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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
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Well Control Philosophy

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 Page 006
01.01 Primary well control barrier
02.01 Secondary well control barrier

02 BOP Configuration Page 007


01.02 Bop stack arrangements
02.02 Stack Components codes
03.02 Drilling spool

03 Diverter systems Page 010


01.03 Purpose of diverter system
02.03 Diverter equipment
03.03 Guidelines for diverting with string on bottom
04.03 Guidelines for diverting with string off bottom
05.03 Rotating head
06.03 Diverter control system

04 Annular Preventer Page 016


01.04 General
02.04 Testing
03.04 Pressure test frequency
04.04 Response time
05.04 Hydril annular preventers
06.04 Shaffer annular preventers
07.04 Cameron annular preventers
08.04 Packing unit

05 Cameron Ram Preventer Page 026


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

06 Choke Manifold Page 043


01.06 General
02.06 Choke Manifold - Installation
03.06 Choke Lines - Installation
04.06 Kill Lines - Installation
05.06 HCR Side Outlet Valves
06.06 Chokes

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07.06 Hydrates
08.06 Mud/Gas Separator
09.06 Degasser

07 Control System Page 051


01.07 General
02.07 Response Time
03.07 Storage Equipment
04.07 Pump Requirements
05.07 Accumulator Bottles and Manifolds
06.07 Hydraulic Control Manifold
07.07 Schematic of Control System
08.07 Remote Control Panel
09.07 Accumulator Volumetric Requirements

08 Auxiliary Equipment Page 061


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

09 Recommended Pressure Test Practices Page 066


01.09 Initial Test
02.09 Subsequent Test

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Abbreviations:

A Annular preventer
API American Petroleum Institute
BOP Blow-out Preventer
C Hydraulic connector
CSO Complete shut off
F Farentheit
FOSV Full Opening Safety Valve
G Rotating head
GAL Gallons
K Pressure 1.000 psi
HCR High Closing Ratio
H2S Hydrogen sulfide
IBOP Inside Blow-out Preventer
ID Internal diameter
LBS Pound
MGS Mud/Gas Separator
OD Outside diameter
P Pressure
PRC Power ram change
PSI Pound per inch
R Ram preventer (single)
Rd Ram preventer (double)
Rt Ram preventer (tripple)
RP Recommended Practice
S Drilling spool
SCF Standard Cubic Feet
V 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 2,000 psi (13.8 MPa)


3K 3,000 psi (20.7 MPa)
5K 5,000 psi (34.5 MPa)
IOK 10,000 psi (69.0 MPa)
15K 15,000 psi (103.5 MPa)
20K 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= Rotating head.

A= Annular type BOP.

R= 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 = Triple ram type BOP with three sets of rams, positioned in accordance with
operator's choice.

S= Drilling spool with side outlet connection for choke and kill lines.

C= Hydraulic well head connector with a minimum rated working pressure equal to
the BOP stack rated working pressure.

K= 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 iden-
tified 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. 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.

c. 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. Open B or C depending on wind direction


b. Close E
c. 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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03.03 Guidelines for diverting with string on bottom

1. Route returns to downwind vent line and close diverter

2. 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)

3. 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. Do not stop pumping and if mud reserves run out, keep pumping seawater at
maximum rate. Do not shut down the pumps.

2. Arrange emergency evacuation of all non-essential personnel and prepare


evacuation of remaining personnel.

3. 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 sys-
tem. 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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02.04 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.

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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03.04 Pressure test frequency

Pressure tests on the well control equipment should be conducted at least:

a. Prior to spud or upon installation.

b. 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.

c. Not to exceed 21 days.

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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Hydril GL annular preventer


See Fig 12

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
CSO
2200
CLOSING PRESSURE

2000
1800
1600
1400
1200
3-1/2
1000
800
600 9-5/8 7
400 5
200 13-5/8

0 1000 2000 3000 4000 5000 6000 7000 8000


WELL PRESSURE

Fig 14

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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

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

CLOSING PRESSURE
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.

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 Fig 21


drilling fluids and can be used at operating
temperatures between - 30 deg F to + 225
deg F

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.

3. 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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Hang-Off Test.

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.

5. 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.

6. 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.

7. Through Bore
Visually inspect through bore for key seating record. Repairs should be initiated
when this bore wear exceeds 3/16.

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. Prior to spud or upon installation.

b. 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.

c. Not to exceed 21 days.

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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In this manual we only look on Cameron type U-II

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: Bonnet bolt B: Ram Change cylinder C: Ram assembly


D: Body E: Bonnet seal F: Ram Change piston
G: Locking screw H: Operating cylinder I: Locking screw housing
J: Intermediate flange K: Bonnet L: 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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1. 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.

2. 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.

3. The weep hole avoid well bore pressure on the opening side of the hydraulic
chamber.

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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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

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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Shear/Blind ram assembly

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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Feedable rubber

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 CLOSING CHAMBER


RAM
Fig 34

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


CLOSING
AREA
range from 6:1 to 9:1. This means that
it takes 1 psi of closing hydraulic
RAM SHAFT
AREA pressure per 6 to 9 psi wellbore
pressure to close the preventer.
WELL CLOSING
PRESSURE PRESSURE 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.
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 Rated Working Pressure


close ram with rated wellbore = -------------------------------------
pressure in the bore Closing Ratio

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Opening Ratio

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
In Fig 36 is an exposed view showing
RESULTANT
RAM SHAFT
forces on a ram block and ram shaft
RESULTANT 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 Rated Working Pressure


open rams with rated working = -------------------------------------
pressure in the wellbore 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.

Fig 39
FLANGE SECTION TOP VIEW
INTERGRAL FLANGE
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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.

Fig 40
FLANGE SECTION TOP VIEW
INTERGRAL FLANGE

RATED FLANGE SIZE RANGE


WORKING PRESSURE TYPE 6 B TYPE 6 BX

2.000 2-1/16 21-1/4 26-3/4 30


3.000 2-1/16 20-3/4 26-3/4 30
5.000 2-1/16 11 13-5/8 21-1/4
10.000 1-13/16 21-1/4
15.000 1-13/16 18-3/4
20.000 1-13/16 13-5/8

MARKING

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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10.05 Ring Joint Gaskets and Grooves

Introduction

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 HARDNESS IDENTIFICATION


BRINELL MARKING
Soft Iron 90 D
Low-Carbon Steel 120 S
Type 304 Stainless Steel 160 S 304
Type 316 Stainless Steel 140 to 169 S 316
Inconel 625 481 to 560

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 ring-
joint 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 con-
nects 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.

SOLID HYDRATE
GAS + WATER
BUILD-UP
(VAPOUR)

Fig 49

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 15 feet


Fluid gradient 0.465 psi/ft
Safety factor 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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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

New Type Annular


Fig 54 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. Customer Air Supply.


Normal air supply is at 125 psi.
3. Bypass Valve.
To automatic hydro-pneumatic pressure switch. When pressures higher than the normal 3.000 psi
are required.
4. Automatic Hydro-Pneumatic Pressure switch.
Pressure switch is set at 3.000 psi cut-out and @ 2.700 psi cut-in.
6. Air Operated Hydraulic Pumps.
Normal operating air pressure is 125 psi.
10. Electric Motor Driven Triplex Pump Assembly.
11. Automatic Hydro-Electric Pressure Switch.
Pressure switch is set at 3.000 psi cut-out and @ 2.700 psi cut-in.
12. Electric Motor Starter.
Works in conjunction with the automatic hydro-electric pressure switch.
16. Accumulator Shut Off Valve.
Manually operated.
17. Accumulators.
Use nitrogen when adding precharge.
18. Accumulator Relief Valve..
Valve set to relieve at 3.500 psi.
20. Manifold Pressure Reducing and Regulating Valve.
Manually operated. Adjust to the required continuous operating pressure of ram type BOPs.
22. Selector Valve 3 position/4 way valve.
With air cylinder operators for remote operation from the control panels.
23. 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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26. Panel Unit Selector.


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.
27. 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.
28. Accumulator Pressure Gauge.
29. Manifold Pressure Gauge.
30. Annular Preventer Pressure Gauge.
31. Pneumatic Pressure Transmitter for Accumulator Pressure.
32. Pneumatic Pressure Transmitter for Manifold Pressure.
33. Pneumatic Pressure Transmitter for Annular Preventer Pressure.
35. Air Regulator for Annular Pressure Reducing and Regulating Valve.
36. Air Regulator for Pneumatic Pressure Transmitter for Annular Pressure.
37. Air Regulator for Pneumatic Pressure Transmitter for Accumulator Pressure.
38. Air Regulator for Pneumatic Pressure Transmitter for Manifold Pressure.
41. 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. Control all the hydraulic functions which operate the BOP's and choke and kill
valves.
2. Display the position of the control valves and indicate when the electric pump is
running (offshore units only).
3. Provide control of the annular BOP regulator pressure setting.

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4. Provide control of the manifold regulator bypass valve or provide direct control of the
manifold regulator pressure setting.
5. The driller's panel should be equipped with displays for readout of:
Accumulator pressure
Manifold regulated pressure
Annular BOP regulated pressure
Rig air pressure
6. 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)
7. 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

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 P2 = Final Pressure
V1 = Initial Gas Volume V2 = Final Gas Volume

Fig 57

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Example:

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 3.000 psi 1.200 psi 1.500 psi 2.110 psi

10 gal 3.33 gal 8.33 gal 6.66 gal 4.74 gal

6.66 gal 1.66 gal 3.33 gal 5.26 gal


Fig 58 a Fig 58 b Fig 58 c Fig 58 d Fig 58 e
Gas Fluid
Fig 58

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

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Usable hydraulic fluid = 8.33 - 3.33 = 5 gal

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.

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Well Control Equipment Training Manual 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.
b. Most top drive manual valves cannot be
stripped into 7 5/8 inch or smaller casing.

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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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. Release Tool Body


2. Valve Release Rod
3. Valve Spring
4. Valve Seat

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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 pre-
vents 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.

b. 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

Fig 65

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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

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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.

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09 Recommended Pressure Test Practices


01.09 Initial Test (Prior to spud or upon installation)

Component to be Recommended Recommended


Tested Pressure Test Pressure Test
Low Pressure psi High Pressure psi

Rotating Head 200 300 Optional

Diverter Element Minimum of 200 Optional

Annular preventer 200 300 Minimum of 70% of annular


BOP working pressure
Operating Chambers N/A Minimum of 1500

Ram Preventers
Fixed Pipe 200 300 Working pressure of ram BOPs
Variable Bore 200 300 Working pressure of ram BOPs
Blind/blind Shear 200 300 Working pressure of ram BOPs
Operating Chamber N/A Maximum operating pressure
recommended by ram BOP
manufacturer

Diverter Flowlines Flow Test N/A

Choke Line & Valves 200 300 Working pressure of ram BOPs

Kill Line & Valves 200 300 Working pressure of ram BOPs

Choke Manifold
Upstream of Last High
Pressure Valve 200 300 Working pressure of ram BOPs
Downstream of Last High
Pressure Valve 200 300 Optional

BOP Control System


Manifold and BOP Lines N/A Minimum of 3000
Accumulator Pressure Verify Precharge N/A
Close Time Function Test N/A
Pump Capacity Function Test N/A
Control Stations Function Test N/A

Safety Valves
Kelly, Kelly Valves and
Floor Safety Valves 200 300 Working pressure of
components

Auxiliary Equipment
Mud/Gas Separator Flow Test N/A
Trip Tank, Flo-Show etc Flow Test N/A

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02.09 Subsequent Test (Not to exceed 21 days).

Component to be Recommended Recommended


Tested Pressure Test Pressure Test
Low Pressure psi High Pressure psi

Rotating Head N/A Optional

Diverter Element Optional Optional

Annular preventer 200 300 Minimum of 70% of annular


BOP working pressure
Operating Chambers N/A Minimum of 1500

Ram Preventers
Fixed Pipe 200 300 Greater than the maximum
anticipated surface pressure
Variable Bore 200 300 Greater than the maximum
anticipated surface pressure
Blind/blind Shear 200 300 Greater than the maximum
anticipated surface pressure
Casing(prior to running csg) Optional Optional
Operating Chamber N/A N/A

Diverter Flowlines Flow Test N/A

Choke Line & Valves 200 300 Greater than the maximum
anticipated surface pressure

Kill Line & Valves 200 300 Greater than the maximum
anticipated surface pressure

Choke Manifold
Upstream of Last High
Pressure Valve 200 300 Greater than the maximum
anticipated surface pressure
Downstream of Last High
Pressure Valve Optional Optional

BOP Control System


Manifold and BOP Lines N/A Optional
Accumulator Pressure Verify Precharge N/A
Close Time Function Test N/A
Pump Capacity Function Test N/A
Control Stations Function Test N/A

Safety Valves
Kelly, Kelly Valves and
Floor Safety Valves 200 300 Greater than the maximum
anticipated surface pressure

Auxiliary Equipment
Mud/Gas Separator Optional Flow Test N/A
Trip Tank, Flo-Show etc Flow Test N/A

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