1)

Why are two valves installed on outlets side of BOP stacks? Which valves are
normally used, and why?
The two choke line valves on or adjacent to the stack, the inner manual valve is
kept open, and the second (the remotely controlled hydraulically activated gate
valve) kept closed during drilling.
Wherever two valves are fitted it is standard practice that the second valve is
the one operated and the first one used as backup, in case the second one fails.
3)
What is the reason why a gate is difficult to open when there is pressure in
the line upstream of it? What can be done to overcome this.
Most gate valves in use on choke and kill systems and indeed most wellheads
are of a floating slab design. That is to say, when pressure is applied
from either direction, with a lower pressure on the other side of the
valve, the slab will move against its seat and seal off. This differential
pressure assists in the sealing mechanism of the valve but also acts as a
force on the slab and seats. Hence a gate valve with a large differential
across the gates and seats, from either upstream or downstream, shall prove
very difficult to open due to the forces acting on the gates and seats.
These forces can be overcome by equalizing the pressures across the gate
valve from both the upstream and downstream sides of the valve, either by
bleeding the pressure down or by applying pressure to the side of the valve
that has a lower pressure, until pressures are equal across the valve. Once
pressures are equalized the valve should open easily.
4)

Which of the two remotely controlled chokes could, if necessary, be used to

close in the well.

a positive sealing choke is the Swaco Super Choke (whereas the Cameron AX
Type is not !), which can be used to hold full well pressure. Most
manufacturers have a positive (sealing) choke in their product brochures,
because customers demand this. But it is not an API RP16 specific
requirement. If you have no detailed information on the capabilities of a
choke, then it must be treated as non-positive sealing, i.e. only meant to
apply backpressure.
5)
Does the well pressure assist in keeping the packing element of an annular
BOP firmly around the drill pipe?
It really differs from manufacturer to manufacturer and from type to type.
Most Hydril Annular Preventers are well pressure assist, but not all of them
are. Shaffer is also well pressure assist as can be seen on the picture
attached. The Cameron type Annular Preventers (like the one used on
Changbei wells, the DL type) are NOT well pressure assist. There are a few
other ones, which are not well pressure assist either.

6) Name three operational factors which will shorten the life span of annular
preventer elements.
The closing pressure as regulated through the control system should be as low as
practically possible in order to maximize the life of the packing unit.
Testing the annular preventer under high test pressures significantly shortens the
life of the packing element.
Closing the annular preventer without pipe in the hole will shorten the life of
the packing element, especially when high closing pressures are required to
achieve this.
The fourth one and also very important is the motion reversal (going up and
down) of the string, especially across the tool joint. We should pay
attention to the condition of the tool joint (because of the detrimental
effects of hardfacing on drill pipe, the tong die marks), as well as the
closing pressure with which we allow the tool joint to pass, the lack of
lubricant when we move the drill string through the packing element, either
up or down etc. as these are all important as well. Reversing the direction
of motion (of drill pipe) when the element is closed around it does indeed
lead to a shorter life span.

We should also store the packing element in a relatively cold place. When
the Preventer is not used it should remain in vertical storage and not be
laid down to prevent deformation of seals (the element itself should be
okay).
7)
If a ram type preventer were to be installed upside down, would it still
operate and function?
The top seals of the rams would upside down as well and not have a seal face to
seal against. The seals would also extrude (and thus damage), making them
ineffective. Also the outlets would be on the wrong end (above the ram, instead of
below).

8)

Describe one situation when you might use variable bore rams?

The variable bore ram extends the versatility of the BOP. It allows a single set
of rams to seal on several different sizes of pipe or even on the hexagonal Kelly.
For example, the variable ram for a 16 bore BOP can seal on diameters from
88.9 to 177.8 mm (3 to 7) Variable rams are used when we use tapered
strings or when we have to run multiple sizes of completion joints.

However, I would NEVER use it on a hexagonal Kelly as these rams are only
meant to seal on round surfaces. Use an Annular Preventer for kellies !
It would also avoid changing the rams when we go from a drilling phase to a
completion phase.
9)

What is a disadvantage of variable bore rams?

1. The variable bore ram should not be used in 103,500kPa (15,000 psi) WP or
higher rated BOP stacks if maximum wellhead pressures in excess of 69,000 kPa
(10,000 psi)could occur during a well control situation.
2. Operationally we can say that the string can ONLY be hung off on VBRs
with limited string weight and with some substantial risk of damage to the
packing elements.
3.Variable Rams also have a temperature limitation [applicable to High
Pressure/High Temperature wells].
4.Last but not least, variable rams are very expensive to buy and to
replace damaged packing elements when worn.
10) a) When would you use shear rams?
would be when there is an uncontrolled flow from the drill string and when
it would be considered or maybe perceived impossible to install a FOSV
(Full Opening Shut-Off Valve) or IBOP (Inside BOP).
A special situation would be if its not possible to drop the drill string
due to depth limitations (close to bottom) or because of relatively high
lifting forces exerted on the drill string by the fluid pressure below it,
trying to push the string upwards. There could also be a combination of
factors, which would jeopardize the well control recovery in general, hence
closing the shear rams might not be as easy a decision as it may seem on
paper.
b) Which factors are important in determining that the shear is successful
and that a seal is established

The size and strength of the pipe

in use is critical (sometimes
forgotten by careless
contractors or operators); it
must match the specified range
and if not correct, could

create an even bigger problem

(and it would then have been
better to drop the string
itself). Some Drillers have
tried to shear HWDP or the
wrong size/grade drill pipe
(again because they were in
panic), but of course.. it
wont work and dropping the
string (if still possible)
might then be the only option
left.
that the string is aligned. Most shear rams have self-aligning features, but prealigning is really helpful. Preferably, the string should be hing off !
11) a) Find out what, in general, are the two methods for gaining access to the
rams in order to replace them. What are they, and which manufacturers uses each?
Cameron type U BOP. For Cameron type U BOP, the bonnet bolts are loosened
allowing the ram closing pressure on the closing port to open the bonnets
and give access to the rams.
Shaffer Ram type BOP. For Shaffer (but also for Hydril, not mentioned by
you !) type BOP, each ram and its operator is completely self-contained in
the end section, with hydraulic connections built into the hinge.

b) Can you think of advantages one over the other?

The special design features of the Shaffer BOP are that each ram and its operator
are completely self contained in the end section, with hydraulic connections
built into the hinge. This eliminates drainage problems and the need to break or
remake connections when changing or servicing ram. Rams are easily changed by
unbolting and swing open the doors. The bottom doors swing out from under the
upper cylinders so a hoisting line can be attached directly to the rams for easy
handling.

When using the Cameron U type BOPs with a double ram configuration and
if we have to change the bottom rams, it is difficult to get access, as
rams have to be pulled side-ways to be removed. The hinged units from
Shaffer and Hydril never have this problem. Note that BOP technicians
prefer Shaffer BOPs for other (technical/ maintenance /service) reasons as
well.

12) If there is a hydraulic system failure, what can still be done with the rams
of the BOPs ?
we must close the rams manually
13) What is the most common method of locking ram type preventers
mechanically? Which method is used by which manufacturer?
Camerons locking mechanism. It is a simple bolt engaging the thread in a
locking screw housing that is flanged onto the bonnet. It can be used to
close the rams in the absence of hydraulic power, but you cannot re-open
these as there is no solid connection with the operating piston.
Shaffers locking mechanism: it is a bolt which screws not into a housing
but into the ram shaft itself. Once the rams are closed the locking shaft
is backed out of the ram shaft until a collar shoulders against the
cylinder head.
Hydrils locking mechanism: it is virtually identical to the one used by
Shaffer. Hydrils hydraulic locking mechanism is called Multiple Position
Locking and also locks the rams automatically each time that they are
closed.

13) Give two situations when you would lock a pair of rams (assuming that does not
happen automatically every time they are closed) ?
When a well has to be closed in for a long period
When the drill string is to be landed on the rams.
14) The three manufacturers of BOPs use very different methods of hydraulically
locking BOP rams.
a) Which is the simplest: the Cameron Wedge Lock
b) What are its disadvantages compared with the others?
The main reason is that is has the additional complication and cost of
a second hydraulic-function for locking the ram.
15) a) What is the function of a "weep hole" ?

A weep hole is a tell tale for seal leakages within the BOP. It is
something we find on every Ram Type BOP. If something drips out of this
weep hole then this could be (a) oil or (b) mud or a combination of both.
If it is oil (accumulator oil) then the O-ring on the Operating End of the
BOP is leaking and if it is mud, then the Hycar Lip Seal will be leaking
(this seal faces the well bore). The weep hole is in the middle of these 2
seals and if everything works fine, then there is no leak.

b) If you were drilling and you noticed the hole "weeping" what would you do?
Of course, it really depends on circumstances on what we do first
If we find to have a leak, then we need to replace the seals, but this
means dismantling the BOPs and this can only be done when the well is made
safe. If we cannot make the well safe or when we are engaged in well
control operations (the worst case..!), then we need to squeeze plastic
sealant across a secondary seal (this seal is located in between the O-Ring
Seal and the Hycar Lip Seal and is normally not activated/energised). So
the secondary seal is a back-up for emergencies only. At the first
opportunity we have/get, we should replace the leaking seal(s).

16) Under what circumstances is a diverter used instead of a BOP?

If a kick is taken when the conductor is set in incompetent formation, the well
will not be shutin, but diverted instead.

17) If there were to be a kick in the above circumstances, what do you think might
happen if a BOP were used (and closed)?
If use BOP to closed the well, gas in the hole would get into and through the
formation possibly to surface due to the high pressure. And even if a casing would
have been set, the gas might go around the casing and cement and find a path to
surface.
18) When operating the remote control of the hydraulic BOP closing unit, how is
the signal transmitted to shift the four-way valve?
Four way valves are used for closing and opening the blow out preventers and
they are actuated either by remote control which activates a hydraulic cylinder,
or by hand. If remotely operated, a pilot signal may first activate a three way
pilot valve. The pilot signal can be either electric (solenoid valves), acoustic,
hydraulic or pneumatic.
19) a) Where are regulators placed in the system?

One is between accumulator and annular. -Annular regulator

One is between accumulator and manifold. Manifold regulator
b) Give two reasons why regulators are used.
The most important and first reason is to allow the accumulator to operate
at high pressures (3000 psi) and thus store sufficient energy for several
operating cycles.
The second reason is to ensure that the correct operating pressure is
maintained even if relatively insignificant leaks allow fluid to escape
from the system, and the third reason is to isolate the system from
pressure fluctuations due to the pump starting and stopping.
We also regulate the pressure for stripping purposes (which is what you
mentioned), but this is not the main reason for which regulators are used.
20) Name three small well-control related items that should be available on the
drill floor while tripping?
o

A Gray Valve should simply be called a IBOP [Inside Blow-Out Preventer],

in accordance with API and IWCF;

o A Kelly Cock should be called FOSV [Full Opening Safety Valve, in
accordance with API and IWCF]
o

Another well control item we could have available on the rig floor is a

dart for the drop-in sub, which is another means of having a IBOP in the
drill string.

21)

What is the advantage of an inside blow-our preventer, like the "Gray" type

of valve when a well starts to flow?

All these valves are check valves closing with flow from below but free to pump
through from above. It also facilitates stripping operations.
22) The kelly cock is provided with a "key" to open/close the ball valve. Where on
the drill floor would you keep this key?
Regulations specify that this key or spanner must always be within the drillers
reach.
23) a) When using a mud/gas separator why do we want to maintain a "mud seal" at
all times?
If gas pressure in the separator overcomes the hydrostatic pressure of the fluid
in the U tube trap at the separator bottom, gas will blow through into the
shaker room.
b) How can we ensure that the mud seal is not breached during the well kill
operation?

The U-tube or liquid outlet system should be arranged to provide a minimum U

tube height of at least 3 m.
24) a) Determine the maximum test pressure the drill pipe can withstand when
testing 13 3/8" 68 lbs/ft, K55, New VAM casing with a cup type tester run on 5"
19.5 lbs/ft, premium class G pipe.
The internal yield pressure of 13 3/8" 68 lbs/ft, K55, New VAM casing=23.8Mpa
(Drilling Data Handbook)
23.8 x 0.91=21.66Mpa
The internal yield pressure of 5" 19.5 lbs/ft, premium class G
pipe=436150lb(Drilling Data Handbook)
436150 x 0.77=335835.5lb Incorrect. It should be multiplied by 0.85 ! The 0.77
is only for installation of casing and not for drill pipe.
335835.5/A=335835.5/(12.4152 - 52)x3.14/4=3313psi=23.19Mpa this would be 25.2
MPa if you would have used a 0.85 SF.
23.19Mpa>21.66Mpa
So the answer is 21.66MPa
b) Determine the maximum test pressure the above casing can withstand when the
string is
3,000 ft long and the buoyancy factor is 0.800. Assume a vertical well. The fluid
inside the casing has a density of 1,200 kg/m3 (10 lbs/gal) and the fluid outside
the casing has a density of 1,680 kg/m3 (14 lbs/gal).
My calculations were as followed:(a)
(b)

Burst strength. Already calculated by you and was indeed 21.66 MPa
Tensile strength

The nominal tensile strength of

the casing is yield x cross
sectional area =
55,000 x 19.45 = 1,070,000 lbs (taking into account the 1.3 design factor
for tensile stresses), > what is left is 1,070,000 / 1.3= 823,076 Lb

The hanging weight: 3,000 x 68

x .80 = 163,200 lbs > what is
left = 823,076-163,200 =
659,876 Lb

Maximum Test Pressure = Force (Tensile) / Area

Hence test pressure is 659,876 / (12.415

x 3.14/4) = 5453 psi or 37.60 MPa

The max test pressure is the lower of these two values, which is 21.66 MPa

26) How often are routine pressure tests of well control equipment made?
The standard EPA procedure [thus also for SDA] is to conduct a test every 2
weeks. To conduct a test every 3 weeks requires an exemption and this
exemption is sometimes given (like for Changbei in China).
27) Name four other situations when BOPs are pressure tested.
After installation of wellhead and BOP assembly and prior to drilling
Every week or every fortnight, depending on type of operation, operators or
governmental procedures/regulations.
Prior to drilling into expected high pressure zones
Prior to a production test.

30) When is a pressure test acceptable?

Indeed, a constant pressure during the full 10 minutes of test is the ideal
result, but a certain drop in pressure is also often acceptable, depending
on the way in which this drop occurs, if the initial drop of less than 10%
and then stable for the remaining time then the test is considered
acceptable.
Note that EPA has a tighter control on this than EP2002-1500, which states
that the pressure drop should be less than 10%. The EPA Standard states a
pressure drop of up to 2% within the first 5 minutes is acceptable,
provided the pressure then remains constant for the remaining 5 minutes.