04 Well Control Equipment

Quartz School

Wellfor IPM Well

Control Site Supervisors
Equipment
Surface Well Head

Assemblies and Well
Control Equipment
Selection and Testing

Well Control Equipment
C. Alvarez Quartz
Quartz School. Module 5: Well School
Heads for IPM
& BOPE Well Site2:Supervisors
/ Section BOPE Description & Selection 1 / 152
References:
1. IPM – ST – WCI – 04: Well Control Equipment Requirements
2. Well Control Manual– Schlumberger IPM
3. API – RP 53:
Recommended Practices for BOPE Systems for Drilling Wells
4. API – RP 16E:
Design of Control Systems for Drilling Well Control Equipment
C. Alvarez Quartz School for IPM Well Site Supervisors 2 / 152

IPM Related Standards
IPM – ST – WCI– 004:

Well Control Equipment Requirements

Well Control Equipment Requirements
IPM-ST-WCI
-004
The BOPs and related equipment must be selected and configured such that they
provide sufficient pressure integrity and operational flexibilityto accommodate all
anticipated well control situations. In addition, the BOPs and related equipment willbe
regularly both functional and pressure tested .
• Function Test:
– The operation of a piece of equipment or a system to verifyits intended operation
• Pressure Test:
– Applicationof pressure to a piece of equipment or a system to verify the pressure
containment capability for the equipment or system
• WorkingPressure of all WC equipment subject to well pressure :
– Shall be greater than or equal to the maximum anticipated surface pressure of the
operational phase during which the equipment willbe used
• For Exploration wells: the maximumanticipated surface pressure must be based on
fullevacuation of the well to gas (drygas, 0.1 psi/ft).
• For Development wells: the maximum anticipated surface pressure should be the
maximumshut-in tubing pressure
• EquipmentSpecification:
– BOP: in accordance with, or exceed APIRP 53.
– H2S areas : NACErequirements .
4– Accumulator and closing times: APISpec 16D and APIRP 53.
– Diverter: APIRP 64.
Well
Well Control
Control Equipment
Equipment Requirements
IPM-ST-WCI-004
• The BOPs and related equipment will be Function and Pressure tested
regularly, as described in the Schlumberger Well Control Manual
Pressure Testing:
• Frequency: Every14 days or during the first trip after the 14-day interval with a
maximuminterval of 21 days.
• Low pressure test (200 to 300 psi) for 5 min . and high pressure tests will be
conducted for a minimum of10 min.
Function Testing:
• BOPs and Diverters will be function tested upon installation and every 7 days or
during the first trip after the 7-day interval with a maximum interval of 14 days
• Function Tests for the Accumulator (BOP Closing Unit) will be tested as
described in the WCM
• Calibration: trip tank, flow meters, and critical sensors/monitors should be
accurately calibrated on a regular basis .

(Design & Maintenance)
HIGH pressure components

LOW pressure components
Pump
Mud Mud LOW pressure
storage mixing Trip tank

PVT
D
P
Mud- gas BOP

Suction Choke
separator stack
To mud pump Well
Accum
head
CSG

Surface BOP Stack Configuration
No hard rules are given regarding the BOP stack arrangement in

respect of the relative position of the different elements .
All stack arrangements have pros and cons, and it is the project
responsibility to decide which arrangement best suits the operational
requirements .
Refer to API RP 53 for recommended arrangements .


ANNULAR
TOP RAMS
BLIND RAMS
Choke line HCR

Kill line
Replace with double gate (pipe rams – blind rams)

BOTTOM RAMS
BOTTOM RAMS
in selected cases
Seat for “VR” plug

BOP Stack

Sub-Sea BOP Stack Arrangement
Kill line
Choke line
UPPER ANNULAR
LMRP CON
LOWER ANNULAR Inner/Outer choke line valve
BOTTOM RAMS
SHEAR RAMS
Outer/Inner kill line valves
BLIND RAMS
BOTTOM RAMS
UPPER RAMS
Inner/Outer choke line valve
BOTTOM RAMS
MIDDLE RAMS
Outer/Inner kill line valves
BOTTOM RAMS
LOWER RAMS
Stack connector
Wellhead
Subsea BOP

Blow Out Prevention and Well Control Equipment
– Surface Installations –

Well Control Equipment for Surface Installations

Components of BOP Stack

Annular BOP(Bag Type BOP, Spherical BOP)
Design and Operational Details:
1. Device with a packing unit capable of closing around any tubular element
across it, including the kelly
2. After closing the packing unit around the pipe in the well, the string can be
reciprocated or rotated while maintaining a seal but this practice requires
prior agreement and approval in case of a well control situation
3. The packing element can close and seal around square or hexagonal Kelly.
4. The packing element closed around the pipe allows the passage of DP tool
joints through it to perform stripping operations (moving the drill string to
bottom while keeping the annular BOPclosed)
-The pressure for closing the packing seal can be regulated
-More common manufacturers are : Hydril: (Types MSP, GK,GLand GX).
Varco/Shaffer: Spherical BOPand Cameron: (Type“D”)
Typical Annular BOP

Operation of Annular BOP
A conical piston slides up inside the housing
when moved by the power of hydraulic
pressure which makes the packing unit
(which has the shape of a perforated donut)
to be squeezed inward to seal around the
pipe positioned across its bore, and so
closing the annular space around the pipe

Examples of Annular BOP

Hydril Type “GK”
Only two moving parts, seals on open hole. Wear plate and Packing unit
replaceable on the field with pipe in hole.

Hydril Type “GX”
Seals on open hole. Wear plate and Packing unit replaceable on the field
same as the GK model. Max Press: 15M.

Hydril Type “GL”
1- Latched Head
2 - Opening Chamber Head
3 - Opening Chamber
4 - Closing Chamber
5 - Secondary Chamber
6 - Piston Seals
7 - Piston
8 - Packing Unit
Mainly designed for Subsea operations, seals on open hole (but not recommended),
Well pressure helps to increase closing pressure.
Offers the longest life packing init for annular BOP in the industry

Hydril Type “GL”
– Secondary Chamber (Subsea)
Standard Surface Hookup OptionalSurface Hookup
Connects the secondary chamber to the Connects the secondary chamber to the closing
opening chamber chamber
- Least amount of fluid to close/open - Increase closing pressure for optimum closing
Cameron Type “DL”
Quick-Release Top
Donut
Packer
Access Flaps
Outer Cylinder
Locking Grooves Lock Down
Packer Insert Vent Port
Operating Piston
Pusher Plate
Closing Hydraulic Port
Opening Hydraulic Port
Vent Port
Components subject to wear are field replaceable, most of the models requires
less hydraulic fluid to operate compared with the other products.

Shaffer “Spherical BOP”
This model is particularly suitable in case of

frequent closures and stripping operations .
Two versions are available:

1. with bolted head in small size models and
with low working pressure values
2. with latched head in larger models and
with high working pressure values
It has a nylon wear gasket (wear band) to

center the piston movement.
Closure is partially assisted by well pressure .

Annular BOP Packing Unit

Fluid Volume Required for Annular BOP Operation



Ram Type BOP- Components

Ring Groove
Body
Upper Seal Seat
Bonnet Gasket
Ram Block
Secondary Piston Rod Seals
Bonnet Bolts
Manual Lock Hinge fluid
Hinge pins
Hydraulic Line Connection

Side Outlet
Ram Cavity Guide Rod
Piston Seals
Piston Seal
Cylinder Sleeve Drain hole

Ram Type BOP– Description and Operation
Opening Line
Ram Shaft
Ram
Piston
Closing Line
1. Two opposite Rams mounted on shafts are displaced one against the other by hydraulic
pressure to close around the pipe inside the BOP (pipe type rams) or to block the bore or cut
pipe across the BOP(blind/shear type rams)
2. Once closed, manual or hydraulic locking devices are activated to prevent its accidental
opening assisted by well pressure below them
3. Fixe size Pipe Rams close the annulus around only one pipe ODwhile Variable Bore Rams can
close against a range of pipe ODthat can be passed across them
4. The DPstring may be hung fromPipe Rams for BOPrepairing or in Emergency Disconnection
Types of Ram BOP
According to the Number of rams installed, the Ram BOP
can be:
Single Ram, Double Ram, or Triple Ram
The pair of Rams can be:

1. Fix Size Pipe Rams: to close the annulus around a
given size of pipe
2. Variable Bore Rams: to close the annulus around a

range of pipe ODs
3. Blind Rams: to close and seal the well bore when no

pipe is in the well
4. Shear Rams: to cut pipe in the well across the BOP

and then seal off the well bore
Ram Type BOP- Operation

Operation (closing or opening) Ratios
Is the relation between the piston rod area and the
2.
ram area that are exposed to the well pressure 1
1. In general the Operation Pressure Ratio is 7:1, 3
Operation Pressure =
-
which means that 1 psi of hydraulic pressure 5
100 psi
is required to close the ram for each 7 psi of /

8
well pressure "
2. Most BOP are manufactured with a safety
5
factor to have an Opening Ratio of 2:1
Well Pressure = 700 psi

Minimum Operating Pressure Calculation
Is the minimum pressure to effectively close and seal a ram BOP

against a well bore pressure equal to the maximum rated working
pressure of the BOP.
This pressure is equal to the maximum working pressure of the BOP
divided by the closing ratio specified for that BOP.

Minimum Operating Pressures
Closing Ratio 13 5/8”– 10 M = 7 : 1
Having 10,000 psi of working pressure, then:
10,000psi÷7 = 1428 psi

is the required operation pressure to close
Opening Ratio 13 5/8”– 10 M = 2.3 :1
If the available pressure in the Accumulator

(closing unit) is 3000 psi:
The opening pressure for the ram will be:
2.3 * 3000 psi = 6900 psi

Ram Type BOP– Stripping Operation
Ram to Ram Stripping
1. In special conditions (well pressure below 500psi) the
drill string located off bottom or at surface can be
returned to bottom with the stripping procedure by
which the pipe is moved across the closed annular
BOP(while keeping the bottom hole pressure constant
and above the formation pressure)
2. An Emergency Stripping using pipe rams can be

performed in critical conditions (inabilityof using the
annular BOP) as long as the well pressure is below
1000 psi. This process is called “Ram-to-Ram
Stripping” and should be carefully evaluated due to
the high risk involvedto lose the well integrity.
3. Pipe rams are alternatively open and closed to allow

the passage of the tool joints. Other restrictions apply
Examples of Ram Type BOP
Cameron – Type “U”
Design Details:
1. Can be used for both surface and subsea applications

2. Pressure in the well assist to keep the rams closed
3. Rams are of the “auto-feed” type
4. Ram piston rods have secondary seals
5. Can be dressed with “fix size” or “variable bore” Rams
6. Manual Ram Locks available only for surface applications
7. Hydraulic Ram Locks used for subsea applications

Cameron – Type “U” (Manual Lock)
Pressure energized system. Is the most widely used RAM BOP for land, platform
and Subsea operations

Cameron – Type “U” (Operation)
U BOP OPERATING DATA AND FLUID REQUIREMENTS

Bore Size 135/8" 163/4"
71/16" All 11" except 11" 135/8" Except 163/4" 183/4" 203/4" 211/4" 211/4" 233/4"
& 15000 psi 15000 psi 15000 psi 3000&5000 psi
WP 15000 psi 10000 psi 10000 psi 3000 psi 5000 psi 10000 psi 3000 psi
Working Pressure Model B Model B
Gallons to Open
1,3 3,4 6,1 6,4 10,4 9,8 11,6 21,2 7,9 27,2 24,5 10,1
Pipe Rams (1 set)
Gallons to Close
1,3 3,5 6,2 5,8 10,6 10,6 12,4 23,1 8,4 29,9 26,9 10,8
Pipe Rams (1 set)
Locking Screw
18 27 32 32 45 38 45 54 46 54 51 58
Turns (Each End)
Closing Ratio 6,9 : 1 7,3 : 1 9,8 : 1 7,0 : 1 10,6 : 1 6,8 : 1 6,8 : 1 7,4 : 1 7,0 : 1 6,2 : 1 7,2 : 1 7,0 : 1
Open Ratio 2,2 : 1 2,5 : 1 2,2 : 1 2,3 : 1 3,6 : 1 2,3 : 1 2,3 : 1 3,7 : 1 1,3 : 1 4,0 : 1 4,0 : 1 1,0 : 1

BOP Components
Ram Type BOP
Main advantages of ram BOP compared with annular BOP :

1. Better resistance to high pressure values
2. Less control fluid volume required, which implies shorter closing time
3. They can support the drill string weight (during hang-off)
4. They allow stripping in case of very high pressure values (ram to ram)
5. Once they have been closed they prevent the drill string from being expelled

Ram Type BOP
Ram Options

Ram Type BOP
Variable Rams

Ram Type BOP
Pipe Rams (Fixed Size)
• Rubber front packer for sealing off around tubing

• Rubber upper (or top) sealing for sealing off between ram and BOPbody
• During closing rams, are assisted by well pressure, which energises the top seal
• Ram front packers are self-energised .

Ram Type BOP
Blind & Shear Rams
Blind Rams
1. They can only be used without pipes in the wellbore. During drill bit
replacement they can be closed to prevent objects from falling inside the well.
2. The controls (opening and closing) to operate blind and shear rams are usually
protected to avoid unlooked-for operations.
Shear rams
1. They can cut drill pipes only and are mainly adopted in offshore
operations to allow emergency abandoning.
2. They can be used on land to face particularly serious emergency
situations which cannot be solved by adopting standard procedures.

Ram Type BOP
Blind & Shear Rams
Upper Shear Ram Top Seal
Blade
Side Packer
Lower Shear Ram

assembly
Face Seal

Ram Type BOP
Shear Rams Operation Sequence

Cameron Type– “U” (Shear / Blind Rams)
Upper Shear Ram Top Seal
Blade
Side Packer
Lower Shear
Ram assembly
Face Seal
Cameron Type– “U” (Variable Ram Assembly)
Top Seal
Packer
Ram Body


Cameron – Type “U” (Wedge Lock Ram)

Saffer – Type “LWS”
Design Details:
1. Can be used for surface and subsea installations
2. Well pressure helps to keep the rams closed
3. Rams are “auto-fed”
4. Ram piston rods have secondary seals
5. Can be dressed with “fix size” or “variable bore” pipe rams
Saffer – Type “LWS”
Design Details (continued…)

6. Manual Ram Locks only available for surface installations
7. HydraulicRam Locks for subsea installations
8. Packing elements are resistant to H2S
9. The operation pressure is not used to open or close the bonnets
Saffer – “Poslock” (One Position Locking Mechanism)
Locks the RAM regardless of the wear on the

RAMS packing
Saffer – “Ultralock”


Rams Saffer – NL

Hydril– Types “V” and “X”
Design Details:
1. Can be used in surface or subsea installations

2. Well pressure assists in keeping rams closed
3. Rams are “auto-fed”
4. Rams pipe rods have secondary seals
5. Can be dressed with “fix size” or “variable bore”
rams
6. Manual Ram Locks only for surface installations
7. HydraulicRam Locks for subsea installations
8. Packing elements resistant to H2S
9. Operation pressure is not transmitted to the bonnets
Hydril “MPL” (Multi Position Lock)
Hydraulically-actuated mechanical clutch mechanism

Ram Type BOP– Operation Guidelines



Ram Type BOP– Maintenance Guidelines
1. It is not recommended to close the rams not having pipe in the

well bore as it may damage the sealing element (front packing)
2. Rams can be closed with just 300 psi in the hydraulic system.
Should they require more pressure is a sign of not good working
conditions and further inspection or repairing may be required
3. Pie or blind/shear Rams are not designed to withstand pressure

from above. Assure that the ram blocks are installed in the
correct “side up” position, not upside down..!

BOP Control System: The Closing Unit

For Operation of BOP Equipment

Surface Stack Accumulator

The Closing Unit- Schematic

The Closing Unit– Remote Operation of BOP Functions
3000
1500
1500

The Closing Unit– Accumulator Bottles
Accumulators:
Are containers tat store hydraulic fluidunder pressure to:
Reduce the response time of BOP functions.

Be able to shut in the well in case of a power failure
Specification of Accumulators:
Volumeof each accumulator bottle: 10 gal
WorkingPressure : 3000psi (Surface BOP)or 5000psi (Sub sea)
Pre-charged with NITROGENGASto 1000psi for 3000psi accumulators and

to 1500psi for 5000psi accumulators
MinimumOperating Pressure : 200psi above the pre-charge

The Closing Unit– Components
Manifold Regulator
4 Ways Valves
Principle
Note : It must not stay in neutral position.

The Closing Unit– Remote Control Panel

The Closing Unit– Bank of Accumulators
Usable Hydraulic fluid is:

The fluid recoverable from the accumulator system between the
maximum accumulator pressure and 200 psi above pre-charge
pressure.

The Closing Unit– Bank of Accumulators Capacity
The BOP Control System should havesufficient usable hydraulic fluid volume,
(with the recharging pumps inoperative) to:
- Close one annular BOP
- Close all Pipe Rams
- Open one HCR (hydraulic valve in the Choke Line)
With a remaining pressure of 200 psi or more above the pre-charge pressure
Accumulator volumetric requirement as per the API 16E:
Pumps inoperative, the minimumstored volume has to satisfy the
greater of the 2 followingrequirements :
1. Close all the BOP’sin the BOP stack, plus 50% reserve, at 0
well bore pressure .
2. After closing all the BOP’s, the pressure of the remaining

stored accumulator fluid should exceed the minimum
calculated operated pressure required to close any ram
BOP(excluding the shear rams) at the maximum rated
wellbore pressure of the stack .
New Schlumberger
Standard
The accumulatorsystem shall be designed such that the loss of an individual

accumulatorand/or bankwillnot result in morethan 25% loss of the total accumulator
system capacity. The BOPaccumulatorsshall have a minimumusable power fluid
volume,withpumpsinoperative,to satisfythe two followingrequirements:
· A FVR(FunctionalVolumeRequirement)of one hundredpercent (100%) of the BOP

manufacturer’sspecifiedvolumeto close froma fullopen positionat zero(0) wellbore
pressure,one annularBOPand all of the ram BOPsin the BOPstack and to open the
valve(s)of one side outleton the BOPstack. Ifmorethan one annularBOPis present,the
largerclosingvolumerequirementshallbe usedforsizingpurposes.
The Closing Unit– Reservoir Capacity
Each closing unit should have a fluid reservoir with a capacity

equal to at least twice the usable fluid capacity of the accumulator
system

API & NEW SLB RULES

requests Surface BOP
EXAMPLE
: for a BOP stack : 1 Annular + 3 Rams + HCR Valve
Closing Volume (CV): 20 + (3 x 10) = 50 Gal

Open Choke Line Valve (OV): 1 = 1 Gal
Usable Volume (UV): = 51 Gal
Nominal Volume (NV): 2 x UV = 102 Gal
11 accumulator bottles

The Closing Unit– Accumulators Charging Pumps
Each surface BOP control system should have a minimum of

2 pump system having independent power sources , such as
electric or air.

The Closing Unit– Air Operated Charging Pumps
1. Each pump should provide a discharge pressure

at least equivalentto
the BOP control system pressure.
2. Air pumps should be capable of charging the accumulators to the
system working pressure
with 75 psi.

Electric, and or, air supply should be available at all

times such that the pumps will automatically start
when the system pressure has decreased to
approximately 90 % of the system working pressure
and automatically stop within +0 to - 100 psi of the
control system working pressure .

Each pump should be protected from over pressurization byat least of 2 devices:
1. One device (pressure limit switch) should limit the discharge pressure so that
it will not exceed the working pressure of the BOP control system.
2. The second device (relief valve) should be size to relieve at a flow rate at least
equal to the design flow rate of the pump and should be set to relieve at not
more than 10 % over the control unit pressure.

Choke / Kill Manifold

The Choke Manifold and Well Control Lines
Description and Functions:
The Choke Manifold is an assembly of valves,

conduits and flow restrictors which is connected
to one the side outlet of the BOPstack to regulate
the out coming flow from the annulus via the
“choke line”. The fluids are then deviated to the
MGS,mud pits or to the gas burner
Requirements for Design and Construction:
1. Working Pressure of all its components to be

equal or larger than the maximumanticipated well
pressure at surface
2. Designed for the application of conventional well
control procedures (circulating Methods) and no
conventional procedures (Volumetric,Stripping)
The Choke Manifold: Specifications
At least three flow paths must be provided that are capable of flowing well
returns through conduits that are 76.14 mm (3”) nominal diameter or larger.
At least one flow path:
1. Shall be equipped with a remotely controlled, pressure operated

adjustable choke. Simplifiedchoke manifolds without remote control
choke may be acceptable on light rigs with 2 – 3Kpsi stacks
2. Shall be equipped with a manually operated adjustable choke
3. Must permit returns to flow directly to the pit, discharge manifoldor

other downstream piping without passing through a choke.
4. Two gate valves with full rated working pressure must be provided
in this un
un--choked
choked path
The Choke Manifold Lay out

Example of Choke Manifold and Control Lines for 2M and 3M Systems

Example of Choke Manifold and Control Lines for 5M Systems

Example of Choke Manifold and Control Lines for 10M and 15M Systems

Primary Kill Line
Design Considerations:
1. It is used to pump fluids into the annulus at high pressure for

well control purposes when is not longer possible to apply
circulating WC procedures
2. The Killline is connected to the side outlet in the BOP stack

that is opposed to the Choke Line side outlet. It is installed
below the pipe rams most likelyto be closed for WC operations
or more usually below the blind rams
See API – RP 53 (Section 6.6.2) for other guidelines for design,

installation and operation of KillLines.

Secondary Kill Line
Design Considerations:
1. A secondary (emergency) killline is recommended in critical, HP wells

2.
3. It is usually connected to the primary kill line with a “Y” and a gate
valve installed for isolation purposes
4. It runs from the primary kill line to a safe distance far from the rig unit
and well head where can be easily connected to a cementing unit to
perform emergency WC procedures if required
5. As all other high pressure control lines, kill / choke lines shall have
only flanged or welded connections (no threaded fittings allowed)
6. It is not recommended to be hooked up to the well head assembly

Kill Line Installation for 2M and 3M Systems
Kill Line Installation for 5M, 10M and 15M Systems

Kill Line Installation for 5M, 10M and 15M Systems

Choke Manifold Components– Gate Valves
• Manifold equipment subject to well pressure (up-
stream including the choke) should have a
minimum working pressure at least equal to the
rated working pressure of the ram BOP in use.
• All choke manifold valves should befull bore.
• Function Tests: at least once a week.

Choke Manifold Components– Chokes
Positive Choke
Ajustable Choke

Cameron Adjustable & Remotely Operated Choke

Swaco “Super Choke” Adjustable & Remotely Operated
Emergency Operation: Can be closed with a manual hydraulic pump or by hand in case of
power failure.
Flanged Connections & Ring Gaskets

Types of Flanged Connections of BOP Stack
Stand-off Closed Face

has clearance no clearance is left
between flanges
BX
R or RX Ring Gaskets
Ring Gaskets
API 6B Flange API 6BX Flange

Types of Flanged Connections of BOP Stack
The most commonFlanged Connections are:

Flange API Type6B for WP from 2,000 to 5,000 psi
Flange API Type6BX for WP from10,000 to 20,000 psi
---------------------------------------------------
Ring gaskets to be used for specific Flanges are:
Use Ring Gasket Type“R” or “RX”for API 6BFlange
Use Ring Gasket Type“BX”for API 6BXFlange

Ring Gaskets used for Flanged Connections of BOP Stack
Type “R”
“X” type are pressure

energized meaning
Type “RX” that well pressure
helps to effect the
seal
Type “BX”

Types of Connections of BOP Stack Components
Studded
Clamp Hub
Flanged

Flanged Connections of BOP Stack




Flange Identifier Slide Rule
What does this mean ?

a 7 1/16 , 15M flange
Working pressure of 15000

psi and 7 1/16 bore
Other Well Control Equipment

Safety Valves, Inside BOP, Float (Check) Valve
Other WC Equipment: Upper & Lower Kelly Valves
Other Well Control Equipment: Full Opening Safety Valve
Upper seat
Ball
Crank
Lower Seat
Body
Other Well Control Equipment: Inside BOP
(Gray Type Valve)
Release Rod
Locking Screw Release tool
Valve Release rod
Upper Body
Seat
Valve
Valve Spring
Lower Body
Other Well Control Equipment: Float (Check) Valves
USED TO:
• Prevent sudden influx entry into the drill string.
• Prevent back flow of annular cuttings from plugging
bit nozzles.
Schlumberger Policies: I.14

A float (solid or ported) will be run while drilling and
opening hole prior to setting surface casing or any time
the posted well control plan is to divert.
Other Well Control Equipment: Float (Check) Valves
Other Well Control Equipment: Kick Detection Equipment
Minimum Equipment Requirement for early kick

detection (Primary Kick Indicators):
1. Pit Volume Totalizer, PVT: Measure of total mud
volume in active tanks
2. Flow Line Indicator: Flow Back Detector =
Flow Show Indicator, Delta Flow
3. Trip Tank: Measure of displaced volume by RIH
or POH the drill string
Supplementary Equipment for kick confirmation
(Second order detector):
Gas Detector
Pit Volume Totalizer System (PVT)
Monitories the total fluid volume in the active
system and its variations
Components:
1. Floaters and potentiometers installed in
each tank compartment to measure the
fluid level and send an electric signal to a
monitor screen or recording device
2. Electronic recorder of fluid volume and its
variations proportional to the electric
signals received
3. Monitor screen (LCD) or graphic display
4. Visual (color flashing lights) and Sound
(siren type) alarms
Pit Volume Totalizer System (PVT)
Operating tips:
1. Clean floaters periodically especially with

viscous and high density mud
2. Define a proper value for gain or loss of mud
volume and calibrate the alarms to its activation
with the maximumsensibility
3. Set the alarms and keep them operating all the
time
Recorder of Flow Variations in the Flow Line (Delta Flow Meter)
Objective:
To detect any changes in the out coming flow from the

annulus through the flow line
Components:
1. Swinging Paddle: electro mechanical sensor

installed in the flow line to be in direct contact with
the flow which inclination is proportional to the flow
returning from the well
2. Electronic Recorder: analogical signal visible on the

monitor or graphic display that shows relative
increases or reductions in the out coming flow from
the annulus Quartz School for IPM Well Site Supervisors
C. Alvarez 111 / 152
Recorder of Flow Variations in the Flow Line (Delta Flow Meter)
Operating tips:
1. Perform visual inspection to the condition

of the paddle installed inside the flow line
and remove any obstruction or blocking
caused by mud solids or drilled cuttings
2. Perform function tests at different flow

rates and observe the corresponding
signal send to the recorder
3. Set the associated alarms for fluid gain

or fluid loss to its maximum sensibility
and keep them operative all the time
The Trip Tank
Objective of Trip Tank:
Measure of the fluid volume displaced by the drill string when it is run or
pulled out of the well
Components:
1. Separate Container (independent tank from the active mud system) with a
volume commonly ranged from 20 to 100 barrels, which is constructed with
dimensions that let the detection of small volume variations (of about ½
barrels or less)
2. Measuring System: mechanical or digital device to measure and record the
volume in the tank and its variations
3. Electric driven Centrifuge Pump and fill line connected to the bell nipple
above the BOPstack to fillthe well when POOHthe drillstring
4. Return flow line (over flow line) to receive the fluid from the well displaced
C. Alvarez
by the DrillString Quartz School for IPM Well Site Supervisors 113 / 152
Gas Detector in the Flow Line
Components:
1. Gas Trap: a separate and small compartment installed

inside the possum belly (shale shakers distributor box)
2. Gas Analyzer: Chromatograph that identifies and

measures different gases coming from the well
3. Conductor hose: to transport the out coming gases to

the analyzer
4. Recorder: digital or analogical display that shows the

relative concentration of gas in the mud in “%V” or in
“Gas Units”
Mud / Gas Separator
Other Well Control Equipment: Mud Gas Separator
Pressure Build up/operating limit of MGS are

mainly governed by:
Inside Diameter of Vent pipe
Height of the Vent pipe
Circulating through
Circulating through MGS, above design
MGS, no gas no capacity, unloading
pressure gas to shakers
Circulating gas Possible

through MGS, within improvement of mud
design capacity seal height
Typical Offshore Set-up Typical Land Rig Set-up Typical Offshore Set-up Typical Land Rig Set-up
The mud gas separator is a low pressure vessel

GAS
1 - Diameter and length of the vent line controls
the amount of back pressure in MGS
Baffle Plate
From Choke
Manifold 2 - Diameter, height and internal design
controls the separation efficiency in MGS
Siphon Breaker
Mud
To Shakers
3 - Height of the “U” tube control the
working pressure and the fluid level
to stop the gas going out of the MGS
Drain Line with valve
The function of the MGS is to mechanically separate gas from the mud.
Vent line
What is the maximum operating pressure of

this MGS with 11.3 ppg mud ?
From Choke
Manifold
MGS
= 0,052 x 11,3 x 10 = 5,9 psi
In fact we apply a safety coefficient,
depending of Companies
22’
To Shale
Shakers
Other Well Control Equipment: Vacuum Degasser
The Vacuum De-gasser is designed to remove the small

bubbles of gas in mud:
• Left after passing through the MGS
• In case of gas cut mud
• When circulating any trip gas
The Vacuum De-gasser will be line up at all times during the Well Control
operation and should be tested every tour.
The Diverter System
Not a Well Control Equipment..!
The Diverter System (Not a WC Equipment)
Flow line
Annular packing
to Shakers
element
Head
Piston
Diverter
open port
Diverter Body
close port
Functions should be interlocked

Open Vent Line & Close Diverter
Or Vent line to
over board
Open Diverter & Close Vent Line
Functions should be Drill pipe
interlocked Insert packer

lockdown dogs
Diverter close port
Diverter
lockdown dogs
Standard packer
Flow- Line Seal
Insert packer
Flow / Vent line
Support
housing
Flow- Line Seal
The Diverter System– Minimum Requirements
• CLOSING TIME SHOULD NOT EXCEED 30 SECONDS FOR
DIVERTERS SMALLERS THAN
’’ AND
20 45 SECONDS FOR
DIVERTERS OF ABOVE 20’’ NOMINAL BORE
• A DIVERTER HEAD THAT IS CAPABLE OF PACKING OFF AROUND
THE KELLY, DRILL PIPE OR CASIND WILL BE USED
• AT LEAST TWO RELIEF LINES SHALL BE INSTALLED TO PERMIT
VENTING OF THE WELL
-BORE RETURNS AT OPPOSITE ENDS OR
SIDES OF THE RIG.
• ON LAND RIGS A SINGLE LINE IS ACCEPTABLE
• THE DIVERTER RELIEF LINE(S) SHALL BE AT LEAST 8 INCH
DIAMETER.
Schlumberger Policies: I.19

THE DRILLER WILL CHECK ALL DIVERTER AND OVERBOARD VALVES FOR PROPER
SETTING AT THE BEGINNING OF EACH TOUR.
The Diverter System
Remember..! It is Not a Well Control Device
-It just allows for the flow to be diverted in a safe manner
-To contain the hazard for as long as possible
-To leave enough time for proper and safe evacuation of personnel and/or
move off from the location.
BOP Testing
Objectives
Be familiar with the requirements for BOP pressure testing
Know the tools used for BOP testing
Know how to perform a Function and Pressure Tests
Prepare a testing procedure for surface BOP stack
Good Reasons for Testing BOP Equipment
Testing Requirements
All well controlequipmentshall be tested (function,pressure) at

regular intervals. Recordsof the tests shall be kept and should
includethe opening/ closingtimesand volumesof fluidrequiredto
operatethe variousfunctions.
Theymustbe regularlytested to:
Toensurethat theyare operationaland functioncorrectly
To familiarize personnel with equipment operational

procedure
Tocomplywithlocalregulations
Equipment to be tested
Allthe BOPcomponents
Wellhead componentsand connections
Controlsurfaceconnections
Kellyvalvesand safetyvalves
Standpipe,drillinghose and stand pipemanifold
Pumpmanifoldand pumplines
Flexiblehoses and rigidhoses before usingthem
Accumulatorsystem
Function Test Frequency
On installation
Diverter Prior to drilling out the conductor
Daily while drilling surface hole
On initial installation from driller’s panel, remote panel and

closing unit.
Surface BOP Every week or during the first trip after 7 day interval with
a maximum interval of 14 days. It should be alternated from
the driller’s and remote control panel.
Prior to running the assembled BOP stack

On initial installation from driller’s panel, remote panel and
Subsea BOP
closing unit.
Every week or during the first trip after 7 day interval with a
maximum interval of 14 days.
Diverter Function Test
Nopressuretest is recommendedfora Diverterinstallation.

Functiontest canbe performedas follows:
Pickthe drillstringoffbottom
Openthe valveson both vent lines and close the Diverterelement on the
drillstring in the hole. These two functionsmust be inter connectedand
followthe sequencedescribed.
Circulateat maximumrate during5 to 10 minutesand observefor leaks in
ventlines.
Testing the Closing Unit

Thepurposeof this test is to verifythat the accumulatorsystemis properlysized
to supportthe fluidvolumeandpressure.
Thereare seventests that shallbe done,witha jointof pipeinsidethe annularBOP:
1. Controltimeto chargethe bottlesfrom1000to 3000psi

2. Properfunctioningof automaticstart andshut offof chargerpumps
3. Checkthe levelin the reservoirtank
4. Measurethe pre-chargeof eachbottle
5. Measurethe closingtimeof eachchargingsystems
6. Closingcapabilityof bankof accumulatorsalone
7. Closingtimeforeachfunctionof the stack
Accumulator test (1)
Controltimeto chargethe bottles
Theair and electricalpumps,individually,shall be capableto chargethe bottles fromthe
pre-chargepressure(1000psi)to the servicepressure(3000psi)in less than15 min.
Controlstartingandshut-inpressureof the pumps

The air and electricalpumpsshall started when pressure in the bottle droppedby 10%
(2700psi)andshallstop whenthe servicepressure(3000psi)is achieved.
Checkthe levelin the reservoirtank

Thefluidlevelin the reservoirtank shall have a capacityequal at least twice the usable
hydraulicfluidcapacityof the accumulatorsystem.
Controlthe pre-chargepressureof the accumulatingbottles

Measurethe volumeof fluidrecoveredwhen the pressureis bleed-off from3000to 2000
psiandcompareto the theoreticalvalue.
Accumulator test (2)
Controlclosingtimeof eachchargingsystems
Withthe accumulatordisconnected,eachpumpshallbe capableto, in less than2 min:
Closethe annularpreventeraroundDP
Openthe HCR
Haveresidualpressureof 1200psi
Controlthe closingcapabilityofthe bottlesalone

Withthe pumpsinoperative,accumulatorsystemshallsatisfythe greaterof the following
requirements:
Closefroma full open positionat zero wellborepressure,all the BOP’sin the BOP
stack,plus50% reserve
The pressure remainingof the remainingaccumulatorvolumeafter closingall the
BOP’sshouldexceedthe minimumcalculatedoperatingpressurerequiresto closeany
ram(excludingthe shearrams)at the maximumratedwellborepressureof the stack.
BOP Function test
Closing time for each function of the BOP Stack
Response time between activation and complete operation of a function is based on

BOP closure and seal off and definedAPI
by RP 16 E
SURFACE
18 3/4” 18 3/4”
30 sec. 45 sec.
30 sec.
Pressure Test Requirements
Thecomponentsshouldbe tested in directionthey normally“see” wellbore

pressureduringa kick.
Thenecessarypressureis providedbyan auxiliarypump (sucha cementunit)
which allows requiredpressure to be recorded. Generallya high pressure
(10,000a 20,000psi)portabletriplexpump,withsuctionlineof de 1.5” a 2” y
dischargeline of 1” a 1.5” is used.
Afluidfree of solidshouldbe used withunfreezesolutionis required:
• Forwater basedmud,use water
• Foroilbase mud,use dieselor an acceptablealternative
Pressure Test Frequency
Blowout preventers, wellhead components and their connections, BOP
closing unit, choke manifold, kill and choke lines, standpipe manifold, kelly
valves, safety valves and inside BOPSshall be pressure tested :
Every two weeks or during the first trip after the 14-day interval with a
maximuminterval of 21-days or when specified by regulatory body.
Prior to installation where possible
Afterinstallation of wellhead and BOPassembly and prior to drilling
When any component change is made
Prior to drillinginto a suspected high pressure zone
Atany time requested by the Operator drillingrepresentative
Afterrepairs
Prior to the initialopening of the drillstem test tools
Allpressure tests shall be recorded in the daily report and the pressure chart
signed by the WSS and RigManager willbe kept in the well file
API RP 53
– Initial Pressure Test
Theinitial pressure teston components that could be

exposed to well pressure should be to the rated
working
pressure of the ram BOP or to the ratedworking pressure
of the well head( whichever is lower).
Annular BOP should be tested to a minimum of 70% of its

.
rated working pressure
“Initial pressure test” = first test on a new well.
Initial BOP Pressure Test
Theinitialpressuretest is conductedon a test stumppriorto installthe BOPon
the wellandshallbe doneat least every6 month:
• RamBOPsshouldbe tested to their rated workingpressureor to the rated
workingpressureof the wellhead ( whicheveris lowest).
• Annularpreventers,with a jointof drillpipe installed,shouldbe tested to
70% of theirworkingpressure.
A side outlet allows the connection of testing line

Initial Pressure Test as (as per API RP 53)
Pressure Test (Schlumberger IPM)
Low Pressure Test

200 – 300 psi for5 minutes prior to each high pressure test.
High Pressure Test

. Rams-type BOPs and related control equipment including the
choke manifold shall be tested at the anticipated surface
pressure.
. Annular will be tested to 50 % of the rated working pressure of
the components.
. All high pressure tests will be conducted for 10 minutes*.
* Stabilized pressure.
Shell Test (Manufacturer test)
The body of new BOP’s are subjected to ahydrostatic

proof testing or shell test prior shipment:
Rated Working Pressure API Size Designation 13 5/8 API Size Designation 16 3/4
(psi) and Smaller and Larger
2,000 4,000 3,000
3,000 6,000 4,500
5,000 10,000 10,000
10,000 15,000 15,000
15,000 22,500 22,500
20,000 30,000 ---
The hydraulic operating chamber shall be tested at a minimum test pressure equal to 1.5
times the operating chamber’s rated working pressure.
Cup Tester
Run on pipe cup) about 6-10 m below the base flange (i.e.
belowthe wellhead)
At the lower end, one or more pipes are usuallyinstalledto
facilitatethe descent
Allowstestingthe wholeBOPexceptthe blindrams.
Pressureappliedto cup tester directlyimposesa load on drill
pipetest stringwhichcouldcause drillpipefailure,particularly
withgradeE.
Tester cup are swabbingdevicethereforetrippingspeed must
be controlled.
Ensurethe runningpipe is not obstructedand communicateto
surface.
Pressuretests withcuptester shallbe belowthe 80% of casing
burstingrate or wellheadWP,whicheveris lower
Plug Tester
Run with the test joint and set in the bowl inside the
casing head housing / spool.
At the lower end, one or more pipes are usually installed
to facilitate the descent
Some casing head plug testers are manufactured with
an integral port which allows the BOP to be pressured.
Ensure casing head outlet valves are open while
performing the test
Some function as combination plug testers and wear
bushing retriever.
Plug Tester and Cup Tester Comparison
Plug Tester Cup Tester

Advantages Advantages
It allows testing blind rams It can be run below the casing
sealing at the given pressure. spool thus allowing the casing
It does not involve compound spool outward pressure test.
force on the pipe
Disadvantages Disadvantages
It cannot be run below the casing It does not allow blind rams to be
spool tested.
Pipes resistance limit to pull
forces decreases.
Pressure test limited by casing
burst and / or well head WP.
Test Joint
Thetest jointhas an orificein its lowertooljoint. It can be used

incombinationwiththe “cuptester”orwith“plugtester”.
Theuppertesting sub is connectedto the top connectionof the

test joint.
It has an orificethat allowsthe installation of valveand high
pressure(WP>10M)test line(1”)
Thelowertestingsub can be connectedto the kellyor top drive

and allowsthe testing of the kellycockor the top drivesafety
valve.
It has an orificethat allowsthe installation of valveand high
pressuretest line.
Testing Choke manifold, Choke Line and kill line
Manifoldequipmentsubjectto wellpressure(up-streamincludingthe choke)shouldhave

a minimumworkingpressureat least equalto the rated workingpressureof the ramBOP
inuse.
Allchokemanifoldvalvesshouldbe fullbore.
FunctionTests: at least once a week (dailyfunctiontest recommendedfor chokesand
C. Alvarez
manualvalves) Quartz School for IPM Well Site Supervisors 149 / 152
Operational Considerations
• Pipe-rams shouldbe closedonlywhen there is pipe in hole. Closingrams on

the wrongsizeor openholecouldresultinramfrontpackerdamage.
• Carryout enoughcirculationto preventanyair bubblesfrombeingtrappedin

the circuitandaffectingthe test.
• Casingtests and test with tester cup are the onlytests where casing head
valvesare closed. Thesevalvesshouldalways be open to preventcasing or
formationrupture.
• Failureto select the proper size and style test plug can cause problems.
Always consult with the casing head manufacturer to insure that the
appropriateplugtester is beingused.
• Topreventswabbing,pullthe cupslowlyand neverruna test stringthat is not

fullyopento atmosphere.
Some Reasons for pressure test failure
Testplugis toolargeforthe wellhead

Testplugnotsettingproperlyon wellhead bowl
Testplugpackingdamaged
Ramsinstalledupsidedown
Flow line valves will not hold pressure because they are installed
backward
Ringgasketsare in badcondition(scratched,bent,re-used)
Ringgasketsand bonnetseal gasketsare bad
Testplugwillnot seat properlybecausewellhangerholddownstudsleak
Ramsbodiesare inverted…
Testing procedure
Routinepressure testing BOPequipmenttakes approximately3% of the

contractedrig time and, therefore,accountsfor an expenditureof several
millionsdollarsperyear.
Procedurethat minimizethe time requiredto performadequate tests of all

BOPequipmentshouldbe formulatedanddocumented.
Usinga schematiccan help reducingtime and ensures that valvesare not

againstclosedends,whichwouldpreventleaksfrombeingdetected.
Thetesting proceduredependson severalfactors: type of installation,type

of well,companypolicies,Typeof rig,typeof wellintervention,etc.
The followingslides show an exampleof testing procedurefor a surface

installation. It maybe adaptedto the specificconditionsmentionedabove.

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04 Well Control Equipment

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Quartz School

Wellfor IPM Well

Surface Well Head

Selection and Testing

2. Well Control Manual– Schlumberger IPM

C. Alvarez Quartz School for IPM Well Site Supervisors 2 / 152

IPM – ST – WCI– 004:

C. Alvarez Quartz School for IPM Well Site Supervisors 3 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 5 / 152

(Design & Maintenance)

HIGH pressure components

Mud Mud LOW pressure

storage mixing Trip tank

Mud- gas BOP

C. Alvarez Quartz School for IPM Well Site Supervisors 6 / 152

No hard rules are given regarding the BOP stack arrangement in

Refer to API RP 53 for recommended arrangements .

C. Alvarez Quartz School for IPM Well Site Supervisors 7 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 8 / 152

Choke line HCR

Replace with double gate (pipe rams – blind rams)

Seat for “VR” plug

C. Alvarez Quartz School for IPM Well Site Supervisors 9 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 10 / 152

LOWER ANNULAR Inner/Outer choke line valve

C. Alvarez Quartz School for IPM Well Site Supervisors 12 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 13 / 152

Well Control Equipment for Surface Installations

C. Alvarez Quartz School for IPM Well Site Supervisors 14 / 152

Components of BOP Stack

C. Alvarez Quartz School for IPM Well Site Supervisors 15 / 152

Typical Annular BOP

C. Alvarez Quartz School for IPM Well Site Supervisors 17 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 18 / 152

Examples of Annular BOP

Examples of Annular BOP

Examples of Annular BOP

Examples of Annular BOP

Examples of Annular BOP

This model is particularly suitable in case of

Two versions are available:

It has a nylon wear gasket (wear band) to

C. Alvarez Quartz School for IPM Well Site Supervisors 24 / 152

Annular BOP Packing Unit

C. Alvarez Quartz School for IPM Well Site Supervisors 25 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 26 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 27 / 152

C. Alvarez Quartz School for IPM Well Site Supervisors 28 / 152

Ram Type BOP- Components

Secondary Piston Rod Seals

Manual Lock Hinge fluid

Hydraulic Line Connection

C. Alvarez Quartz School for IPM Well Site Supervisors 29 / 152

Single Ram, Double Ram, or Triple Ram

The pair of Rams can be:

2. Variable Bore Rams: to close the annulus around a

3. Blind Rams: to close and seal the well bore when no

4. Shear Rams: to cut pipe in the well across the BOP

Ram Type BOP- Operation