall be pressure tested with the locks engaged and the closing and locking pressure vented.

Initial Pressure Testing, Subsea BOP Stacks

Component to be Pressure Pressure Test—Low Pressure Test—High Pressurea

Tested Pressurea psig (MPa)

Annular preventerb 250–350 (1.72–2.41) MAWHP or 70 % annular RWP, whichever is

lower

BOP side outlet valves

below annular and above
250–350 (1.72–2.41) MAWHP or 70 % annular RWP, whichever is
ram preventers (wellbore
lower
side)

BOP side outlet valves

below annular and above
250–350 (1.72–2.41) MAWHP for the well program
ram preventers (non-
wellbore side)

Fixed pipe and variable 250–350 (1.72–2.41) MAWHP for the well program
bore, ram preventersbc

LMRP and wellhead connectors 250–350 (1.72–2.41) Same as BOP above connector

Choke and kill line and BOP

side outlet valves below ram
250–350 (1.72–2.41) MAWHP for the well program
preventers (both sides)

Choke manifold—upstream 250–350 (1.72–2.41) MAWHP for the well program

of chokesde
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Choke manifold—downstream 250–350 (1.72–2.41) RWP of valve(s), line(s), or MAWHP for the
of chokesde well program, whichever is lower

Kelly, kelly valves, drill

pipe safety valves,
250–350 (1.72–2.41) MAWHP for the well program
IBOPse

a Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.
The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the intended
test pressure.

b Annular(s) and VBR(s) shall be pressure tested on the smallest OD drill pipe to be used in the hole section.

c Ram-type BOPs shall be pressure tested with the locks engaged and the closing and locking pressure vented.

d Adjustable chokes are not required to be full sealing devices. Pressure testing against a closed choke is not
required.

e Pressure testing can be conducted before the BOP is latched to the wellhead.

Subsequent Operational Pressure Testing, Subsea BOP Stacks

Component to be Pressure Pressure Test—Low

Tested Pressurea Pressure Test—High Frequency
psig (MPa) Pressurea

Annular preventerb 250–350 (1.72–2.41) MAWHP or 70 % annular Not to exceed

RWP, whichever is lower 21 days

BOP side outlet valves MAWHP or 70 % annular Not to exceed

above pipe ram preventers RWP, whichever is lower 21 days
250–350 (1.72–2.41)
(wellbore side)

BOP side outlet valves Not to exceed

above pipe ram preventers 21 days
250–350 (1.72–2.41) MAWHP for the hole section
(non- wellbore side)

Fixed and variable bore 250–350 (1.72–2.41) MAWHP for the hole section Not to exceed
pipe ram preventersb 21 days

Choke and kill line and

BOP side outlet valves
250–350 (1.72–2.41) MAWHP for the hole section Not to exceed
below pipe ram preventers
21 days
 OISD-STD-174
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(both sides)

Choke manifold—upstream 250–350 (1.72–2.41) MAWHP for the hole section Not to exceed
of chokesc 21 days

Choke manifold— RWP of valve(s), line(s), or Not to exceed

downstream of chokesc 250–350 (1.72–2.41)
MAWHP for the hole 21 days
section, whichever is lower

Kelly, kelly valves, drill Not to exceed

pipe safety valves, IBOPs 21 days
250–350 (1.72–2.41) MAWHP for the hole section

BSR preventers 250–350 (1.72–2.41) Casing test pressure At casing points

a Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.
The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the intended
test pressure.

bAnnular(s) and VBR(s) shall be pressure tested on the smallest OD drill pipe expected to be used in the next 21
days.

c Adjustable chokes are not required to be full sealing devices. Pressure testing against a closed choke is not required.

Operating Chamber Pressure Testing, Subsea BOP Stacks

Pressure Test—Low Pressure Test—High

Pressure Pressurea
Component to be Pressure Tested Frequencyb
psig (MPa)

Annular preventer open and Not required RWP as specified by Every 12 months
closing operating chambers equipment manufacturer

LMRP connector latch and RWP as specified by

unlatch operating chambers equipment manufacturer
Not required Every 12 months

BOP choke and kill valve open Not required RWP as specified by Every 12 months
and closing operating chambers equipment manufacturer

Ram preventer open and RWP as specified by

closing operating chambers equipment manufacturer
Not required Every 12 months
 OISD-STD-174
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Casing shear ram open and RWP as specified by

closing operating chambers equipment manufacturer
Not required Every 12 months

Wellhead connector latch and Not required RWP as specified by Every 12 months
unlatch operating chambers equipment manufacturer

a Pressure test evaluation periods shall be a minimum of five minutes.

No visible leaks.
The pressure shall remain stable during the evaluation period. The pressure shall not decrease below the intended
test pressure.

b If the BOP is in operation, the test is to be conducted when the BOP is retrieved to surface for the next planned
maintenance.
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ANNEXURE I - MAJOR CHANGES IN REVISED EDITION

The following Major Changes were made.

1. Scope: This document provides Standard practices instead of recommended practices and added
the maintenance aspect of well control equipment. Changed from Recommended Practice to
Standard and also added maintenance aspect of well control equipment in the Scope.

2. Definitions: In definitions, many existing definitions were rewritten and some more were added like
definition of IBOP, BOP control unit, Down hole isolation valve were added. Added in the definition
of Accumulator, Subsea failsafe valves” being an integral part of the system the same is included.
Surface Pressure was added in BHP. The definitions of Influx & kill rate was modified.

3. Well Planning
• Well Completion aspect was added
• Well integrity aspects were added
• Use of Offset well data added
• Cementation details were added
• Contingency plan aspect added
• Risk assessment aspect was added
• Barrier envelop aspect added
• Gas detection aspect was added.

4. Diverter equipment & Control system:

• Shallow gas hazard risk assessment aspect was added
• Vent lines should be minimum 12” for offshore and minimum 8” for onshore
• Field testing & frequency added
• Function test system of diverter added
• Flow test was added with test documentation

5. Well Control Equipment & Control System

• Kill lines shall be of minimum 2” nominal size and choke line shall be of minimum 3” nominal
size for drilling operations and for work over/ well testing operations nominal size of kill &
choke line shall be 2” minimum.
• The procedural aspects of Inspection & Maintenance of well control equipment were
changed as per API-STD-53 ( New version)
• The procedural aspects of Repair & Remanufacturing were changed as per API-16AR
(New version)
• The operator for all classes of BOP arrangements to identify ram placements and
configurations to be installed shall perform a documented risk assessment. This assessment
shall include tapered strings, casings completion equipment, test tools.
• Control unit shall possess two independent power sources at all time to keep the hydraulic
fluid under required accumulator pressure.
• Blow out preventer testing procedure was modified as per API-STD-53 (New Version)
 OISD-STD-174
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• BOP function test procedure was modified as per API-STD-53 ( New version)
• Control System Response Time aspect was added as per API-STD-53 (New Version)
• BOP Pressure test procedure was modified as per API-STD-53 (New Version)
• Main Accumulator Drawdown test was added
• Hydraulic Chamber test was added
• Test documentation was added
• General testing requirements were added
• Surface BOP stack equipment aspects & Chokes, Choke / Kill Manifolds and console
aspects were added as per API-STD-53
• Operator shall carry out risk assessment for defining the safe distance added
• All 4-way valves at BOP control unit shall be either in the fully closed or open position as
required and they shall not be left in the block/neutral position. These shall have provision to
be operated from remote panel.

6. Procedures and Techniques for Well Control (Prevention and Control of Kick)
• The Trip sheet should be compared with the previous trip sheet data recorded in the
previous trip.

7. Drills & Training:

• Drills should be documented, executed, repetitive, and followed-up to correct identified
problems. Drills should be clearly announced so all concerned know that a drill, not an
actual event, is taking place as per API RP 59 – Added.
• Pit/BOP drills were modified as per API-RP-59
• Procedures of Stripping Drill, Choke Drill, Hang Off Drill were added as per API-RP-59
• In well Control training, the definition of key operational personnel & Appropriate level was
modified as per industry requirement/IADC/IWCF

8. Monitoring System.
• Tanks containing two compartments with monitoring arrangements in each compartment are
preferred as this facilitates removing or adding drilling fluid without interrupting rig operations.
(new addition) as per API-STD-53
• Mud Gas Separator (MGS) aspect was modified

9. Underbalance drilling:
• In UBD procedure, H2S contingency and failure of equipment aspects were added.
• If DIV is installed, risk assessment and modelling should be conducted to investigate the
effects of a dropped object (including drill string) on the closed valve and to ensure adequate
dropped object risk mitigation is included in the procedures. For example, a 100-bbl fluid
cushion or equivalent surface backpressure is held above the DIV. ( added) as per API-RP-
92U
• Surface equipment exposed to high pressures and/or high flow velocities shall be inspected
on a regular basis using industry-accepted practices to monitor for materials erosion.( added)
as per API-RP-92U
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10. Well Control Equipment Arrangement For High Pressure High Temperature (HPHT) Wells:
• For HPHT BOP Stack Configuration and Well Control Accessories / Equipment Refer OISD-
RP-242.

11. Annexures
• Configuration of BOP stacks were modified as per latest API & OEM requirement and BOP
testing formats were also modified and added
 OISD-STD-174
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ANNEXURE-J

List of previous functional Committee(s)

3rd FUNCTIONAL COMMITTEE
(2016)

NAME ORGANISATION

LEADER

Sunil Upadhyay BGEPIL

MEMBERS

Tarsem Singh Oil Industry Safety Directorate

Ajay Dixit ONGC, Ahmedabad

Sanjay Bhatt ONGC, Mumbai

Krantijyoti Deka Oil India Limited

Jagannath Chetia Oil India Limited

COORDINATOR

A. K. Jain Oil Industry Safety Directorate

 OISD-STD-174
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List of previous functional Committee(s)

2nd FUNCTIONAL COMMITTEE

(2008)

NAME ORGANISATION

LEADER

K. Satyanarayan Oil and Natural Gas Corporation Ltd.,

Ankleshwar.

MEMBERS

V.P. Mahawar Oil and Natural Gas Corporation Ltd.,

R.K. Rajkhowa Oil India Ltd

S.K. Ahuja Oil and Natural Gas Corporation Ltd.,

B.S. Saini Oil and Natural Gas Corporation Ltd.,

A.J. Phukan Oil India Ltd.,

MEMBER COORDINATOR

H.C. Taneja Oil Industry Safety Directorate, New Delhi.

 OISD-STD-174
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List of previous functional Committee(s)

1st FUNCTIONAL COMMITTEE
(1998)

NAME ORGANISATION DESIGNATION

LEADER
A.K. Hazarika ONGC, Mumbai GM (D)

MEMBERS

S.L. Arora ONGC, Ahmedabad GM (D)

A. Borbora Dy. CE (D)

OIL, Duliajan

C.S. Verma Dy. CE (D)

Oil, Rajasthan

A. Verma CE (P)
ONGC, Mumbai

V.P. Mahawar CE (D)

ONGC, Dehradun

B.K. Baruah ONGC, ERBC DGM (D)

S.K. Ahuja ONGC, ERBC SE (D)

CO-ORDINATOR

P.K. Garg (E&P) Addl. Director