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API Standard RP 53 Recommended Practice

For Blowout Equipment

Contents of substraction from API Recommended

Practice 53 Recommended Practice for Blow-Out
Prevention Equipment.

7.1.1 Surface BOP Arrangements

Choke Manifold and Choke Lines Surface BOP
7.4.1
Installations
7.4.3 Kill Lines Surface BOP Installations
7.9.9 Control System for surface BOP stacks.
7.5.4 Trip tank Surface BOPs
Testing and maintenance - surface BOP stacks and well
7.11.1
control equipment.
7.11.2 Surface BOP stack equipment.
Chokes and choke manifolds for Surface BOP
7.4.6
installations.
7.11.2 Accumulator system for Surface BOP installations
7.11.5 Blow-out preventers for hydrogen sulphide service.

Comments
Standards and
No. Instructions and recorded
instructions
values
7.1.1 Surface BOP Arrangements
Every installed ram BOP should have, as a minimum, a
API RP 53
7.1.1.1 working pressure equal to the maximum anticipated
chapter 6.2
surface pressure to be encountered.
 Ram type preventers should be equipped with extension API RP 53
7.1.1.2
hand wheels or hydraulically operated locks. chapter 6.3
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. 10K, 15K and 20K
arrangements should have two side outlets, one 3-inch API RP 53
7.1.1.3 (7.62 cm) and one 2-inch (5.08 cm) nominal diameter as chapter 6.6.1
a minimum, and be flanged, studded, or hubbed. b. a,b and c
Have a vertical bore diameter the same internal diameter
as the mating BOPs and at least equal to the maximum
bore of the uppermost casing/tubing head. 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 API RP 53
7.1.1.4
employed for choke or kill lines. chapter 6.6.2
Choke Manifold and Choke Lines Surface BOP
7.4.1
Installations
Manifold equipment subject to well and/or pump
pressure (normally upstream of and including the
chokes) should have a working pressure equal to or
API RP 53
7.4.1.1 greater than the rated working pressure of the ram BOPs
chapter 8.2.a
in use. This equipment should be tested when installed
in accordance with provisions of Section 17 of API RP
53
For working pressures of 3,000 psi (20.7 MPa) and
above, flanged, welded, clamped, or other end
API RP 53
7.4.1.2 connections that are in accordance with API
chapter 8.2.b
Specification 6A, should be employed on components
subjected to well pressure.
The choke manifold should be placed in a readily
API RP 53
7.4.1.3 accessible location, preferably outside the rig
chapter 8.2.c
substructure.
When buffer tanks are employed, provision should be API RP 53
7.4.1.4
made to isolate a failure or malfunction. chapter 8.2.d
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
API RP 53
7.4.1.5 pressures of 5,000 psi (34,5 MPa) and above, One of
chapter 8.2.e
these two valves should be remotely controlled. During
operations, all valves should be fully opened or fully
closed.
7.4.1.6 A minimum of one remotely operated choke should be API RP 53
installed on 10,000 psi (69.0 MPa), 15,000 psi (103.5 chapter 8.2.f
 MPa), and 20,000 psi (138.0 MPa) rated working
pressure manifolds.
Choke manifold configurations should allow for re-
API RP 53
7.4.1.7 routing of flow (in the event of eroded, plugged, or
chapter 8.2.g
malfunctioning parts) without interrupting flow control.
Consideration should be given to the low temperature
properties of the materials used in installations to be
API RP 53
7.4.1.8 exposed to unusually low temperatures and should be
chapter 8.2.h
protected from freezing by heating, draining, filling
with appropriate fluid, or other appropriate means.
Pressure gauges suitable for operating pressure and
drilling fluid service should be installed so that drill
API RP 53
7.4.1.9 pipe and annulus pressures may be accurately monitored
chapter 8.2.I
and readily observed at the station where well control
operations are to be conducted.
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 API RP 53
7.4.1.10
situation. The ability to monitor and control from the chapter 8.2.j
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 API RP 53
7.4.1.11
operated choke should be equipped with an emergency chapter 8.2.k
backup system such as a manual pump or nitrogen for
use in the event rig air becomes unavailable.
Installation guide lines-Choke lines
The choke lines should be as straight as possible,
API RP 53
because erosion at bends is possible during operations,
7.4.1.12 chapter
consideration should be given to using flow targets at
8.3.1.a.1
bends and on block ells and tees.
In general, short radius pipe bends (R/d<10) should be
targeted in the direction of expected flow. For large
radius pipe bends (R/d>10), targets are generally
unnecessary. Bends sometime have a wall thickness
API RP 53
greater than the straight pipe in the choke system (such
7.4.1.13 chapter
as the next higher schedule) to further compensate for
8.3.1.a.1
the effect of erosion. 90° block ells and tees should be
targeted in the direction of flow. Where: R= Radius of
pipe bend measured at the centreline. d= Nominal
diameter of the pipe.
7.4.1.14 For flexible lines, consult the manufacturer's guidelines API RP 53
 on working minimum bend radius to ensure proper chapter
length determination and safe working configuration. 8.3.1.a.2
For articulated line assemblies, consult with the
API RP 53
manufacturer's written specifications to determine the
7.4.1.15 chapter
degree of relative movement allowable between end
8.3.1.a.3
points.
API RP 53
The lines and the lines down stream the choke should be
7.4.1.16 chapter
firmly anchored to prevent excessive ship or vibration.
8.3.1.b
The choke line and the lines downstream the choke
should have a bore of sufficient size to prevent
excessive erosion or fluid friction: 1.Minimum API RP 53
7.4.1.17 recommended size for choke lines is 2-inch (5.08 cm) chapter
nominal diameter for 3K and 5K arrangements and 3- 8.3.1.c.1
inch (7.62 cm) nominal diameter for 10K, 15K and 20K
arrangements.
The choke line and the lines down stream the choke
should have a minimum recommended nominal inside API RP 53
7.4.1.18 diameter for lines downstream of the chokes should be chapter
equal to or greater than the nominal connection size of 8.3.1.c.2
the chokes.
The choke line and the lines down stream the chokes API RP 53
7.4.1.19 lines downstream of the choke manifold are not chapter
normally required to contain pressure. 8.3.1.c.3
The choke line and the lines down stream the choke API RP 53
7.4.1.20 should have for air or gas drilling operations, minimum chapter
4-inch (10.16 cm) nominal diameter lines installed. 8.3.1.c.4
The bleed line (the line that bypasses the chokes) should
be at least equal in diameter to the choke line. This line
API RP 53
allows circulation of the well with the preventers closed
7.4.1.21 chapter
while maintaining a minimum back pressure. It also
8.3.1.c.5
permits high volume bleed off of well fluids to relieve
casing pressure with the preventers closed.
7.4.3 Kill Lines Surface BOP Installations
All lines, valves, check valves and flow fittings should
have a working pressure at least equal to the rated API RP 53
7.4.3.1 working pressure of the ram BOPs in use. This chapter
equipment should be tested when installed in 10.2.1.a
accordance with provisions of Section 17 of API RP 53
For working pressures of 3,000 psi (20.7 MPa) and
API RP 53
above, flanged, welded, hubbed, or other end
7.4.3.2 chapter
connections that are in accordance with API
10.2.1.b
Specification 6A, should be employed.
7.4.3.3. Component should be of sufficient diameter to permit API RP 53
reasonable pumping rates without excessive friction. chapter
 The minimum recommended size is 2-inch (5.08mm)
10.2.1.c
nominal diameter.
Two full bore manual valves plus a check valve or two
full bore valves (one of which is remotely operated)
API RP 53
between the stack outlet and the kill line are
7.4.3.4 chapter
recommended for installations with rated working
10.2.1.d
pressure of 5,000 psi (34.5 MPa) or greater. Refer to
Figures 11 and 12 of API RP 53
Periodic operation, inspection, testing and maintenance
API RP 53
should be performed on the same schedule as employed
7.4.3.5 chapter
for the BOP Stack in use (Refer to API RP 53 section
10.2.1.e
17.10)
All components of the kill line system should be API RP 53
7.4.3.6 protected from freezing by heating, draining, filling chapter
with proper fluid, or other appropriate means. 10.2.1.f
Consideration should be given to the low temperature
properties of the materials used in installations to be API RP 53
7.4.3.7 exposed to unusually low temperatures and should be chapter
protected from freezing by heating, draining, filling 10.2.1.g
with appropriate fluid, or other appropriate means.
Lines should be as straight as possible. When bends are
required to accommodate either dimensional API RP 53
7.4.3.8 variation(s) on sequential rig ups or to facilitate hook-up chapter
to the BOP, the largest bend radius allowable under the 10.2.1.h
hook-up restraints should be provided.
For rigid pipe, the bend radius should be maximized.
Because erosion at bends is possible during operation,
consideration should be given to using flow targets at
bends and on block ells and tees. The degree to which
pipe bends are susceptible to erosion depends on the
bend radius, flow rate, flow medium, pipe wall
thickness, and pipe material. However, in general, short
API RP 53
radius pipe bends (R/d<10) should be targeted in the
7.4.3.9 chapter
direction of expected flow. For large radius pipe bends
10.2.1.h.1
(R/d>10), targets are generally unnecessary. Bends
sometime have a wall thickness greater than the straight
pipe in the kill system (such as the next higher schedule)
to further compensate for the effect of erosion. 90°
block ells and tees should be targeted in the direction of
flow. Where: R=Radius of pipe bend measured at the
centreline. d=Nominal diameter of the pipe.
For flexible lines, consult the manufacturer's guidelines API RP 53
7.4.3.10 on working minimum bend radius to ensure proper chapter
length determination and safe working configuration. 10.2.1.h.2
7.4.3.11 For articulated line assemblies, consult with the API RP 53
 manufacturer's written specifications to determine the
chapter
degree of relative movement allowable between end
10.2.1.h.3
points.
API RP 53
All lines should be firmly anchored to prevent excessive
7.4.3.12 chapter
whip or vibration.
10.2.1.I
The kill line should not be used as a fill-up line during API RP 53
7.4.3.13
normal drilling operations. chapter 10.2.2
7.9.9 Control System for surface BOP stacks.
The elements of the BOP control system normally
include: a. Storage (reservoir) equipment for supplying
ample control fluid to the pumping system. b. Pumping
systems for pressurizing the control fluid. c.
Accumulator bottles for storing pressurized the control API RP 53
7.9.9.1 fluid. d. Hydraulic control manifold for regulating the chapter
control fluid pressure and directing the power fluid flow 12.1.a-f
to operate the system functions (BOPs and choke and
kill valves). e. Remote control panels for operating the
hydraulic control manifold from remote locations. f.
Hydraulic control fluid.
Accumulator Volumetric Capacity
Stored hydraulic fluid. The fluid volume recoverable
API RP 53
from the accumulator system between the maximum
7.9.9.2 definition chapter
designed accumulator operating pressure and the
12.3.1.a
precharge pressure.
Usable hydraulic fluid. The hydraulic fluid recoverable
API RP 53
from the accumulator system between the maximum
7.9.9.3 definition chapter
accumulator operating pressure and 200 psi (1.38 MPa)
12.3.1.b
above precharge pressure.
Minimum calculated operating pressure. The minimum
calculated pressure to effectively close and seal a ram- API RP 53
7.9.9.4 type BOP against a wellbore pressure equal to the definition chapter
maximum rated working pressure of the BOP divided 12.3.1.c
by the closing ratio specified for that BOP.
Component minimum operating pressure recommended
by the manufacturer. The minimum operating pressure API RP 53
7.9.9.5 to effectively close and seal ram-type or annular-type definition chapter
preventers under normal operating conditions, as 12.3.1.d
prescribed by the manufacturer.
7.9.9.6 BOP systems should have sufficient usable hydraulic API RP 53
fluid volume (with pumps inoperative) to close one chapter 12.3.2
annular-type preventer, all ram-type preventers from a
full-open position, and open one HCR valve against
zero wellbore pressure. After closing one annular
preventer, all ram-type preventers, and opening one
 HCR valve, the remaining pressure shall be 200 psi
(1.38 MPa) or more above the minimum recommended
precharge pressure.
Accumulator 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
API RP 53
7.9.9.7 time should not exceed 30 seconds for annular BOPs
chapter 12.3.3
smaller than 18 ¾ inches (47.63 cm) nominal bore and
45 seconds for annular preventers of 18¾ inches (47.63
cm) nominal bore and larger. Response time for choke
and kill valves (either open or close) should not exceed
the minimum observed ram close response time.
Operating pressure. No accumulator bottle should be
API RP 53
7.9.9.8 operated at a pressure greater than its rated working
chapter 12.3.4
pressure.
Accumulator precharge. The precharge pressure on each
accumulator bottle should be measured prior to each API RP 53
7.9.9.9
BOP stack installation on each well and adjusted if chapter 12.3.5
necessary.
The minimum precharge pressure for a 3,000 psi (20.7
MPa) working pressure accumulator should be 1,000 psi
API RP 53
7.9.9.10 (6.9 MPa). The minimum precharge pressure for a 5,000
chapter 12.3.5
psi (34.5 MPa) working pressure accumulator should be
1,500 psi (10.3 MPa).
Only nitrogen gas should be used for accumulator
precharge. The precharge pressure should be checked
API RP 53
7.9.9.11 and adjusted to within 100 psi (0.69 MPa) of the
chapter 12.3.5
selected precharge pressure at the start of drilling each
well.
Multi-bottle accumulator banks should have valving for API RP 53
7.9.9.12
bank isolation. chapter 12.3.6
An isolation valve should have a rated working pressure
at least equivalent to the designed working pressure of
API RP 53
7.9.9.13 the system to which it is attached and must be in the
chapter 12.3.6
open position except when accumulators are isolated for
servicing, testing, or transporting.
A pressure gauge for measuring the accumulator
precharge pressure should be readily available for
API RP 53
7.9.9.14 installation at any time. Pressure gauges should be
chapter 12.3.6
calibrated to 1 percent of full scale at least every three
(3) years.
Pump Systems
7.9.9.15 A pump system consists of one or more pumps. Each API RP 53
 pump system ( primary and secondary) should have
chapter 12.4.1
independent power sources, such as electric or air.
With the accumulators isolated from service, the pump
system should be capable of closing the annular BOP
(excluding the diverter) on the minimum size drill pipe
API RP 53
7.9.9.16 being used, open the hydraulically operated choke
chapter 12.4.1
valve(s), and provide the operating pressure level
recommended by the annular BOP manufacturer to
effect a seal on the annulus within two minutes.
The same pump system(s) may be used to provide
API RP 53
7.9.9.17 power fluid to control both the BOP stack and the
chapter 12.4.2
diverter system.
Each pump system should provide a discharge pressure
at least equivalent to the BOP control system working
API RP 53
7.9.9.18 pressure. Air pumps should be capable of charging the
chapter 12.4.3
accumulators to the system working pressure with 75
psi (0.52 MPa) minimum air pressure supply.
Each pump system should be protected from over
pressurization by a minimum of two devices to limit the
pump discharge pressure. One device, normally a
pressure limit switch, should limit the pump discharge
pressure so that it will not exceed the working pressure API RP 53
7.9.9.19
of the BOP control system. The second device, normally chapter 12.4.4
a relief valve, should be sized to relieve at a flow rate at
least equal to the design flow rate of the pump systems
and should be set to relieve at not more than ten percent
over the control unit 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
API RP 53
7.9.9.20 have isolation valves or any other means that could
chapter 12.4.4
defeat their intended purpose. Rupture disc(s) or relief
valve(s) that do no automatically reset are not
recommended.
Electrical and/or (pneumatic) supply for powering
pumps should be available at all times such that the
pumps will automatically start when the system pressure
API RP 53
7.9.9.21 has decreased to approximately 90 percent of the system
chapter 12.4.5
working pressure and automatically stop within plus
zero or minus 100 psi (0.69 MPa) of the BOP control
system working pressure.
7.9.9.22 All valves, fittings, and other components, such as API RP 53
pressure switches, transducers, transmitters, etc., should chapter 12.5.1
have a working pressure at least equal to the rated
working pressure of the control system. BOP control
system rated working pressure is usually 3,000 psi (20.7
 MPa).
All piping components and all threaded pipe
connections installed on the BOP control system should
conform to the design and tolerance specifications for API RP 53
7.9.9.23
American National Standards Taper Pipe Threads as chapter 12.5.2
specified in ANSI B1.20.1. Pipe and pipe fittings should
conform to specifications of ANSI B31.3.
If weld fittings are used, the welder shall be certified for
the applicable procedure required. Welding should be
performed in accordance with a written weld procedure API RP 53
7.9.9.24
specification (WPS), written and qualified in chapter 12.5.2
accordance with Article II of ASME Boiler and Pressure
Vessel Code, Section IX.
All rigid or flexible lines between the control system
and BOP stack should be flame retardant, including end API RP 53
7.9.9.25
connections, and should have a working pressure equal chapter 12.5.2
to the working pressure of the BOP control system.
All control system interconnect piping, tubing, hose,
API RP 53
7.9.9.26 linkages, etc., should be protected from damage during
chapter 12.5.2
drilling operations, or day-to-day equipment movement.
The manifold should be equipped with a full-bore valve API RP 53
7.9.9.27 to which a separate operating fluid pump can be easily chapter
connected. 12.5.3.a
The control system should be equipped to allow
API RP 53
isolation of both the pumps and the accumulators from
7.9.9.28 chapter
the manifold and annular control circuits, thus allowing
12.5.3.b
maintenance and repair work.
The control system should be equipped with accurate
API RP 53
pressure gauges to indicate: (1) accumulator pressure,
7.9.9.29 chapter
(2) regulated manifold pressure, (3) annular pressure,
12.5.3.c
and (4) air supply pressure.
The control system should be equipped with a pressure API RP 53
7.9.9.30 regulating valve to permit manual control of the annular chapter
preventer operating pressure. 12.5.3.d
The control system should be equipped with a
regulating valve to control the operating pressure on the API RP 53
7.9.9.31 ram BOPs. The control unit should be equipped with a chapter
bypass line and valve to allow full accumulator pressure 12.5.3.e
to be applied on the manifold, if desired.
Control valves must be clearly marked to indicate (1)
which preventer or choke line valve each control valve
API RP 53
operates, and (2) the position of the valves (i.e., open,
7.9.9.32 chapter
closed, neutral). Each BOP control valve should be in
12.5.3.f
the open position (not the neutral position) during
drilling operations.
 The choke line hydraulic valve should be in the closed
position during normal operations. The control valve API RP 53
7.9.9.33 handle that operates the blind rams should be protected chapter
to avoid unintentional operation, but allow full 12.5.3.f
operation from the remote panel without interference.
All pressure gauges on the BOP control system should API RP 53
7.9.9.34 be calibrated to an accuracy of 1 percent of full scale at chapter
least every 3 years. 12.5.3.g
The use of diesel oil, kerosene, motor oil, chain oil, or
API RP 53
7.9.9.35 any other similar fluid is not recommended because of
chapter 12.6.1
the possibility of explosions or resilient seal damage.
Each closing unit should have a fluid reservoir with a
API RP 53
7.9.9.36 capacity equal to at least twice the usable fluid capacity
chapter 12.6.2
of the accumulator system.
Air breather outlets, of sufficient size, should be
installed to avoid pressurization of the tank during API RP 53
7.9.9.37
hydraulic transfers or nitrogen transfers if a nitrogen chapter 12.6.2
backup system is installed.
The hydraulic control unit should be located in a safe
API RP 53
7.9.9.38 place that is easily accessible to rig personnel in an
chapter 12.7
emergency.
The hydraulic control unit should also be located to
prevent excessive drainage or flow back from the
operating lines to the reservoir. Should the accumulator
API RP 53
7.9.9.39 banks be located a substantial distance from or below
chapter 12.7
the BOP stack, additional reservoir volume or
alternative means should be provided to compensate for
flow back in the closing lines.
The installation should be equipped with a driller
remote control panel such that the operation of each
BOP and control valve can be controlled from a position API RP 53
7.9.9.40
readily accessible to the driller. Consideration should be chapter 12.8
given to the need for and additional remote control
station(s) at a safe distance from the rig floor.
7.4.5 Trip tank Surface BOPs
A trip tank is a low-volume, [100 barrels(15.9 m³) or
less] calibrated tank that can be isolated from the
remainder of the surface drilling fluid system and used API RP 53
7.4.5.1
to accurately monitor the amount of fluid going into or chapter 15.6
coming from the well. A volume change of half a barrel
should be easily detected.
A trip tank may be of any shape provided the capability
exists for reading the volume contained in the tank at API RP 53
7.4.5.2
any liquid level. The readout may be direct to remote, chapter 15.6
preferably both.
 The size and configuration of the tank should be such
API RP 53
7.4.5.3 that volume changes on the order of one-half barrel can
chapter 15.6
be easily detected by the readout arrangement.
Tanks containing two compartments with monitoring
arrangements in each compartment are preferred as this API RP 53
7.4.5.4
facilitates removing or adding drilling fluid without chapter 15.6
interrupting rig operations.
Other uses of the trip tank include measuring drilling
fluid or water volume into the annulus when returns are API RP 53
7.4.5.5
lost, monitoring the hole while logging or following a chapter 15.6
cement job, calibrating drilling fluid pumps, etc.
The trip tank is also used to measure the volume of
API RP 53
7.4.5.6 drilling fluid bled from or pumped into the well as pipe
chapter 15.6
is stripped into or out of the well.
Testing and maintenance - surface BOP stacks and well
7.11.1
control equipment.
The purposes for various field test programs on drilling
well control equipment are to verify: a. That specific API RP 53
7.11.1.1 functions are operationally ready. b. The pressure chapter
integrity of the installed equipment. c. The control 17.1.a-c
system and BOP compatibility.
Test programs incorporate visual inspections, functional
operations, pressure tests, maintenance practices, and API RP 53
7.11.1.2
drills. For purposes of this document, the following chapter 17.2
definitions are used for the basic types of tests.
The inspection test. The common collective term used to
state the various procedural examination of flaws that
may influence equipment performance. These
inspection tests may include, but are not limited to
visual, dimensional, audible, hardness, functional, and
API RP 53
7.11.1.3 pressure tests. Inspection practices and procedures vary definition.
chapter 17.2.1
and are outside the scope of this document. An example
of some inspection guidelines can be found in
IADC/SPE paper 23900. A field guide for surface BOP
Equipment Inspections, W.J Kandel and D.J. Streu,
February 1992.
The function test. The operation of a piece of equipment
or a system to verify its intended operation. Function
testing typically does not include pressure testing. API RP 53
7.11.1.4 definition.
Actuation test, operating test, and readiness test are chapter 17.2.2
other terms commonly used synonymously for function
test.
7.11.1.5 The pressure test. Periodic application of pressure to a definition. API RP 53
piece of equipment or a system to verify the pressure chapter 17.2.3
containment capability for the equipment or system.
 "Wellbore test" is another descriptive term frequently
used synonymously for pressure test.
The hydraulic operator test. The application of a
pressure test to any hydraulic operated component of
hydraulic-actuated equipment. Hydraulic operator tests
are typically specified by the manufacturer for such
items as: BOP operator cylinders and bonnet
assemblies, hydraulic valve actuators, hydraulic
API RP 53
7.11.1.6 connectors, etc. Operating chamber test is frequently definition.
chapter 17.2.4
used synonymously for hydraulic operator test. (Note:
The definitions of test pressure, design pressure,
operational characteristic tests, etc., as used in other API
documents, may have meaning/intent more appropriate
to manufacturing processes and the intended description
may differ with field usage.)
Site-specific applications of the different types of tests
on well control equipment should be incorporated
during field acceptance tests, initial rig-up tests, drills,
periodic operating tests, maintenance practices, and
drilling operations. (Note: Techniques and step-by-step
or how-to-test procedures should be developed for each
rig because of the varying equipment, different
installation arrangements and well-specific drilling
API RP 53
7.11.1.7 programs. The procedure for testing the BOP stack, drill definition.
chapter 17.2.4
string safety valves, choke/kill lines, and manifold
upstream of the buffer chamber are usually similar for
most rigs. Pressure test programs for the wellhead and
casing should be prescribed by the operator on an
individual well bases. Manufacturer operating and
maintenance documents, contractor maintenance
programs, and operating experiences should be
incorporated into the specific test procedures.
Function tests. 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
API RP 53
7.11.1.8 location. (Refer to worksheets in API RP 53 Appendix definition.
chapter 17.3.1
A). Actuation times should be recorded as a data base
for evaluating trends. (Refer to worksheets in API RP 53
Appendix A).
Pressure tests
All blow-out prevention components that may be
API RP 53
exposed to well pressure should be tested first to a low
7.11.1.9 chapter
pressure of 200 to 300 psi (1.38 to 2.1 MPa) and then to
17.3.2.1
a high pressure.
7.11.1.10 When performing the low pressure test, do not apply a API RP 53
higher pressure and bleed down to the low test pressure. chapter
 The higher pressure could initiate a seal that may
continue to seal after the pressure is lowered and 17.3.2.1
therefore misrepresenting a low pressure condition.
API RP 53
A stable low test pressure should be maintained for at
7.11.1.11 chapter
least 5 minutes.
17.3.2.1
The initial high pressure test on components that could
be exposed to well pressure (BOP stack, choke
API RP 53
manifold, and coke/kill lines) should be to the rated
7.11.1.12 chapter
working pressure of the ram BOPs or to the rated
17.3.2.2
working pressure of the wellhead that the stack is
installed on, whichever is lower.
Initial pressure tests are defined as those tests that
API RP 53
should be performed on location before the well is
7.11.1.13 chapter
spudded or before the equipment is put into operational
17.3.2.2
service.
API RP 53
Diverter systems are typically pressure tested to a low
7.11.1.14 chapter
pressure only (refer to API Recommended Practice 64).
17.3.2.2
Annular BOPs, with a joint of drill pipe installed, may
API RP 53
be tested to the test pressure applied to the ram BOPs or
7.11.1.15 chapter
to a minimum of 70 percent of the annular preventer
17.3.2.2
working pressure, whichever is the lesser.
The lower kelly valves, kelly, kelly cock, drill pipe
safety valves, inside BOPs and top drive safety valves, API RP 53
7.11.1.16 should be tested with water pressure applied from below chapter
to a low pressure of 200-300 psi (1.38 to 2.1 MPa) then 17.3.2.2
to the rated working pressure.
There may be instances when the available BOP stack
and/or the wellhead have higher working pressures than
API RP 53
are required for the specific wellbore conditions due to
7.11.1.17 chapter
equipment availability. Special conditions such as these
17.3.2.2
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 API RP 53
7.11.1.18 exceed the working pressure of the ram BOPs. The chapter
maximum anticipated surface pressure should be 17.3.2.3
determined by the operator based on specific anticipated
well conditions.
7.11.1.19 Annular BOPs, with a joint of drill pipe installed, API RP 53
should be tested to a minimum of 70 percent of their chapter
working pressure or to the test pressure of the ram 17.3.2.3
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 API RP 53
7.11.1.20 rubber mass for prolonged periods after pressure is chapter
applied. This packer creep movement should be 17.3.2.3
considered when monitoring the pressure test of the
annular.
API RP 53
Pressure test operations should be alternately controlled
7.11.1.21 chapter
from the various control stations.
17.3.2.3
The pressure test performed on hydraulic chambers of API RP 53
7.11.1.22 annular BOPs should be to at least 1,500 psi (10.3 chapter
MPa). 17.3.2.4
Initial pressure tests on hydraulic chambers of ram
API RP 53
BOPs and hydraulically operated valves should be to the
7.11.1.23 chapter
maximum operating pressure recommended by the
17.3.2.4
manufacturer.
API RP 53
The test should be run on both the opening and the
7.11.1.24 chapter
closing chambers.
17.3.2.4
API RP 53
7.11.1.25 Pressure should be stabilized for at least 5 minutes. chapter
17.3.2.4
Subsequent pressure tests are typically performed on API RP 53
7.11.1.26 hydraulic chambers only between wells or when the chapter
equipment is reassembled. 17.3.2.4
The initial pressure test on the closing unit valves,
API RP 53
manifolds, gauges, and BOP hydraulic control lines
7.11.1.27 chapter
should be to the rated working pressure of the control
17.3.2.5
unit.
Subsequent pressure tests of closing unit systems are
typically performed following the disconnection or API RP 53
7.11.1.28 repair of any operating pressure containment seal in the chapter
closing unit system, but limited to the affected 17.3.2.5
component.
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 API RP 53
7.11.1.29
containment seal in the BOP stack, choke line, or choke chapter 17.3.3
manifold, but limited to the affected component. c. Not
to exceed 21 days.
7.11.1.30 Well control equipment should be pressure tested with API RP 53
water. Air should be removed from the system before chapter 17.3.5
 test pressure is applied. Control systems and hydraulic
chambers should be tested using clean control system
fluids with lubricate and corrosion additives for the
intended service and operating temperatures.
Pressure gauges and chart recorders should be used and
all testing results recorded. Pressure measurements API RP 53
7.11.1.31
should be made at not less than 25 percent nor more chapter 17.3.6
than 75 percent of the full pressure span of the gauge.
The results of all BOP equipment pressure and function
tests shall be documented and include, as a minimum,
API RP 53
7.11.1.32 the testing sequence, the low and high test pressures, the
chapter 17.3.7
duration of each test, and the results of the respective
component tests.
Pressure tests shall be performed with a pressure chart
recorder or equivalent data acquisition system and API RP 53
7.11.1.33
signed by pump operator, contractor's tool pusher, and chapter 17.3.7
operating company representative.
Problems observed during testing and any actions taken API RP 53
7.11.1.34
to remedy the problems should be documented. chapter 17.3.7
Manufacturers should be informed of well control
API RP 53
7.11.1.35 equipment that fails to perform in the field. (Refer to
chapter 17.3.7
API Specification 16A).
General Testing Considerations
Rig crews should be alerted when pressure test
operations are to be conducted and when testing API RP 53
7.11.1.36
operations are underway. Only necessary personnel chapter 17.3.8
should remain in the test area.
Only personnel authorized by the well site supervisor
API RP 53
7.11.1.37 should go into the test area to inspect for leaks when the
chapter 17.3.8
equipment involved is under pressure.
Tightening, repair, or any other work is to be done only
after pressure has been released and all parties have API RP 53
7.11.1.38
agreed that there is no possibility of pressure being chapter 17.3.8
trapped.
Pressure should be released only through pressure- API RP 53
7.11.1.39
release lines. chapter 17.3.8
All lines and connections that are used in the test API RP 53
7.11.1.40
procedures should be adequately secured. chapter 17.3.8
All fitting, connections and piping used in pressure
API RP 53
7.11.1.41 testing operations shall have pressure ratings greater
chapter 17.3.8
than the maximum anticipated test pressure.
Verify the type, pressure rating, size, and end
connections for each piece of equipment to be tested, as API RP 53
7.11.1.42
documented by permanent markings on the equipment chapter 17.3.8
or by records that are traceable to the equipment.
 When a BOP stack is tested on the wellhead, a
API RP 53
7.11.1.43 procedure should be available to monitor pressure on
chapter 17.3.8
the casing should the test plug leak.
If the control system regulator circuit is equipped with
hydro-pneumatic regulators, a backup supply is API RP 53
7.11.1.44
recommended to pilot the regulators in case the rig air chapter 17.3.8
supply is lost.
Functional tests of the control system should include a
API RP 53
7.11.1.45 simulated loss of power to the control unit and to the
chapter 17.3.8
control panel.
Vertical stack alignment should be checked and flange
API RP 53
7.11.1.46 bolt make-up should be torqued to prescribed ratings
chapter 17.3.8
established in API Specification 6A.
If hydrogen sulphide bearing formations are anticipated,
manufacturer's certification for compliance with NACE
API RP 53
7.11.1.47 Standard MR0175 should be available and reviewed for
chapter 17.3.8
well control equipment, as described in API RP 53
Section 20.
7.8.3 Diverter System Surface BOP Installations
All diverter system components shall be inspected and
tested to ascertain proper installation and functioning.
API RP 53
7.8.3.1 Simulate loss of rig air supply to the diverter control
chapter 17.4.1
system and determine, effects, if any, on the diverter
system, vent line valves, and backup supply systems.
Check and verify the proper structural mounting of the API RP 53
7.8.3.2 annular sealing device assembly, and, if applicable, that chapter
the insert packing element is secured in place. 17.4.1.a
For installations using remote operators, record
API RP 53
hydraulic pressure and air supply pressure with the
7.8.3.3 chapter
accumulator fully charged and the controls in the
17.4.1.b
normal drilling position.
Actuate the diverter close and open sequence with drill
API RP 53
pipe or test mandrel in the diverter to verify control
7.8.3.4 chapter
functions, proper equipment operating sequence and
17.4.1.c
interlock, if applicable, and record response time(s).
A pressure integrity test [200 psi (1.38 MPa) minimum]
should be made on the diverter system after each
API RP 53
installation. The tests may be made on parts of the
7.8.3.5 chapter
system or on individual components of the system
17.4.1.d
should certain components of the casing string or riser
components not support a complete system test.
7.8.3.6 Pump water or drilling fluid through the diverter system API RP 53
at low pressure and high flow rates and check vent chapter
line(s) for returns. Examine the entire system for leaks, 17.4.1.e
excessive vibrations, and proper tie down while
 pumping fluid at high rates.
In cold climates, the diverter vent lines shall be
API RP 53
protected from freezing. Possible methods include
7.8.3.7 chapter
flushing with anti-freeze solution, draining, insulation,
17.4.1.f
and heat tracing.
7.11.2 Surface BOP stack equipment.
Unless restricted by height, the entire stack should be API RP 53
7.11.2.1
pressure tested as a unit. chapter 17.5.2
Annular BOPs should be tested with the smallest OD API RP 53
7.11.2.2
pipe to be used. chapter 17.5.3
Fixed bore pipe rams should be tested only on the pipe API RP 53
7.11.2.3
OD size that matches the installed pipe ram blocks. chapter 17.5.4
Variable bore rams should be initially pressure tested on
API RP 53
7.11.2.4 the largest and smallest OD pipe sizes that may be used
chapter 17.5.5
during the well operations.
Blind ram BOPs and blind shear ram BOPs should not API RP 53
7.11.2.5
be tested when pipe is in the stack. chapter 17.5.6
The capability of the shear ram and ram operator should
API RP 53
7.11.2.6 be verified with the BOP manufacturer for the planned
chapter 17.5.6
drill string.
The shear ram and preventer design and/or metallurgical
API RP 53
7.11.2.7 differences among drill pipe manufacturers may require
chapter 17.5.6
high closing pressures for shear operations.
Prior to testing each ram BOP, the secondary rod seals
API RP 53
7.11.2.8 (emergency packoff assemblies) should be checked to
chapter 17.5.7
ensure the seals have not been energized.
Should the ram shaft seal leak during the test, the seal
API RP 53
7.11.1.9 shall be repaired rather than energizing the secondary
chapter 17.5.7
packing.
Ram BOPs equipped with ram locks should be pressure
API RP 53
7.11.1.10 tested with ram locks in the closed position and closing
chapter 17.5.8
pressure bled to zero.
Manual locks either screw clockwise or counter- API RP 53
7.11.1.11
clockwise, to hold the rams closed. chapter 17.5.8
Hand wheels should be in place and the threads on the
API RP 53
7.11.1.12 ram locking shaft should be in a condition that allows
chapter 17.5.8
the locks to be easily operated.
The BOP elastomeric components that may be exposed
to well fluids should be verified by the BOP
API RP 53
7.11.1.13 manufacturer as appropriate for the drilling fluids to be
chapter 17.5.9
used and for the anticipated temperatures to which
exposed.
Consideration should be given to the temperature and
API RP 53
7.11.1.14 fluid conditions during well testing and completion
chapter 17.5.9
operations.
 Manufacturers' markings for BOP elastomeric
components should include the durometer hardness, API RP 53
7.11.1.15 generic type of compound, date of manufacture, part chapter
number, and operating temperature range of the 17.5.9.1
component.
Consider replacing critical BOP elastomeric API RP 53
7.11.1.16 components on well control equipment that has been out chapter
of service for six (6) months or longer. 17.5.9.2
Flexible choke and kill lines should be tested to the API RP 53
7.11.1.17 same pressure, frequency, and duration as the ram chapter
BOPs. 17.5.10
Verify that a properly precharged surge bottle is or can
API RP 53
be installed adjacent to the annular preventer if
7.11.1.18 chapter
contingency well control procedures include stripping
17.5.12
operations.
The drill pipe test joint and casing ram test sub should
API RP 53
be constructed of pipe that can withstand the tensile,
7.11.1.19 chapter
collapse, and internal pressures that will be placed on
17.5.12
them during testing operations.
Chokes and choke manifolds for Surface BOP
7.4.6
installations.
The choke manifold upstream of and including the lost
API RP 53
7.4.6.1 high pressure valves (refer to API RP 53 figure 8)
chapter 17.6.1
should be tested to the same pressure as the ram BOPs.
The configuration of pipes and valves downstream of
the last high pressure valve varies from installation to API RP 53
7.4.6.2
installation. Each configuration should be verified for chapter 17.6.2
mechanical integrity.
The valves and adjustable chokes should be operated to API RP 53
7.4.6.3
verify smooth operation. chapter 17.6.3
Adjustable chokes are not required to be full sealing
API RP 53
7.4.6.4 devices. Pressure testing against a closed choke is not
chapter 17.6.4
required.
The rig maintenance and inspection schedule should
provide for periodic non-destructive examination of the API RP 53
7.4.6.5 mud/gas separator to verify pressure integrity. This chapter
examination may be performed by hydrostatic, 17.11.8
ultrasonic, or other examination methods.
7.11.2 Accumulator system for Surface BOP installations
Accumulator closing test. The purpose of this test is to
verify that the accumulator system is properly sized to
support the fluid volume and pressure requirements of API RP 53
17.11.2.20
the BOPs on the rig using the following procedure; chapter 17.7.1
(Refer to sample worksheets and examples in API RP 53
Appendix A).
 Accumulator closing test procedure. a. Position a
properly size joint of drill pipe or a test mandrel in the
BOPs. b. Turn off the power supply to all accumulator
charging pumps (air, electric, etc.) c. Record the initial
accumulator pressure. (The initial accumulator pressure
should be the designed operating pressure of the
accumulator.) Manifold and annular regulators should
be set at the manufacturer's recommended operating
pressure for the BOP stack. d. Individually close each
API RP 53
ram BOP (excepting blind or blind/shear ram BOPs)
17.11.2.21 chapter 17.7.1
and record the closing time. To simulate closure of the
a-g
blind or blind/shear rams, open one set of the pipe rams.
Closing times shall meet the response time stipulated in
API RP 53 Section 12.3.2. e. Function the hydraulic
operated valve(s) and record the time and volume
required f. Close the annular BOP and record the
closing time. g. Record the final accumulator pressure.
The final accumulator pressure shall be equal to or
greater than 200 psi (1.8 MPa) above precharge
pressure.
After each well, the well control equipment should be
API RP 53
cleaned, visually inspected, preventative maintenance
17.11.2.22 chapter
performed, and pressure tested before installation on the
17.10.1
next well.
The manufacturer's test procedures, as prescribed in
their installation, operation, and maintenance (IOM)
API RP 53
manual, should be followed along with the test
17.11.2.23 chapter
recommendations of API RP 53 Table 1. All leaks and
17.10.1
malfunctions should be corrected prior to placing the
equipment in service.
Visual inspection flexible choke and kill lines
A visual external inspection of flexible choke and kill
lines through the entire length of the line should
include: a. Outer Jacket. Visually inspect to ensure that
the outer jacket is intact to protect the polymeric sheath
API RP 53
underneath from tearing and being punctured. Verify
17.11.2.24 chapter
that the outer jacket is properly attached at both end
17.10.2.a
fittings. Verify that the entire surface of the polymeric
sheath is protected. If any damage is noticed on the
outer jacket, verify that it will not be detrimental to the
polymeric sheath.
Termination. Record any damage to the coating on the API RP 53
17.11.2.25 end-fitting, and monitor progression of damage. chapter
Facilitate repair, if necessary. 17.10.2.b
17.11.2.26 Connector. Particularly inspect the seal area of the API RP 53
connectors recording any damage and monitor chapter
 progression of damage. 17.10.2.c
Major inspections
After every 3-5 years of service, the BOP stack, choke
API RP 53
manifold, and diverter components should be
17.11.2.27 chapter
disassembled and inspected in accordance with the
17.10.3
manufacturer's guidelines.
Elastomeric components should be changed out and
surface finishes should be examined for wear and
API RP 53
corrosion. Critical dimensions should be checked
17.11.2.28 chapter
against the manufacturer's allowable wear limits.
17.10.3
Individual components can be inspected on a staggered
schedule.
A full internal and external inspection of the flexible API RP 53
17.11.2.29 choke and kill lines should be performed in accordance chapter
with the equipment manufacturer's guidelines. 17.10.3
Manufacturer's installation, operation, and maintenance API RP 53
17.11.2.30 (IOM) manuals should be available on the rig for all the chapter
BOP equipment installed on the rig. 17.11.1
Studs and nuts should be checked for proper size and
grade. Using the appropriate lubricant, torque should be
applied in a criss-cross manner to the flange studs. All API RP 53
17.11.2.31 bolts should then be rechecked for proper torque as chapter
prescribed in API Specification 6A. When making up 17.11.2
connections, excessive force should not be required to
bring the connections into alignment.
Ring gaskets coated with a resilient material such as
rubber or polyetrafluorethylene (PTFE) should not be API RP 53
17.11.2.32 used. Due to the limited amount of deformation which a chapter
groove can make in a ring as it is compressed during 17.11.2
installation, it is not recommended to reuse ring gaskets.
When making up proprietary clamp hubbed API RP 53
17.11.2.33 connections, the manufacturer's recommended chapter
procedure should be followed. 17.11.2
Spare parts should be designed for their intended use by
industry approved and accepted practices. After spare
API RP 53
part installation, the affected pressure-containing
17.11.2.34 chapter
equipment shall be pressure tested. Elastomeric
17.11.3
components shall be stored in a manner recommended
by the equipment manufacturer.
The original equipment manufacturer should be
consulted regarding replacement parts. If replacement
API RP 53
parts are acquired from a non-original equipment
17.11.2.35 chapter
manufacturer, the parts shall be equivalent to or superior
17.11.3
to the original equipment and fully tested, design
verified, and supported by traceable documentation.
 Manuals or bulletins containing torque specifications
should be available on the rig. As stated in API RP 53
API RP 53
section 17.11.2, torque specifications and the lubricant's
17.11.2.36 chapter
coefficient of friction should be considered when
17.11.4
trolling fasteners. Deviating from the specified lubricant
can alter the required torque.
A planned maintenance system, with equipment
identified, tasks specified, and the time intervals
API RP 53
between tasks stated, should be employed on each rig.
7.11.2.37 chapter
Records of maintenance performed and repairs made
17.12.1
should be maintained on file at the rig site or readily
available for the applicable BOP equipment.
Copies of equipment manufacturers' product alerts or API RP 53
7.11.2.38 equipment bulletins should be maintained at the rig site chapter
or readily available for the applicable BOP equipment. 17.12.2
Drawing showing ram space-out and bore of the BOP
stack and a drawing of the choke manifold showing the API RP 53
7.11.2.39 pressure rating of the components should be on the rig chapter
and maintained up to date. Refer to API RP 53 figure 19 17.13.1
for an example drawing
A bill of material should accompany the equipment API RP 53
7.11.2.40 drawings to correctly identify the equipment and allow chapter
the procurement of correct replacement parts. 17.13.1
Changes to the BOP control system should be
API RP 53
documented. A method should be established to control
7.11.2.41 chapter
the drawings, ensuring that up-to-date documentation is
17.13.1
maintained.
Equipment records such as API manufacturing
documentation, NACE certification, and factory
API RP 53
acceptance testing reports should be retained. Where
7.11.2.42 chapter
required, copies of the manufacturer's equipment data
17.13.2
book and third party certification should be available for
review.
A maintenance and repair historical file should be
maintained by serial number on each major piece of
API RP 53
equipment. This file should follow the equipment when
7.11.2.43 chapter
it is transferred. Equipment malfunctions or failures
17.13.3
should be reported in writing to the equipment
manufacturer as stated in API Specification 16A.
Shop testing after major inspection or equipment weld API RP 53
7.11.2.44 repairs should be performed according to the chapter
manufacturer's written procedures. 17.13.4
7.11.5 Blow-out preventers for hydrogen sulphide service.
7.11.5.1 Where there is reasonable expectation of encountering API RP 53
hydrogen sulphide gas zones that could potentially chapter 20.1
 result in the partial pressure of the hydrogen sulphide
exceeding 0.05 Asia (0.00034 MPa) in the gas phase at
the maximum anticipated pressure, BOP equipment
modifications should be made. Recommended safety
guidelines for conducting drilling operations in such an
environment can be found in API Recommended
Practice 49.
Equipment modifications should be considered since
many metallic materials in a hydrogen sulphide
API RP 53
7.11.5.2 environment (sour service) are subject to a form of
chapter 20.2.1
hydrogen embrittlement known as sulphide stress
cracking (SSC).
This type of spontaneous brittle failure is dependent on
the metallurgical properties of the material, the total
API RP 53
7.11.5.3 stress or load (either internal or applied), and the
chapter 20.2.1
corrosive environment. A list of acceptable materials is
given in NACE Standard MR0175.
A list of specific items to be changed on annular and
ram type BOPs and valves for service in a hydrogen API RP 53
7.11.5.4
sulphide environment should be furnished by the chapter 20.2.2
manufacturer.
As a guide, all metallic materials which could be
exposed to hydrogen sulphide under probable operating API RP 53
7.11.5.5
conditions should be highly resistant to sulphide stress chapter 20.2.2
cracking.
The maximum acceptable harness for all preventer and
API RP 53
7.11.5.6 valve bodies and spools shall be in accordance with
chapter 20.2.3
NACE Standard MR0175.
Ring-joint gaskets should meet the requirements of API
API RP 53
7.11.5.7 Specification 16A and be of the material and hardness
chapter 20.2.4
specified in API Specification 6A.
All bolts and nuts used in connection with flanges,
API RP 53
7.11.5.8 clamps, and hubs should be selected in accordance with
chapter 20.2.5
provisions of API Specification 6A.
All lines, crosses, valves, and fittings in the choke
manifold system and the drill string safety valve should
API RP 53
7.11.5.9 be constructed from materials meeting applicable
chapter 20.2.6
requirements of API Specification 5L and API
Specification 6A.
Heat treating and other applicable requirements, as
stipulated in NACE Standard MR0175 should also be
reviewed and considered. Field welding upstream of the API RP 53
7.11.5.10
chokes should be kept to a minimum and, if performed, chapter 20.2.6
should meet original shop construction standards and
procedures.
 Elastomeric components are also subject to hydrogen
sulphide attack. Nitrile elastomeric components which
meet other requirements may be suitable for hydrogen
sulphide service provided drilling fluids are properly
treated. Service life shortens rapidly as temperature
API RP 53
7.11.5.11 increases from 150°F to 200°F (65.6°C to 93°C). In the
chapter 20.2.7
event flowline temperatures in excess of 200°F (93°C)
are anticipated, the equipment manufacturer should be
consulted. Elastomeric components should be changed
out as soon as possible after exposure to hydrogen
sulphide under pressure.
Changes prescribed by the primary equipment
manufacturer to render equipment acceptable for service
API RP 53
7.11.5.12 in a hydrogen sulphide environment should not be
chapter 20.2.8
overlooked in providing for replacement and repair
parts.

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Comment by bill the drill on October 27, 2011 at 8:20am

has any one got the iwcf traning manual on pdf need to do sum home study beffore
cource in aberdeen

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