Professional Documents
Culture Documents
Atr En05
Atr En05
________________________________________________________________________________________________________
BOP STACK
_________________________________________________________________________________________ 111
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
112 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
_________________________________________________________________________________________ 113
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
and can be represented by a defined components code. API RP 53 regulations list the components
reading upwards and identify them by the following codes:
A= Annular BOP
R = Single-ram BOP
Rd = Double-ram BOP
Rt = Triple-ram BOP
S = Drilling spool
Example:
composed of
- a drilling spool,
- two single-ram BOP
- one annular BOP
is represented as follows:
5M 13 5/8" - SRRA
With reference to working pressure ratings, API RP 53 regulations classify BOP stacks into:
114 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
2M 3M 5M 10M 15M
On the basis of this classification, the number of the BOP to be used and the typical configurations
are indicated, without specifying the ram positions.
SRR RSR
3M - 5M 3 BOP are included, one ram BOP and one annular BOP:
SRRA RSRA
10M - 15M 4 BOP are included, 3 ram BOP and one annular BOP:
_________________________________________________________________________________________ 115
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
RSRRA SRRRA
Notes: In the 10M-15M configurations the annular BOP can have a working pressure lower than the standard
annular-BOP working pressure.
The BOP stack complete configuration also includes the ram positioning, which is selected
depending on a variety of evaluations and considerations. The most important are:
this defines the type of rams (blind or shear rams) which is more likely going to be used, and
it tells whether the blind rams or the pipe rams should be positioned above.
116 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
_________________________________________________________________________________________ 117
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
118 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
- drilling-spool fixing
_________________________________________________________________________________________ 119
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
3M - 5M
10M - 15M
In the following, the annular BOP is not being examined, and the blind rams are treated as blind-
shear rams, and we assume that drilling spools have been installed but there are no BOP side
outlets (Drill. spool).
120 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
-Reduction of connections
With pipes inside the well: Without pipes inside the well:
-Rams replacement
_________________________________________________________________________________________ 121
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
Note 1: stripping is possible if blind rams are replaced with pipe rams
Note 2: if a double BOP has been installed the hang-off procedure is not possible for lack of space.
122 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
_________________________________________________________________________________________ 123
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
Considerations
124 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
All BOP stack components must be periodically checked and inspected to detect any
malfunctioning or losses. Periodic tests must therefore be carried out including the following:
b. hydraulic test
- annular BOP they must not be actuated at every round trip. They must be actuated at
intervals not longer than seven days.
- with pipes inside the well - without pipes inside the well
open and close the BOP open and close the BOP without waiting for
the BOP complete closure.
_________________________________________________________________________________________ 125
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
- ram BOP operating test is recommended at every round trip, not more than once per
day.
carry out the test during tripping with the rams must not be tested.
bit in the shoe.
Note: since sealing is not required during operating tests, the test aim being that of checking operations, the
lesser of rated working pressure should be applied to avoid damages to the packing units.
Test procedure
The test requires pressurisation of the whole high-pressure circuit to test sealing of all the circuit
components.*
An initial pressure test must be performed on the BOP's that have been installed after the first
assembly (to be done before drilling the casing concrete plug). The test is then to be carried out in
the following situations:
When a choke manifold component is replaced, the test must be performed on that component
only.
Note*: in practice, the choke manifold is sometimes tested separately to speed up the operations.
126 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
Minimum pressure
The equipment should be tested to at least 70% of the BOP working pressure, but limited to the
component with the lowest rated working pressure and to 70% of the minimum yield pressure of
the upper part of the casing string.
The test pressures should never be lower than the expected surface pressure in case a kick should
occur. An exception is the annular BOP which may be tested to 50% of its rated working pressure
to minimize pack-off element wear.
_________________________________________________________________________________________ 127
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
Pressurisation
The test should be performed with water and the necessary pressure is supplied by an auxiliary
pneumatic pump which allows required pressures to be recorded.
The high-pressure pneumatic pump features a low flowrate. Initial pressurisation is therefore
started by means of mud pumps, which allow the maximum allowable pump pressure to be
obtained, and is then continued through the auxiliary pump.
Pressurisation, which is necessary to conduct a pressure test, can also be obtained by means of a
cementing unit (if there is any).
In case of a first installation, start by applying a pressure value lower than the maximum estimated
value; test at 200-300 psi to verify:
rubber elastomers
if no leaks are detected, proceed to perform the high-pressure test. In case of leaks, after
eliminating them, pressurise again to reset the pressure test value.
Tests should be conducted for at least 3 minutes, and is normally kept for 5, 10 minutes.
Conduct pressure test on each component, while keeping upstream and downstream valves
opened.
128 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
- inside BOP
_________________________________________________________________________________________ 129
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
Note (*): carry out enough circulation to prevent any air bubbles from being trapped in the circuit and affecting
the test.
130 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
_________________________________________________________________________________________ 131
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
Test procedure
The test is conducted by using suitable tools which allow the stack BOP pressurisation: cup tester
and plug tester.
Cup tester
Notes: - To start the test, first close the casing spool side outlets.
- To facilitate the tester descent, 2/3 pipes can be screwed in at the lower end.
Plug tester
132 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
The pipe that is used to run in the tester will be recuperated when the
blind rams are tested. The plug tester allows testing of the blind rams,
but not of the casing connections.
During BOP tests the adequate measures should be followed to prevent the casing from being
accidentally pressurised open the casing spool valve to prevent the casing from being pressurised
in case of leaks.
Pressure test
Pressurise the circuit and perform a pressure test on the following components
5. Ram BOP
- sagomate superiori
- sagomate inferiori
_________________________________________________________________________________________ 133
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
- valve 5,9
- valve 6,10
134 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
Plug tester
Before running it in, make sure its size and shape fit the casing spool seat.
When pressure is applied, the casing spool side outlets must be opened to avoid, in case of leaks,
well pressurisation.
Cup tester
It is composed of:
- two screwed-in
elements with a hole
and threaded
connections at their
ends to be connected
to pipes
- a cone-shaped packing
unit (cup), locked
between the two
elements.
_________________________________________________________________________________________ 135
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
The mandrel is screwed in on the connection with the cup element in between, whereas drill pipes
are screwed in on upper and lower ends.
During the test, the pipe is subject to the cup-tester pulling, which adds to thrust (due to pressure).
This double effect involves a decrease of the pipes resistance to stretching and imposes a test-
pressure reduction.
If the cup tester is inserted on the drill string head, to define the pipes thrust schiacciamento
pressure, the pull force created by the weight of the string below also has to be considered.
Note 1: as a rule, a set of pipes in good condition and marked for identification are kept to be used only for
cup-tester pressure tests.
Note 2: during the test the lift supporting the test pipe should rest on the rotary table to reduce hanging force
on the whole system and to ease the pipe passage through the BOP packing units.
To calculate the crush residual pressure residua di schiacciamento(PRC) value, the following
formula can be applied:
where:
136 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi
BOP Stack
________________________________________________________________________________________________________
Note: Maximum pressure values and corresponding pull force values are calculated without any safety
coefficient.
_________________________________________________________________________________________ 137
Saipem - Training center E.Gandolfi
SURFACE WELL CONTROL EQUIPMENT
________________________________________________________________________________________________________
Advantages Advantages
- It allows testing blind rams sealing at the - It does not imply risks of well pressurisation
given pressure because it allows keeping because in case the cup element does not
the well clear of tubing seal, pipes ensure water outlet, preventing
the lower casing section from being
- It does not involve compound force presasurised.
(pulling and external pressure) on the
pipe. It can be run below the casing spool thus
allowing:
Disadvantages
Disadvantages
- It cannot be run below the casing spool.
- it does not allow the blind rams to be tested
without pressurising the well
138 ____________________________________________________________________________________________
Saipem - Training centre E.Gandolfi