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Well Control Equipment Training Manual
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MAERSK TRAINING CENTRE

DRILLING SECTION
Copyright Maersk Training Centre a/s. All rights reserved. No part of this publication may be reproduced, stored in or introduced into a retrieval system, or transmitted, in any form, or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of Maersk Training Centre a/s.
WELL CONTROL EQUIPMENT TRAINING MANUAL

M:\IWCF Surface\3\1\Section 2.doc MTC
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Well Control Equipment Training Manual Well Control Philosophy
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It is the philosophy that during the drilling, - testing, completion water injection and work-over of an oil or gas well, any work undertaken should be executed in such a manner that: 1. Loss of human life and injury to crew members shall be avoided. 2. Pollution of the surrounding environment shall be avoided. 3. Loss of rig and damage to equipment shall be avoided. If all of the aforementioned conditions are fulfilled then the economic and ecological result shall be successful. It is also the philosophy : 1. That detection and controlling a kick takes a team effort from all members of the rig crew. Each member must be completely familiar with his duties so that any well control operation can proceed smoothly and efficiently. 2. To maintain all well control equipment in first class condition and ready for use whenever required. 3. To ensure that all personnel directly involved in a well control situation shall be educated to a standard that ensures complete understanding of any situation that may arise. In implementing this philosophy Maersk Contractors Drilling Division shall comply with relevant government legislation and as a prudent safety conscious contractor promote the welfare of all personnel along with protection of the environment. Well Control Policies Maersk Contractors Drilling Division requires, as a stated policy, the holding of a pre-spud meeting prior to each well or other major offshore activity. At these meetings, the methods of handling various routine and non-routine operations can be covered by all parties concerned, and mutually acceptable methods worked out. Maersk Contractors Drilling Division has compiled a Well Control Manual, that will govern in the absence of any other acceptable set of procedures and guidelines. By setting out our preferred Well Control procedures and guidelines, is not intending to suggest that the procedures used by others are not equally or perhaps more valid. Only discussion of each situation can resolve that issue. However, for any other Well Control procedures and guidelines to take precedence over the ones shown in the Well Control Manual, the modified set must be communicated in writing to the Management of the rig. In the absence of such official notice, the Maersk Contractors Drilling Divisions personnel shall be required to follow the Well Control Manual. The basic of this well control manual is found according to recommendation in API 16E and APIRP 53. Well control equipment and control system according to APIRP 53 and API (spec) 16a.
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Table of content:
01 Well control barrier 01.01 Primary well control barrier 02.01 Secondary well control barrier BOP Configuration 01.02 Bop stack arrangements 02.02 Stack Components codes 03.02 Drilling spool Diverter systems 01.03 02.03 03.03 04.03 05.03 06.03 Annular Preventer 01.04 02.04 03.04 04.04 05.04 06.04 07.04 08.04 Purpose of diverter system Diverter equipment Guidelines for diverting with string on bottom Guidelines for diverting with string off bottom Rotating head Diverter control system Page 016 General Testing Pressure test frequency Response time Hydril annular preventers Shaffer annular preventers Cameron annular preventers Packing unit Page 026 Page 006
02
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03
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04
05
Cameron Ram Preventer 01.05 General 02.05 Testing 03.05 Pressure test frequency 04.05 Response time 05.05 Cameron Ram Preventer 06.05 Cameron Ram Assembly 07.05 Operating Ratio 08.05 BOP and side outlet connections 09.05 API type flanges 10.05 Ring joint gaskets and grooves Choke Manifold 01.06 02.06 03.06 04.06 05.06 06.06 General Choke Manifold - Installation Choke Lines - Installation Kill Lines - Installation HCR Side Outlet Valves Chokes
06
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Well Control Equipment Training Manual 07.06 08.06 09.06 07 Control System 01.07 02.07 03.07 04.07 05.07 06.07 07.07 08.07 09.07 Hydrates Mud/Gas Separator Degasser
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Page 051 General Response Time Storage Equipment Pump Requirements Accumulator Bottles and Manifolds Hydraulic Control Manifold Schematic of Control System Remote Control Panel Accumulator Volumetric Requirements Page 061
08
Auxiliary Equipment 01.08 Kelly Valves 02.08 Top Drive Valves 03.08 Drillpipe Safety Valve 04.08 Inside Blowout Preventer 05.08 Drillstring Float Valve 06.08 Test Plug 07.08 Cup Type Tester 08.08 Triptank 09.08 Pit Volume Measuring Devices 10.08 Flow Rate Sensor Recommended Pressure Test Practices 01.09 Initial Test 02.09 Subsequent Test
09
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Abbreviations:
A API BOP C CSO F FOSV G GAL K HCR H2S IBOP ID LBS MGS OD P PRC PSI R Rd Rt RP S SCF V Annular preventer American Petroleum Institute Blow-out Preventer Hydraulic connector Complete shut off Farentheit Full Opening Safety Valve Rotating head Gallons Pressure 1.000 psi High Closing Ratio Hydrogen sulfide Inside Blow-out Preventer Internal diameter Pound Mud/Gas Separator Outside diameter Pressure Power ram change Pound per inch Ram preventer (single) Ram preventer (double) Ram preventer (tripple) Recommended Practice Drilling spool Standard Cubic Feet Volume
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01
Well control barrier.
01.01 Primary well control barrier. During normal drilling operation it will always be the hydrostatic pressure of the drilling fluid that creates the primary barrier to avoid any flow of formation fluid into the well bore. If for any reason the primary barrier is lost the well control equipment together with the drilling fluid in the well bore will be the secondary barrier. This will allow us to re-establish the primary barrier on a safe and efficient way. 02.01 Secondary well control barrier. The well control equipment must be able to close and secure the well under all circumstances. Further to that circulation of heavy drilling fluid into the well bore and formation fluid out of the well bore under controlled manner must be possible. The well control equipment should be able to close on open hole(without tubular), around BHA and other tubular used in the drilling operation. It should also be able to cut the drill string or lighter tubular and seal the well bore and allow the drill string to be hanged off on the pipe rams or stripped into the well bore. To avoid single components to create total failure of the system a contingency (back up) function should be build into the system. All well control equipment must be maintained, function- and pressure tested according to company policy and procedures to assured correct function and integrity when required. With the well closed in and the drill string in the well bore, formation pressure can be obtained through the drill string by adding SIDPP with pressure hydrostatic. To secure the drill string and obtain integrity following barriers can be used: FOSV (full opening safety valve) One way valves (IBOP, Dart sub) Check valves (Drill pipe floats) To secure the annulus and obtain integrity following barriers can be used: Annular Preventer Ram Preventer Shear/Blind Ram Rotating head During normal drilling operation two barriers must always be in place where the hydrostatic head of the drilling fluid is one and the BOPs the other.
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02
BOP Configuration
01.02 Bop stack arrangements Example arrangements for BOP equipment are based on rated working pressures. Example stack arrangements shown in Figures 1 and 2 should prove adequate in normal environments, for rated working pressures of 2K, 3K, 5K,IOK, 15K, and 20K. Arrangements other than those illustrated may be equally adequate in meeting well requirements and promoting safety and efficiency. Rated Working Pressure 2K 3K 5K IOK 15K 20K 2,000 psi (13.8 MPa) 3,000 psi (20.7 MPa) 5,000 psi (34.5 MPa) 10,000 psi (69.0 MPa) 15,000 psi (103.5 MPa) 20,000 psi (138.0 MPa)
Fig 01
Fig 02
02.02 Stack Component Codes Every installed ram BOP should have, as a minimum, a working pressure equal to the maximum anticipated surface pressure to be encountered. The recommended component codes for designation of BOP stack arrangement are as follows: G= A= R= Rotating head. Annular type BOP. Single ram type BOP with one set of rams, either blank or for pipe, as operator prefers.
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RD = Double ram type BOP with two sets of rams, positioned in accordance with operator's choice. RT = S= C= K= Triple ram type BOP with three sets of rams, positioned in accordance with operator's choice. Drilling spool with side outlet connection for choke and kill lines. Hydraulic well head connector with a minimum rated working pressure equal to the BOP stack rated working pressure. 1 000 psi rated working pressure.
BOP components are typically described upward from the uppermost piece of permanent wellhead equipment, or from the bottom of the BOP stack. A BOP stack may be fully identified by a very simple designation, such as: 15K - 13 5/8 - RSRRAG This BOP stack would be rated 15,000 psi (103.5 MPa) working pressure, would have a throughbore of 13-5/8 (34.61 cm), and would be arranged as in Figure 2b. Annular BOPs may have a lower rated working pressure than the ram BOPS. 03.02 Drilling Spool Choke and kill lines may be connected either to side outlets of the BOPs, or to a drilling spool installed below at least one BOP capable of closing on pipe. Utilization of the BOP side outlets reduces the number of stack connections and overall BOP stack height. However, a drilling spool is used to provide stack outlets (to localize possible erosion in the less expensive spool) and to allow additional space between preventers to facilitate stripping, hang off, and/or shear operations. See Fig 03
Fig 03
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Drilling spools for BOP stacks should meet the following minimum qualifications: a. 3K and 5K arrangements should have two side outlets no smaller than a 2-inch (5.08 cm) nominal diameter and be flanged, studded, or hubbed. IOK, 15K, and 20K arrangements should have two side outlets, one 3-inch (7.62 cm) and one 2-inch (5.08 cm) nominal diameter as a minimum, and be flanged, studded, or hubbed. b. c. Have a vertical bore diameter the same internal diameter as the mating BOPs and at least equal to the maximum bore of the uppermost casing/tubing head. Have a rated working pressure equal to the rated working pressure of the installed ram BOP.
For drilling operations, wellhead outlets should not be employed for choke or kill lines.
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03
Diverter Systems
Fig 04
01.03 Purpose of Diverter system A diverter system is often used during top-hole drilling. A diverter is not designed to shut in or halt flow, but rather permits routing of the flow away from the rig. The diverter is used to protect the personnel and equipment by re-routing the flow of shallow gas and wellbore fluids emanating from the well to a safe distance away from the rig. See Fig 04 The system deals with the potentially hazardous flows that can be experienced prior to setting the casing string on which the BOP stack and choke manifold will be installed. The system is designed to pack-off around the Kelly, drill string, or casing to divert flow in a safe direction. Diverters having annular packing units can also close on wire line and open hole. Valves in the system direct the well flow when the diverter is actuated. The function of the valves may be integral to the diverter unit. 02.03 Diverter equipment The diverter system consists of a low pressure diverter or an annular preventer of sufficient internal bore to pass the bit required for subsequent drilling. Vent line(s) of adequate size [6 inches (15.24 cm) or larger] are attached to outlets below the diverter and extended to a location(s) sufficiently distant from the well to permit safe venting. Conventional annular BOPs See Fig 05, insert-type diverters See Fig 06, or rotating heads See Fig 10 can be used as diverters. The rated working pressure of the diverter and vent line(s) are designed and sized to permit diverting of well fluids while minimizing wellbore back pressure. Vent lines are typically 10 inches (25.4 cm) or larger ID for offshore and 6 inches (15.24 cm) or larger ID for onshore operations.
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Fig 06
Fig 05
If the diverter system incorporates a valve(s) on the vent line(s), this valve(s) should be full opening and full bore (have at least the same opening as the line in which they are installed). The system should be hydraulically controlled such that at least one vent line valve is in the open position before the diverter packer closes. The older systems have separate operating handles for each components as seen in Fig 07, but most have now been changed so the valves is integral to the diverter unit.
Fig 07
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To operate the system in Fig 07 the following sequence must be used to avoid shutting in or halt the flow from the well bore: a. b. c. Open B or C depending on wind direction Close E Close A
In modern systems the diverter is integral to an annular preventer and is only equipped with one diverter line witch is diverted into two lines by a Selector valve that makes it possible to divert fluid and gas to either side of the rig depending of wind direction or to both side at the same time. See Fig 08
Fig 08
The diverter and all valves should be function tested when installed and at appropriate times during operations to determine that the system will function properly. CAUSION: Fluid should be pumped through the diverter and each diverter vent line at appropriate times during operations to ascertain the line(s) is not plugged. Inspection and clean-out ports should be provided at all low points in the system. Drains and/or heat tracings may he required in colder climates. The hydraulic supply pressure to the diverter control panel is routed directly from the hydraulic control unit with 3.000 psi.
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Well Control Equipment Training Manual 03.03 Guidelines for diverting with string on bottom 1. 2. 3.
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Route returns to downwind vent line and close diverter Pump at maximum rate and switch to kill fluid without shutting down pumps. If no kill fluid use sea water. (Do not shut down the pumps) If diverter system fails before control of the well is regained or broaching to surface occurs, evacuate all personnel, leaving the mud pumps running on sea water at maximum rate.
04.03 Guidelines for diverting with string off bottom If it becomes necessary to divert gas, water and/or sand debris, route returns to downwind vent line and close diverter. 1. 2. 3. Do not stop pumping and if mud reserves run out, keep pumping seawater at maximum rate. Do not shut down the pumps. Arrange emergency evacuation of all non-essential personnel and prepare evacuation of remaining personnel. If diverter system fails before control of the well is regained or broaching to surface occurs, evacuate all personnel, leaving the mud pumps running on seawater at maximum rate.
05.03 Rotating Head

Fig 09
Rotating control heads or rotating blow-out preventers are not a new concept. The rotating head maintains a constant seal around all of the rotating elements in the drill string except such large diameter pieces as the bit and reamer. This seal is maintained when going in, coming out or holding in static position. The original equipment was designed for air drilling and later used for mud, gas and geothermal applications. Later generation equipment was applied by industry for the flow drilling applications that cause high pressures at the wellhead. The original design and engineering principals for its use have held and still apply today. Within the BOP system the API recognizes the rotating head as a diverter. See Fig 09. The rotating BOP is always used on top of a regular BOP stack consisting of ram and annular BOPs.
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The rotating head seals off around almost any shape of Kelly and will also seal on any type of drill pipe whether flush joint, upset or coupled. No special operations are required for handling the pipe. As the various elements of the drill string are raised or lowered, the stripper rubber changes shape to conform to the OD of these elements. In this way the hole is closed at all times. A flanged out let below the stripper rubber allows pressure to be directed out through the flow line. The rotating blow-out preventer is ideal for use wherever there is: Drilling where H2S is encounted. Circulating with air or gas. Under balanced drilling. Drilling with reverse circulation. Drilling in areas susceptible to blow-outs. Geothermal drilling. The rotating blow-out preventer consists of three major assemblies. See Fig 10. The rotating assembly The Body Kelly drive unit
Fig 10
The body is flanged to the top of the blow-out preventer and the rotating assembly is locked in with a quick release mechanism. The kelly drive unit is installed on the kelly and turns the rotating sleeve that has the stripper rubber attached to the lower end. The stripper rubber seals off the well pressure between the annulus of the hole and the outside of the drill pipe. The rotating sleeve packing effectively seals between the outside of the rotating sleeve and rotating assembly housing. The stripper rubber is constructed in such manner that as the well pressure increases, the stripper forms a tighter seal. Some rotating heads is build with hydraulic pressurizes stripping rubbers. Underbalanced drilling is now being more widely reborn in the oil and gas industry. The major advances of underbalanced drilling is to lower costs, reduce drilling days, reduce
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differential sticking and hole drag caused by mud cake, and reduce trouble time during drilling. Because underbalanced drilling creates the condition for fluid to flow from the formation into the well bore, successful underbalanced drilling must include the selection of proper control equipment to handle the drilling fluids and formations fluid. The rotating control head is one of the major elements of the system. 06.03 Diverter control system The diverter control system should be designed to preclude closing-in the well with the diverter. This requires opening one or more vent lines prior to closing the diverter as well as closing normally open mud system valves. A diverter control system should be capable of operating the vent line and flow line valves (if any) and closing the annular packing element on pipe or open hole within thirty seconds of actuation if the packing element has a nominal bore of twenty inches or less. For elements of more than twenty inches nominal bore, the diverter control system should be capable of operating the vent line and flow line valves (if any) and closing on pipe in use within forty-five seconds. The diverter control system may be supplied with hydraulic control pressure from the BOP control system. In this case there is usually more accumulator capacity, pump capacity and reservoir capacity than is required for the diverter system. These should, however, comply with the recommendations which follow for a self-contained diverter control system. An isolation valve should be installed in the line from the main hydraulic supply to shut off the supply to the diverter control system when it is not in use. The function of this valve should be clearly labeled and its position status should be clearly visible. All of the diverter control functions should be operable from the rig floor. A second control panel should be provided in an area remote from the rig floor. The remote area panel should be capable of operating all diverter system functions including any necessary sequencing and control of the direction of the diverted flow.
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04
Annular Preventers
01.04 General In the industry to-day we are normally taking about three different manufactures of Annular Preventers used both for SubSea or Surface application: Cameron Cooper: Type D Type DL Hydril: Model GK Model GL Model GX Model MSP Shaffer: Shaffer Spherical.
Visual Inspection:
1. Packer Visually inspect condition of packer. Check for gouges in seal area. Verify and record age of packer. Ensure within shelf life of manufacturer. Record drilling fluid and inquire about compatible. 2. Throughbore Ensure no key seat damage in annular cap wear band. Record if any. 3. Drift Ensure that the packer is fully open and not protruding into the wellbore. 4. Surge Bottle Check for proper nitrogen pre-charge in accumulator bottle. Consider water depth for sub-sea application. 5. Milling Check for metal shavings if milling operations have been performed. 6. Operating Pressures Ensure that a operating range pressure chart in relation to pipe size and wellbore pressure is posted. 7. Drift test Drift test the annular preventer to ensure that it returns to full open bore within 30 min.
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Well Control Equipment Training Manual 02.04 Testing
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Function test: All operational components of the BOP equipment systems should be functioned at least once a week to verify the component's intended operations. Function tests may or may not include pressure tests. Function tests should be alternated from the driller's panel and from mini-remote panels, if on location. Pressure test: All blowout prevention components that may be exposed to well pressure should be tested first to a low pressure of 200 to 300 psi (1.38 to 2.1 MPa) and then to a high pressure. When performing the low pressure test, do not apply a higher pressure and bleed down to the low test pressure. The higher pressure could initiate a seal that may continue to seal after the pressure is lowered and therefore misrepresenting a low pressure condition. A stable low test pressure should be maintained for at least 5 minutes. The initial high pressure test on components that could be exposed to well pressure (BOP stack, choke manifold, and choke/kill lines) should be to the rated working pressure of the ram BOPs or to the rated working pressure of the wellhead that the stack is installed on, whichever is lower. Initial pressure tests are defined as those tests that should be performed on location before the well is spudded or before the equipment is put into operational service. Annular BOPS, with a joint of drill pipe installed, may be tested to the test pressure applied to the ram BOPs or to a minimum of 70 percent of the annular preventer working pressure, whichever is the lesser. Subsequent high pressure tests on annular BOPs, with a joint of drill pipe installed, should be tested to a minimum of 70 percent of their working pressure or to the test pressure of the ram BOPs, whichever is less. Subsequent pressure tests are tests that should be performed at identified periods during drilling and completion activity on a well. A stable high test pressure should be maintained for at least 5 minutes. With larger size annular BOPs some small movement typically continues within the large rubber mass for prolonged periods after pressure is applied. This packer creep movement should be considered when monitoring the pressure test of the annular. Pressure test operations should be alternately controlled from the various control stations. The pressure test performed on hydraulic chambers of annular BOPs should be to at least 1,500 psi (10.3 MPa). The tests should be run on both the opening and the closing chambers. Pressure should be stabilized for at least 5 minutes. Subsequent pressure tests are typically performed on hydraulic chambers only between wells or when the equipment is reassembled.
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Well Control Equipment Training Manual 03.04 Pressure test frequency
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Pressure tests on the well control equipment should be conducted at least: a. b. Prior to spud or upon installation. After the disconnection or repair of any pressure containment seal in the BOP stack, choke line, or choke manifold, but limited to the affected component. Not to exceed 21 days.
c.
04.04 Response time Response time between activation and complete operation of a function is based on BOP or valve closure and seal off. Closing time should not exceed 30 seconds for annular preventers smaller than 18-3/4 nominal bore and 45 seconds for annular preventers of 18-3/4 and larger. Measurement of closing response time begins at pushing the button or turning the control valve handle to operate the function and ends when the BOP or valve is closed effecting a seal. A BOP may be considered closed when the regulated operating pressure has recovered to its nominal setting. 05.04 Hydril annular preventer Hydril GK annular preventer See Fig 11 The GK annular blow-out preventer was designed especially for surface installations and is also used on offshore platforms and sub-sea. The GK is a universal annular blow-out preventer with a long record of proven performance. Only three major components. Only two moving parts. Closing pressure should be reduced as wellbore pressure increases in order to prevent excessive closing force. Standard operation requires both opening and closing pressure. Seal off is effected by hydraulic pressure applied to the closing chamber which raises the piston, forcing the packing unit into a Fig 11 sealing engagement. The GK is designed to be well pressure assisted in maintaining packing unit seal off once initial seal off has been effected. As well bore pressure further increase closure is maintained by well pressure alone.
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Well Control Equipment Training Manual Hydril GL annular preventer See Fig 12
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Hydril GL annular preventer are designed and developed both for subsea and surface operations. The proven packing unit provides full closure at maximum working pressure on open hole and vitually anything in the bore - casing, drill pipe, tool joints, Kelly or tubing. Screwed or latched head are available. Opening chamber head separates sealing element from hydraulic opening chamber. Closing pressure depends upon the manner in which the secondary port is connected into the hydraulic operating Fig 12 system. The secondary chamber, which is unique to the GL BOP, provides this unit with great flexibility of control hook-up and acts as backup closing chamber to cut operation cost and increase safety factors in critical situations. Hydril GX annular preventer See Fig 13
Fig 13
The Hydril GX offers extra performance and serviceability while retaining the field proven features of Hydril annular BOPs. The GX will close on vitually any drill stem member and seal off the open bore.
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This feature is called CSO (complete shut off). Operating volumes are lower, resulting in faster closing times and smaller accumulator requirements. No secondary chamber. Latched head design. Opening chamber head separates sealing element from the hydraulic opening chamber. Reduce closing pressure proportionally as well pressure is increased. Hydril GX annular preventer closing chart Fig 14 shows the relationship of closing pressure and well bore pressure for minimum seal off for GX 18-3/4 10.000 psi annular preventer. Closing pressures are average and will vary slightly with each packing unit. Use closing pressure shown at initial closure to establish seal off, and reduce closing pressure proportionally as well pressure is increased. Well pressure will maintain closure after exceeding the required level. See Fig 14.
3000 2800 2600 2400 CLOSING PRESSURE 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 1000 2000
CSO
3-1/2 9-5/8 13-5/8

3000 4000 5000 6000 7000 8000
7 5
WELL PRESSURE
Fig 14
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Well Control Equipment Training Manual 06.04 Shaffer annular preventer Wedge cover spherical BOP See Fig 15 Spherical contour of the sealing element gives a long lasting element life. Element able to close on open hole (CSO). Small numbers of seal and components. Adapter ring separates the wellbore pressure from the hydraulic area. The preventer is balanced - that is wellbore pressure does not assist the preventer to remain closed. Hydraulic pressure must be maintained on the closing chamber to force the preventer to seal.
Fig 15
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Bolted cover spherical BOP See Fig 16 Spherical contour of the sealing element gives a long lasting element life. Element able to close on open hole (CSO). Small numbers of seal and components. Adapter ring separates the wellbore pressure from the hydraulic area. The preventer is balanced - that is wellbore pressure does not assist the preventer to remain closed. Hydraulic pressure must be maintained on the closing chamber to force the preventer to seal.
Fig 16
As the preventer is balanced it require 1500 psi closing pressure for all size pipe smaller than 7 and reduced pressure for pipe larger than 7. See Fig 17.
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For stripping operation the size of the pipe being stripped into the well bore and the well bore pressure have to taking into consideration. See Fig 17.
Fig 17
07.04 Cameron annular preventer Type D and DL See Fig 18 In the unique design of the Cameron DL annular preventer, closing pressure forces the operating piston and pusher plate upward to displace the solid elastomer donut and force the packer to close inward. As the packer closes, steel reinforcing inserts rotate inwards to form a continuous support ring of steel at the top and bottom of the packer. The inserts
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remain in contact with each other whether the packer is open, closed on pipe or closed on open hole. Replaceable liners around operating piston. Weep hole between the wellbore pressure seals and the hydraulic system seals. A two piece packer. See Fig 19 Operates at higher pressures than most other annular BOPs. The preventer is balanced - that is wellbore pressure does not assist the preventer closed. Hydraulic pressure must be maintained on the closing chamber to force the preventer to seal.
Fig 18
Fig 19
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The graph in Fig 20 allow determination of the approximate closing pressure required to seal a given well bore pressure when stripping into the well. As a new packer wears during stripping, sealing is improved and the closing pressure required to seal on pipe will decrease. For this reason, closing pressure should be reduced as often as is necessary to maintain slight leakage for lubrication of the packer.
CLOSING PRESSURE
WELL BORE PRESSURE
Fig 20
08.04 Packing unit Packing units for the annular BOPs are available in NITRILE, NEOPRENE or NATURAL rubber. See Fig 21 NITRILE rubber is for use with oil base or oil additive drilling fluids, provides the best overall service life when operated at temperatures between + 20 deg F to + 190 deg F. NEOPRENE rubber is for low temperature operating service and oil base drilling fluids. It can be used at operating temperatures between - 30 deg F to + 170 deg F. NATURAL rubber is for use in non-oil base drilling fluids and can be used at operating temperatures between - 30 deg F to + 225 deg F
Fig 21
In extreme emergencies and when no other alternatives are available sealing elements can be replaced while drill pipe is in the hole. However, this potentially hazardous procedure involves a high degree of risk unacceptable in any circumstances other than emergency. The packing units consist of two components as steel segments and rubber compound.
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The steel segments are moulded into the rubber and will partially close over the rubber to prevent excessive extrusion when sealing under high pressure. The segment will ensure the element maintains it shape. When the element is closed the steel segment will compress the rubber out against the well bore and create a seal. When the element is opened up the compressed rubber will expand and bring the element to full open position again within 30 min.
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05
Ram Preventer
01.05 General In the industry to-day we are normally taking about four different manufactures of Ram Preventers used both for Sub-Sea or Surface application: Cameron Cooper: Type U Type U-II Model T Hydril: Hydril Ram Preventer Shaffer: Model SL Model LWS Koomey: J-line
Visual Inspection:
After each well open the Ram Bonnets (doors). The ram cavity and ram block should be cleaned prior to the following visual inspection. This visual examination is generic and valid for all ram preventers. A few additional areas are required when inspecting the Cameron or Koomey J line ram preventer. 1. Ram Packers, Top Seals and Bonnet Seals Ram Packers. Ram packers and top seals should be in good condition. Rubber should not be missing from the pipe contact area on the front packer or sheared off on the top seal Bonnet Seals. Bonnet seals are generally replaced each time the bonnets are opened. Top Seals. When top seals are not proud above ram block, in order of .075 to .140 for manufactures in general, the low pressure integrity of the preventer is jeopardized. 2. Ram Cavity Visually inspect cavity upper seal seat for damage. The surface finish at the top of the cavity is the most critical aspect of this inspection. Sharp scratches make it difficult for top seal rubber to flow into these grooves for pressure integrity. Ram Blocks If rams are to be used for hang off, record the part number of the ram blocks and verify their capabilities. Tagging rams is the usual cause of damage to the top of a ram block.
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Well Control Equipment Training Manual Hang-Off Test.
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According to API 16A the following minimum value is given before leaks develop for fixed pipe rams: 5 fixed rams 600.000 lbs 3-1/2 fixed rams 425.000 lbs For variable rams always check with manufacturer for correct value. 4. Connecting Rods/Ram Shaft Packing To visually examine the connecting rod, the operating piston must be stroked to the closed position when the bonnets or doors are open. Power Ram Change Piston Cameron and Koomey rams use PRC pistons to open and close the bonnets. The surface finish of these chrome rods should also be checked to assure that the operating system has good pressure integrity. Packing Injection Check to ensure that secondary packing has not been energized. Check weep hole to ensure it is free of sealant. Sealant could prevent a primary wellbore seal from leaking during a stump test which is performed to find such leaks. Through Bore Visually inspect through bore for key seating record. Repairs should be initiated when this bore wear exceeds 3/16.
5.
6.
7.
02.05 Testing Function test All operational components of the BOP equipment systems should be functioned at least once a week to verify the component's intended operations. Function tests may or may not include pressure tests. Function tests should be alternated from the driller's panel and from mini-remote panels, if on location. Pressure test All blowout prevention components that may be exposed to well pressure should be tested first to a low pressure of 200 to 300 psi (1.38 to 2.1 MPa) and then to a high pressure. When performing the low pressure test, do not apply a higher pressure and bleed down to the low test pressure. The higher pressure could initiate a seal that may continue to seal after the pressure is lowered and therefore misrepresenting a low pressure condition. A stable low test pressure should be maintained for at least 5 minutes.
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The initial high pressure test on components that could be exposed to well pressure (BOP stack, choke manifold, and choke/kill lines) should be to the rated working pressure of the ram BOPs or to the rated working pressure of the wellhead that the stack is installed on, whichever is lower. Initial pressure tests are defined as those tests that should be performed on location before the well is spudded or before the equipment is put into operational service. There may be instances when the available BOP stack and/or the wellhead have higher working pressures than are required for the specific wellbore conditions due to equipment availability. Special conditions such as these should be covered in the site-specific well control pressure test program. Subsequent high pressure tests on the well control components should be to a pressure greater than the maximum anticipated surface pressure, but not to exceed the working pressure of the ram BOP's. The maximum anticipated surface pressure should be determined by the operator based on specific anticipated well conditions. Subsequent pressure tests are tests that should be performed at identified periods during drilling and completion activity on a well. A stable high test pressure should be maintained for at least 5 minutes. Pressure test operations should be alternately controlled from the various control stations. Initial pressure tests on hydraulic chambers of ram BOPs and hydraulically operated valves should be to the maximum operating pressure recommended by the manufacturer. The tests should be run on both the opening and the closing chambers. Pressure should be stabilized for at least 5 minutes. Subsequent pressure tests are typically performed on hydraulic chambers only between wells or when the equipment is reassembled. 03.05 Pressure test frequency Pressure tests on the well control equipment should be conducted at least: a. b. Prior to spud or upon installation. After the disconnection or repair of any pressure containment seal in the BOP stack, choke line, or choke manifold, but limited to the affected component. Not to exceed 21 days.
c.
04.05 Response time Response time between activation and complete operation of a function is based on BOP or valve closure and seal off. For surface installations, the BOP control system should be capable of closing each ram BOP within 30 seconds. Response time for choke and kill valves (either open or close) should not exceed the minimum observed ram close response time. Measurement of closing response time begins at pushing the button or
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turning the control valve handle to operate the function and ends when the BOP or valve is closed effecting a seal. A BOP may be considered closed when the regulated operating pressure has recovered to its nominal setting. If confirmation of seal off is required, pressure testing below the BOP or across the valve is necessary. 05.05 Cameron ram preventer
Fig 22
COT manufactures three models of ram preventers specifically designed for sub-sea and surface applications. See Fig 22 They are the type U - U-II - Model T. In all three product the following features are incorporated: Power ram change, PRC, system. Four bonnet bolts or studs used per bonnet. Using wedgelock. Ram cavities are parallel, top and bottom. Bonnet and body are forged. Specific Model Features: Type U: Can be fitted with hydraulic bonnet bolts Plastic ram shaft packing and weep hole standard Type U-II: Hydraulic bonnet studs Plastic ram shaft packing and weep hole standard Model T: Hydraulic bonnet studs Replaceable wear pad fitted beneath ram block
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Well Control Equipment Training Manual In this manual we only look on Cameron type U-II
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The Cameron U-II ram type blow-out preventer includes an internally ported hydraulic bonnet tensioning system, a short stroke bonnet, bore type bonnet seals and the proven advance of the U BOP design. The U-II can be provided in single and double configurations with either API flange, clamp hub or studded connections, and flange or clamp hub outlets. In Fig 23 the single components of a single ram BOP is showed.
Fig 23
A: D: G: J:
Bonnet bolt Body Locking screw Intermediate flange
B: E: H: K:
Ram Change cylinder Bonnet seal Operating cylinder Bonnet
C: F: I: L:
Ram assembly Ram Change piston Locking screw housing Operating piston
The short stroke bonnet reduces the opening stroke by about 30%, reduces the length of the BOP and reduces the weight supported by the ram change pistons. The bore type bonnet seal fits into a seal counter bore in the body and has a metal anti-extrusion ring. When talking about Shear rams large bore shear bonnets provides the largest capacity operating piston to increase shearing force. This means that the operating cylinder is removed and the piston size increased to obtain higher pressure area. Due to the shear rams operating piston needs longer travel the intermediate flange is increased in thickness to facilitate this requirement. The U II blowout preventer is designed so that hydraulic pressure opens and closes the rams, and provides the means for quick ram change out. See Fig 24 Ram closing pressure, shown in red in Fig 24 closes the rams. When the bonnet bolts are removed, closing pressure opens the bonnet. When the bonnet has moved to the fully extended position, the ram is clear of the body. An eyebolt can be installed into the top of each ram to lift it out of the preventer. Ram opening pressure, shown in blue in Fig 24 opens the rams and closes the bonnets after ram change out. The rams are pulled outward, close to the bonnets before the
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bonnets begin moving toward the preventer body. This assures that the rams never obstruct the bore or interfere with pipe in the hole. Hydraulic pressure draws the bonnets tightly against the preventer body and the bonnet bolts are reinstalled to hold the bonnets closed.
U II BLOWOUT PREVENTER HYDRAULIC CONTROL SYSTEM
Fig 24
The four bonnet studs are simultaneously stretched to the correct pre-load by hydraulic pressure applied behind a piston which acts on a load rod in the stud. The nut is then tightened and pressure is released. Pressure is supplied by an air powered hydraulic pump via internal porting in the BOP body. See Fig 25
Fig 25
The intermediate flange is the barrier between the well bore and the hydraulic operating chamber and contains the seals around the operating shaft. In the bottom of the intermediate flange a weep or vent hole is positioned witch must always be clean. The weep hole has several functions:
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Well Control Equipment Training Manual 1.
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During pressure test of the ram BOP leakage through the weep hole indicates worn seals against the wellbore and require immediately change out prior to commence operation. Leakage during pressure test of the hydraulic chamber indicates worn seal against the hydraulic operating side and require immediately change out prior to commence operation. The weep hole avoid well bore pressure on the opening side of the hydraulic chamber.
2.
3.
A secondary seal is installed in the top of the intermediate flange. In the event of leakage during a well control situation the secondary can be engaged by injecting plastic packing through a packing ring that will seal against the well bore. See Fig 26.
Fig 26
All ram BOPs must be equipped with a ram lock system that can either be manual operated or hydraulic operated to assure that the ram does not open if the hydraulic closing pressure is lost. If it is a manuel system it should be equipped with extension hand wells. For hydraulic operated system Cameron is using the wedge-lock system. The U-II wedge-locks act directly on the operating piston tailrod. The operating system can be interlocked using sequence caps to ensure that the wedge-lock is opened before pressure is applied to open the BOP. See Fig 27
Fig 27
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Well Control Equipment Training Manual 06.05 Cameron ram assembly All BOP manufactures supply three different type of rams: Fixed ram assemblies. Variable ram assemblies. Shear/Blind ram assemblies. Fixed ram assembly
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The ram assembly consist of Ram Body, Front Packer and Top Seal. To dress the ram body the front packer must be installed first. The top seal is then installed and lock the front packer in place. See Fig 28. The fixed ram assembly can be obtained in different sizes from 2-3/8 to 6-5/8.
Fig 28
Ram packers and top seals should be in good condition. Rubber should not be missing from the pipe contact area on the front packer or sheared off on the top seal. As a general rule, ram packers should be considered acceptable when 80% of the rubber in the pipe contact area is still in place. Variable ram assembly One set of variable bore rams can be used to seal on a range of pipe. A set of variable bore rams installed in a BOP saves a round trip of a SubSea BOP stack by eliminating the need to change rams when different diameter drill strings are used. A set of variable bore rams in a stack provides backup for two or more sizes of standard pipe rams or serves as the primary ram for one size and the backup for the other. See Fig 29.
Fig 29
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Well Control Equipment Training Manual Shear/Blind ram assembly
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Shear/Blind rams are designed to shear drill pipe and lighter tubular like tubing and establish a seal against wellbore pressure using high hydraulic closing pressure. The Shear/Blind rams consist of a upper and lower ram body. To dress a Shear/Blind ram body (C) the blade or front packer (F) is installed first. The side packers (B) is then installed to keep the blade packer in place and finally the top packer (E) is inserted to lock the side packers. See Fig 30.
Fig 30
Importance of ram packer pressure Packer pressure is the internal elastomer compressive force generated in the ram packers when closing hydraulic pressure drives the ram assemblies into contact with each other. For a ram assembly to contain wellbore pressure the packer pressure must be higher than the wellbore pressure trying to get past the rubbers. Typically, closing hydraulic operating pressure generates several thousand psi elastomer pressure inside the ram packers. This is sufficient to initially contain wellbore pressure. See Fig 31. As wellbore pressure rises, the packer pressure rises as well due to the closing effect that the wellbore pressure has upon the ram blocks. See Fig 32. With this mechanism, packer pressure is maintained above wellbore pressure.
Fig 31
Fig 32
When we have a worn out ram cavity or worn ram rubbers, the closing operating pressure is not able to generate the required packer pressure with a leak resulting.
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Well Control Equipment Training Manual Feedable rubber
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All of the major ram type BOP manufactures use the feedable rubber design concept in their ram packers. This includes Cameron, Hydril, Shaffer and MH Koomey. Extrusion plates moulded into the front packer into the front packer serves several purpose: To support the rubber to prevent unwanted extrusion due to wellbore forces in the vertical direction. Act as pistons to extrude feedable rubber to the point of pipe contact. See Fig 33.
Fig 33
A new front packer contains large volume of feedable rubber. When seal off is obtained, a large clearance exists between the ram and pipe. A moderately worn packer still retains a large but reduced volume of feedable rubber. The clearance between the ram and pipe is reduced at the seal off position. The extensively worn front packer has used almost all of the feedable rubber volume, but still able to effect a full rated seal off. The clearance between the ram and pipe is now approaching zero, indicating completion of the useful life of the front packer. All ram type BOPs are only designed to contain and seal Rated Working Pressure from below the ram. 07.05 Operating Ratio The first ram preventers used in drilling operations were manually operated. Threaded stems were provided to move ram blocks back and forth between the open and close position. It soon became apparent that a faster operating method was needed to close the rams when a well kicked. This led to the development of hydraulic operated pistons to close or open the rams.
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In Fig 34 is showed a simplified sketch of a hydraulic operated ram preventer. Fluid operating on the operating piston closes or opens the rams. Each type and size of ram preventer has a specified closing and opening ratio, which is a function of that rams particular geometry.
RAM SHAFT OPENING CHAMBER
PISTON
Fig 34
RAM
CLOSING CHAMBER
Closing Ratio A dimensionless factor equal to the wellbore pressure divided by the operating pressure necessary to close the ram BOP against wellbore pressure. When closing the rams, hydraulic closing pressure acting on the ram operating piston area must overcome the wellbore pressure acting on the ram shaft area which is attempting to force the ram in to open position. This ratio exists because of difference in areas that the closing hydraulic pressure acts upon compared to the ram rod area exposed to wellbore pressure. See Fig 35. Closing ratios are generally in the range from 6:1 to 9:1. This means that it takes 1 psi of closing hydraulic pressure per 6 to 9 psi wellbore pressure to close the preventer. Stated in another way, on a preventer with closing ratio of 6:1, if the wellbore pressure is 3.000 psi it should take 500 psi hydraulic pressure to close the preventer.
CLOSING AREA RAM SHAFT AREA WELL PRESSURE CLOSING PRESSURE
Fig 35
The extreme case is closing the ram preventer while it is exposed to maximum rated pressure in the wellbore. This required closing pressure is calculated by the following formula:
Closing pressure required to close ram with rated wellbore pressure in the bore Rated Working Pressure = ------------------------------------Closing Ratio
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Well Control Equipment Training Manual Opening Ratio
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A dimensionless factor equal to the wellbore pressure divided by operating pressure necessary to open a ram BOP containing wellbore pressure. Opening rams under pressure is not recommended. The following are for information and understanding purposes only!!!!! When opening rams, hydraulic opening pressure acting on the ram operating piston area must overcome the wellbore pressure acting on the back side of the ram blocks. This wellbore pressure is holding the rams in the closed position. The area behind the ram blocks is fairly large, so the opening ratios are much lower. Opening ratios between 1:1 and 4:1 are common. Some preventers have opening ratios less than 1:1 which means that the opening pressure much exceed the wellbore pressure.
RAM BLOCK RESULTANT
RAM SHAFT RESULTANT
In Fig 36 is an exposed view showing forces on a ram block and ram shaft while containing pressure below the ram cavity. The packer is sealed on pipe and opening force is being applied to the operating piston.
Fig 36
The extreme case is opening the ram preventer while it is exposed to maximum rated pressure in the wellbore. This required opening pressure is calculated by the following formula:
Opening pressure required to open rams with rated working pressure in the wellbore Rated Working Pressure = ------------------------------------Opening Ratio
08.05 BOP end and Side Outlet Connections On all type of BOPs three different types of connections is used both as end connections and side outlet connections. This includes ram preventer, annular preventer, drilling spools, casing spools and hydraulic connectors. The three types are Studded, Clamp Hub and flanged connection. See Fig 36,37,38.
Studded Connection
Fig 36
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Clamp Hub Connection

Fig 37
Flanged Connection
Fig 38
09.05 API Type Flanges Two types of flanges are used in wellcontrol equipment according to API. API Type 6B Flange. API Type 6 BX Flange. API Type 6B Flange API Type 6B flange is a low pressured flange with maximum pressure rating of 5.000 psi. API Type R or RX ring gaskets are used for this type flange and does not allow face to face contact between hubs or flanges, so external loads are transmitted through the sealing surfaces of the ring. The flange face might be flat or raised. See Fig 39.
FLANGE SECTION INTERGRAL FLANGE

TOP VIEW
Fig 39
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API Type 6 BX Flange API Type 6 BX flange is a high pressure flange with maximum pressure rating of 20.000 psi. API Type BX ring gaskets are used for this type of flange allowing face to face contact of the flanges. The flange face shall be raised except for studded flanges which may have flat faces. See Fig 40.
FLANGE SECTION INTERGRAL FLANGE
Fig 40
TOP VIEW
RATED WORKING PRESSURE 2.000 3.000 5.000 10.000 15.000 20.000 MARKING
FLANGE SIZE RANGE TYPE 6 B TYPE 6 BX 2-1/16 21-1/4 2-1/16 20-3/4 2-1/16 11 26-3/4 30 26-3/4 30 13-5/8 21-1/4 1-13/16 21-1/4 1-13/16 18-3/4 1-13/16 13-5/8
According to API the following marking should be visible on the flanges OD: Manufacturers name and mark API monogram Size Thread size End and outlet connection size Rated working pressure Ring gasket type and number Ring gasket material
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Well Control Equipment Training Manual 10.05 Ring Joint Gaskets and Grooves Introduction
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Ring Joint gaskets and grooves are described within API RP 16A and API RP 53. Ring gaskets have a limited amount of positive interference which assures the gaskets will be joined into sealing relationship within the flanges grooves. These gaskets shall not be re-used. Material The purchaser can specify one of the four different materials when he produces API gaskets: MATERIAL Soft Iron Low-Carbon Steel Type 304 Stainless Steel Type 316 Stainless Steel Inconel 625 HARDNESS BRINELL 90 120 160 140 to 169 481 to 560 IDENTIFICATION MARKING D S S 304 S 316
API Type R Ring Joint Gasket This type R ring joint gasket is not energized by internal pressure. Sealing takes place along small bands of contact between grooves and the gasket on both the OD and ID of the gasket. The gasket may be either octagonal or oval in cross section. The Type R design does not allow face to face contact between hubs and flanges, so external loads are transmitted through the sealing surfaces of the ring. Vibration and external loads may cause small bands of contact between the ring and the groove to deform plastically, so that the joint may develop a leak unless the flange bolting is periodically tighten. Standard procedure with type R joints in the BOP stack is to tighten the flange bolting weekly. See Fig 41/43.
Type R
Type RX
Fig 41
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API Type RX Pressure-Energised Ring Joint Gasket The RX pressure-energised ring joint gasket was developed by CIW and adopted by API. Sealing takes place along small bands of contact between the grooves and the OD of the gasket. The gasket is made slightly larger in diameter than the grooves, and is compressed slightly to achieve initial sealing as the joint is tightened. The RX design does not allow face to face contact between hubs and flanges. The gasket has large load bearing surfaces on its inside diameter to transmit external loads without plastic deformation of the sealing surfaces of the gasket. See Fig 41/43. API Type BX Pressure-Energised Ring Joint Gasket In an effort to develop a more compact flange design for high pressure us the BX series was developed. By allowing face to face contact of the flanges, ring gasket compression and elastic deformation could be controlled. This allowed a proportionally smaller gasket to be used with the effect of reducing bolt and ultimately overall flange size. Sealing takes place along small bands of contact between the grooves and the OD of the gasket. The gasket is made slightly larger in diameter than the grooves, and is compressed slightly to achieve initial sealing as the joint is tightened. Although the intent of the BX design was face to face contact between hubs and flanges, the groove and gasket tolerances which were adopted are such that if the ring dimension is on the high side of the tolerance range and the groove dimension is on the low side of the tolerance range, face to face contact may be very difficult to achieve. Without face to face contact vibration and external loads can cause plastic deformation of the ring, eventually resulting in leaks. The BX gasket frequently is manufactured with axial holes to insure pressure balance, since both the ID and OD of the gasket may contact the grooves. See Fig 42/43.
Type BX
MARKING
Fig 42
According to API the following marking should be visible on the ring gaskets OD: Manufacturers name and mark API monogram Type and Number (Example BX 159) Ring gasket material (Example S 304)
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Fig 43
API Type RX and BX ring-joint gaskets should be used for flanged and hub type blow-out preventer connections in that they are self-energized type gaskets. API type R ring gaskets are not a self-energized type gasket and are not recommended for use on well control equipment. RX gaskets are used with API type 6B flanges and 16B hubs and BX gaskets are used with type 6BX flanges and 16BX hubs. Detailed specifications for ringjoint gaskets are included in API Specification 6A and in API Specification 16A. Gasket materials, coatings and platings should be in accordance with API Specification 6A. Identification markings should be in accordance with API Specification 6A and API Specification 16A.
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06
Choke Manifold
01.06 General The choke manifold consists of high pressure pipe, fittings, flanges, valves, and manual and/or hydraulic operated adjustable chokes. This manifold may bleed off wellbore pressure at a controlled rate or may stop fluid flow from the wellbore completely, as required. See Fig 44.
Fig 44
02.06 Choke Manifold Installation Recommended practices for installation of choke manifolds for surface installations include: Manifold equipment subject to well and/or pump pressure (normally upstream of and including the chokes) should have a working pressure equal to or greater than the rated working pressure of the ram BOPs in use. For working pressures of 3,000 psi and above, flanged, welded, clamped should be employed on components subjected to well pressure. The choke manifold should be placed in a readily accessible location, preferably outside the rig substructure.
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Buffer tanks are sometimes installed downstream of the choke assemblies for the purpose of manifolding the bleed lines together. All choke manifold valves should be full bore. Two valves are recommended between the BOP stack and the choke manifold for installations with rated working pressures of 5,000 psi and above. One of these two valves should be remotely controlled. During operations, all valves should be fully opened or fully closed. A minimum of one remotely operated choke should be installed on 10,000 psi, 15,000 psi and 20,000 psi rated working pressure manifolds. Choke manifold configurations should allow for re-routing of flow (in the event of eroded, plugged, or malfunctioning parts) without interrupting flow control. Pressure gauges suitable for operating pressure and drilling fluid service should be installed so that drill pipe and annulus pressures may be accurately monitored and readily observed at the station where well control operations are to be conducted. 03.06 Choke Lines Installation The choke line and manifold provide a means of applying back pressure on the formation while circulating out a formation fluid influx from the wellbore. The choke line (which connects the BOP stack to the choke manifold) and lines downstream of the choke should: Be as straight as possible. Be firmly anchored to prevent excessive whip or vibration. Have a bore of sufficient size to prevent excessive erosion or fluid friction: Minimum recommended size for choke lines is 2 nominal diameter for 3K and 5K arrangements and 3 nominal diameter for IOK, 15K, and 20K arrangements. Minimum recommended nominal inside diameter for lines downstream of the chokes should be equal to or greater than the nominal connection size of the chokes. Lines downstream of the choke manifold are not normally required to contain pressure . The bleed line (the line that bypasses the chokes) should be at least equal in diameter to the choke line. This line allows circulation of the well with the preventer closed while maintaining a minimum back pressure. It also permits high volume bleed off of well fluids to relieve casing pressure with the preventer closed. 04.06 Kill Lines Installation Kill lines are an integral part of the surface equipment required for drilling well control. 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. The location of the kill line
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connection to the stack depends on the particular configuration of BOPs and spools employed. The connection should be below the ram type BOP most likely to be closed. On selective high-pressure, critical wells a remote kill line is commonly employed to permit use of an auxiliary high pressure pump if the rig pumps become inoperative or inaccessible. This line normally is tied into the kill line near the blowout preventer stack and extended to a site suitable for location of a pump. This site should be selected to afford maximum safety and accessibility. The same guidelines which govern the installation of choke manifolds and choke lines apply to kill line installations. 05.06 HCR Side Outlet Valves Two valves are recommended between the BOP stack and the choke manifold for installations with rated working pressures of 5,000 psi and above. One of these two valves should be remotely controlled. During operations, all valves should be fully opened or fully closed. Of the two valves installed on the BOP side outlet the manual valves is installed as the first coming from the BOP and is always left in open position during normal drilling operation. See Fig 45.
Fig 45
Fig 46
The outside valve is a hydraulic operated valve, which can be operated from the Control Unit or from remote operation panels using 1.500 psi operating pressure. The maximum operating pressure of the valves is normally 3.000 psi. See Fig 46.
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06.06 Chokes The purpose of the chokes in the overall BOP system is to control back pressure in the wellbore while circulating out a kick. The chokes might either be manual and/or hydraulic operated. A minimum of one remotely operated choke should be installed on 10,000 psi, 15,000 psi and 20,000 psi rated working pressure manifolds. The choke control station, whether at the choke manifold or remote from the rig floor, should be as convenient as possible and should include all monitors necessary to furnish an overview of the well control situation. The ability to monitor and control from the same location such items as standpipe pressure, casing pressure, pump strokes, etc., greatly increases well control efficiency. Rig air systems should be checked to assure their adequacy to provide the necessary pressure and volume requirements for controls and chokes. The remotely operated choke should be equipped with an emergency backup system such as a manual pump or nitrogen for use in the event rig air becomes unavailable.
Hydraulic actuator
Fig 47
Position indicator
Cameron hydraulically actuated drilling choke are available in working pressures from 5.000 psi to 20.000 psi. See Fig 47. Cylindrical gate and large body cavity provide high flow capacity. Gate and seat are constructed of erosion resistant tungsten carbide and are reversible for double life. An air operated hydraulic pump in the control console ensures positive action gate movement. Hydraulic pressure of 300 psi applied to the actuator results in an opening or closing force of 21.500 lbs at the gate.
Fig 48
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Cameron manually actuated choke are available in working pressures from 5.000 psi to 20.000 psi See Fig 48. Thrust bearings in the actuator provide low torque handwheel operation. Upstream pressure has no thrust loading on the actuator, only downstream pressure affects the torque. Cylindrical gate and large body cavity provide high flow capacity. Gate and seat are constructed of erosion resistant tungsten carbide and are reversible for double life. The manually operated choke is normally used as a back up in case of problems with the hydraulically operated choke and during special well control operations such as stripping and volumetric well control. 07.06 Hydrates Hydrates are ice-like solids which are formed when gases are flowing in the presence of small quantities of water vapour. The temperatures at which hydrates can form may be well above the temperature at which pure ice would normally be formed, particularly at pressures above atmospheric. Hydrates form as small lattices of water with interstices which contain gases. The water forms an ice with molecules of gas locked into the frozen solid lattice. Those can build up into large pieces of solid hydrate at bends or restrictions, such as chokes or other valves. See Fig 49.
GAS + WATER (VAPOUR)

Fig 49
SOLID HYDRATE BUILD-UP
When hydrates form, the gas becomes "locked" into the solid at the local pressure. It is estimated that 1 cu ft of hydrate may hold the equivalent of 170 SCF compressed gas. This can be released when the hydrate is melted by the application of heat. Once hydrates have formed they may lead to complete plugging of chokes, fail-safe valves, choke lines and expansion points at entry to the MGS. It is normal to try to prevent hydrates from forming by the injection of a suppressant at the upstream side of the choke or at the BOP, on the occasions when hydrate formation is likely. Prevention of hydrate formation is always regarded as the preferential action. Monoethylene glycol is the most common suppressant and it has a freezing point of 8.6F
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(-13C). It should be noted that it is the water-vapour associated with the gas which has to be inhibited, rather than the whole volume of water in the mud. It is common in HPHT wells to make provision for the injection of glycol hydrate suppressant at a point into the BOP upstream of the inner choke line valves and upstream of the choke at the choke manifold. This is done by a glycol injection pump which can deliver at a pressure up to the rated pressure of the choke manifold. The injection is started at a point when the gas influx is some depth below the BOP, such as 1500 to 2000 ft. The minimum injection rate is about .05 gpm but should be increased as necessary. During severe problems with hydrates Methanol might be injected as it has a lower freezing point than Glycol. 08.06 Mud/Gas Separator The mud/gas separator is the primary means of removing gas from the drilling fluid. There are several advantages to removing a large percentage of the gas from the drilling fluids before the drilling fluid flows to the degasser tank at the sand trap area and the pit room. See Fig 50. The primary reason is to reduce the quantity of gas which may percolate out of the drilling fluid in the mud pits an begin the process of regaining the proper density. As the atmospheric mud/gas separator is the primary type used, there are two types of atmospheric designs which are available. The vertical type and the horizontal type. The horizontal type is gaining recognition within the industry because of its design advances and they are: a.Larger exposed liquid surface area. b.Longer retention time of the fluid. c.The gas flows perpendicular to the direction of the fluid flow.
Fig 50
Due to space problems the vertical mud/gas separator is still the most common used in the industry. As the gas and drilling fluid is separated the gas flows up through the vent stack into the atmosphere. It can be shown that for the average 6 schedule 80, 5.85 ID pipe, that extends 150 ft above the mud/gas separator there is a back pressure reading in the range of 8 psi. The 8 psi back pressure is at the transition from the mud/gas separator to the vent line. Many variables must be taken into account in the calculations to this back pressure,
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such as the size and length of line in which the gas flowing, compressed isothermal flow, relative roughness, friction factors for the pipe and Reynolds numbers. However this 8 psi gauge pressure can be calculated and is fairly representative of actual situations. Due to the high friction loss in the vent line 10 to 12 lines are normally used. The objective of the dip tube or U-tube is to exert a hydrostatic head by column of fluid which will create a greater resistance to flow than the vent line going up the derrick. The design objective is to assure oneself that the path of least resistance is always through the derrick vent line. Considering that the dip tube or U-tube is always full of fluid when flowing gas through the mud/gas separator, the worst case will be with water in the tube which is often mounted below the mud/gas separator. As shown on a typical vertical mud/gas separator drawing, where the dip tube goes into the trip tank, the trip tank frequently has a centrifugal hole fill pump installed at its base as well as a float and wireline extending to the rig floor and used as a trip tank indicator. See Fig 51 A U-tube does not have an indicator installed, but a pressure gauge.
Fig 51
Even that most mud gas separators have a design pressure of 150 psi the actual maximum operating pressure is below psi depending of the high of the U-/Dip Tube and the fluid it contains. Eks: High of U-tube Fluid gradient Safety factor 15 feet 0.465 psi/ft 0.75
15 x 0.465 x 0.75 = 5.2 psi
09.06 Degasser Degassers are the secondary means of removing gas from gas cut drilling fluid. The two most predominant types of secondary degassers are the WELLCO and the SWACO. See Fig 52.
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51
Fig 52
A degasser may be used to remove entrained gas bubbles in the drilling fluid that are to small to be removed by the mud/gas separator. Most degassers make use of some degree of vacuum to assist in removing this entrained gas. The drilling fluid inlet line to the degasser should be placed close to the drilling fluid discharge line from the mud/gas separator to reduce the possibility of gas breaking out of the drilling fluid in the pit.
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07
Control System
01.07 General
BOP control systems for surface installations (land rigs, offshore jack-ups and platforms) normally supply hydraulic power fluid in a closed loop circuit as the actuating medium. The elements of the BOP control system normally include (See Fig 53): Storage (reservoir) equipment for supplying ample control fluid to the pumping system. Pumping systems for pressurizing the control fluid. Accumulator bottles for storing pressurized control fluid. Hydraulic control manifold for regulating the control fluid pressure and directing the power fluid flow to operate the system functions (BOP's and choke and kill valves). Remote control panels for operating the hydraulic control manifold from remote locations. - Hydraulic control fluid.
Fig 53
02.07 Response Time
Response time between activation and complete operation of a function is based on BOP or valve closure and seal off. For surface installations, the BOP control system should be capable of closing each ram BOP within 30 seconds. Closing time should not exceed 30 seconds for annular preventers smaller than 18-3/4 nominal bore and 45 seconds for annular preventers of 18-3/4 and larger. Response time for choke and kill valves (either open or close) should not exceed the minimum observed ram close response time.
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Measurement of closing response time begins at pushing the button or turning the control valve handle to operate the function and ends when the BOP or valve is closed effecting a seal. A BOP may be considered closed when the regulated operating pressure has recovered to its nominal setting. If confirmation of seal off is required, pressure testing below the BOP or across the valve is necessary.
03.07 Storage Equipment
A suitable control fluid should be selected for the system operating medium based on the control system operating requirements, environmental requirements and user preference. Water-based hydraulic fluids are usually a mixture of portable water and a water soluble lubricant additive. When ambient temperatures at or below freezing are expected, sufficient volume of ethylene glycol or other additive acceptable to the control system manufacturer should be mixed with the water-based hydraulic fluid to prevent freezing. The hydraulic fluid reservoir should have a capacity equal to at least twice the usable hydraulic fluid capacity of the accumulator system.
04.07 Pump Requirements
A pump system consists of one, or more pumps driven by a dedicated power source. Two (primary and secondary) or more pump systems should be employed having independent power sources. The combined output of all pumps should be capable of charging the entire accumulator system from precharge pressure to the maximum rated control system working pressure within 15 minutes. The same pump system(s) may be used to produce power fluid for control of both the BOP stack and the diverter system Each pump system should provide a discharge pressure at least equivalent to the system working pressure. Air driven pump systems should require no more than 75 psi air supply pressure. Devices used to prevent pump system over-pressurization should be installed directly in the control system supply line to the accumulators and should not have isolation valves or any other means that could defeat their intended purpose. Electrical and/or air (pneumatic) supply for powering pumps should be available at all times such that the pumps will automatically start when the system pressure has decreased 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.
05.07 Accumulator Bottles and Manifolds
Accumulators are pressure vessels designed to store power fluid.

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Accumulator designs include bladder, piston and float types. Selection of type may be based on user preference and manufacturer's recommendations considering the intended operating environment. The accumulator system should be designed so that the loss of an individual accumulator and/or bank should not result in more than approximately twenty-five percent loss of the total accumulator system capacity. Supply pressure isolation valves and bleed down valves should be provided on each accumulator bank to facilitate checking the precharge pressure or draining the accumulators back to the control fluid reservoir. The precharge pressure in the system accumulators serves to propel the hydraulic fluid stored in the accumulators for operation of the system functions. The amount of precharge pressure is a variable depending on specific operating requirements of the equipment to be operated and the operating environment, but most common 1.000 psi. Because of the presence of combustible components in hydraulic fluids, accumulators should be precharged only with nitrogen.
06.07 Hydraulic Control Manifold
The hydraulic control manifold is the assemblage of hydraulic control valves, regulators and gages from which the system functions are directly operated. It allows manual regulation of the power fluid pressure to within the rating specified by the BOP manufacturer. The hydraulic control manifold provides direct pressure reading of the various supply and regulated pressures. A dedicated control circuit on the hydraulic control manifold should operate the annular BOP(s). The components in this circuit should include a pressure regular to reduce upstream manifold pressure to the power fluid pressure level that meets the BOP manufacturer's recommendations. The regulator should respond to pressure changes on the downstream side with sensitivity, sufficient to maintain the set pressure within plus or minus one hundred and fifty psi. The annular BOP pressure regulator should be remotely controllable. Direct manual valve and regulator operability should permit closing the annular BOP and/or maintaining the set regulated pressure in the event of loss of the remote control capability. See Fig 54
Old Type Annular Pressure Regulator
Fig 54
New Type Annular Pressure Regulator
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The hydraulic control manifold includes a common power fluid circuit with pressure regulation and control valves for operation of the ram type BOP's and choke and kill valves. This circuit may be provided with a manifold regulator bypass valve or other means to override the manifold regulator to permit switching from regulated pressure to direct accumulator pressure for operating functions. The regulator should respond to pressure changes on the downstream side with sensitivity, sufficient to maintain the set pressure within plus or minus one hundred and fifty psi. Placing the control valve handle on the right side (while facing the valve) should close the BOP or choke or kill valve, the left position should open the BOP or choke or kill valve. The center position of the control valve is called the "block" position. In the block position, power fluid supply is shut off at the control valve. The other ports on the four-way valve may be either vented or blocked depending on the valve selected for the application. Protective covers or other means which do not interfere with remote operation should be installed on the blind/shear ram and other critical function control valves. Lifting of these covers is required to enable local function operation.
07.07 Schematic of Control System
See Fig 55. 1. 3. 4. 6. 10. 11. 12. 16. 17. 18. 20. 22. 23. Customer Air Supply.
Normal air supply is at 125 psi.
Bypass Valve.
To automatic hydro-pneumatic pressure switch. When pressures higher than the normal 3.000 psi are required.
Automatic Hydro-Pneumatic Pressure switch.

Pressure switch is set at 3.000 psi cut-out and @ 2.700 psi cut-in.
Air Operated Hydraulic Pumps.

Normal operating air pressure is 125 psi.
Electric Motor Driven Triplex Pump Assembly. Automatic Hydro-Electric Pressure Switch.
Pressure switch is set at 3.000 psi cut-out and @ 2.700 psi cut-in.
Electric Motor Starter.

Works in conjunction with the automatic hydro-electric pressure switch.
Accumulator Shut Off Valve.

Manually operated.
Accumulators.
Use nitrogen when adding precharge.
Accumulator Relief Valve..

Valve set to relieve at 3.500 psi.
Manifold Pressure Reducing and Regulating Valve.

Manually operated. Adjust to the required continuous operating pressure of ram type BOPs.
Selector Valve 3 position/4 way valve.

With air cylinder operators for remote operation from the control panels.
Bypass Valve.
With air cylinder operator for remote operation from the control panels. Kept closed unless 3.000 psi is required on the ram type BOPs
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Fig 55
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Well Control Equipment Training Manual 26. 27. 28. 29. 30. 31. 32. 33. 35. 36. 37. 38. 41. Panel Unit Selector.
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Used to allow pilot air pressure to the annular preventer reducing and regulating valve either from the air regulator on the unit or from the air regulator on the remote control panel.
Annular Pressure Reducing and Regulating Valve.

Reduces the accumulator pressure to the required annular operating pressure. Pressure can be varied for pipe size and operation carried out.
Accumulator Pressure Gauge. Manifold Pressure Gauge. Annular Preventer Pressure Gauge. Pneumatic Pressure Transmitter for Accumulator Pressure. Pneumatic Pressure Transmitter for Manifold Pressure. Pneumatic Pressure Transmitter for Annular Preventer Pressure. Air Regulator for Annular Pressure Reducing and Regulating Valve. Air Regulator for Pneumatic Pressure Transmitter for Annular Pressure. Air Regulator for Pneumatic Pressure Transmitter for Accumulator Pressure. Air Regulator for Pneumatic Pressure Transmitter for Manifold Pressure. Hydraulic Fluid Fill Hole.
08.07 Remote Control Panel
A minimum of one remote control panel should be furnished. This is to ensure that there are at least two locations from which all of the system functions can be operated. The remote panel should be accessible to the Driller to operate functions during drilling operations. The Driller's remote control panel display should be physically arranged as a graphic representation of the BOP stack. See Fig 56.
Fig 56
Its capability should include the following: 1. 2. 3. Control all the hydraulic functions which operate the BOP's and choke and kill valves. Display the position of the control valves and indicate when the electric pump is running (offshore units only). Provide control of the annular BOP regulator pressure setting.
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Well Control Equipment Training Manual 4. 5.
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6.
7.
Provide control of the manifold regulator bypass valve or provide direct control of the manifold regulator pressure setting. The driller's panel should be equipped with displays for readout of: Accumulator pressure Manifold regulated pressure Annular BOP regulated pressure Rig air pressure Offshore rig driller's panels should have an audible and visible alarm to indicate the following: Low accumulator pressure Low rig air pressure Low hydraulic fluid reservoir level Panel on standby power (if applicable) All panel control functions should require two handed operation. Regulator control may be excluded from this requirement. The BOP stack functions should also be operable from the main hydraulic control manifold. This unit should be installed in a location remote from the drill floor and easily accessible to rig personnel in an emergency.
Remote control from the remote panels of the hydraulic control manifold valves may be actuated by pneumatic (air), hydraulic, electro-pneumatic, or electro-hydraulic remote control systems. The remote control system should be designed such that manual operation of the control valves at the hydraulic control unit will override the position previously set by the remote controls.
09.07 Accumulator Volumetric Requirements
The BOP control system should have a minimum stored hydraulic fluid volume, with pumps inoperative, to satisfy the greater of the two following requirements: Close from a full open position at zero wellbore pressure, all of the BOP's in the BOP stack, plus fifty percent reserve. The pressure of the remaining stored accumulator volume after closing all of the BOP's should 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.
The about mentioned requirements are from API (RP 16E) and are just guidelines. The actual volumetric requirements depends on working area, national rules and company policy and can vary a lot.
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10.07 Accumulator Volumetric Capacity
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For the purpose of this section, the following definitions apply:

Stored Hydraulic Fluid. The fluid volume recoverable from the accumulator system between the maximum designed accumulator operating pressure and the precharge pressure. Usable Hydraulic Fluid. The hydraulic fluid recoverable from the accumulator system between the maximum accumulator operating pressure and minimum calculated operating pressure or 200 psi above precharge pressure whichever is greatest. Minimum Calculated Operating Pressure. The minimum calculated pressure to effectively close and seal a ram-type BOP against a wellbore pressure equal to the maximum rated working pressure of the BOP divided by the closing ratio specified for that BOP. Component Minimum Operating Pressure Recommended by the Manufacturer. The minimum operating pressure to effectively close and seal ram-type or annular-type preventers under normal operating conditions, as prescribed by the manufacturer.
The equation for volumetric capacity calculation according to Boyles law is:
P1 x V1 = P2 x V2 or Pressure x Volume = Constant
where: P1 = Initial Pressure V1 = Initial Gas Volume P2 = Final Pressure V2 = Final Gas Volume
Fig 57
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Example:
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Accumulator bottle size 10 gallons. Precharge pressure 1.000 psi Initial condition with only gas (See Fig 58a):
Pressure x Volume = Constant 1.000 x 10 = 10.000
The pump system is started and hydraulic fluid is pumped into the accumulator bottle until maximum operating pressure is reached at 3.000 psi (See Fig 58b):
P1 x V1 = P2 x V2 1.000 x 10 = 3.000 x V2
10.000 = 3.33 V2 = -----------3.000

Stored hydraulic fluid = 10 - 3.33 = 6.66 gal
1.000 psi 10 gal
3.000 psi 3.33 gal
1.200 psi 8.33 gal
1.500 psi 6.66 gal
2.110 psi 4.74 gal
6.66 gal Fig 58 a

Fig 58
1.66 gal Fig 58 c
3.33 gal Fig 58 d Fluid
5.26 gal Fig 58 e
Fig 58 b Gas
The pump system is isolated and the BOPs functioned until accumulator pressure reach precharge pressure + 200 psi (See Fig 58c):
P1 x V1 = P2 x V2 1.000 x 10 = 1.200 x V2
10.000 = 8.33 V2 = -----------1.200

DOCUMENT ID
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REVISION

DRILLING SECTION
SUBJECT:
03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER

Usable hydraulic fluid = 8.33 - 3.33 = 5 gal
JOA
07
61
If the minimum operating pressure recommended by the manufacture is 1.500 psi as for Shaffer Annular Preventer with pipe size smaller than 7 the usable hydraulic fluid would be (See Fig 58d):
P1 x V1 = P2 x V2 1.000 x 10 = 1.500 x V2
10.000 = 6.66 V2 = -----------1.500
Usable hydraulic fluid = 6.66 - 3.33 = 3.33 gal
If the minimum calculated operating pressure to effectively close and seal a ram-type BOP against maximum wellbore pressure is used the usable hydraulic fluid would be (See Fig 58e): Shaffer 15.000 psi Bop with closing ratio 7.11 Minimum operating pressure = 2110 psi
P1 x V1 = P2 x V2 1.000 x 10 = 2.110 x V2
10.000 = 4.74 V2 = -----------2.110

Usable hydraulic fluid = 4.74 - 3.33 = 1.41 gal
To determine the total number of accumulator bottles to be present divide the required total volume according to rules and regulations to operate the functions on the BOP with the calculated usable hydraulic fluid per bottle. Round off to next larger whole bottle or accumulator bank.
MTC
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DRILLING SECTION
SUBJECT:
03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
08
62
08
Auxiliary Equipment
01.08 Kelly Valves
An upper kelly valve is installed between the swivel and the kelly. A lower kelly valve is installed immediately below the kelly. See Fig 59/60.
Fig 59
Fig 60
02.08 Top Drive Valves
There are two ball valves (sometimes referred to as kelly valves or kelly cocks) located on top drive equipment. The upper valve is air or hydraulically operated and controlled at the driller's console. The lower valve is a standard ball kelly valve (sometimes referred to as a safety valve) and is manually operated, usually by means of a large hexagonal wrench. Generally, if it becomes necessary to prevent or stop flow up the drill pipe during tripping operations, a separate drill pipe valve should be used rather than either of the top drive valves. However, flow up the drill pipe might prevent stabbing this valve. In that case, the top drive with its valves can be used, keeping in mind the following cautions: a. Once the top drive's manual valve is installed, closed, and the top drive disconnected, a crossover may be required to install an inside BOP on top of the manual valve. Most top drive manual valves cannot be stripped into 7 5/8 inch or smaller casing.
b. c.
Once the top drive's manual valve is disconnected from the top drive, another valve or spacer must be installed to take its place. See Fig 61.
Fig 61
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DRILLING SECTION
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03-13-01
ORIGINAL DATE
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REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
08
63
03.08 Drillpipe Safety Valve (FOSV)
A spare drill pipe safety valve should be readily available (i.e., stored in open position with wrench accessible) on the rig floor at all times. This valve or valves should be equipped to screw into any drill string member in use. The outside diameter of the drill pipe safety valve should be suitable for running into the hole. See Fig 62.
Fig 62
04.08 Inside Blowout Preventer (IBOP or GREY Valve)
An inside blowout preventer, drill pipe float valve, or drop-in check valve should be available for use when stripping the drill string into or out of the hole. The valve(s), sub(s), or profile nipple should be equipped to screw into any drill string member in use. No direct read-out of SIDPP can be obtained. See Fig 63.
1. 2. 3. 4. Release Tool Body Valve Release Rod Valve Spring Valve Seat
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DRILLING SECTION
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03-13-01
ORIGINAL DATE
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REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
08
64
Fig 63
05.08 Drillstring Float Valve
A float valve is placed in the drill string to prevent upward flow of fluid or gas inside the drill string. The float valve is a special type of back pressure or check valve. A float valve in good working order will prohibit backflow and a potential blowout through the drill string. The drill string float valve is usually placed in the lowermost portion of the drill string, between two drill collars or between the drill bit and drill collar. Since the float valve prevents the drill string from being filled with fluid through the bit as it is run into the hole, the drill string must be filled from the top at the drill floor, to prevent collapse of the drill pipe. Tripping time will be increased and excess surge pressure created when running with float valves. No direct read-out of SIDPP can be obtained. There are two types of float valves: a. The flapper-type float valve offers the advantage of having an opening through the valve that is approximately the same inside diameter as that of the tool joint. This valve will permit the passage of balls, or go-devils, which may be required for operation of tools inside the drill string below the float valve. See Fig 64. The spring-loaded ball, or dart, and seat float valve offers the advantage of an instantaneous and positive shut off backflow through the drill string. See Fig 65.
Fig 64
b.
Fig 65
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DRILLING SECTION
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03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
08
65
06.08 Test Plug
A test plug is used to test BOPs and associated well control equipment without exerting pressure on well head and casing. When using test plug well head side outlet valves should be open to avoid damage to casing and formations. See Fig 66.
Fig 66
07.08 Cup Type Tester
A cup type tester is used to test well head and well head side outlet valves without exerting pressure on casing and formation. Cup type tester should be run on open ended drill pipe to release any build up of pressure below the cup. See Fig 67.
Fig 67
08.08 Triptank
A trip tank is a low-volume, [100 barrels or less] calibrated tank that 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 from the well. A trip tank may be of any shape provided the capability exists for reading the volume contained in the tank at any liquid level. The readout may be direct or remote, preferably both. The size and configuration of the tank should be such that volume changes on the order of one-half barrel can be easily detected by the readout arrangement. Tanks containing two compartments with monitoring
MTC
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DRILLING SECTION
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03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
08
66
arrangements in each compartment are preferred as this facilitates removing or adding drilling fluid without interrupting rig operations. Other uses of the trip tank include measuring drilling fluid or water volume into the annulus when returns are lost, monitoring the hole while logging or following a cement job, calibrating drilling fluid pumps, etc. The trip tank is also used to measure the volume of drilling fluid bled from or pumped into the well as pipe is stripped into or out of the well.
09.08 Pit Volume Measuring Devices
Automatic pit volume measuring devices are available which transmit a pneumatic or electric signal from sensors on the drilling fluid pits to recorders and signaling devices on the rig floor. These are valuable in detecting fluid gain or loss.
10.08 Flow Rate Sensor
A flow rate sensor mounted in the flow line is recommended for early detection of formation fluid entering the wellbore or a loss of returns.
MTC
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DRILLING SECTION
SUBJECT:
03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
08
67
MTC
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DRILLING SECTION
SUBJECT:
03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER
JOA
09
68
09
Recommended Pressure Test Practices
01.09 Initial Test (Prior to spud or upon installation)
Component to be Tested
Rotating Head Diverter Element Annular preventer Operating Chambers Ram Preventers Fixed Pipe Variable Bore Blind/blind Shear Operating Chamber
Recommended Pressure Test

Low Pressure psi 200 300 Minimum of 200 200 300 N/A 200 300 200 300 200 300 N/A

High Pressure psi Optional Optional Minimum of 70% of annular BOP working pressure Minimum of 1500 Working pressure of ram BOPs Working pressure of ram BOPs Working pressure of ram BOPs Maximum operating pressure recommended by ram BOP manufacturer N/A Working pressure of ram BOPs Working pressure of ram BOPs
Diverter Flowlines Choke Line & Valves Kill Line & Valves Choke Manifold Upstream of Last High Pressure Valve Downstream of Last High Pressure Valve BOP Control System Manifold and BOP Lines Accumulator Pressure Close Time Pump Capacity Control Stations Safety Valves Kelly, Kelly Valves and Floor Safety Valves Auxiliary Equipment Mud/Gas Separator Trip Tank, Flo-Show etc
Flow Test 200 300 200 300
200 300 200 300 N/A Verify Precharge Function Test Function Test Function Test
Working pressure of ram BOPs Optional Minimum of 3000 N/A N/A N/A N/A
200 300
Working pressure of components N/A N/A
Flow Test Flow Test
MTC
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DRILLING SECTION
SUBJECT:
03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY ITEM
01 0
PAGE
1/8/02
PREPARED BY
MCL
CHAPTER

02.09 Subsequent Test (Not to exceed 21 days).
JOA
09
69
Component to be Tested
Rotating Head Diverter Element Annular preventer Operating Chambers Ram Preventers Fixed Pipe Variable Bore Blind/blind Shear Casing(prior to running csg) Operating Chamber Diverter Flowlines Choke Line & Valves Kill Line & Valves Choke Manifold Upstream of Last High Pressure Valve Downstream of Last High Pressure Valve BOP Control System Manifold and BOP Lines Accumulator Pressure Close Time Pump Capacity Control Stations Safety Valves Kelly, Kelly Valves and Floor Safety Valves Auxiliary Equipment Mud/Gas Separator Trip Tank, Flo-Show etc

Low Pressure psi N/A Optional 200 300 N/A 200 300 200 300 200 300 Optional N/A Flow Test 200 300 200 300

High Pressure psi Optional Optional Minimum of 70% of annular BOP working pressure Minimum of 1500 Greater than the maximum anticipated surface pressure Greater than the maximum anticipated surface pressure Greater than the maximum anticipated surface pressure Optional N/A N/A Greater than the maximum anticipated surface pressure Greater than the maximum anticipated surface pressure
200 300 Optional N/A Verify Precharge Function Test Function Test Function Test
Greater than the maximum anticipated surface pressure Optional Optional N/A N/A N/A N/A
200 300
Greater than the maximum anticipated surface pressure N/A N/A
Optional Flow Test Flow Test
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