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6. 6.1.

SUBSEA WELL CONTROL EQUIPMENT Subsea Well Control Equipment

Subsea BOP systems were initially developed by adaptation from the equipment used on land, so in many respects have similar components to those of surface BOP systems. However, it is apparent that when a BOP stack is located on the seabed there are also many modifications necessary. This section reviews the major features of the subsea BOP system. 6.1.1. Components of the Subsea System

The subsea BOP is most commonly used from a floating drilling unit and must meet unique specifications.

All BOP operations must be capable of being performed remotely with no manual intervention. This includes connection to/from the wellhead. Closed Circuit Television (CCTV) is essential during landing procedures. There must be systems and instrumentation to monitor wellhead position relative to the rotary table. The riser system incorporates the kill and choke lines. It must have flexible elements to accommodate lateral movement of the drilling unit and must have a telescoping element to accommodate vertical motion. It must be supported by tensioners which may be assisted by buoyancy modules. There must be a disconnect system that allows the BOP to be left on the subsea wellhead in a secure state while separated from the riser. There must be guidance system to enable remote mating of connectors. This may be done with or without guidelines. Operating and control systems must meet performance standards despite there being very long hydraulic lines and seawater hydrostatic pressure. Redundancy is important, as the system must not be compromised by the failure of one element. Reliability is important as the system can only be repaired on surface. ROV or diver operable systems should be available for ring gasket change out and for connector release. Hot stabs may be available for other functions. Equipment

6.1.2.

See Figure 6.1.1. BOP Guide Frame Must be compatible with wellhead guidance system.

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Figure 6.1.1: Typical single stack system Wellhead Connector Must be compatible with the wellhead profile. Wellhead suppliers will usually supply profiles to suit the connector installed on a particular rig's BOP rather than change out the connector. The connector must be robust enough to resist bending moments imposed by rig offset, non-perpendicular wellhead and environmental forces, without leaking. Stabbing guide devices must be designed to prevent hydrate accumulation in and around connectors. Ram Type Preventers All high-pressure subsea BOP systems should have four ram type preventers, each equipped with ram locks. One of the preventers is to be equipped with Shearing Blind Rams (SBRs) and the other three with the correct size Pipe Rams (PR) or Variable Bore Rams (VBRs). At least one ram type preventer below the SBRs should be equipped with fixed PRs spaced sufficiently apart to facilitate hang-off and shear. These shall be

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designated the Hang-off Rams. The rated hang-off data of the fixed PR and the VBRs must be available on site. Kill and Choke Outlets Each stack shall have no less than two (preferably four or more) side outlets rated to the same working pressure as the ram preventers, connected one (or more) each to the kill and choke lines. The through diameter shall be not less than 77.8mm (3-1/16). An additional kill/choke line outlet must be installed immediately below the upper annular if local conditions dictate that well kill operations will be done with the annular rather than the pipe rams. This uppermost line is to facilitate removal of trapped gas. All side outlets should be fitted with two fail safe valves each prior to connection with the kill and choke lines. The valves shall be 'fail-safe' in the closed position. The outermost valve in each pair should be pressure competent on the "back" side to facilitate pressure testing the kill and choke lines as the BOP is run. Circulating access to the well bore (or annulus) should always be possible, hence one kill/choke line may be connected to the side outlet below the lowermost preventer. All unused side outlets shall be blanked off. Annular Preventers All BOP stacks must have at least one annular preventer in the main structure. High pressure and single stack systems should preferably have two annulars. The second annular may be mounted in the main structure or alternatively, in the Lower Marine Riser Package (LMRP). This latter configuration may provide the advantage of being able to change the upper annular packing unit without retrieving the entire BOP. Annulars should have a rated working pressure equal to that of the ram type preventers (except for 15,000 psi). However, it is permissible to have a 34,500kPa (5000psi) WP annular preventer on a 69,000kPa (10,000psi) WP BOP stack, and a 69,000kPa (10,000psi) WP annular preventer on a 103,500kPa (15,000psi) WP BOP stack. LMRP Connector Can be similar to the wellhead connector, but should be of a design that allows disconnect even when there is not vertical alignment. The LMRP connector interface will also be the interface for the BOP control system. (See Section 6.3) Lower Flexible Joint (or Lower Ball Join) This accommodates lateral movement of the drilling vessel by transmission of bending moments to the BOP and wellhead rather than being absorbed by the riser. Pressure balancing and correct riser tension are important operating parameters to ensure correct function and longevity of ball joints. The unit must also provide flexible sections for both the kill and choke lines. Forces generated by these components under pressure should be understood. Marine Riser Supplied with integral kill and choke lines that should have an internal diameter no less than 65mm (2-1/2) for shallow water (<50m) subsea wells, 75mm (3) for medium depth (>50m <1000m) and 112mm (4-1/2) for deepwater (>1000m). Choke & kill lines must have working pressure rating equal to the BOP. A third, booster line, is often integral. Apart from its function in assisting clearance of cuttings from the riser at low circulating drilling rates the booster line allows displacement of the riser without interference with BOP functions. Pressure rating of the booster line and valves must be no less than that of the Diverter or Gas Handler system.

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Riser Dump Valve A rarely used remote operated large diameter valve, usually situated at the base of the Marine Riser, that can provide direct connection between the riser contents and the seawater. A Riser Dump Valve may be used to avert riser collapse in the event of riser evacuation or severe loss of circulation. Installed in conjunction with a Gas Handler it may be used to divert a shallow gas flow subsea. Gas Handler (GH) A specialised annular closing device for deepwater floating drilling. The GH is located in the marine riser below the telescopic joint, and has integral valves to permit circulating mud to neutralise a gas intrusion trapped in the riser above the subsea BOPs. Telescopic Joint Permits vertical motion of the drilling vessel without buckling the marine riser. The telescopic joint does not have high-pressure rating on the seals. Telescopic joints should incorporate double seals, to improve the sealing capability when gas has to be circulated out of the marine riser. Kill and Choke line goosenecks at the top of the outer barrel are connected to flexible moonpool hoses that provide the pressure integrity of the well control system connection to the kill and choke manifold. These hoses should be adequately protected from damage. Upper Flexible Joint The inner barrel of the telescopic joint is suspended by an upper ball joint to compensate for pitch, roll and minor off-station of the drilling vessel. Surface Diverter System Situated between the upper ball joint and the rotary table. This enables the annulus to be closed at surface and the returns channelled through the diverter system. Diverter housing, telescopic joint etc. must be locked down. Rigs that can 'weather vane' (i.e. dynamically positioned or turret moored rigs) may have just one diverter discharge line. Diverter lines should be as short as possible, but long enough to conduct flow past the extremity of the drilling vessel. Storm Chokes A retrievable packer to support the weight of the drill string and seal off the casing, with a combination back-off tool/valve, to seal the drill string. When a subsea BOP stack is in use, storm chokes shall be available, sized to match the casing and drill pipe in use. The equipment is used when it is necessary to work on the BOP equipment, or may be used when it is too hazardous to rack pipe in the derrick during adverse weather conditions. Emergency Hang-Off Tool To enable the drill string to be hung off in the wellhead below the BOP. It is run with an IBOP below it and a short slick joint matching the pipe rams above it. After disconnecting from the tool the pipe rams can be closed around the slick joint and the blind rams closed above it, thus securing the well and allowing a riser disconnect with the drill string remaining in the hole. Normally run prior to the onset of forecast bad weather. Care must be taken to ensure that the tool can actually be hung off safely on the wear bushing. It is usually not possible to hang off on a bore protector, in which case it is necessary to use the Storm Choke device.

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Pressure and temperature gauges Should be mounted on subsea BOPs used in deep water. A number of variations in the position of pipe rams, shear rams, and kill and choke line connections are in use in subsea BOP stacks throughout the industry. Many have been designed by Contractors and/or Operating Companies with well control philosophies that differ from those espoused herein, and cannot be changed without major expense. However, if a particular stack configuration is accepted by an OU, the drilling manual/well programme should highlight the differences, limitations and possibilities of the particular layout. 6.2. Operating and Control Systems for Subsea BOPs

Subsea BOP operating and control equipment shall include: 6.2.1. An Independent Automatic Accumulator Unit: Which shall; Be rated for 20,700kPa (3000psi) WP for use with the underwater BOP control system Be complete with a soluble oil/water reservoir, Include automatic proportioning equipment for soluble oil and water, Include a control manifold.

Without recharging, the accumulator capacity shall be adequate for closing and opening all ram type preventers and one annular preventer around the drill pipe, and for closing again one ram type preventer and one annular preventer around the drill pipe and holding them closed against pressure equal to the rated working of the preventers.

Include one electrically driven triplex charging pump and Include two air-driven pumps for charging the accumulators. Be fitted with a regulator, similar to the Koomey type TR-5, which will not "fail open", causing loss of operating pressure. Be located in a safe area away from the drilling floor and the spider deck. Part of the accumulator bank may be installed on the BOP stack for rapid response of the functions, and for operation via an acoustic control. Closing systems of subsea BOPs should be capable of closing each ram preventer within 45 seconds. Closing time should not exceed 60 seconds for annular preventers (see also API RP-53) Two Graphic Remote Control Panels Each one clearly showing 'open' and 'closed' positions for all underwater functions. One panel must be located near the Driller's position. The other panel to be located at a safe distance from the substructure and adjacent to the escape route from the drilling unit, or in the Toolpusher's office.

6.2.2.

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6.2.3.

A meter for indicating control fluid flow should be located on each remote control panel. The panels should be connected to the control manifold in such a way that all functions can be operated independently from each panel. A Dual Hydraulic Or Electro-hydraulic Cable and/or Hose System Must provide 100% redundancy of control for all functions of the BOP stack. The nature of the interconnections between the surface control equipment and the underwater BOP stack depends on the type of control system. For the direct hydraulic and pilot-operated hydraulic systems, integrated multiple hose bundles are commonly used. For electro-hydraulic systems the electrical interconnections may be combined into integrated 'umbilical' cable bundles. Alternatively the hydraulic hose can be handled separately. As a general rule, the original total lengths of the flexible control cables and hoses should be 90m (300ft) greater than the maximum water depth for which the system is designed. An Independent Emergency Control System (Acoustic System) Installed on all deep water and dynamically positioned rigs. When installed, should have as a minimum, the capability to close one pipe ram and the shear rams, and open one hydraulic connector, in the event that the BOP functions are inoperable due to a failure of the primary control system. The dedicated accumulator bottles on the BOP stack for the acoustic system should be fitted with non-return valves to prevent accidental dumping and should be of sufficient capacity for one activation of each of the emergency control functions plus 50%. General Remarks Electrical equipment shall be suitable for the zone in which it is installed (Zone 1 or 2). BOP control fluid shall be protected against freezing. When a surface diverter system and a subsea BOP stack are employed, two separate control/accumulator systems are required. This will allow the BOPs to be operated and the riser disconnected in case the diverter control system is damaged and loses pressure. Testing Subsea Wellheads and BOP Equipment

6.2.4.

6.2.5.

6.3.

Regular function and pressure tests are the only way of checking the performance of a subsea BOP system. This section covers testing requirements.

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6.3.1.

Philosophy

Although the results of a test are only an indication of the condition of the equipment at the time of the test, regular testing is the best means of;

6.3.2.

Checking that the equipment maintains the ability to perform its function. Monitoring changes in functional characteristics that may indicate prudent intervention prior to actual failure. Tests Before Lowering the BOP Stack All subsea BOP stack components which can be tested at surface shall be installed, checked, and pressure tested to their rated working pressure and to a low pressure of 3450kPa (500psi) whilst the stack is mounted on the test stump. Control components subject to frequent failure (e.g. SPM) should have their pressure resistance verified prior to installation of the BOP stack by testing to anticipated operating / hydrostatic pressure in a pressure-cabin on the rig. After the surface tests, all clamp connections and all studded connections must be checked for tightness. The complete BOP operating unit shall be tested in accordance with manufacturers' recommendations and pressure tested to its rated working pressure. The test shall include at least the following:

To test every BOP control; To check that each function is properly connected; To activate the functions which are indicated from both control pods; To check operating volumes and response times for each function.
The choke manifold, valves, kill and choke lines and failsafe valves shall be pressure tested with water to the rated working pressure of the ram type preventers, or the rated working pressure of the manifold, whichever is the lower. All lines shall be flushed to ensure they are not blocked. No tests shall be performed against closed chokes. The kelly or top drive and kelly cocks shall be pressure tested to their rated working pressure with a test sub. Tests During Lowering And After Connecting The BOP Stack, Kill & Choke Lines, Marine Riser And Operating Hoses. When running the BOP stack on riser joints, the kill and choke lines shall be pressure tested at least when the stack is below the splash zone and both before and after landing. The frequency of other tests during running the stack will depend on water depth and equipment reliability. After the BOP stack is connected to the wellhead, a full function test on both pods, plus a low pressure test of 3450kPa (500psi) under the blind ram, shall be carried out prior to rig down of running/retrieving tools.

6.3.3.

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All blowout preventers, wellhead components, their connections, and the kill and choke lines shall be pressure tested with fresh (drill) water whenever feasible. A small amount of soluble oil should be added to the test water. This has the benefit of minimizing injection of corrosive fluids into components at high pressure, and assists in leak detection. To prevent excessive pressuring of the kill and choke lines, the BOP stack may be tested through the string by using a perforated test sub or test joint connected to the Plug Type Tester (PTT). The PTT or combination Cup Type Tester (CTT/hang-off tool) is landed inside the wellhead housing and packs off the hole below the test tool seals. Caution is required to ensure that the casing below the test tool, or the casing/casing annulus, is not pressurized should the test tool or casing hanger seals fail to seal. This can be done by monitoring accurately the fluid volume pumped during each pressure test. The test single of drill pipe must be rated to withstand the collapse pressure applied. Heavyweight pipe with center upset removed is often suitable. The test single of drill pipe should be painted white when run for the first pressure test. The rams will leave imprints on the white paint and the depth of each relative to Rotary Table (RT) and the wellhead landing shoulder should be noted. The pressure applied on the initial test should be the rated working pressure of the wellhead or the ram type preventers, whichever is lower. It shall also be pressure tested to a low pressure of 3450kPa (500psi). Subsequent pressure tests of the wellhead and/or ram preventers should be to the maximum anticipated wellhead pressure (as per original well design if not subsequently modified). They should also be pressure tested to a low pressure of 3450 kPa (500 psi). Subsequent pressure tests for the annular preventers should be to maximum anticipated wellhead pressure with a maximum limit of 70% of the rated working pressure. They should also be pressure tested to a low pressure of 3450 kPa (500 psi). All equipment shall hold the applied test pressure for at least 10 minutes. The opening/closing times and the volumes of hydraulic operating fluid required for the operation of the various underwater stack components (i.e. rams, kill and choke line valves, annular preventers, hydraulic connectors, etc.) should be recorded during testing of the stack underwater and compared with the normal opening/closing times and volumes required of the hydraulic system. Any major differences are an indication that the system is not operating 'normally' and requires further investigation and possible repair. All pressure tests should be done according to a schedule drawn up to ensure that all components are tested and it is done in the most efficient manner. Tests For Accumulators The accumulator bottles pre-charge pressure (nitrogen) should be checked at minimum 30-day intervals. Unless otherwise specified, the pre-charge pressure for a 20,700kPa (3000psi) WP system should be 6900kPa (1000psi) 10%.

6.3.4.

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Accumulator tests should be performed prior to first use of BOP's, or after repairs have been made to the accumulator system, i.e. bottles, bladders, pumps, etc. The accumulator unit performance test is made by operating all BOP's on the stored energy in the accumulator, i.e. the pressure and the volume available without recharging. The complete test procedure is as follows: 1. 2. 3. 4. Check accumulator fluid pressure. Check accumulator reservoir level. Switch off accumulator pumps. Close and open all preventers in sequence and check accumulator fluid pressure after each function and the volume of fluid used for each function for subsea units. Record closing times. Adequate pressure and volume should still be present to close one annular and one ram type preventer. Pre-charge pressure should still be the same in all accumulator bottles. Switch on accumulator pumps. Record accumulator recharging time. It is recommended to check the recharging capacity of the air pumps with the electric power switched off prior to start up of a newly contracted rig. Check BOP closing times and accumulator recharge time with manufacturer's data for the system in use. Cycle the annular preventer and check that the pumps will automatically start when the closing unit pressure has decreased to less than 90 percent of the accumulator operating pressure. This should be checked with only the electric pumps operative. Should an emergency control system be employed, this should also be tested at the same time as the accumulator unit. Results should be recorded on the daily tour sheets and the Blowout Prevention Equipment Checklist

5. 6. 7. 8. 9.

10. 11.

It is of utmost importance that the accumulator unit can be charged with only one of the two power systems operative. 6.3.5. Test Frequency The pressure tests of all blowout preventers, wellhead components and their connections, BOP operating unit, choke manifold, kill and choke lines, kelly or top drive and kelly stop-cocks shall be made in line with government regulations and/or: 1. 2. 3. After installation of wellhead and BOP assembly and prior to drilling. Normally on a bi-weekly basis that may be extended to accommodate ongoing operations or anticipated activities during the extension period. At any time requested by the Company drilling representative.

Results of all pressure tests shall be recorded on the daily tour sheets and the Blowout Prevention Equipment Checklist.

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6.3.6.

Functional Tests, Inspections and Precautions All preventers which close around pipe, all pressure and manually operated kill and choke line valves, and all kelly cocks, shall be operated a minimum of once per week. All ram type BOP's should be function tested at a reduced operating pressure of not more than 10,350kPa (1500psi). The blind/shear rams should be functioned at least once a week.

Should any of the above tests indicate faulty equipment, this equipment must be repaired and re-tested before drilling resumes, or before any other operation related thereto is continued.

6.4.

Inspect the tightness of flange bolts and clamps frequently, particularly after pressure testing. Pump through kill and choke lines at regular intervals (daily), and displace weighted mud from choke manifold and kill lines. In freezing or hydrate conditions replace mud in lines with inhibited fluid. Operations Related to Subsea BOP Systems

Floating drilling vessels are constantly in motion and subjected to environmental forces. Special operations and procedures have been developed to enable them to safely survive severe weather conditions and station keeping difficulties. This section reviews those operations that involve the subsea BOP system. 6.4.1. Running The BOP Stack. The BOP stack can only be run if weather conditions are reasonable and vessel movement is such that heavy lifts can be safely restrained. The rig operations manual should specify maximum limits for heave, roll and pitch for these operations, otherwise the contractor's Senior representative (Toolpusher) should be responsible for the final decision. Stack running procedures are very much rig specific and the contractor must have a detailed procedure included in the rig operations manual. Some special considerations are listed; The rig must be moved away (minimum 15m - 50ft) from the wellhead and any subsea installation before any part of the BOP assembly is moved over the moon pool. Several joints of marine riser must be made up first so that when the stack is run it can be lowered through the splash zone with minimal delay. New original manufacturers or approved gasket seals must be installed in the LMRP connector and the wellhead connector. The kill and choke lines should be pressure tested when the stack is just below the splash zone, at regular intervals whilst running, and prior to landing the stack on the wellhead.

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After landing the stack and before nippling up the diverter, the wellhead connector should be checked with a test pull with the motion compensator and pressure tested to 3500kPa (500psi) below the shearing blind rams. Hanging-off

6.4.2.

Whenever forecasts predict that severe weather can be expected and that there is a likelihood that it will exceed the operational limits of the drilling vessel, the drill string should be pulled (or run) to place the bit at the casing shoe and hung-off. There are three types of hang-off tool that can be used in different situations; 1. Emergency hang-off tool which lands in the wellhead. These tools are wellhead specific and most cannot be used until after the first string of casing has been run and landed in the wellhead. i.e. It cannot be used while drilling 17-1/2" hole through an 18-3/4" wellhead. Hang-off Donut which is landed on a lower pipe ram. These tools are suitable for any hole/casing size provided the hang-off capability of the pipe ram is not exceeded. Storm Choke which is set in the casing. Usually reserved for sealing the well to enable BOP repairs to be effected, but can be used for foul weather hang-off when neither of the above two systems is suitable. This packer should be set in a section of casing that is well cemented. Subsequent retrieval operations should be performed with the section of the work string in the BOP pipe or VBR ram compatible and capable of being sheared by the SBR.

2.

3.

Only tools designed for this purpose can be used, and they must have left hand release and centralized right hand recovery threads. It is not acceptable practice to hang off on a drill pipe tooljoint and back out of the string.

The appropriate tool should be made up to a stand of drill pipe and stood in the derrick where it can be easily retrieved and run. An inside BOP should be run below the tool. Space out is critical and it must allow a set of pipe rams to be closed around the body of the tool and the shearing blind rams to be closed above the tool after the landing string is disconnected. Well pressure must always be checked through the kill and choke lines before opening the rams for retrieval of the drill string. There should be BOP outlets above and below the ram used to seal around the hung off string so that both annulus and drill pipe pressure can be checked. Shearing Drill Pipe When faced with either well control or station keeping problems and where conventional hang-off is impossible, it may become necessary to shear the drill string. This may be achieved with pre-programmed emergency disconnect systems. The urgency of the problem will dictate the procedure to be used, but whenever possible, the pipe should be hung-off on a tooljoint on the designated hang-off ram before activating the shear rams. If this cannot be accomplished then it is better to set the bit on bottom first rather than allow the string to drop after shear.

6.4.3.

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All well control operations should be conducted with the pipe hung off on a tooljoint on the designated hang-off pipe rams and the ram lock closed. This is to allow the pipe to be sheared immediately without loss off control of the well, in the event that it becomes necessary.

There must be absolute certainty that the tubular section opposite the shear ram can in fact be sheared. If it cannot (i.e. Heaviwate through the BOP) then the string (containing an IBOP) must be dropped and the shearing blind rams closed above the dropped string. The dropped string should be planned to be below the BOP. Shearing Casing It is only possible to shear certain casing strings. The shear capabilities of the BOP should be known before commencing any casing job. When shearing is not possible procedures must be developed for dropping the casing string provided the hanger has not been made-up. It will not be possible to hang-off the casing prior to shear. Disconnecting The necessity to disconnect is dependent upon the prevailing and forecast weather conditions, the rig's motion characteristics and station keeping ability. Whenever it has been deemed prudent to disconnect at the LMRP connector, the drill string should have been hung-off or it must be sheared. The BOP must be closed and the well secured. Disconnection may not be possible if rig offset exceeds the design limits of the connector. Alarms and auto-disconnect parameters should be defined in accordance with wellhead specification, water depth etc. Once disconnected, the LMRP should be pulled well clear of the BOP. This may entail laying down the telescopic joint if adequate clearance cannot be gained by ballasting. The rig should be moved away from the wellhead and any subsea installations. The guidelines (if used) should be slackened.

6.4.4.

6.4.5.

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