Well Control Equipment PDF

Section 7: Well Control Equipment
PVD Training
May 8, 2015
Authored by: Pham Van Thien
PVD Training
Contents
7.1 Ram Blowout Preventer ..........................................................................................................................2
RAM BLOWOUT PREVENTERS - CAMERON U BOP .............................................................................2
SHAFFER SL RAM BLOWOUT PREVENTERS ..................................................................................... 11
SHAFFER MODEL SL POSLOCK SYSTEM ........................................................................................... 13
SHAFFER ULTRALOCK LOCKING SYSTEM ..................................................................................... 13
HYDRIL RAM PREVENTER .................................................................................................................... 13
HYDRIL MPL AUTOMATIC RAM LOCKING ........................................................................................... 14
EXAMPLE OF CLOSING FORCES IN RELATION TO AREA ................................................................. 15
7.2 Annular Preventers................................................................................................................................ 16
CAMERON MODEL D ANNULAR PREVENTER .................................................................................. 16
HYDRIL GK ANNULAR ........................................................................................................................... 17
HYDRIL TYPE GL 5000 PSI ANNULAR BLOWOUT PREVENTERS PATENTED ................................. 18
SHAFFER SPHERICAL BLOWOUT PREVENTERS .............................................................................. 19
7.3 Diverters ................................................................................................................................................ 20
7.4 Gaskets, Seals and Wellheads.............................................................................................................. 23
7.4.1 API Flanges .................................................................................................................................... 23
7.4.2 API Flanges [Subsea BOP] ............................................................................................................ 24
7.4.3 Hub Connections ............................................................................................................................ 24
7.4.4 Ring Joint Gaskets.......................................................................................................................... 24
7.5 Manifolds ............................................................................................................................................... 26
7.6 Inside BOPs ......................................................................................................................................... 31
Full Opening Safety Valve (FOSV) .......................................................................................................... 32
VALVES................................................................................................................................................... 32
7.7 Blowout Preventer Stack Arrangements Surface Installations............................................................... 34
7.8 Testing and Inspection .......................................................................................................................... 36
7.8.1 Hydrostatic Body or Shell Test........................................................................................................ 36
7.8.2 Function Test .................................................................................................................................. 36
7.8.3 Pressure Tests................................................................................................................................ 36
7.9 Closing Units Surface Installations ..................................................................................................... 38
Accumulators ........................................................................................................................................... 40
Surface BOP Control Systems ................................................................................................................ 40
| 7.1 Ram Blowout Preventer 1

PVD Training
7.1 Ram Blowout Preventer
Ram type preventers consist of two hydraulically actuated horizontally opposed rams which are designed to
either seal off an open hole or annulus containing a pipe of a specific diameter. At least one ram
preventer should be fitted with rams to suit each size of pipe in the hole. Variable bore pipe rams are
also available for most ram preventers. The working pressure of ram type preventers should be equal
to the maximum anticipated surface pressure, plus a margin for pumping into the hole.
There are different types of ram preventer, as outlined below:
RAM BLOWOUT PREVENTERS - CAMERON U BOP

The Cameron Type U preventer is a wellbore pressure assisted ram preventer suitable for surface or
subsea installations. Since the tail end of the operating rod is enclosed within the preventer, it is not
possible to determine the position of the rams through exterior observation.
The outstanding feature of the Type U preventer is its ability to pump open the bonnet doors.
After removing four bonnet bolts, applied closing pressure will open the bonnets for easy top-load ram
changing. The Cameron Type U preventer is shown below.
Fig 7.1.1 - Blowout Preventer

The Cameron U BOP is the most widely used ram-type BOP for land, platform and subsea applications
worldwide and offers the widest range of sizes of any ram-type BOP. Like all other Cameron preventers,
the rams in the U BOP are pressure-energized.
Wellbore pressure acts on the rams to increase the sealing force and maintain the seal in case of
hydraulic pressure loss. Seal integrity is actually improved by increased well bore pressure. Other
features of the U BOP include:
Hydraulic stud tensioning available on larger sizes to ensure that stud loading is consistently accurate and
even.
Bonnet seal carrier is available to eliminate the need for high makeup torque on bonnet studs and nuts.
Hydraulically operated locking mechanisms, wedge-locks, lock the ram hydraulically and hold the rams
mechanically closed even when actuating pressure is released. The operating system can be interlocked
using sequence caps to ensure that the wedge-lock is retracted before pressure is applied to open the
BOP

PVD Training
Fig 7.1.2 - Cameron U - Type BOP

Pipe Rams
Cameron pipe rams are available for use in Cameron ram-type BOPs to centralize and seal around all
specific sizes of tubing, drill pipe, drill collar or casing.
Cameron pipe rams are self-feeding and incorporate a large reservoir of packer rubber to ensure a long
lasting seal under all conditions.
Ram packers lock into place and are not dislodged by well flow
All Cameron pipe rams are suitable for H2S service per NACE MR-01-75.
CAMRAM top seals are standard for all Cameron pipe rams (except U BOPs larger than 13-3/4).
CAMRAM 350 packers and top seals are available for high temperature service and for service in which
concentrations of H2S are expected
Fig 7.1.3 - Pipe Rams

PVD Training
Variable Bore Rams
Variable bore pipe rams are designed to pack-off around a range of sizes. For example, one set will
provide backup for two different pipe rams, e.g. 3 and 5 or 5 and 7.
Some variable bore rams have a limited hang-off capacity, which is dependent on tool joint size and ram
range. If the tool joint outside diameter (O.D.) is less than the maximum capability of the variable ram, the
tool joint can be forced through the ram packer by surface pressure.
Cameron offers the following range of variable bore rams [ VBRTM and VBR-IITM] sizes to suit units U, UL and
UM.
Table: 7.11
One set of Cameron variable bore rams (VBRs) seals on several sizes of pipe or hexagonal kelly,
eliminating the need for a set of pipe rams for each pipe size.
Features include:
VBR packer contains steel reinforcing inserts which rotate inward when the rams are closed so the
steel provides support for the rubber which seals against the pipe.
All VBRs are suitable for H2S service per NACE MR-01-75.
CAMRAM top seals are standard for all Cameron VBRs.
Fig 7.1.4 - VBRs

PVD Training
Shearing Blind Rams
Shear/Blind Rams are designed to cut the drillpipe and then act as blind rams to contain well bore
pressure.
The pipe should be stationary and in tension, if practical, before shearing. Care should be taken to ensure
the tool joint is not opposite the rams.
It may be necessary to increase manifold pressure above 1500 psi to shear. Pipe size and grade may
be limiting factors to the shear process, even at maximum manifold pressures.
Cameron Shearing Blind Rams (SBRs)
Cameron shearing blind rams (SBRs) shear the pipe in the hole, and then bend the lower section of sheared
pipe to allow the rams to close and seal. SBRs may also be used to close on open hole
for normal drilling/completions/work-over operations.
Features include:
Large frontal area on the blade face seal reduces pressure on the rubber and increases service life.
Cameron SBRs can cut pipe numerous times without damage to the cutting edge.
The single-piece body incorporates an integrated cutting edge.
CAMRAM top seals are standard for all Cameron SBRs.
H2S SBRs are available for critical service applications and include a blade material of hardened
high alloy suitable for H2S service. DVS rams are shearing blind rams which are similar to SBRs
with the following features:
DVS (double V shear) rams fold the lower portion of the tubular over after shearing so that the lower
blade can seal against the blade packer
DVS rams include the largest blade width available to fit within existing ram bores

PVD Training
Fig 7.1.6 - Shaffer Type 72 Shear Rams

Type 72 Shear Rams
Type 72 Shear Rams shear pipe and seal the well bore in one operation. They also function as blind or
CSO (complete shut-off) rams for normal operations.
The hydraulic closing pressure required to shear commonly used drill pipe is below 1,500 psi for BOPs

PVD Training
with 14' pistons. These pistons are standard in all BOPs rated at 10,000 psi working pressure and
higher. On lower pressure preventers, optional 14" pistons can be supplied for shearing instead of the
standard 10" pistons.
When shearing, the lower blade passes below the sharp lower edge of the upper ram block and shears the
pipe. The lower section of cut pipe is accommodated in the space between the lower blade and the upper
holder. The upper section of cut pipe is accommodated in the recess in the top of the lower ram block.
Closing motion of the rams continues until the ram block ends meet. Continued closing of the holders
squeezes the semicircular seals upward into sealing contact with the seat in the BOP body and energizes the
horizontal seal. The closing motion of the upper holder pushes the horizontal seal forward and
downward on top of the lower blade, resulting in a tight sealing contact. The horizontal seal has a moulded-
in support plate which holds it in place when the rams are open.
General Comments:
The majority of ram type preventers in use are manufactured by Cameron (types U and T), NL Shaffer (types
LWS and SL) and Hydril (types V and X). Most models share common features:
Self-Feeding Action of Ram Packer Elastomer.
The front elements of ram seals have steel plates bonded to the rubber elastomer. The steel plates are
designed to contain and extrude the rubber elastomer, thereby affecting a seal. If the rams are used for
stripping pipe, the front face of the ram seal will wear.
The self-feeding action will ensure worn rubber is replaced.
Ram Locking Devices
Hydraulically operated ram preventers are provided with a locking-screw stem extensions and large diameter
hand wheels similar to the operating screws of manually closed preventers.
Purpose of the locking screws: to manually lock the ram in the closed position after they are closed
hydraulically.
In an emergency, the screws can be used to close the rams if the hydraulic system fails. If the locking
screws are used to close the rams, the closing unit selector valve should be in the closed position.
This will eliminate the possibility of hydraulic oil being trapped on the opening side of the actuating pistons.
An optional hydraulic lock mechanism (Cameron Wedgelock, Shaffer Ultralock and Poslock, and
Hydrils Multiposition Lock) can be used in place of locking screws to lock the ram in the closed position.
Fig 7.1.7 - Blowout Preventer Wedgelock Assembly

RAM LOCKS
Ram type preventers should be equipped with extension hand wheels or hydraulic locks. The main purpose
of the locking system is to manually lock the rams in the closed position after they are closed hydraulically.
PVD Training
Spare Parts
As per API, the following recommended minimum blowout preventer spare parts approved for the service
intended should be available at each rig:
a) Plastic packing for BOP secondary seals.
b) A complete set of drill pipe rams and ram rubbers for each size of drill pipe being used.
c) A complete set of bonnet or door seals for each size and type of ram preventers being used.
d) Ring gaskets to fit flange connections, and
e) Appropriate spare parts for annular preventers, when used.
Secondary Piston Rod Seal
All ram type preventers with a rated working
pressure of 5,000 psi, or higher, should be
equipped with secondary piston rod seals in case
the primary rod seal fails. The secondary seal is
plastic which is stored inside a container until it is
activated.
SECONDARY SEAL
The secondary seal is activated by screwing down
on the piston which forces plastic through the check
valve and into the space between the two swab cup
seals. Further piston displacement causes pressure
to build up between the swab cups, forcing them to
flare out and provide a seal. When the pressure
exerted by the plastic packing reaches the proper
valve, additional displacement of the piston will
overcome the spring tension in the relief valve and
plastic packing will begin to extrude from it.
The secondary seal should be activated only if the
primary connecting-rod seal leaks during and
emergency operation. The secondary seal is designed for static conditions and movement of the
connecting rod causes rapid seal and rod wear.
U II Blowout Preventer
The Cameron U II BOP takes all of the features of the U BOP and adapts them for subsea use in the
18-3/4- 10,000 and 15,000 psi WP sizes. Like all other Cameron preventers, the rams in the U II BOP
are pressure energized. Wellbore pressure acts on the rams to increase the sealing force and maintain
the seal in case of hydraulic pressure loss. Seal integrity is actually improved by increased well bore
pressure.
Other features of the U II BOP include:
Internally ported hydraulic stud tensioning system ensures that stud loading is consistently accurate and
even.
Bonnet seal carrier is available to eliminate the need for high makeup torque on bonnet studs and nuts.
Hydraulically operated locking mechanisms, wedgelocks, lock the ram hydraulically and hold the rams
mechanically closed even when actuating pressure is released. The operating system can be interlocked
using sequence caps to ensure that the wedgelock is retracted before pressure is applied to open the
BOP
A pressure balance chamber is used with the wedgelocks to eliminate the possibility of the wedgelock
becoming unlocked due to hydrostatic pressure.

PVD Training
Other features include hydraulically opening bonnets, forged body and a wide selection of rams to
meet all applications.
Fig 7.1.9 - Cameron 18-3/4" Double U II Blowout Preventer

Optional Equipment
Bonnet Seal Carriers for TL, U, UL and U 11 BOPs. The bonnet seal carrier is a boretype sealing assembly
which replaces the face seal used as the previous bonnet seal.
Sealing capability is not dependent upon bonnet bolt torque. One seal is captured in a machined bore in
the BOP body while the other seal is captured in a machined bore in the intermediate flange.
The seal carrier was designed, developed and
performance-verified for use in newly manufactured
BOPs or as a replacement seal assembly for BOPs
where either the BOP bodyor the intermediate flange
requires weld repair on the sealing surfaces
Fig 7.1.10 - Seal Carrier
. Fig 7.1.13 - Cameron UII BOP Hydraulic Control System

PVD Training
Fig 7.1.14 - Cameron UII Exploded BOP and Part Numbers

PVD Training
SHAFFER SL RAM BLOWOUT PREVENTERS
The Shaffer SL is a subsea ram preventer which can be fitted with an automatic locking provision
called Poslock. SL preventers are trimmed for H2S service and special rams are available that can be
used to hang-off the drillpipe. The Shaffer hydraulic system is routed through the door hinges and into the
operating cylinder.
Shaffer preventers (and all hinged door preventers) should never be pumped open by applying closing
pressure, as this will almost surely damage the operating rod and the foot. The Shaffer SL preventer is
shown below.
Fig 7.1.15 - Shaffer SL-Ram BOP

Shaffer Model SL ram blowout preventers may also be fitted with other styles of locking devices,
which will accommodate wear and various pipe sizes in the event of VBR use. The PosLock system
allow closure and sealing on various pipe sizes, but will lock on one particular pipe size selected and
adjusted for prior to use.
Special Features:
Flat doors simplify ram changes. To change the rams, apply opening hydraulic pressure to move the
rams to the full open position. Remove the door cap screws and swing the door open. Remove the
ram from the ram shaft and replace it. It is not necessary to apply closing hydraulic pressure to move
the rams inward to clear the door.
Door seals on most sizes have a hard backing moulded into the rubber. This fabric and phenolic
backing
prevents extrusion and pinching at all pressures to assure long seal life.
Internal H2S trim is standard. All major components conform to API and NACE H2S requirements.
Maximum ram hardness is Rc22 to insure H2S compatibility of pipe and blind rams. Shear rams
have
some harder components.
Manual-lock and Pos-lock pistons can be interchanged on the same door by replacing the ram shaft,
piston assembly and cylinder head.

PVD Training
Wear rings eliminate metal-to-metal contact between the piston and cylinder to increase seal life and
virtually eliminate cylinder bore wear.
Lip type piston seals are long-wearing polyurethane with molybdenum disulfide moulded in for lifetime
lubrication.
Lip-type ram shaft seals hold the well bore pressure and the opening hydraulic pressure. No known
failures of this highly reliable high pressure seal have occurred.
Secondary ram shaft seals permit injection of plastic packing if the primary lip-type seal ever fails.
Fluid dripping from the weep hole in the door indicates that the primary seal is leaking and the
secondary seal should be energized.
Rams are available which will support 600,000 pounds when a tool joint is lowered onto the closed
rams. These rams conform to H2S requirements.
Shear rams cut drill pipe and seal in one operation. Most common weights and grades of drill pipe are
sheared with less than 1,500 psi hydraulic pressure.
Poslock operators automatically lock the rams each time they are closed. This eliminates the cost of
a second hydraulic function to lock. It also simplifies emergency operation because the rams are both
closed and locked just by activating the close function.
Fig 7.1.16 - Locking Systems

PVD Training
SHAFFER MODEL SL POSLOCK SYSTEM
SL preventers equipped with Poslock pistons are automatically locked in the closed position each time they
are closed. The preventers will remain locked in the closed position even if closing pressure is removed.
Opening hydraulic pressure is required to reopen the pistons.
The hydraulics required to operate the Poslock are provided through opening and closing operating
ports. Operation of the Poslock requires no additional hydraulic functions, such as are required in some
competitive ram locking systems. When closing hydraulic pressure is applied, the complete piston
assembly moves inward and pushes the rams into the well bore. As the piston reaches the fully closed
position, the locking segments slide toward the piston O.D. over the locking shoulder as the locking cone
is forced inward by the closing hydraulic pressure.
Note: Poslock pistons are adjusted in the factory and normally do not require adjustment in the field except
when changing between pipe rams and shear rams. The adjustment is easy to check and easy to change
SHAFFER ULTRALOCK LOCKING SYSTEM

UltraLock, the most versatile locking system available, provides a maintenance-free and adjustment-free
locking system that is compatible with any ram assembly that the blowout preventers can
accommodate. Once the UltraLock is installed, no further adjustments will be needed when changing
between Pipe Rams, Blind/ Shear or MULTIRAM assemblies.
Fig 7.1.18 - ULTRALOCK - Unique Position Locking System
BOPs that are equipped with the UltraLock are automatically locked in the closed position each time the
BOPs are closed; no preset pressure ranges are needed. The BOPs will remain locked in the closed
position, even if closing pressure is lost or removed. Hydraulic opening pressure is required to re-open the
preventer, and this opening pressure is supplied by the regular opening and closing ports of the
preventer.
No additional hydraulic lines or functions are required for operations of the locks. Stack frame modifications
are not required because all operational components are in the hydraulic operating cylinders.
HYDRIL RAM PREVENTER

The Hydril ram preventer is designed for land applications and is available in a range of working pressures

PVD Training
from 3M to 15M psi. The Hydril ram preventer can be equipped with automatic "Multi-position" locks, or
manual locks, which can lock the preventer in the closed position. The bonnet doors swing open on hinges
to gain access to the cavity of the preventer and to change the ram blocks. Hydril ram blocks are loaded
from the top onto the operating rod. The Hydril ram preventer is shown below.
Hydril Type V Preventer
Fig 7.1.19 - HYDRIL 13-5/8 15,000 psi Ram BOP Manual Lock
Fig 7.1.20 - Hydril 18 15,000 psi Ram BOP Multiple Position Lock (MPL)
HYDRIL MPL AUTOMATIC RAM LOCKING

Hydril Ram Blowout Preventers are available with automatic Multiple-Position Ram Locking. Multiple-
Position Locking (MPL) allows the ram to seal off with optimum seal squeeze at every closure. MPL
automatically locks and maintains the ram closed with the optimum rubber pressure required for seal off in the
front packer and upper seal.

PVD Training
Fig 7.1.21 - HYDRIL Multi-Position Lock (MPL)

Front packer seal wear (on any ram BOP) requires a different ram locking position with each closure to
ensure an effective seal off. Multiple-Position Locking is required to ensure retention of that seal off position.
A mechanical lock is automatically set each time the ram is closed. Ram closure is accomplished by
applying hydraulic pressure to the closing chamber which moves the ram to a seal off position. The
locking system maintains the ram mechanically locked while closure is retained and/or after releasing
closing pressure. The ram is opened only by application of opening pressure which releases the locking
system automatically and opens the ram, simultaneously.
Note: MPL is available on all Hydril Ram Blowout Preventers.
How MPL works
This figure shows the ram maintained closed and sealed off by the MPL. Hydraulic closing pressure has
been released. The Hydril Ram Blowout Preventer with MPL automatically maintains ram closure and seal
off. MPL will maintain the required rubber pressure in the front packer and upper seal to ensure a seal off
of rating working pressure. MPL will maintain the seal off without closing pressure and with the opening
forces created by hanging the drill string on the ram.
Locking and unlocking of the MPL are controlled by a unidirectional clutch mechanism and a lock nut.
The unidirectional clutch mechanism maintains the nut and ram in a locked position until the clutch is
disengaged by application of control system pressure to open the ram.
Hydraulic opening pressure disengages the front and rear clutch plates to permit the lock nut to rotate and
the ram to open. As the ram and piston move to the open position, the lock nut and front clutch plate rotate
freely.
EXAMPLE OF CLOSING FORCES IN RELATION TO AREA

a. When closing the well in on a floating rig the hard shut in method is usually applied. The string is
picked up say 20 off bottom, the rotary table or top drive is shut off and both pumps are shut
down. The annular preventer is then closed and the fail-safe's opened against a closed choke.
b. The tool joint is then spaced out for the correct pipe rams.

PVD Training
c. The string is stripped down until the tool joint is "hung off on the rams. The correct operating
pressure to set on the manifold regulator is directly related to the well bore pressure. For example,
Operating ratio 10:56:1. Working pressure of BOP stack 10,000 psi.
This pressure does not include an allowance for friction losses so the minimum pressure would be say 1000
psi x 10.56 = 10560 lbs closing force.
Fig 7.1.22 - Ram Closing Forces
7.2 Annular Preventers

Annular preventers have a doughnut-shaped element with bonded steel internal reinforcing. Extrusion
of the element into the wellbore is effected by upwards movement of a hydraulically actuated piston. The
element is designed to seal around most shapes or size of pipe and to close off on an open hole.
An important function of annular preventers is to facilitate the stripping of drillpipe into or out of the hole,
with pressure on the wellhead. Undue wear on the element is avoided by the use of a pilot-operated hydraulic
regulator to control closing pressures.
The majority of annular preventers in use are manufactured by Hydril (types MSP, GK, GL, and GX),
Shaffer (Spherical) and Cameron (type D). These are illustrated below together with a summary of the
major operating features.
The most important aspects of the operation of annular preventers are:
Can close and seal around drill pipe, tool joint, casing, non-cylindrical objects such as the Kelly and
even on open hole.
Not design to seal on wireline, stabilisers or spiral drill collars.
Closing times are longer than that of ram preventers as more hydraulic fluid is required.
It is susceptible to wear upon usage
It cannot be locked.
CAMERON MODEL D ANNULAR PREVENTER

The Cameron Model D preventer uses two elastomer elements consisting of a donut and a rubber packer.
When closing pressure is applied, the contractor piston moves upwards against the donut, which deforms
| 7.2 Annular Preventers 16

PVD Training
inward onto the outside of the rubber packer. This action displaces the rubber packer radially inward to
produce the seal. The packer is internally steel reinforced to help prevent excessive deformation of the
packer under pressure. Since the Model D preventer is not wellbore pressure assisted, closing
pressure above 1,500 psi may be needed in extreme circumstances to effect a seal. The normal operating
pressure of the Model D is 1500 psi. Most sizes of the Model D pre-venter use less closing fluid than the
Hydril and Shaffer equivalents, and have a smaller over-all height. The Cameron D Annular Preventer is
shown in Figure 7.2.1
Fig 7.2.1 - Cameron Model D Annular Blowout Preventer

In the unique design of the Cameron DL annular BOP, closing pressure forces the operating piston and
pusher plate upward to displace the solid elastomer donut and force the packer to close inward. As the
packer closes, steel reinforcing inserts rotate inward to form a continuous support ring of steel at the top
and bottom of the packer. The inserts remain in contact with each other whether the packer is open, closed
on pipe or closed on open hole.
Fig 7.2.2 - CAMERON 2000 psi WP Annular Blowout Preventer Sealing Element
HYDRIL GK ANNULAR
The Hydril GK preventer shown in Figure 7.2.3 is a highly wellbore pressure assisted annular preventer

PVD Training
which is designed for land applications. The 15M psi GK is not wellbore pressure assisted. This preventer
can close on open hole in an emergency, but damage to the sealing element may result and element life
will be reduced. In a closed position, element wear can be determined through an access port located in
the top of the preventer. The lifting eyes, shown below should be used to lift the annular preventer only -
never the entire stack.
Fig 7.2.3 - HYDRIL GK Annular
HYDRIL TYPE GL 5000 PSI ANNULAR BLOWOUT PREVENTERS PATENTED

The Hydril GL preventer is designed primarily for subsea use, but is also utilized in deeper land
operations. The unique feature of the GL preventer is its secondary closing chamber which can be
used to compensate for marine riser hydrostatic pressure effects in deep water. The secondary chamber
also allows additional closing force on the contractor piston. This may be necessary in some instances
since the preventer is only slightly wellbore pressure assisted. The secondary chamber port should never
be plugged; either connect the port to the accumulator or leave it open.
The GL preventer shown in Figure 7.2.6 has a latched head for easier sealing element change.
Hydril GL Annular Blowout Preventers are designed and developed both for subsea and surface
operations. The GL family of BOPs represents the cumulation of evolutionary design and operator
requirements. The proven packing unit provides full closure at maximum working pressure on open hole or
on virtually anything in the bore casing, drill pipe, tool joints, kelly, or tubing. Features of the GL make it
particularly desirable for subsea and deep well drilling. These drilling conditions demand long-life packing
elements for drill pipe stripping operations and frequent testing. The GL BOP offers the longest life
packing unit for annular blowout preventers available in the industry today - especially for the
combination of BOP testing and stripping pipe into or out of a well under pressure. The latched head
permits quick, positive head removal for packing unit replacement or other maintenance with only
minimum time required.

PVD Training
Fig 7.2.7 - HYDRIL GL Opening and Closing sequence

The following outstanding features of the Hydril GL BOPs make these units particularly qualified to
meet the industrys needs for simple and reliable blowout protection. The Secondary Chamber, which is
unique to the GL BOP, provides this unit with great flexibility of control hookup and acts as a backup
closing chamber to cut operating costs and increase safety factors in critical situations. The chamber
can be connected four ways to optimize operations for different effects:
1. Minimize closing/opening fluid volumes.
2. Reduce closing pressure.
3. Automatically compensate (counter balance) for marine riser hydrostatic pressure effects in deep
water.
4. Operate as a secondary closing chamber.
Automatic Counter Balance can be achieved in subsea applications by selection of one of the optional
hookups of the secondary chamber. The Latched Head provides fast, positive access to the packing
unit and seals for minimum maintenance time. The latching mechanism releases the head with a few
turns of the Jaw Operating Screws, while the entire mechanism remains inside the blowout preventer.
There are no loose parts to be lost downhole or overboard.
The Opening Chamber Head protects the opening chamber and prevents inadvertent contamination
of the hydraulic system while the head is removed for packing unit replacement.
The optimum closing pressure for the standard hookup is obtained using the following formula:
Closing Pressure = Surface Closing Pressure + Adjustment Pressure (P)
Only packing elements which are supplied by the manufacturer of the annular preventer should be used.
New or repaired units obtained from other service companies should not be used since the preventer
manufacturers cannot be held responsible for malfunction of their equipment unless their elements are
installed.
SHAFFER SPHERICAL BLOWOUT PREVENTERS

Shaffer Spherical blowout preventers are compact, annular type BOPs which reliably seal on almost any
shape or size - kellys, drill pipe, tool joints, drill collars, casing or wireline. Sphericals also provide positive
pressure control for stripping drill pipe into and out of the hole. They are available in bolted cover, wedge
cover and dual wedge cover models. There are also special lightweight models for airlifting and Arctic
models for low temperature service.

PVD Training
Fig 7.2.12 - SHAFFER Annular
Hydril Sealing Elements

All preventer manufacturers provide sealing elements of different composition that are designed for use in
specific wellbore environments. Table 7.2.3 provides the packing unit selection and Table 7.2.4 lists some
types of sealing elements.
Table 7.2.3 - Packing Unit Selection (from Hydril)
Table 7.2.4 - Shaffer Sealing Elements
7.3 Diverters
The occurrence of shallow gas zones or steam zones can be extremely dangerous and demand unique
well control considerations. If these zones are shallow enough that it is not possible to obtain the
necessary casing shoe integrity before encountering the pressure, then a kick cannot be shut-in and will
| 7.3 Diverters 20
PVD Training
have to be diverted.
Diverting is a method of directing the flow from an unloading well in such a way as to minimize physical
damage to rig personnel and equipment. Diverting equipment and procedures are designed to impose as
little backpressure as possible on the weak downhole formations. Diverting is not a well control procedure,
per se, and a successful diverting operation is one that allows the well to bridge over, be dynamically killed
or deplete itself without loss of life or equipment.
Purpose
A diverter system can provide a degree of protection prior to setting the casing string upon which the BOP
stack and choke manifold will be installed. The system is designed to pack off around the Kelly, drill string, or
casing and direct flow to a safe location. Valves in the system direct the well flow when the diverter is
actuated. A diverter is not designed to shut-in or stop flow, but rather permits routing of the flow to a safe
distance away from the rig. The diverter system could be defined as a low pressure annular (not always
an annular - ie the old Reagan style diverter for floating operations), with a large internal diameter, with
vent lines of sufficient size to safely dispose of flow from the well.
High Risk Operation
Diverting, which is typically associated with shallow gas, is a high risk operation. In fact, there is ample
evidence to support the contention that shallow gas divert operations pose the single greatest well control
hazard to the drilling industry. The US Minerals Management Service (MMS) defines all divert events
as blowouts, regardless of technical success, since by definition, a divert, is an uncontrolled flow of
formation fluid(s). The technical success of any diverting operation depends largely on how the inherent risk
is managed. The best approach to manage the risk is to avoid the need for diverting in the first place.
The best way to avoid having to divert is not to drill through any shallow gas. While shallow seismic data can
help to avoid drilling through shallow gas zones, it is not always possible to simply drill where there is no
potential for shallow gas. If it is necessary to drill through potential shallow gas zones, and it is not
possible to design the casing program so that shutting in on kicks is possible, then the only way to avoid
diverting is not to take a shallow kick. Swabbed kicks are examples of avoidable kicks, but drilled kicks can
be caused by hydrostatic imbalances that are sometimes unavoidable. In these instances, the best chance
for technical success lies in making sure that the key elements of a good drilling diverting system (i.e.,
people, technique, training and equipment) are all well integrated into an effective response plan.
Recognizing the critical nature of diverting operations, the American Petroleum Institute issued
Recommended Practice 64 entitled "Recommended Practices for Diverter Systems Equipment and
Operations". API RP 64 is a useful reference document for both surface and subsea diverting.
There are two governing criteria for use of a diverter system as opposed to a BOP stack:
a. A diverter system is used when drilling below drive or structural pipe.
b. A diverter system is used when drilling below conductor without enough formation integrity to
withstand shut-in pressure, meaning the formation fluids would broach the casing shoe if the well
was shut-in on a kick. It must be emphasized again that full shut-in, if possible, is the preferred
course of action.
All diverter systems shall incorporate a full opening hydraulic valve(s) on the vent line.
The valve will be either an integral part of the closing diverter or have the control system plumbed to
automatically open the valve when the diverter is closed.
Industry best practices recommend that all valves should be hydraulic ball valve type with full bore to the
outlet and the vent line.
| 7.3 Diverters 21
PVD Training
Fig 7.3.1 - Diverter Systems - Surface Installations
Fig 7.3.4 Combination Stack
Diverter Control Stations

The component most often lacking in consistency and definition is the control station that will be used to
execute the divert function. Simplicity and reliability of a diverter system demands the control station be
readily accessible and simple in operation, leaving no room for error. The system should operate as a
remote station to the main accumulator system
| 7.3 Diverters 22
PVD Training
Fig 7.3.5 - Diverter Control Station

A typical diverter control station would consist of two levers in a panel that are labelled as to their function.
One lever should be used to divert the flow overboard. When this handle is moved to Divert, the four way
valve on the main accumulator for the annular preventer will shift to the close position, closing the annular
preventer.
Simultaneously, the four way valves on the main accumulator for both port and starboard divert valves will
shift to the open position, opening both overboard lines.
If at this time the need arises to close the upwind overboard line, the second lever on the control station
should be used. This lever, when moved to port, will shift the starboard four way valve on the main
accumulator to the close position and shift the port four way valve to the open position, if closed,
opening the port divert valve. No combination of these handles should allow the well to be shut in. A
diverter control station rigged-up this way is shown in the last picture.
Two separate diverter control stations are required; one on the rig floor, and the other station at a safe and
remote distance from the rig floor. The diverter control stations will be air operated, supplied by the rigs
continuous air supply. As a safety precaution, the control stations should contain an air reserve bottle with
adequate volume to function each operation two times, independent of rig air, in the event the rig air supply
is disrupted for any reason.
The major advantages of a separate diverter control system are:
a. It has the sole function of controlling the divert operation.
b. It will be a permanent fixture of the rig.
c. The chance of human error in diverting a well is eliminated.
d. By using the main accumulator system, the stored energy of the system is utilized.
e. The control lines from the unit to the component are high pressure steel lines that are permanently installed
on the rig.
7.4 Gaskets, Seals and Wellheads

7.4.1 API Flanges
API flanges fall in two types: 6B and 6BX. The table below indicates sizes and pressure rating. The
nominal flange diameter refers to the ID of the flange.
| 7.4 Gaskets, Seals and Wellheads 23

PVD Training
Type 6B flanges are not designed for face-to-face make-up and use R or RX ring joint gaskets.
Type 6BX flanges are designed for face-to-face make-up and use BX ring joint gaskets. Face-to-face
make-up is not necessary for the proper functioning of type 6BX flanges.
7.4.2 API Flanges [Subsea BOP]

API Flanges - Size Ranges and Pressure Ratings
Type 17SS, 17SV and 6BX flanges are designed for face-to-face make-up and use SBX ring joint gaskets.
BX ring joint gaskets may be used when made up at surface.
7.4.3 Hub Connections

API hub connections fall in two types: 16B and 16BX. The table below indicates sizes and pressure rating.
API Hub connection - Size Ranges and Pressure Ratings
Type 16B hub connections are designed for face-to-face make-up and use RX ring joint gaskets. Face-to-
face make-up requires the special type SR ring groove.
Type 16BX hub connections are designed for face-to-face make-up and use BX ring joint gaskets.
7.4.4 Ring Joint Gaskets

Ring joints gaskets are metal seal rings that are placed in a ring groove to create a seal between two
flanges or hub connections. The ring joint gasket and the ring groove should be cleaned, free of scratches

PVD Training
or corrosion and dry before installation. Ring joint gaskets cannot be re-used unless specifically designed
for that purpose or used for stump testing.
Ring joint gasket types that include X are energised by wellbore pressure.
R-type Ring Joint Gasket

Seal is created on both sides (ID and OD) of the gasket;
Does not allow face-to-face contact;
Can be oval or octagonal in shape;
Connection may need re-tightening;
The R and RX ring joint gaskets are interchangeable;
Shall not be used on pressurised well control equipment
RX-type Ring Joint Gasket
Seal is created on the outside of the ring and therefore enhanced by wellbore pressure;
Does not allow face-to-face contact;
Increase the stand-off between flange faces;
May contain a pressure balance hole to equalise pressure across sealing faces.
The RX and BX ring joint gaskets are not interchangeable;
BX-type Ring Joint Gasket
Seal is created on the outside of the ring and therefore enhanced by wellbore pressure;
Designed for face-to-face contact but may be difficult to achieve;
Contains a pressure balance hole to equalise pressure across sealing faces;
The RX and BX ring joint gaskets are not interchangeable;
SRX and SBX-type Ring Joint Gasket [Subsea BOP]
Intended for underwater make-up
Have cross-drilled vent holes to allow trapped water to escape and prevent pressure lock when
connections are made up underwater;
Have identical measurements to RX & BX ring joints and fit corresponding connectors.
Type 6B flanges are not designed for face-to-face make-up;

Type 6BX flanges are designed for face-to-face make-up;

PVD Training
Type 16B and 16BX hub connections are designed for face-to-face make-up;
X-type ring joints are energised by wellbore pressure;
R- and RX-type ring joints are interchangeable;
RX- and BX-type ring joints are not interchangeable;
All BX-type ring joints contain a pressure balance hole.
Subsea BOP:
Type 17SS, 17SV and 6BX flanges are designed for face-to-face make-up and use SBX-type ring
joint gaskets;
S-type ring joints are for underwater make-up.
7.5 Manifolds
If the hydrostatic head of the drilling fluid is insufficient to control formation pressure in a permeable
formation, formation fluids are likely to flow into the well. To maintain well control, back pressure is applied
by routing returns through a choke. The choke is connected to the BOP stack through an arrangement of
valves, fittings and lines which provide alternative flow routes or permit the flow to be stopped entirely.
This collection of equipment is generally called the choke manifold.
Choke Manifolds
The choke manifold is an arrangement of valves, fittings, lines and chokes which provide several flow
routes to control the flow of mud, gas and oil from the annulus during a kick. It is API recommended
practice is to have a manual valve located on the inside of the Remotely Operated Valve (HCR) i.e located
towards the BOP. The HCR valve shall be located on the outside of the manual valve.
| 7.5 Manifolds 26
PVD Training
Fig 7.5.3
| 7.5 Manifolds 27
PVD Training
The Manifold must have a minimum working pressure rating equivalent to the working pressure rating of
the BOP ram preventer, and must also be able to handle the temperatures and range of fluids and gases
that flow through it.
Variable chokes control the release of well fluids under pressure. However, because of abrasive wear and
possible plugging, at least two chokes are required. These chokes must be manifolded in order to quickly
change from one to the other.
The choke manifold and the kill choke lines should be circulate through every couples of day and
whenever the mud weight has been change in the well. This should be to:
Ensure the barite has not dropped out of suspension in the mud.
Ensure choke and kill line & Choke manifold are clear and have not plugged.
Ensure the correct weighted mud is in the Choke and Kill lines and choke manifold. This is to
ensure when you close the BOP in a well control situation that you will be able to read the correct
pressure on the choke panel gauge.
Circulating Routes through a Choke Manifold
The Choke Manifold opposite has 4 chokes (2 manual and 2 automatic). Any of the 4 chokes could be
used to control a well control incident by closing and opening the required valves.
If while, circulating out a kick through the choke and back through the poorboy degasser, there was a
heavy flow of gas displacing the fluid at the bottom of the poorboy degasser (U tube), the flow could then
be diverted over board to prevent the gas from invading the Shaker house.
Circulation can be done down through the kill line from the mud pumps or cement unit.
Circulating from Cement unit to Choke line
| 7.5 Manifolds 28
PVD Training
Circulating from Cement unit to Kill line
Circulating from Mud pump to Flare Boom
| 7.5 Manifolds 29
PVD Training
Circulating from Mud pump to Kill line
Manual choke valve

The manual choke valve is situated on the choke manifold. These valve are used to control the flow of fluid
and regulate the pressure in a well control situation. Please aware that only handful of Chokes actually
hold pressure.
| 7.5 Manifolds 30
PVD Training
Auto Choke valve

The automatic choke valve are situated on the choke manifold
and are used to control the flow of fluid and regulate the
pressure in a well control situation. The control for the auto
chokes are from the choke panel normally situated in the
Drillers dog house
Choke panel Drill pipe Pressure gauge

In a well control situation, the control panel readout gives the Driller information.
When a well is shut in, the Drill pipe pressure (SIDPP) and the casing pressure (SICP) gauges will
indicators of the down hole conditions.
The shut-in Drill pipe pressure is a measure of the difference between the pressure at the bottom of the
hole (Formation pressure) and the hydrostatic pressure inside the Drill Pipe.
While circulating out a kick precautions must be taken to make ensure the choke do not plug, this would be
seen on a Gauges on the choke panel starting to increase in pressure, this would also increase the bottom
hole pressure.
7.6 Inside BOPs

An inside blowout preventer, drill pipe float valve, or drop-in check
valve should be available at all times during a drilling, completion or
work-over operation.
The tool is especially useful when stripping into or out of the hole. The
valve, sub, or profile nipple should be equipped to screw into any drill
string member in use.
The inside blowout preventer, float valve, or drop-in check valve should
be field tested to a pressure at least equal to 70% of the rated internal
pressure at minimum yield strength for new pipe of the size and grade
used in the upper part of the drill string (refer to API RP 7G:
Recommended Practice for Drill Stem Design and Operating Limits), but
limited to the BOPs maximum rated working pressure.
| 7.6 Inside BOPs 31

PVD Training
Full Opening Safety Valve (FOSV)
A Full Opening Safety Swivel (FOSV) should be installed between

the swivel and the kelly.
The FOSV should be field tested to a pressure at least equal to
70% of the rated internal pressure at minimum yield for new pipe of
the size and grade used in the upper part of the drill string (refer to
API RP 7G: Recommended Practice for Drill Stem Design and
Operating Limits) but limited to the rated working pressure of the
BOPs up to a maximum of 10,000 psi.
Ball Valves
The principal component of a ball valve is a ball with a hole bored
through the center.
When aligned with the flow path, it allows for fluid to pass with little or no restriction.
When closed, the flow path is completely blocked and flow is stopped. Ball valves are ordinarily not utilized
in well control operations (with the exception of Full Opening Safety Valves) for the following reasons:
Ball valves are difficult to operate in medium to high pressure situations.
Although metal-to-metal seals are preferred, they utilize a resilient seal ring.
Ball valves have a history of seizing when not used frequently and maintained properly. They cannot be back-
seated to repair stem packing.
Lower Kelly Valve
A lower kelly valve should be installed below the kelly. The lower kelly valve should be field tested to a
pressure at least equal to 70% of the rated internal pressure at minimum yield strength for new pipe of the
size and grade used in the upper part of the drill string (refer to API RP 7G: Recommended Practice
for Drill Stem Design and Operating Limits), but limited to the rated working pressure of the BOPs
up to a maximum of 10,000 psi.
Drill Pipe Safety Valve
A drill pipe safety valve should be available on the rig floor in the open position at all times. The valve(s)
should be equipped to screw into any drill string member in use.
VALVES
Gate Valves
Gate Valves are designed to perform a seal and hold pressure by means of a gate operating within the body
of the valve. A gate valve is the preferred type of valve for use in well control and production hookups. There
are several different designs of gate valves, but at the present time there are no clear preferences for one
design or model over another. While a specific manufacturer or model will be utilized almost exclusively in
some areas, all of the models available from the various manufacturers meet the design and testing criteria
set forward by API Standard 6A.
Note: It is very important to understand and be able to differentiate between various design features. This
section will discuss the major design features in use today.
Split Gate and Floating Gate Valves
The Split Gate design utilizes a gate mechanism that is actually two separate plates. As the valve is
closed, a wedge or expander forces the gates against the seats. Since both gates come into contact with a
metal seal on each side of the body of the valve, it is capable of holding pressure from either side
equally as well. Other advantages to this design are: a) the design does not rely on pressure to effect an
PVD Training
initial seal, and b) it gives better overall sealing characteristics for both high and low pressure applications.
HCR Valves
HCR Valves are essentially gate valves which have been fitted with a
hydraulic actuator to operate the valve remotely. The term HCR stands
for High Closing Ratio and is derived from the design of the hydraulics of
the closing pistons. A HCR receives its power fluid from the accumulator
unit and is operated from the BOP panel(s). These valves can also be
equipped with a fail safe assembly that will automatically close the valve
should power fluid (or opening pressure) be lost. The typical operating
pressure is 1,500psi. HCR valves are usually designed with a rising stem
design and there's no allowance for back-seating.
Plug Valves
Plug Valves are very versatile and have a number of applications for work-
overs. Plug valves are often referred to as Lo-Torc valves because they are
easy to operate, quick opening valves that are relatively simple to maintain
and repair. They are not usually utilized in choke and kill manifolds as they
can be difficult to open in the higher pressure ranges. The valves are utilized
on many cementing and stimulation manifolds and pump systems.
Check Valves
Check valves are installed in kill line hookups to prevent flow
back to the pump. Figure 7.6.8 shows a typical installed check
valve. The operating principal of a check valve is simple. Fluid
can be pumped through the valve (left to right in the figure
shown), while preventing fluid from flowing out of the well.
Pressure from the pump moves the valve off its seat and allows
the fluid to pass through the valve. When pumping stops, the
valve is forced back onto its seat by a spring. Ordinarily, the
newer valves use a metal to-metal seal between the valve and
its seat.
Back Pressure Valves
A Back Pressure Valve (BPV), or tubing plug, is usually a one-
way check valve that is installed in a specially machined profile in
the tubing hanger or plug bushing. The BPV is designed to prevent
the flow of fluids and gases through the hanger, but still allows the
pumping of fluid into the tubing string. They are installed in the
well to remove the production tree and allow the initial nipple up of
the BOP stack, to install the tree while nippling down the BOP
stack, and while heavy lifts are being made over the wellhead.
The BPV can be installed or removed with either the tree or BOP
stack nippled up on the tubing head. They can also be installed
with or without pressure on the tubing.
Installation of the BPV through the tree, with pressure on the
well, requires the use of a lubricator. Wellhead manufacturers
have various designs for Back Pressure Valves depending on the
size and make of the hanger and wellhead. The installation and
removal of Back Pressure Valves should only be performed by
specific personnel trained by wellhead manufacturers.

PVD Training
Drill Pipe Float Valves
The drill pipe float valve and the flapper back pressure valve serve essentially the same purpose, but differ
in design. These valves provide instantaneous shut-off against high or low back pressure and allow full
fluid flow through the drill string. Another advantage is that it prevents cuttings from entering the drill string,
thus reducing the likelihood of pulling a wet string. Abnormal pressures and anticipated subnormal
pressure zones should be the deciding factor regarding what type of valve to run or the possibility of not
running any valve at all. Expectations of abnormal pressures have shown the vented type of flapper valve
to be the most popular because of the ease involved in recording shut-in drill pipe pressures. The
disadvantages are that the pipe must be filled while tripping in, and reverse circulation is not possible.
7.7 Blowout Preventer Stack Arrangements Surface Installations

API classification of example arrangements for blowout preventer equipment is based on rated working
pressure.
Stack Component Codes
The recommended component codes for designation of BOP stack arrangements are as follows:
A = annular type blowout preventer.

G = rotating head
R = single ram preventer with one set of rams, either blank or for pipe, as operator prefers.
Rd = double ram preventer with two sets of rams, positioned in accordance with operators choice.
Rt = triple ram preventer with three sets of rams, positioned in accordance with operators choice.
S = drilling spool with side outlet connections for choke and kill lines.
M = 1000 psi rated working pressure.
| 7.7 Blowout Preventer Stack Arrangements Surface Installations 34

PVD Training
Components are listed reading upward from the uppermost piece of permanent wellhead equipment, or from
the bottom of the BOP stack. A BOP stack may be fully identified by a very simple designation, such as:
5M 13 5/8 SRRA.
This BOP stack would have a rated working pressure of 5000 psi, would have a through bore of 13 5/8
inches and would consist of: drilling spool, ram, ram, and annular.
| 7.7 Blowout Preventer Stack Arrangements Surface Installations 35

PVD Training
7.8 Testing and Inspection

The purpose of testing well control equipment is to verify:
Specific functions of well control and related equipment;
Pressure integrity of well control and related equipment;
The BOP control system and BOP compatibility;
Crew competence.
Test programs can include visual inspections, functional operations, pressure tests, maintenance practices
and drills.
7.8.1 Hydrostatic Body or Shell Test

Prior to shipment from the manufacturers facility, drill-through equipment is subject to a hydrostatic proof
test of 1.5 times the rated working pressure of the equipment.
7.8.2 Function Test

All operational components of the BOP equipment systems should be function tested at least once a week
to verify the component's intended operations. Function tests may or may not include pressure tests.
Function tests should be alternated from the drillers panel and from remote panels. Actuation times should
be recorded for evaluating trends. A function test of the BOP control system shall be performed following
the disconnection or repair, limited to the affected component.
7.8.3 Pressure Tests

Pressure tests on the well control equipment should be conducted at least:
| 7.8 Testing and Inspection 36

PVD Training
1. Before the equipment is put into operational service;
2. After the disconnection or repair of any pressure containment seal in the BOP stack, choke line, or
choke manifold, but limited to the affected component;
3. Once per 21 days.
All BOP that may be exposed to well pressure should be tested first to a low pressure of 250 to 350 psi
and then to a high pressure. Full details as per API Standard 53.
Initial pressure tests are performed before the well is spudded or before the equipment is put into
operational service. Components that could be exposed to well pressure should be tested to the RWP of
the ram BOPs or to the rated working pressure of the wellhead, whichever is lower. Annular preventers are
tested to 70% of the annular RWP. Drill pipe safety valves and inside BOPs are tested to the components
RWP. During the initial test, the ram BOPs shall be pressure tested on the ram locks with the closing
pressure bled to zero. Initial pressure tests shall be conducted with water.
Subsequent pressure tests are carried out to the maximum anticipated wellhead pressure (MAWHP) for
the hole section. Annular preventers are tested to the MAWHP or 70% of the annular RWP whichever is
lower. The MAWHP occurs when the well is fully displaced to gas and is therefore the reservoir pressure
minus the HH of the gas column. lt may be higher based on specific anticipated well conditions or operator
requirements. Subsequent tests on subsea BOP stacks may be conducted with the drilling fluid in use.
Pressure Gauges
Pressure gauges should be installed so that drill pipe and annulus pressures can be monitored at the
station where well control operations are to be conducted. Pressure gauges and chart recorders should be
used and all testing results recorded.
Test pressure-measuring devices shall be either pressure gauges or pressure transducers and shall be
accurate to at least 1 0.5% of full-scale range. Pressure measurements shall be made at not less than 25%
or more than 75% of the full-pressure span of the gauge. Pressure-measuring devices shall be periodically
recalibrated with a master pressure- measuring device or a deadweight tester at 25%, 50% and 75% of full
scale.
There might be a number of different locations on the rig where pressures can be observed. Due to height
differences, frictional effects and slight inaccuracies, not all of these gauges will read the exact same
values. Small differences between the gauges can be tolerated but for proper trend analysis it is important
to use a single pressure gauge.
| 7.8 Testing and Inspection 37

PVD Training
7.9 Closing Units Surface Installations
| 7.9 Closing Units Surface Installations 38

PVD Training

PVD Training
General
A Blowout Preventer (BOP) Control System is a high pressure hydraulic power unit fitted with directional
control valves to safely control kicks and prevent blowouts during drilling operations. A typical system
offers a wide variety of equipment to meet the customers specific operational and economic criteria. The
following text gives a brief description of the equipment and some of its major components.
The primary function of the accumulator unit module is to provide the atmospheric fluid supply for the pumps
and storage of the high pressure operating fluid for control of the BOP stack. It includes accumulators,
reservoir, accumulator piping and a master skid for mounting of the air operated pumps, electric motor
driven pumps and the hydraulic control manifold.
Accumulators
Accumulators are ASME coded pressure vessels for storage of high pressure fluid. These accumulators
are available in a variety of sizes, types, capacities and pressure ratings. The two (2) basic types are
bladder and float which are available in cylindrical or ball styles. The accumulators can either be bottom or
top loading.
Top loading means the bladder or float can be removed from the top while it is still mounted on the
accumulator unit. Bottom loading accumulators must be removed from the accumulator unit to be
serviced. Bladder and buoyant float type accumulators can be repaired in the field without destroying
their stamp of approval.
Surface BOP Control Systems

Reservoir
A rectangular reservoir is provided for storage of the atmospheric fluid supply for the high pressure
pumps. It contains baffles, fill and drain ports and troubleshooting inspection ports. For filling and cleaning
procedures see the Maintenance section. It should be able to store 2 times the capacity of the usable fluid
capacity.
Accumulator Piping
This piping connects the high pressure discharge lines of the pumps to the accumulators and the
hydraulic manifold. It is comprised of 1 or 1-1/2" Schedule 80 or 160 pipe, isolator valves and a 3300 psi
relief valve to protect the accumulators from being over pressured. Cylindrical type accumulators are
mounted on machined headers to minimize line restrictions and leaks.
Air Pump Assembly
The air pump assembly consists of one (1) or more air operated hydraulic pumps connected in parallel to
the accumulator piping to provide a source of high pressure operating fluid for the BOP Control
System. These pumps are available in a variety of sizes and ratios.

PVD Training
Electric Pump Assembly
The electric pump assembly consists of a duplex or triplex reciprocating plunger type pump driven by an
explosion-proof electric motor. It is connected to the accumulator piping to provide a source of high
pressure operating fluid for the BOP Control System. It is available in a variety of horsepower and voltage
ranges.
Closing Units- Surface Installations

Accumulator Requirements
General
Accumulator bottles are containers which store hydraulic fluid under pressure for use in effecting blowout
preventer closure. Through use of compressed nitrogen gas, these containers store energy which can be
used to effect rapid preventer closure. There are two types of accumulator bottles in common usage,
separator and float types. The separator type uses a flexible diaphragm to effect positive separation of the
nitrogen gas from the hydraulic fluid. The float type utilizes a floating piston to effect separation
of the nitrogen gas from the hydraulic fluid.
Volumetric Capacity
As a minimum requirement, all blowout preventer closing units should be equipped with accumulator
bottles with sufficient volumetric capacity to provide the usable fluid volume (with pumps inoperative) to
close one pipe ram and the annular preventer in the stack plus the volume to open the hydraulic choke line
valve. Usable fluid volume is defined as the volume of fluid recoverable from an accumulator between the
accumulator operating pressure and 200 psi above the pre-charge pressure. The accumulator operating
pressure is the pressure to which accumulators are charged with hydraulic fluid. The design case for
accumulator capacity is governed by MMS regulation, Order 30 CFR Part 250.56(d), in the U.S. which
states that all BOP systems shall be equipped with:
1. An accumulator system which shall provide sufficient capacity to supply 1.5 times the volume of
fluid necessary to close and hold closed all BOP equipment units with a minimum pressure of 200
psi above the pre-charge pressure without assistance from a charging system.
2. A backup to the primary accumulator charging system which shall be automatic, supplied by a
power source independent from the power source to the primary accumulator charging system and
possess sufficient capability to close all BOP components and hold them closed.
A 50% safety factor base is recommended by most Operator Companies because it provides complete
replenishment of fluid in the closing lines at the time preventers are activated. The safety factor also allows
for loss of fluid capacity due to interflow in the four- way valves and possible loss through the packing of
PVD Training
the preventer units. A less demanding base is not recommended, but may be used with Class II stacks,
provided prior management approval has been obtained. Requirements vary with the size of preventers
and are principally controlled by annular preventer requirements. Opening/closing volume tables provide
the necessary information to calculate individual requirements as to accumulator size needed.
Hydraulically operated choke and kill line valves require added fluid capacity. It must be remembered that
only one-half to two/thirds of the accumulator bottle is liquid filled when fully charged, depending on the
unit.
The minimum recommended accumulator volume (nitrogen plus fluid) should be determined by multiplying
the accumulator size factor (refer to Table below) times the calculated volume to close the annular
preventer and one pipe ram plus the volume to open the hydraulic choke line valve.
Note: Based on minimum discharge pressure of 1200 psi.
Response Time
The closing unit should be able to close each ram preventer within 30 seconds. Closing time should not
exceed 30 seconds for annular preventers smaller than 18 inches and 45 seconds for annular
preventers 18 inches and larger.
Function Tests
As per API, all operational components of the BOP equipment systems should be functional at least once a
week to verify the components intended operations.
Function tests should be alternated from the Drillers panel and from mini remote panels, if on
location.
Operating Pressure and Pre-charge Requirements for Accumulators

PVD Training
No accumulator bottle should be operated at a pressure greater than its rated working pressure. The pre-
charge pressure on each accumulator bottle should be measured during the initial closing unit
installation on each well and adjusted if necessary. Only nitrogen gas should be used for accumulator
pre-charge. The pre-charge pressure should be checked frequently during well drilling operations.
Requirements for Accumulator Valves, Fittings and Pressure Gauges
Multi-bottle accumulator banks should have valving for bank isolation. An isolation valve should have a
rated working pressure at least equivalent to the designed working pressure of the system to which it is
connected and must be in the open position except when the accumulators are isolated for servicing,
testing or transporting. Accumulator bottles may be installed in banks of approximately 160 gallons
capacity if required, but with a minimum of two banks. The necessary valves and fittings should be
provided on each accumulator bank to allow a pressure gauge to be attached without having to remove all
accumulator banks from service. An accurate pressure gauge for measuring the accumulator pre-charge
pressure should be readily available for installation at any time.
Closing Unit Pump Requirements:
Requirements for Closing Unit Valves, Fittings, Lines and Manifold
Pump Capacity Requirements
Each closing unit should be equipped with sufficient number and sizes of pumps to satisfactorily perform
the operation described in this paragraph. With the accumulator system isolated, the pumps should be
capable of closing the annular preventer on the size of pipe being used plus opening the hydraulically
operated choke line valve and obtain a minimum of 200 psi pressure above accumulator pre-charge
pressure on the closing unit manifold within two minutes or less.
Pump Pressure Rating Requirements
Each closing unit must be equipped with pumps that will provide a discharge pressure equivalent to the
rated working pressure of the closing unit.
Pump Power Requirements
Power for closing unit pumps must be available to the accumulator at all times such that the pumps will
automatically start when the closing unit manifold pressure has decreased to less than 90 per cent of the
accumulator operating pressure. Two or Three independent sources of power should be available on
each closing unit. Each independent source should be capable of operating the pumps at a rate that will
satisfy the requirement described above in Pump Capacity Requirements. The dual source power system
recommended is an air system plus an electrical system. Minimum recommendations for the dual air
system and other acceptable but less preferred dual power source systems are as follows:
A dual air/electrical system may consist of the rig air system (provided at least one air compressor is driven
independent of the rig compound) plus the rig generator.
A dual air system may consist of the rig air system (provided at least one air compressor is driven
independent of the rig compound) plus the rig generator.
A dual air system may consist of the rig air system (provided at least one air compressor is driven
independent of the rig compound) plus an air storage tank that is separated from both the rig air
compressors and the rig air storage tank by check valves. The minimum acceptable requirements for the
separate air storage tank are volume and pressure which will permit use of only the air tank to operate the
pumps at a rate that will satisfy the operation described in the pump capacity requirements.

PVD Training
A dual electrical system may consist of the normal rig generating system and a separate generator. A dual
air/nitrogen system may consist of the rig air system plus bottled nitrogen gas. A dual electrical/nitrogen
system may consist of the rig generating system and bottled nitrogen gas. On shallow wells where the
casing being drilled through is set at 500 feet or less and where surface pressures less than 200 psi are
expected, a backup source of power for the closing unit is not essential.
Requirements for closing Unit Fluids and Capacity:
A suitable hydraulic fluid (hydraulic oil or fresh water containing a lubricant) should be used as the closing
unit control operating fluid. Sufficient volume of glycol must be added to any closing unit fluid containing
water if ambient temperatures below 320F are anticipated. The use of diesel oil, kerosene, motor oil, chain
oil, or any similar fluid is not recommended due to the possibility of resilient seal damage. Each closing
unit should have a fluid reservoir with a capacity equal to at least twice the usable fluid capacity or the
accumulator system.
Closing Unit Location and Remote Control requirements:
The main pump accumulator unit should be located in a safe place which is easily accessible to rig
personnel in an emergency. It should also be located to prevent excessive drainage or flow back from the
operating lines to the reservoir. Should the main pump accumulator be located a substantial distance
below the BOP stack, additional accumulator volume should be added to compensate for flow back in the
closing lines.
Each installation should be equipped with a sufficient number of control panels such that the operation of
each blowout preventer and control valve can be controlled from a position readily accessible to the driller
and also from an accessible point at a safe distance from the rig floor.
Closing Unit Pump Capability Test:
Prior to conducting any tests, the closing unit reservoir should be inspected to ensure it does not contain
any drilling fluid, foreign fluid, rocks or other debris. The closing unit pump capability test should be
conducted on each well before pressure testing the BOP stack. This test can be conveniently scheduled
either immediately before or after the accumulator closing time test. The test should be conducted
according to the following procedure:
a. Position a joint of drill pipe in the BOP stack.
b. Isolate the accumulators from the closing unit manifold by closing the required valves.
c. If the accumulator pumps are powered by air, isolate the rig air system from the pumps. A
separate closing unit air storage tank or a bank of nitrogen bottles should be used to power the
pumps during this test. When a dual power source system is used, both power supplies should be
tested separately.

PVD Training
d. Simultaneously turn the control valve for the annular preventer to the close position and turn the
control valve for the hydraulically operated valve to the open position.
e. Record the time (in seconds) required for the closing unit pumps to close the annular preventer
plus open the hydraulically choke line valve and obtain 200 psi above the pre-charge pressure on
the closing unit manifold. It is recommended that the time required for the closing unit pumps to
accomplish these operations not exceed two minutes.
f. Close the hydraulically operated valve and open the annular preventer. Open the accumulator
system to the closing unit and charge the accumulator system to its designed operating pressure
using the pumps.
Accumulator Tests:
Accumulator Pre-charge Pressure Test
This test should be conducted on each well prior to connecting the closing unit to the BOP stack. The test
should be conducted as follows:
a. Open the bottom valve on each accumulator bottle and drain the hydraulic fluid into the closing
unit fluid reservoir.
b. Measure the nitrogen pre-charge pressure on each accumulator bottle using an accurate pressure
gauge attached to the pre-charge measuring port and adjust if necessary.
Accumulator Closing Test
This test should be conducted on each well prior to testing the BOP stack. The test
should be conducted as follows:
a. Position a joint of drill pipe in the BOP stack.
b. Close off the power supply to the accumulator pumps.
c. Record the initial accumulator pressure. This pressure should be the designed operating pressure
of the accumulators. Adjust the regulator to provide 1500 psi operating pressure to the annular
preventer
d. Simultaneously turn the control valves for the annular preventer and for one pipe ram (having the
same size ram as the pipe used for testing) to the closing position and turn the control valve for the
hydraulically operated valve to the opening position.
e. Record the time required for the accumulators to close the preventers and open the hydraulically
operated valve. Record the final accumulator pressure (closing unit pressure). This final pressure
should be at least 200 psi above the pre-charge pressure.
f. After the preventers have been opened, recharge the accumulator system to its designed
operating pressure using the accumulator pumps.

PVD Training
Calculation of Accumulator Size

The volume of the accumulator system as calculated by using Boyles law:
P1V1 = P2V2
Where -
P1 = Maximum pressure of the accumulator when completely charged
P2 = Minimum pressure left in accumulator after use. (Recommended minimum is 1200 psi)
V = Total volume of accumulator (fluid and nitrogen)
V1 = Nitrogen gas volume in accumulator at maximum pressure P1.
V2 = Nitrogen gas volume in accumulator at minimum pressure P2.
V2 = V plus usable fluid maximum to minimum pressure.
V2-V1 = Total usable fluid with safety factor usually 50% included.
3000 psi system pre-charged to 1000 psi; V = 3V1
Surface Accumulators
For the purpose of simplicity, the effects of temperature and nitrogen gas compressibility will be ignored

PVD Training
and Boyles gas law applied to determine the volume of nitrogen present in the accumulator bottle when
fully charged and when usable hydraulic fluid has been expelled to operate the BOP functions. In an 11
gallon accumulator bottle the volume of nitrogen it contains before any fluid is pumped in will be 10 gallons
(the rubber bladder occupies a volume of 1 gallon). According to Boyles gas law:
P1 x V1 = P2 x V2 and also P1 x V1 = P3 x V3
where:-
P1 = nitrogen pre-charge pressure of 1000 psi
P2 = minimum operating pressure of 1200 psi
P3 = maximum operating pressure of 3000 psi
V1 = bladder internal volume at pre-charge pressure (11 gal - 1 gal)
V2 = bladder internal volume at minimum operating pressure, P2 (in gals)
V3 = bladder internal volume at maximum operating pressure, P3 (in gals)
therefore:- 1000 psi x 10 gals = 1200 psi x V2
and
1000 psi x 10 gals = 3000 psi x V3

Well Control Equipment PDF

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Well Control Equipment PDF

Transféré par

Droits d'auteur :

Formats disponibles

Section 7: Well Control Equipment

| 7.1 Ram Blowout Preventer 1

RAM BLOWOUT PREVENTERS - CAMERON U BOP

Fig 7.1.1 - Blowout Preventer

| 7.1 Ram Blowout Preventer 2

Fig 7.1.2 - Cameron U - Type BOP

Fig 7.1.3 - Pipe Rams

| 7.1 Ram Blowout Preventer 3

Fig 7.1.4 - VBRs

| 7.1 Ram Blowout Preventer 4

| 7.1 Ram Blowout Preventer 5

Fig 7.1.6 - Shaffer Type 72 Shear Rams

| 7.1 Ram Blowout Preventer 6

Fig 7.1.7 - Blowout Preventer Wedgelock Assembly

| 7.1 Ram Blowout Preventer 8

Fig 7.1.9 - Cameron 18-3/4" Double U II Blowout Preventer

Fig 7.1.10 - Seal Carrier

. Fig 7.1.13 - Cameron UII BOP Hydraulic Control System

Fig 7.1.14 - Cameron UII Exploded BOP and Part Numbers

| 7.1 Ram Blowout Preventer 10

Fig 7.1.15 - Shaffer SL-Ram BOP

| 7.1 Ram Blowout Preventer 11

Fig 7.1.16 - Locking Systems

| 7.1 Ram Blowout Preventer 12

SHAFFER ULTRALOCK LOCKING SYSTEM

Fig 7.1.18 - ULTRALOCK - Unique Position Locking System

HYDRIL RAM PREVENTER

| 7.1 Ram Blowout Preventer 13

HYDRIL MPL AUTOMATIC RAM LOCKING

| 7.1 Ram Blowout Preventer 14

Fig 7.1.21 - HYDRIL Multi-Position Lock (MPL)

EXAMPLE OF CLOSING FORCES IN RELATION TO AREA

| 7.1 Ram Blowout Preventer 15

Fig 7.1.22 - Ram Closing Forces

7.2 Annular Preventers

CAMERON MODEL D ANNULAR PREVENTER

| 7.2 Annular Preventers 16

Fig 7.2.1 - Cameron Model D Annular Blowout Preventer

| 7.2 Annular Preventers 17

Fig 7.2.3 - HYDRIL GK Annular

HYDRIL TYPE GL 5000 PSI ANNULAR BLOWOUT PREVENTERS PATENTED

| 7.2 Annular Preventers 18

Fig 7.2.7 - HYDRIL GL Opening and Closing sequence

SHAFFER SPHERICAL BLOWOUT PREVENTERS

| 7.2 Annular Preventers 19

Fig 7.2.12 - SHAFFER Annular

Hydril Sealing Elements

Table 7.2.3 - Packing Unit Selection (from Hydril)

Table 7.2.4 - Shaffer Sealing Elements

Fig 7.3.1 - Diverter Systems - Surface Installations

Fig 7.3.4 Combination Stack

Diverter Control Stations

Fig 7.3.5 - Diverter Control Station

7.4 Gaskets, Seals and Wellheads

| 7.4 Gaskets, Seals and Wellheads 23

7.4.2 API Flanges [Subsea BOP]

7.4.3 Hub Connections

7.4.4 Ring Joint Gaskets

| 7.4 Gaskets, Seals and Wellheads 24

R-type Ring Joint Gasket

Type 6B flanges are not designed for face-to-face make-up;

| 7.4 Gaskets, Seals and Wellheads 25

Circulating from Cement unit to Choke line