Kazakh - British Technical University

School of Energy and Oil and Gas Industry

Well Workover

Assignment №5

Done by: Kanapiyeva Sharizada

Checked by: Zholmurzaeva Aliya Batyrbaevna

MSc in Oil and Gas Business

Almaty, 2023
 Assignment 5 – INSPECTION, TESTING AND MAINTENANCE
SELECTION OF PRESSURE RATING

1) Problem
An operator proposes to reperforate the producing zone in a well for which the BOP
requirement has been determined. The operator provides the following information
concerning the well:
8-5/8", 32#, J-55 casing cemented at 4,000'.
5-1/2", 17#, J-55 liner cemented from 3,960' to 4,500'.
Water shut-off (WSO) on 5-1/2" x 8-5/8" lap.
Liner perforated from 4,400' to 4,500'.
Total depth: 4,500'.
Producing clean, 38o API gravity oil (sp. gr. 0.835).
Static fluid level at 1,500' below surface.
Shut-in casing pressure: 50 psig.
Proposed workover fluid weight: 73.5 pcf.
Formation pressure gradient : 0.465 psi/ft.

Find the time

Working pressure, max testing pressure
Max predictable casing pressure
MPCP = BHP * BACK PRESSURE = 157,8 * 0,91 = 143,5 psi
BHP = SPECIFIC GRAVITY * 0.043 (conventional factor ) * TVD 3000(4500-1500) +
SICP = 0,835 * 0,043 * (4500-1500) + 50 = 157,8 psi
BACK PRESSURE (from the graph 1. Find the TVD and connect with x axes) =
MPCP/BHP = 0,91 (TVD = 4500’)

Max allowable casing pressure MACP = 1450 psi

Proposed workover fluid weight: 73.5 pcf.
TVD = 4500’

Pressure gradient = Proposed workover fluid weight * Convetional factor = 73.5 *

0.0069 = 0,507 psi/ft

Overbalance or overburden pressure gradient = Pressure Gradient – Formation

pressure gradient = 0,507 – 0.465 = 0,042 psi/ft.

Overbalance pressure P = Overbalance pressure gradient * TVD (linear cemented) =

0,042 * 3960 = 167 psi

Casing Yield Pressure = Formation Pressure – Overbalance pressure = 0,465 * 4500 +

167 = 2259,5 psi
 2) Theoretical part – Purpose of Inspection
Type of testing
a) Visually inspection
Visually inspect ram type preventers for:
1) Wear, pitting, and or damage to the bonnet or door seal area, bonnet or door seal grooves, ram
bores, ram connecting rod, and ram operating rods.
2) Packer wear, cracking, and excessive hardness.
3) Measure ram and ram bore to check for maximum vertical clearance according to
manufacturer’s specifications. This clearance is dependent on type, size, and trim of the
preventers.
4) If preventer has secondary seals, inspect secondary seals and remove the plugs to expose
plastic packing injection ports used for secondary sealing purposes. Remove the plastic injection
screw and the check valve in this port. Probe the plastic packing to ensure it is soft and not
energising the seal. Remove and replace packing if necessary.
 b) Pressure testing
An initial pressure test should be conducted on all preventer installations prior to drilling the
casing plug. Conduct each component pressure test for at least three minutes. Monitor secondary
seal ports and operating lines on each preventer while testing to detect internal seal leaks.
c) Hydraulic testing
1) Connect closing line(s) to preventer(s).
2) Set preventer test tool on drill pipe below preventer(s) if testing preventer with pipe rams.
3) Check for closing chamber seal leaks by applying closing pressure to close the rams and
check for fluid leaks by observing opening line port(s). Closing pressure should be equivalent to
the manufacturer’s recommended operating pressure for the preventer’s hydraulic system.
4) Release closing pressure, remove closing line(s), and connect opening line(s).
5) Check for opening chamber seal leaks by applying opening pressure to open rams and check
for fluid leaks by observing closing line port(s).Opening pressure should be equivalent to the
manufacturer’s recommended operating pressure for the preventer’s hydraulic system.
6) Release opening pressure and reconnect closing line(s).
7) Check for ram packer leaks at low pressure by closing rams with 1500 psi operating pressure
and apply pressure under rams to 200-300 psi with blowout preventer test tool installed (when
testing preventer containing pipe rams). Hold for three minutes. Check for leaks. If ram packer
leaks, refer to step 9. If ram packer does not leak, proceed to step 8.
8) Check for ram packer leaks by increasing pressure slowly to the rated working pressure of the
preventer. Hold for three minutes. Check for leaks .If ram packer leaks, proceed to step 9.
9) If rams leak, check for worn packers and replace if necessary. If the preventer is equipped
with an automatic locking device, check same for proper adjustment in accordance with
manufacturer’s specifications. Continue testing until a successful test is obtained.
10) Test the connecting rod for adequate strength by applying opening pressure as recommended
by the manufacturer with rams closed and blowout preventer rated working pressure under the
rams.
11) Release opening pressure and release pressure under rams.
12) Repeat procedure (steps 1 through 9) for each set of pipe rams.
13) Test blind rams in same manner as pipe rams (step 1, steps 3 through 9)with test plug
installed but test joint removed.Test plugs
d) Test joints
The test joint should be made of pipe of sufficient weight and grade to safely withstand tensile
yield, collapse or internal pressures that will be placed on it during, testing operations Refer to
API RP 7G: Recommended Practice for Drill Stem Design and Operating Limits* for tabulated
data listed by pipe size, grade, weight, and class (condition of pipe). The test joint, or a box and
pin sub on top of a standard joint of drill pipe, should have a tapped or welded connection below
the box end connection equipped with a valve, gauge, and fittings having a working pressure at
least equal to the rated working pressure of the preventer stack. Weep holes may be drilled in the
pin end of the test joint or may be installed in the test plug.
e) Periodic field testing
• Blowout Preventer Hydraulic Tests
a. Verify wellhead type and rated working pressure.
b. Check for wellhead bowl protector.
c. Verify preventer type and rated working pressure.
d. Verify drilling spool, spacer spool, and valve types and rated working pressures.
e. Verify ram placement in preventers and pipe ram size.
f. Verify drill pipe connection size and type in use.
g. Open casing valve during test, unless pressure on the casing or hole is intended.
h. Test pressure should not exceed the manufacturer’s rated working pressure for the body or the
seals of the assembly being tested.
i. Test pressure should not exceed the values for tensile yield, collapse and internal pressure
tabulated for the appropriate drill pipe as listed in API RP 7G: Recommended Practice for Drill
Stem Design and Operating Limits*.
j. Verify the type and pressure rating of the preventer tester to be used
• Blowout Preventer Operating Test
a. Install drill pipe safety valve.
b. Operate the choke line valves.
c. Operate adjustable chokes. Caution: Certain chokes can be damaged if full closure is effected.
d. Position blowout preventer equipment to check choke manifold. Open adjustable chokes and
pump through each choke manifold to ensure that it is not plugged. If choke manifold contains
brine, diesel or other fluid to prevent freeze-up in cold weather, some other method should be
devised to ensure manifold, lines, and assembly are not plugged.
e. Close each preventer until all pipe rams in the stack have been operated. Caution: Do not close
pipe rams on open hole. If blind rams are in the stack, operate these rams while out of the hole.
f. Return all valves and preventers to their original position and continue normal operations.
Record test results.
g. Annular preventers need not be operated on each round trip. They should, however, be
operated at an interval not to exceed seven (7) days.
• Accumulator Tests
This test should be conducted on each well prior to connecting the closing unit to the blowout
preventer stack. Test should be conducted as follows-Open the bottom valve on each
accumulator bottle and drain the hydraulic fluid into the closing unit fluid reservoir.
Measure the nitrogen precharge pressure on each accumulator bottle, using an accurate pressure
gauge attached to the precharge measuring port, and adjust if necessary.
• Auxiliary Equipment Testing
Testing The lower kelly valve, kelly, kelly cock, and inside blowout preventer should be tested
to the same pressure as the blow out preventer stack at the same time the preventer assembly
tests are made. This equipment should be tested with pressure applied from below.
• Closing Unit Pump Capability Test
Test should be conducted according to the following procedure:
Position a joint of drill pipe in the blowout preventer stack.
Isolate the accumulators from the closing unit manifold by closing the required valves.
If the accumulator pumps are powered by air, isolate the rig air system from the pumps. A
separate closing unit air storage tank or a bank of nitrogen bottles should be used to power the
pumps during this test. When a dual power source system is used, both power supplies should be
tested separately.
Simultaneously turn the control valve for the annular preventer to the closing position and turn
the control valve for the hydraulically operated valve to the opening position.
Record the time (in seconds) required for the closing unit pumps to close the annular preventer
plus open the hydraulically operated valve and obtain 200 psi above the precharge pressure on
the closing unit manifold. It is recommended that the time required for the closing unit pumps to
accomplish these operations not exceed two minutes.
Close the hydraulically operated valve and open the annular preventer. Open the accumulator
system to the closing unit and charge the accumulator system to its designed operating pressure
using the pumps.

Casing Inspections/Testing
Illustrates a casing ram test sub. Casing rams can be tested by connecting this test sub
between the test joint and the test plug so that the sub can be placed in the casing rams to
be tested. A casing ram test sub can be made by welding tool joint connections on the
ends of a short length of casing of desired diameter.
Maintenance procedures
Field welding on a blowout preventer or related equipment is not recommended. The
service life of annular preventer packing units can be extended by: Closing on pipe rather
than full closure. Using closing pressures recommended by the manufacturer. Utilising
the type of elastomer packing unit that best suits the drilling fluid conditions and
environment expected .d. Proper use of a regulator or accumulator when stripping tool
joints. Rapid movement of a tool joint through the preventer packing unit may cause
severe damage and early failure of the packing unit.