Welcome to

IWCF Rotary Well Control Training

My name is Richard Ryerson

Surface or Subsea Combined

Level 3 Driller
Level 4 Supervisor

Please fill in the personal information form

1
IWCF Well control equipment

Pretest 45
minutes

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• API RP 53 gives the following definition of
Rated Working Pressure (RWP):

• The maximum internal pressure that equipment

is designed to contain or control.

• The required working pressure of the BOP stack

for a particular well is based on the maximum
anticipated surface pressure.

• This is determined from the maximum

anticipated formation pressure, less the
hydrostatic pressure of a column of gas back to
surface.

6
API documentation uses codes for designation of BOP stack
arrangements.

G = rotating head
A = annular type BOP
R = single ram type BOP
Rd = double ram type BOP
Rt = triple ram type BOP
S = drilling spool with side outlet
connections for choke and kill lines.

7
BOP stack
A BOP stack may be fully identified by a
very simple designation:

10k-135/8-SRRA

This BOP stack would have a RWP of

10,000 psi, a through bore of 135/8
inches and arranged as shown

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Response time between activation and complete operation of a function is
based on BOP or valve closure and seal off.

Closing time for Surface installation should not exceed:

30 seconds for annular BOP’s smaller than 18-3/4” nominal bore
and
45 seconds for annular BOP’s of 18-3/4” nominal bore and larger

SUBSEA
60 seconds for all annular BOP’s

Measurement of closing response time begins at pushing the button or

turning the control valve handle to operate the function and ends when the
BOP or valve is closed effecting a seal.
A BOP is considered closed when the regulated operating pressure has
recovered to its nominal setting

23
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TEST FLUIDS
Well control equipment should be pressure tested with water.
Air should be removed from the system before test pressure is applied.
Control systems and hydraulic chambers should be tested using clean control
system fluids with lubricant and corrosion additives for the intended service
and operation temperatures.
Hydraulic chambers of annular BOP’s 1.500 psi
Hydraulic chambers of ram BOP’s etc 3.000 psi

A pressure test should be maintained for at least 5 minutes.

25
All Blow-out prevention components that may be exposed to well pressure
should be tested first to a low pressure of 200 to 300 psi and then to high
pressure.

A stable low pressure test should be maintained for at least 5 minutes.

Initial high pressure test on BOP stack, choke manifold and choke/kill lines
should be to rated working pressure on the ram BOP’s or to the rated
working pressure of the wellhead that the stack is installed on, whichever is
the lowest.

Subsequent high pressure tests on well control components should be to a

pressure greater than the maximum anticipated surface pressure, but not to
exceed the working pressure of the ram BOP’s.

A stable high pressure test should be maintained for at least 5 minutes.

26
Body Test at manufacturer Plant
1 ½ times BOP rating I.e. 150% of pressure rating.

Closing Ratio
Ratio of well head pressure to pressure required to close the BOP.

27
Pressure tests on well control equipment should be conducted at least:

• Prior to spud or upon installation

• After disconnection or repair of any pressure containment seal in the
BOP stack etc.
• Within 21 days

TEST FLUIDS
Hydraulic chambers are to be tested “in between wells” according to API. Does
not specify it better than that.

Well control equipment should be pressure tested with water.

Air should be removed from the system before test pressure is applied.
Control systems and hydraulic chambers should be tested using clean
control system fluids with lubricant and corrosion additives for the
intended service and operation temperatures.

28
Initial pressure test
When subject to well pressure:
 Pressure test to RWP of BOP or wellhead (whichever is lowest)
 Drill pipe safety valves (FOSV/IBOP) pressure test to RWP of BOP
 PT Annular to 70% of RWP
 Pressure test with water or water with additives

Subsequent pressure test to maximum anticipated wellhead pressure

for the hole section

Rated Working Pressure-Inside BOP-Pressure Test - Full Open Safety

Valve

29
 Well head

Test Plug

Cup tester

𝜋𝑑2
Annullar 𝐴 = 4 Tensile force on DP is equal F = p x A
Circle l 𝐴 = 𝜋𝑟 2 The pressure test is done on 5 ” DP in 7 ” casing

Test pressure = 5000 psi.

Calculate the tension on the DP.
The tension on the DP is eqaual 94.247 lbs

30
TEST PROCEDURES:

In general; a BOP test consumes a lot of rig time and often more than
necessary.

The main reasons why these tests take longer than required are not
related to equipment problems. The reasons are related to:

 Little understanding of the wellhead and test-tools.

 The wrong set-up.
 The preparation, before the actual testing commences, is not
thoroughly enough.

This leads to downtime

31
 The preparation of a BOP-test starts with a
proper understanding of the wellhead, the
way the test-tools are situated in there and
the BOP's itself.
 A manual should be onboard/onsite and
should be consulted.
Most(All) manuals have proper drawings of
the test tools and the way they fit.
Two test-tools are available:

 Plug-type tester
 Cup-type tester.

32
 A Plug-type tester sits in the top of the
wellhead and does not enter the casing.
Normally, the wellhead is rated higher than
the casing and therefor the test-pressure
with a plug tester can be higher.

Apply test
pressure
 To safeguard the casing against a too high a
pressure; with a PLUG-type tester:
always have a outlet on the wellhead, below
the Plug, open to atmosphere in case the
tester leaks past the seals. Calculate the
volume required to get to test pressure.
Often not more then a few gallon. Open
outlet

33
 A Cup tester enters the casing. A standard F
tester can be put anywhere in the casing.
The Test-pressure should not exceed 80% of
the casing burst pressure.
 There have been occasions, where the test
pressure exceeded the rating of the Cup-
tester and the drillpipe parted or the cup
failed. (In smaller size casings with a high Casing
burst-pressure). out
 Therefore Shell-Cameron designed a Cup- let valves
tester which is wellhead supported and there closed
is no strain on the drillpipe.
 With a CUP-type tester: Always have the Well head
drillpipe open to atmosphere in case the
Cup leaks into the casing. (The casing Cup-tester
in casing
might be drilled out and the test pressure will
go onto the formation)
34
HCR and Pipe rams test
1. Pick up top drive, connect test plug on the bottom of 5-1/2″ DP, run test plug
and seat in wellhead.
2. Connect pressure source to the kill line and open kill line valve 1 and 2, valve 3,
and keep HCR (valve 4) close.
3. Close pipe rams.
4. Pump into the well through kill line. Monitor and record the test pressure.
5. Conduct low-pressure test and high-pressure test
6. Bleed off pressure at choke line(close J1,open 4,then open J1 to bleed off).
7. Open pipe rams.

3-7
5
6
p 2 4
1

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• Installed TP inside wellhead
• Open side outlet valve below test plug to protect
casing when pressure test take place and see if
the TP holds pressure.
• Pressure test BOP valves with
• DP inside BOP
• Close pipe ram or annular
• Pressure test from below.
• W/O DP pressure test blind/shear ram from
below.

36
Run DP with cup tester inside the casing
open ended.

Pressure test:
• Annular / pipe rams and lower wellhead
valves

37
From the following select which are the API recommendations for
periodic pressure testing of BOPs: (Select TWO answers)

a) After installing and cementing casing.

b) Every five days.

c) No more than 21 days between tests.

d) After every 1,000 ft drilled.

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BOPs set back on a test stump will normally be pressure tested
to:

a) 50% of its maximum safe working pressure.

b) 100% of its maximum safe working pressure.

c) 150% of its maximum safe working pressure.

API recommends that, the closing unit should be capable of

closing an annular BOP smaller than 18 3/4" within.

a) 30 seconds.

b) 45 seconds.

c) 60 seconds.

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When testing the BOP stack with a test plug or a cup type tester, why
is pressure communication maintained from below the tool to
atmosphere?

a) To avoid potential damage to the casing/open hole.

b) To avoid the creation of extreme hook load.

c) Otherwise reverse circulation will be needed to release the tool.

d) To avoid swabbing a kick during the test.

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a) The maximum expected formation pore pressure.

b) The maximum allowable annular surface pressure.

c) The maximum internal surface pressure.

d) The maximum anticipated surface pressure.

e) The maximum internal test pressure.

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A 5,000 psi 13 5/8 BOP will have factory body shell pressure test
that is:

a) 70% of its rated working pressure.

b) 100% of its rated working pressure.

c) 150% of its rated working pressure.

d) 200% of its rated working pressure.

What does 13 5/8 refer to, when describing a BOP?

a) Through Bore diameter.

b) OD of the flange.

c) Diameter of ring gasket.

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• Shaffer
• Hydril GK
• Hydril GX
• Cameron ‘D’

Operating pressures

• Range between 500 and 1500 psi for normal

operations
• May require 3000 psi for open hole.

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• Annular preventers are BOPs which use
circular rubber or rubber-like elements.

• They are extremely versatile in use and

can close on most items.

• They are normally used on top of several

ram type BOPs.

• The annular BOP is usually the first to be

closed when a kick occurs.

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• Seal around smooth objects in the
wellbore e.g. drill collars, drill pipe, casing,
tubing, square kelly and wireline.
• Seal off an open hole although not
necessarily at full R.W.P. (this will shorten
the working life).
• Allow stripping of drill pipe under pressure
while maintaining a seal.
• Allow reciprocation of the drillstring during
well control operations.
• Allow rotation of the drillstring during well
control operations.

47
Three types of materials are used:

• Natural rubber
– WBM from -20o F to 170o F
– Good wear resistance

• Nitrile synthetic compound

– OBM from 40o F to 170o F

• Neoprene synthetic compound

– OBM from -30o F to 170o F

48
 Annular sealing element
If drilling in Arctic Sea. Cold weather. What type of rubber would
you use ?

-30F to 225F Used in -30F to 170F

High Temperatures Used in Cold
Extremely Cold Temps Temps
20F – 180F
Good wear resistance

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 Annular design
• While testing the
annular it may
needed to pump
up the pressure
several times to let
the packing unit
take the shape of
the pipe.

51
Which of the following is the most appropriate type of material to use for a
BOP packing insert when operating at low temperatures?

(Select TWO answers).

 a) Neoprene.
 b) Nitrile.
 c) Natural.

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 • Closing on tool joints
– Can cause severe damage
• Closing on casing
– Consider initial closing pressure
• Stripping Operations
– Provide for tool joints
• Operating pressures
Tooljoints
Although annular preventers have the ability to allow stripping of tooljoints, extreme care
must be taken to ensure that tooljoints do not interfere with initial closure. This could
cause severe damage to the metal segments and in turn damage to the upper housing.
Casing
Due to the low collapse resistance of most casing, consideration has to be given to the
initial closing pressure used.
Normal practice is to close with minimum closing pressure then increase to maintain a
seal as wellbore pressure increases.

53
 ShafferSpherical BOP. Part identification is not longer Supervisor/
Driller question

Locking Ring

Locking Segment

Upper Housing

Annular Element

Adapter Ring

Opening Chamber Opening

Chamber

Piston

Seal

Lower Housing

Closing Chamber

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Shaffer Spherical
Operating features;
• will close on open hole
• affected by mud weight in riser, so will require higher closing pressure in
subsea applications
• some assistance gained from wellbore pressure.

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Hydril GK
Operational features;
- designed for surface but but also used subsea;
- will close on open hole;
- wellbore pressure assists in maintaining closure;
- requires higher closing pressure subsea to compensate for mud in riser.

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Annular HYDRIL GK Preventer
The “GK” annular blowout preventer was designed especially for surface
installations and is also used on offshore platforms and subsea. The “GK” is a
universal annular blowout preventer with a long record of proven performance.
Only two moving parts (piston and packing) on the Hydril annular BOP mean
few areas are subjected to wear. The BOP is safer and more efficient, requiring
less maintenance and less downtime.
A long piston with a length to diameter ratio approaching one eliminates
tendencies to cock and bind during operations with off-center pipe or unevenly
distributed accumulations of sand, cuttings or other elements. This design
enhances the ability of the packing unit to reopen to full bore position.
The conical bowl design of the piston provides a simple and efficient method of
closing the packing unit. With the piston serving as a sealing surface against the
rubber packing unit, there is no metal to metal wear on the sealing surface and
thus longer life results.
A field replaceable wear plate in the BOP head serves as an upper non-sealing
wear surface for the movement of the packing unit, making field repair fast and
economical.
Maximum packing unit life is possible with the provision for measuring piston
stroke. This measurement indicates remaining packing unit life without
disassembly and ensures the longest and safest use of the packing unit.
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61
 A B C

1+2: Installed with stripping bottle

3. Riser tied into sec. chamber, via a mud/hydrostatic bottle

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 Latch head
Cutaway view
Screw Head HYDRILL GK BOP Wear plate
13 5/8” 10K Packing unit
Opening chamber
Identify the below parts.
Piston
Closing chamber port

6
5

4
Packing Unit
Nitrile
3
2

1
Hydril GK
Operational features;
- designed for surface bit but also used subsea;
- will close on open hole;
- wellbore pressure assists in maintaining closure;
- requires higher closing pressure subsea to compensate for mud in
riser.

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 Only two moving parts (piston and packing unit) on the Hydril annular preventer
mean few areas are subjected to wear. The BOP is thus safer and more efficient,
requiring less maintenance and downtime.
 A field replaceable wear plate in the BOP head serves as an upper non-sealing
wear surface for the movement of the packing unit, making field repair fast and
economical.
 NACE MR-01-75 material standards for resistance to sulphide stress cracking are
standard.
 A long piston with a length to diameter ratio approaching one eliminates tendencies
to cock and bind during operations with off-center pipe or unevenly distributed
accumulations of sand, cuttings or other elements. This design enhances the ability
of the packing unit to reopen to full bore position.
 Maximum packing unit life is possible with the provision for measuring piston
stroke. This measurement indicates remaining packing unit life without disassembly
and ensures the longest and safest use of the packing unit.
 Large pressure energized seals are used for dynamically sealing piston chambers
to provide safe operation, long seal life and less maintenance.
 Piston sealing surfaces protected by operating fluid lowers friction and protects
against galling and wear to increase seal life and reduce maintenance.
 The operating chambers are tested to full BOP working pressure to ensure
strength, reliability and the ability to over-pressurize the chambers in emergencies.
 Acoustic emission hydrostatic test monitoring is used during final acceptance test
on all BOP’s to provide 100% volumetric assurance of pressure vessel soundness
and assure a safe and reliable BOP.
 Finite element analysis of the body design is the most advanced in-depth technique
of pressure vessel design and ensures a structurally sound body configuration.
 (Secondary Chamber to Opening Chamber)

Type GL Blowout Preventer

Pipe 13-5/8- 5000 16-3/4-5000 18-3/4 5000 21-1/4-5000

O.D.
(inches)
Well pressure (psi) Well pressure (psi) Well pressure (psi) Well pressure (psi)

2000 3500 5000 2000 3500 5000 2000 3500 5000 2000 3500 5000

7” 900 950 1100 700 825 950 700 825 950 640 780 925

5” 900 1000 1100 725 850 1000 800 900 1000 670 725 800

3-1/2” 1200 1200 1200 800 925 1050 1000 1050 1100

Full Closure 1400 1500 1500 1400 1500 1500 1500 1500 1500 1500 1500 1500

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CLOSING PRESSURE
CHART WHEN PIPE IS STATIC

CLOSING PRESSURE
CHART WHILE STRIPPING

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 RAM SHAFT OPENING CHAMBER

PISTON CLOSING CHAMBER

RAM

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 Make: Nom. Rated Vol. to Vol. to Clo- Ope-

Cameron U
Size:
(in)
21-1/4
WP:
(psi)
10 m
Open:
(gal)
24,5
Close:
(gal)
26,9
sing
Ratio:
7,2
ning
Ratio:
4,0
Ram BOP
Cameron U 18-3/4 10 m 21,2 23,1 7,4 3,7

Cameron U 13-5/8 15 m 10,4 10,6 10,6 3,6

RAM BLOWOUT
Cameron UII 18-3/4 15 m 32,3 34,7 9,3 3,5

Cameron T 18-3/4 15 m 22,2 24,2 6,7 3,1

PREVENTER
Hydril ml 21-1/4 5m 16,6 17,5 10,2 1,9 OPERATING DATA
Hydril ml 13-5/8 10 m 11,8 11,8 10,2 3,8

Hydril MPL 21-1/4 5m 16,6 19,3 10,6 1,9

Hydril MPL 18-3/4 15 m 16,7 19,4 7,27 2,15

Hydril MPL 13-5/8 15 m 11,0 12,6 7,74 3,56

NL Shaffer SL 21-1/4 10 m 13,86 16,05 7,11 1,63

NL Shaffer SL 18-3/4 15 m 13,33 14,62 10,85 1,68

NL Shaffer SL 13-5/8 15 m 10,52 11,56 7,11 2,14

NL Shaffer SL 13-5/8 10 m 10,52 10,58 7,11 4,29

NL Shaffer LWS 21-1/4 2m 4,46 5,07 5,57 0,78

Koomey PB-PRC 13-5/8 10 m 5,78 6,25 7,75 2,50

Koomey PL-H 21-1/4 10 m 4,40 4,40 18,32 13,3

Koomey PL-H 18-3/4 15 m 11,50 11,50 30,0 25,0

Koomey PL-H 13-5/8 15 m 3,34 3,54 42,86 25,0

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 Ram BOP’s
API CLOSING RATIO:
A dimensionless factor equal to the wellbore pressure divided by
the operating pressure necessary to close the ram BOP
against wellbore pressure
CLOSING
AREA

RAM SHAFT
AREA

WELL CLOSING
PRESSURE PRESSURE

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79
Closing pressure required to Rated Working Pressure
close ram with rated wellbore = -------------------------------------
pressure in the bore Closing Ratio

Piston closing area

Closing Ratio = -------------------------------------
Ram shaft area

The well is closed in. The pipe ram closing ratio is equal to 7.4. If
the rated WP is equal 10000 psi and the well must be closed in at
this pressure. How much pressure would be needed to apply at the
closing chamber to close the ram against 10000 psi ?

80
Is a dimensionless factor equal to the wellbore pressure divided by
the operating pressure necessary to open a ram BOP
containing wellbore pressure

RAM BLOCK
RESULTANT
RAM SHAFT
RESULTANT

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Opening pressure required to Rated Working Pressure
open rams with rated working = -------------------------------------
pressure in the wellbore Opening Ratio
Piston opening area
Opening Ratio = ------------------------------------------------------
Resultant of vertical plane areas
exposed to wellbore Pressure

The well is closed in and the locks are not activated.

The pipe ram opening ratio is equal to 1.63. If the rated
WP is equal 10000 psi and the well was closed in at
this pressure. How much pressure would be needed at
the opening chamber to open the ram?
10000/1.63 = 6135 psi

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 Ram design

Rams for Ram-type BOP designed to:

1-Hang off drill string
2-Tested and hold pressure from bottom
3-Top and bottom plates provide Elastomer with self feeding
(extrusion) in the wear direction.

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A ram BOP should never be attempted opened unless the
pressure above and below the rams are equalized.

If rams are attempted opened while containing pressure

a major equipment destruction can occur.

84
 Various manufacturers
 Cameron
 Hydril
 Shaffer
 Pipe rams
 Variable Bore Rams
 Blind-Shear Rams
 Blind Rams

Rams are designed to close on rated working

pressure of the BOP. They are not designed to
open at RWP.

85
 Standard pipe rams are designed to
centralise and seal around one specific
size of pipe (or casing).

 Hang off capability

 Feed able rubber

Normal pipe rams are designed to centralise

and seal around one specific pipe size (or
casing).

Pipe rams in use on a subsea stack are

designed to be able to hang off the string
although this may not be true of all pipe rams
on surface BOPs.

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 Designed to close and seal on a range of pipe diameters

 2 7/8 inch - 5 inch

 3 1/2 inch - 7 inch

 Limited hang off capability

Variable bore rams are normally designed to

provide closure on two different sizes of pipe,
although they will close on anything within the
specified range.

Most variable rams have a limited hang-off

capability depending on pipe size.

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88
 The Intermediate Flange is Thicker in the shear Rams.

Increase pressure to maximum closing pressure if you need to cut the

DP = 3000 psi
Blind shear rams are designed to cut drill pipe and then seal on the open
hole.
Most sizes bend the pipe in order to allow closure on open hole, large sizes
require the string to be dropped.

89
The Cameron ‘U’ type ram has several major
features:
- Bonnets not hinged - uses intermediate flanges.
- Ram change piston and cylinder.
- Locks - wedgelocks.

Cameron type U and UII preventers are

hydraulically operated ram preventers with internal
hydraulic systems through a forged steel body.

The bonnets are not hinged but have an

intermediate flange. Control fluid is used not only
to operate the rams but to open and close the
rams.

With the bolts removed, closing pressure will force

the bonnet off. Opening pressure does the reverse.

Cameron rams in subsea use would be fitted with

Wedgelocks.

91
Complete assemblies type “U” blowout
preventer

Ram
Intermediate Flange
Assembly

Piston Cylinder
Body
Bonnet

Connecting rod Seal Ring

Locking Screw
92
93
Shaffer rams use the floating ram concept in
which the top seal of the ram is energised by
pressure from the holder.

Pipe Rams
Consist of a block, a single piece rubber seal
and a holder.
The blocks are equipped with pipe guides.

Variable (Multirams)
Two piece packer and seal. The packer has
steel inserts which rotate inwards.

Blind Shear Rams

Shearing is achieved as the lower blade
(detachable) passes below the sharp edge of
the upper ram block.

94
 Pipe ram

 Variable Pipe Ram

 Blind Shear Ram

95
Shaffer rams have hinged bonnets which are
opened manually. All hydraulic connections
are built into the hinge.

Shaffer manufacture a variety of locking

devices:
- Poslocks.
- Multilocks.
- Ultralocks.

96
 Fixed Ram’s

5” Pipe 600.000 lbs

3-1/2” Pipe 425.000 lbs

Low Pressure Test

Hang off Variable Ram’s

Consult manufacture's
recommendation's

Only for fixed rams

VBS’s check with manufactures
recommendations

97
Before running 7 inch casing, with a set of variable pipe
rams (5 to 7 inch) already installed, is it necessary to
change over to 7 inch casing rams?

a) Yes.
b) No.

Which one of the following statements defines “Well

Pressure Assistance”?

a) The well pressure acting on the piston produces an

increasing pressure in the closing chamber.

b) The pressure exerted by the well on the exposed surface of

the piston gives a resultant force that is added to the force
produced by the pressure in the closing chamber.

c) The pressure exerted by the well on the exposed surface of

the piston gives a resultant force that is subtracted from the
force produced by the pressure in the closing chamber.
98
Problems may occur when shutting in the pipe ram at the remote
BOP panel on a surface BOP installation.
What has happened if the close light does not illuminate and the
manifold pressures remain unchanged?

a) The hydraulic closing line to the BOP is plugged.

b) The 3-position / 4-way valve on the hydraulic BOP control unit failed to
operate.

c) The light bulb has blown.

d) There is a leak in the hydraulic line to the BOP.

f) Standpipe pressure gauge.

99
Which of the following allow a Driller to recognise he may
be entering an Abnormal Pressure Zone?
(Select THREE answers)

a) ROP recorder.

b) Pump stroke counter.

c) Gas detector.

d) Casing pressure gauge.

e) Mud temperature recorder

100
When annular BOP’s are hydraulically pressure tested, test
pressure may have to be charged up two or more times before an
acceptable test is obtained.
What is the most likely reason?

a) Annular BOP’s always leak at first.

b) The compressibility of the hydraulic fluid from the hydraulic control

unit below the closing piston causes the test pressure to drop.

c) As a result of the applied hydraulic test pressure the packing unit

elastomer is flowing into a new shape.

101
When should well control equipment on a surface BOP stack be
pressure tested? (Select TWO answers)

a) Prior to spud or upon installation.

b) At intervals not exceeding two months.

c) After circulating out a gas kick.

d) After the disconnection or repair of any pressure containment seal in

the BOP stack, choke line or choke manifold.

102
Surface BOP
 Manual locking systems

Subsea BOP
 Automatic locking systems

1. Cameron: Wedgelock or ST locking system

2. Hydril: MPL
3. NOV Shaffer
 Poslock (locks in one position only and do not compensate for
wear and tear
 Multilock (locks in 2 positions for Multiram)
 Ultralock (locks in all positions)

103
Ram type preventers
should be equipped with
extension hand wheels
or hydraulically
operated locks

104
 Manual locking system
Model LWS Manual-Lock
System
Manual-lock pistons move inward and close the rams
when closing hydraulic pressure is applied. If desired,
the rams can be manually locked in the closed
position by turning each locking shaft to the right until
it shoulders against the cylinder head. Should
hydraulic pressure fail, the rams can be manually
closed and locked. They cannot be manually
reopened.
The manual locking shafts are visible from outside and
provide a convenient ram position indicator. Threads
on the manual locking shaft are enclosed in the
hydraulic fluid and are not exposed to corrosion from
mud and salt water or to freezing.
Rams are opened by first turning both locking shafts
to their unlocked position, then applying opening
hydraulic pressure to the pistons, which move outward
and pull the rams out of the well bore.

105
Manual locking system

106
 Close Locking
Port Head

Wedge lock
To Balance
Chamber

Locking
Piston

Hydraulically operated locking mechanisms,

Wedge Piston
(Whistle Piston) wedgelocks, lock the ram hydraulically and
Tail Rod
Extension hold the rams mechanically closed even when
Operating
Piston actuating pressure is released.
The operating system can be interlocked using
sequence caps to ensure that the wedgelock is
Bonnet
Wedgelock
Housing retracted before pressure is applied to open
the BOP.
Ram Change
For subsea applications, a pressure balance
Assembly
chamber is used with the wedgelocks to
Open Unlocking
WEDGE1.DRW
Port Head eliminate the possibility of the wedgelock
becoming unlocked due to hydrostatic
pressure.

107
 Primary seal: situated on the piston
rod
 Secondary seal: activated only if
primary seal leaks during a well control
situation Opening
chamber
 Mud indicates leak of the primary seal
 BOP fluid indicates leak of operating
seal
 Weep hole: between secondary seal
and operating seal prevents well bore
fluids from entering ram BOP opening
chamber

108
Ram BOP
PRIMARY SEAL AND
SECONDARY SEAL

Closing
Chamber

109
Secondary seal
(Emergency only)

Weep hole
G
a
S
Closing chamber
T
1500 psi
O
P
s
110
Primary Mud Seal
Seal to prevent mud leaking from wellbore.
Rated to RWP of BOP.

Piston Rod to Bonnet Seal

Seals hydraulic fluid in operating chamber.
Rated to 3,000 psi (as Accumulator Unit).

Weep Hole
A vent to atmosphere to show whether the
primary mud seal is leaking and to relieve
pressure to protect the operating chamber.

Secondary Seals
All ram preventers (for surface BOPs) rated
5000 psi or higher should be equipped with
secondary piston rod seals. This secondary
seal is plastic packing which is activated by
being forced around the ram rod.
 •If the Weep hole leak while testing BOPs… Immediate repair
•If the Weep hole leak while Killing Operation… energize with Plastic
sticks, Use Secondary Packing

Leak Closing
Pipe ram
Chamber

112
• Flange
• Studded
• Open-ended
• API categories: 6B and 6BX
• Hub connection
• API categories: 16B and
16BX

114
Ring Joint Gaskets
Metal seal rings placed in a ring groove to create a
seal between two flanges or hub connections

Not for re-use

115
Flange 6B 6Bx Hub 16B 16BX

R RX BX Ring joint gasket RX BX

• X-types are energized by well bore pressure
• R and RX are interchangeable
• RX and BX are not interchangeable
• SRX and SBX for subsea make-up, dimensions identical
to RX and BX
116
Type 6B (box) flanges insert R (Ring) seals

6B flanges are of the ring joint type and are not designed to make up
face to face - the bolting force acts to compress the gasket.

6B flanges use type R gaskets

ROVAL, ROCTAGONAL, RX

117
Type 6BX flanges insert BX box seal (Box/square)

 6BX flanges are designed for face to face make up - the bolting
force acts on the flange itself.
 6BX flanges use type BX seal.

118
 Flanges and Sealing Rings
The most common flange types are
•API 6B Rate work pressure 2,000-5,000 psi
•API 6BX Rate work pressure 5,000-2,0000 psi

Flanges type API 6B Use Sealing Rings API type R or API type RX
Flanges type API 6BX Use Sealing Rings API type BX

type RX type BX
type R
119
 BX Rings
X Types are pressure-energized rings .
Well bore pressure assist .
Studs torque is not completely relied on .

120
121
 Annular preventer coupled with a large diameter piping
systems underneath.
 Are used to protect personnel and equipment from shallow
gas flows.
 Should be used if a well cannot be shut in for fear of lost
circulation or formation breakdown.
 On floating rigs - diverters may be used throughout the entire
drilling operation.
 Typically installed on conductor casing or as part of the
marine riser, with diverter lines running to a safe downwind
area.

124
 BALL VALVE

Full Opening

VENT LINE Same Opening

Offshore 10” or larger

Onshore 6” or larger

125
Rotating control heads or rotating blowout preventers are not a new concept. The
rotating blowout preventer or rotating wellhead maintains a constant seal around all of
the rotating elements in the drill string except such large diameter pieces as the bit or
reamer.
This seal is maintained when going in, coming out or holding in static position. The
original equipment was designed for air drilling and later used for mud, gas and
geothermal applications. Later generation equipment was applied by industry for the
flow drilling applications which cause high pressures at the wellhead. The original design
and engineering principals for its use have held and still apply today. Within the BOP
system, the API recognizes the rotating head as diverter. Rotating heads are generally
recognized in industry as being applied to lower pressure requirement systems which
have been extensively used on air, air and foam, and air and mist operations using
hexagonal kelly.
The RBOP is always used on top of regular BOP stack consisting of ram and annular
BOP’s.

126
 Example diverter with
Vetco KFDJ Diverter annular packing element

127
128
Diverter system

129
 Diverter system.
The fixed support housing, a proprietary
feature, is securely bolted to the rotary beams
and provides fixed outlets for flowline, fill-up
line and vent lines.

The support housing allows installation of

outlets of up to 20” diameter to virtually any
configuration.

Diverter, spacer spool, and overshot packer

assembly may be pulled or run without
connecting or disconnecting the flowline, fill-
up line and vet lines.

Mudline suspension hangers and bit sizes up

to 27.41” for 37.5” rotaries or 36.41” for 49.5”
rotaries can be run without removing the
diverter assembly.
Purpose: A Diverter system is often used during top-hole drilling.

A Diverter is not designed to shut-in or halt flow, but rather permit routing of the flow
away from the rig to protect personnel and equipment by re-routing the flow of
shallow gas and wellbore fluids emanating from the well to a remote vent line.

The system deals with the potentially hazardous flows that can be experienced prior
to setting the casing string on which the BOP stack and choke manifold will be
installed.

The system is designed to

pack-off around the Kelly, Drill String or Casing to divert flow in a safe direction.

Diverters having Annular Packing elements can also close on open hole.
Valves in the system direct the well flow when the diverter is actuated.
The function of the valves may be integral to the Diverter unit.

132
 Diverter system
Equipment & Installation Guidelines

The Diverter system consists of a low pressure Diverter or an Annular Preventer of

sufficient internal bore to pass the bit required for subsequent drilling.

Vent line(s) of adequate size (6” or larger) are atached to outlets below the Diverter and
extended to a location(s) sufficiently distance away from the well to permit safe venting.

Conventional Annular BOP’s., insert type Diverters or rotating heads can be used as
Diverters.
The rated working pressure of the Diverter and vent line(s) are designed and sized to permit
diverting of well fluids while minimising wellbore back pressure.
Vent lines are typically 10” or larger ID for offshore and 6” or larger ID for onshore.

If the Diverter system incorporates a valve(s) on the vent line(s), this valve(s) should be
fully opening and full bore (have at least the same opening as the line in which
they are installed).

The system should be hydraulically controlled such that at least one vent line valve
is in the open position before the diverter packer closes.

133
 Diverter system
The Diverter and all valves should be function tested when installed and at appropriate
times during operations to determine that the system will function properly.

Fluid should be pumped through the Diverter and each Diverter line at appropriate times
during operation to ascertain the line(s) is not plugged.

Inspection and clean-out ports should be provided at all low points in the system.

134
135
136
137
 The upper kelly cock is a
standard part of the upper
kelly assembly.

 Basic purpose of the upper

kelly cock is to protect the
kelly hose, swivel and
surface equipment from
high well pressure.

138
 The lower kelly cock is full-opening safety
valve which back up the upper kelly cock.

 It allows removal of kelly when pressure on the

string is grater than surface equipment rating.

 It is common practice to use the lower kelly cock

as fluid or mud saver valve.

 The valve is operated at every connection so it is

kept free and in operating condition.

139
 The upper and lower safety
valves on top drive systems are
connected together.

 They are ball valves

 Both are very likely to be

inaccessible should a kick occur
during drilling operations, so the
upper valve is remote operated.

140
Full Opening Safety Valve
or
Kelly Cock
or
TIW (Texas Iron Works)

Or

Drill Pipe
Safety Valve

141
Drill Pipe Safety Valve (kelly cock)

 Always available during tripping and

casing running operations
 Correct connections or crossover to
allow stabbing in
 In open position
 Key readily available
 OD suitable for running downhole

142
 A method of closing off the string is a basic part of well control
equipment.

 Equipment for closing off tubing or drill pipe includes FOSV, floats
and ISBOP inside blowout preventers.

 The equipment is handled by the floor crew.

 It is essential that the driller and Toolpusher make sure the crew
understands the rules for operating and maintaining this essential
equipment and can connect to the pipe at all time (x-overs)

143
Inside BOPs
 Gray valve
 Stab-in non-return valve
 Allows (kill) fluid to be pumped
 Stripping Operations
 Drop-in check valve
 Pumped down
 Float valve
 Prevents back flow

144
 The inside IBOP (sometimes
called Grey valve) is a
backpressure or check valve.
 Its primary use to stripp back
into a closed in well
 The inside BOP allows the well
to be circulated and prevents
pressure or flow up back into
the drill string.
 It is a simple and reliable tool,
but since it is not full-open, the
inner diameter of the drill string
is restricted and do not allow
WL through passage or
reverse circulation.

145
Also called a pump down valve or dart. This
non-return type valve is dropped (or pumped)
into the string to land on a special landing sub.

The advantage of the dart and dart sub is that

the dart may be retrievable by wireline.

146
 Floats, inside BOPs, backpressure
and check valves all act similarly to
prevent flow and pressure flowing
up the drill string.

 The standard float valve are

installed just behind the drilling bit
and stops back flow and inside
blowout up the drilling string.

 The two most common types or SPRING LOADED

floats are spring operated piston FLAPPER TYPE BPV
FLOAT VALVE
(plunger) and flapper types.

147
Float valves in general
will.
• Will need to pump valve open
to monitor SIDPP
• Will not allowed WL through it
• Will increase surge pressure
• Will require pipe fill while
running drill string down the
well
• Will not allow reverse circulate
Float valve Flapper
type
• Solid or with a bored
hole
Float valves are used to:
• Prevent sudden influx entry
into the drill string.
• Prevent back flow of annular
cuttings from plugging bit
nozzles
148
Which one of the following statements about an Inside Blowout
preventer is correct?

a) It is opened by drilling fluid pumped down the drill string.

b) It requires a double box sub in order to be installed in the drill string.

c) It allows reverse circulation when installed in the drill string.

d) It can be opened or closed by turning a wrench connected to an operating

crank.

149
 During tripping operations a conventional flapper type float valve is
installed in the bit sub in the closed position. What effect does this
have on the operation when tripping into the well?
(Select THREE answers)

a) Back- flow through the drill string increases.

b) If the drill pipe is not filled the risk of hydraulic collapse will increase.

c) Reverse circulation may be performed at any time.

d) Surge pressure on the formation will reduce.

e) Returns to the trip tank increase.

f) Surge pressure will increase if tripping speeds are not decreased.

Should diverter vent lines have small internal diameters to create

sufficient back pressure for control?

a) Yes.

b) No.
150
 Pit Volume Totaliser (PVT)
 Better accuracy with small surface
area
 Float or ultrasonic
 Return flow
 Hinged paddle type
 Differential flow meter

151
In which order should the valves for the choke line be installed on
a surface BOP with a ‘Rated Working Pressure’ of 10000 psi,
according to best practice? (Note; inside means – closest to the
BOP).

a) Inside – a manual valve, Outside - a hydraulically operated valve.

b) Inside – a hydraulically operated valve, Middle – a manual valve,

Outside – a hydraulically operated valve.

c) Inside – a check valve, Middle – a hydraulically operated valve,

Outside – a hydraulically operated valve.

d) Inside – a hydraulically operated valve, Outside – a manual valve.

e) Inside – a manual valve, Middle – a check valve, Outside – a

hydraulically operated valve.

152
 During a trip out of the well a kick was taken while the bit was half way
up inside the casing. A drill pipe safety valve was installed on the drill
pipe and closed. There was no float in the drill string. The well was
shut in on the Annular BOP.

What is the Driller’s next action before commencing to strip back to

bottom?

a) Install the inside blowout preventer above the drill pipe safety valve and
open the drill pipe safety valve.

b) Open the drill pipe safety valve and install the inside blowout preventer.

c) Keep the drill pipe safety valve in the closed position.

d) Install a drill pipe safety valve on top in the closed position.

e) Replace the drill pipe safety valve with an inside blowout preventer.

153
 Choke manifold and valves
2
CEMENT
PUMP
1 REMOTE
MUD
PUMP CHOKE
17 18 19
MUD GAS
SEPERATOR
6

16
3 ANNULAR PREVENTER
(BAG)

7 8
5” PIPE RAMS 13 14 15
VENT
20 LINE
KILL 4 5 Hyd. Man.
LINE BLIND/SHEAR RAMS

5” PIPE RAMS
9
WELLHEAD

10 11 12
FLARE
BOOM
MANUAL
CHOKE

154
MANUAL OPERATED
CHOKE

HYDRAULIC OPERATED
CHOKE

155
156
157
158
 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.

 The manifold provides alternate

routes so that chokes and valves can
be changed out or repaired.

159
 Manifold equipment subject to well
and/or pump pressure should
have working pressure at least
equal to the rated working
pressure of blowout preventer in
use.

160
 The choke manifold gives safety
and flexibility when circulating out a kick.

D
O
W
N

S
T
R
E
A
M

U
P

S
T
R
E
A
M

161
The choke control station, whether at
the choke manifold or remote from the
rig floor, should be convenient as
possible and should include all
monitors necessary to furnish an
overview of the well control situation.

Rig air systems should be checked to

assure their adequacy to provide the
necessary pressure and volume
requirements for controls and chokes.
The remotely operated choke should
be equipped with an emergency
backup system such as a manual
pump or nitrogen for use in the event
rig air becomes unavailable.

162
REMOTE HYDRAULIC OPERATED
CHOKE

REMOTE CHOKE PANELS

163
 A choke controls the flow rate of fluids. By
restricting flow through an orifice, friction or
backpressure is placed on the system,
allowing a control of flow rate and well bore
pressure.

 Well control chokes are of different design

than gas and oil production chokes. In
general, the production choke is not suitable
for well control.

 Manual adjustable chokes are used for

some well control applications but most
pressure operations use remote adjustable
chokes.

164
 Basic choke type is a tapered
tip and seat.

 As the tip gets closer to the

closing area, there is less
clearance and more
restriction for fluid passage
and backpressure on the well
will increase.

165
 Remote adjustable chokes are preference in
well control operations and for pressure control
work.

 They provide the ability to control down hole

pressure and control the position of the choke
from the Remote Choke Panel.

 Choke producer are Cameron and MI SWACO

 All chokes have operating panels that give

choke position, stroke counts ,total stroke
count, stand pipe and casing pressure, choke
valve position and a pump for hydraulic for
remote control

166
HARD SHUT IN
1 Pick off bottom and position string

2 Stop pumps

3 Close BOP (Ram or Annular) 5

4 Open hydraulic side outlet valve

5 1
Observe pressure

2
3 4

167
168
169
Atmospheric
- Most Common
• Partially Pressurized
• Pressurized
•Siphon breaker

170
Atmospheric
- Most Common
• Partially Pressurized
• Pressurized

171
A Mud Gas Separator are
designed to separate mud and
gas while circulated out a kick
from the well by leading gas up
the vent line and mud back to
down to the active pit.

172
 Derrick Vent

Inlet Hot Mud

Tangential Inlet

Seal

Shaker

175
Siphon Derrick Vent
Vent line

Inlet Hot Mud P

Tangential Inlet

Seal

Shaker

176
 PRESSURE BUILD UP

LENGTH OF VENT LINE

How does it work??
ID OF VENT LINE
Pressure buildup is
made by the
resistance in the
ventline (hight, ID
and Raynolds
number)
Max pressure is
depending on the
height of liquid
seal.
PRESSURE LIMITATION
HEIGHT OF U-TUPE/DIP TUBE

GRADIENT OF FLUID
177
Mud-gas separator Poor boy (Gas poster)
Length and Diameter of vent line creates
pressure build-up in vessel as gas is vented

Mud wt x 0.052 x length of liquid seal = Blow-through

pressure
If the mud weight is 12 ppg and the mud leg
is 20 ft. Calculate the maximum pressure we
can see on the pressure gauge
12ppg x 0.052 x 20ft = 12 psi

This pressure acts on the

liquid seal.

If the pressure in the vessel exceeds

the mud seal hydrostatic a blow-
through to the shakers would occur.

178
• Separates small entrained gas
bubbles from fluid
• Installed downstream of the
mud/gas separator
• The vacuum makes the gas less
soluble

SWACO
VACUUM DEGASSER
WELCO
VACUUM DEGASSER

179
180
 Trip Tank

Trip Tanks are small metal tanks with small capacity about 20-40 bbls
with 1 bbl divisions inside and it is used to monitor the well.

181
182
TOH – Tripping Out of Hole

183
 Hydraulic fluid tank

Electric and hydraulic pump

Accumulator bottles

BOP manual Close and opning handle control

Remote BOP control

184
BOP control systems for surface installations (land rigs, offshore jackups, and
platforms) normally supply hydraulic power fluid in a closed loop circuit as the
actuating medium. The elements of the BOP control system normally include:

1. Storage (reservoir) equipment for supplying ample control fluid to the

pumping system.
2. Pumping systems for pressurizing the control fluid.
3. Accumulator bottles for storing pressurized control fluid.
4. Hydraulic control manifold for regulating the control fluid pressure and
directing the power fluid flow to operate the system functions.(BOPs and
choke and kill valves).
5. Remote control panels for operating the hydraulic control manifold from
remote locations.
6. Hydraulic control fluid.
BOP closing unit ( Koomey unit )

186
 BOP control system

1. Custom air supply 3. By-pass valve 4. Automatic Hydro-Pneumatic pressure switch

6. Air operated Hydraulic pumps 10. Electric Triplex pump 11. Automatic Hydro-Electric pressure switch
16. Accumulator shut off valves 17. Accumulators 18. Accumulator relief valve
20. Manifold pressure reducing and regulating valve 22. Selector valve (3 position/4 way valve)
23. By-pass valve 26. Panel-Unit selector 27. Annular pressure reducing and regulating valve
28. Accumulator Pressure gauge 29. Manifold Pressure gauge 30. Annular Preventer Pressure gauge 187
31-32-33 Pressure transmitter 35-36-37 Air regulators 41. Hydraulic fluid fill hole
190
Recoverable fluid volume from accumulator system between
max. operating (3000 psi) pressure and the pre-charge (1000 psi)
pressure.

USABLE HYDRAULIC FLUID:

Recoverable fluid volume from accumulator system between
max. operating pressure and 200 psi above pre-charge pressure= 1200
psi

MINIMUM CALCULATED OPERATING PRESSURE:

Minimum calculated pressure to effectively close and seal a ram-type BOP
against maximum rated wellbore pressure divided by closing ratio.

MINIMUM OPERATING PRESSURE:

Minimum operating pressure to effectively close and seal ram-type or
annular-type preventers under normal operating conditions.

191
By pass valve gives the possibility to increase manifold pressusse
to maximum Air supply
Accumulator ¾ Valve

Fully charged Regulated

hydraulic fluid Rig Air
hydraulic fluid
3000 psi in the 1500 psi in the Regulated air
bottle manifold Unregulated hydraulic fluid
192
Manifold
regulator Annular
3000 psi regulator
Bypass
valve
cut
¾ valve

Hydro electric
pressure switch
Air
pump

Electric pump
Starts at 2700
psi

193
 By pas valve Annular reduction valve

Accumulator ¾ Valve

Manifold Eletric triplex pump Air driven

reduction valve pump

194
 Panel-Unit selector Pressure transmitter
Air regulators Manifold Pressure gauge

Manifold pressure Electric Triplex Air operated

reducing and pump Hydraulic pumps
regulating valve

195
 Panel-Unit selector Pressure transmitter
Air regulators Manifold Pressure gauge

Manifold pressure Electric Triplex Air operated

reducing and pump Hydraulic pumps
regulating valve

196
Where are the electric pressure (activating) switches for the
remote BOP control panel lights located?

a) On the hydraulic BOP control unit.

b) Inside the BOP operating chambers.

c) On the pressure gauge mounted on the remote control panel.

d) On the remote control panel operating handles..

What would be the hydraulic pressure in the ram operating lines

between the hydraulic BOP control unit and the BOP stack
normally be while drilling?

a) 1500 psi.
b) 3000 psi.
c) Zero.
d) 500 psi.

197
198
Indicator Lights on BOP Remote Panel
A micro switch is located at the main unit, it
will send a signal to the indicator lights to
change color only when the 4-way valve
shifts.
Indicator lights, don’t tell us that the BOP’s
function has completed, but they tell us that
the 4-way valve is already shifted and the oil
is flowing under pressure to move the
functions piston to complete the close or open
operations.

202
Indicator lights Problem
While shutting in a well from remote panel

If indicator light does not illuminate, but gauges drop and

later rise back up which means that oil has been used to
move the piston of the BOP and the function is completed
so the cause is ?

BULB has blown.

If indicator light does not illuminate and pressure gauges don’t drop, it
means that no oil has been used and BOP piston does not move, the
cause could be
a) 4-way valve failed to shift.
b) Master control valve is not depressed with the control valve of the
function.
c) No air pressure is going to the remote panel.

203
Indicator lights Problem
• If indicator light illuminates but pressure gauges do
not drop it means that the 4-way valves has shifted
but hydraulic line between the 4-way valve and the
BOP is plugged.
• If indicator light illuminates and pressure
dropped but not rise back up it means that oil
has been used, function completed but there is
LEAK in hydraulic system.
• If indicator light illuminates and pressure dropped
then the manifold pressure raised back up to 1500
psi but accumulator pressure did not raise back up to
3000 psi. This indicates a defect charging pressure
transmitter on the system

204
205
206
No Air

207
208
209
 11

12

4 5
7
8
13 15
1 2

6 10

14 20
16 17 18
19

210
211
 Accumulator Bottles
If a 10 gallons accumulator bottle is used than each bottle contain 10
gallons of hydraulic fluid .
The Pre-charge pressure is 1000 psi for the 3000 psi working pressure
The accumulator unit and the bottles are pre- charge using Nitrogen
and minimum working pressure is set to 200 psi above pre-charge
pressure equal 1200 psi

N
3000
psi
Usable fluid Oil
(Recoverable oil)

1200 psi

212
1. Charged accumulator bottles must be able to with pumps off
• Close one annular
• Close all pipe rams one the BOP and open one HCR
• After these sequence's of event the remaining accumulator p
must be at least 200 psi above pre-charge pressure (1200 psi ).

2. Definition of useable hydraulic

control fluid is: Fluid recoverable
between operating pressure (3000 psi)
and minimum operating pressure (1200
psi) or (200 psi) above pre charge
pressure.

213
3. Reservoir Capacity: At least twice useable fluid of bottles.

• The pre-charge pressure must be measured before we start drilling

the well.
• Minimum pre-charge pressure for 3000 psi working pressure
accumulator is 1000 psi.
• Only nitrogen gas must be used to pre-charge the bottles.

N2
1000 psi 3000 psi

214
 Accumulator Pumps
A accumulator pump system consists of one or more pump each pump
should have independent power source.

With accumulators isolated the pump must be capable to

close one annular and open one hydraulic choke (HCR) and
return regulated accumulator annular pressure under 2 minutes.

Electric pump must automatically start when accumulator pressure

decreased by90% of accumulator maximum working pressure.

215
216
 Position of equipment in the control system. You should be familiar with the equipment and
be able to located specific items by name. You should also be able to determine where
individual items are located such as SPM valves, shuttle valves, pod selector valves etc.
 Identifying which components are duplicated in the control system and which components
have no duplication. e.g. There are two SPM valves for each function (one in each pod) but
only one shuttle valve.
 The sequence of events required to operate a particular function on the BOP. These
sequences can be followed. These should be understood and remembered.
 Knowledge of the pressure of fluids in particular systems. Rig air pressure, manifold
pressure, accumulator pressure, annular closing pressure, pilot fluid pressure and power
fluid pressure should all be familiar to you.
 Remember that pilot signals go to both pods every time whereas power fluid goes only to
the active pod.
 Sizing of accumulators should be understood. You should understand the reasons for
locating the accumulators at the subsea stack. Understand the difference between float
and bladder type accumulators.
 Methods used for trouble shooting problems such as leaks and malfunctions.

217
 Hydraulic control fluid and
reservoir
 Pumping system
 Accumulator system
 Hydraulic control manifold for
regulating pressure
 Remote control panels
 Umbilical's and reels
 Emergency systems
 Secondary systems

218
Connectors: There are two connectors. One on the bottom of the BOP
stack and the other between the two Annulars. If the BOP needs to be left on
bottom, then the top connector is unlatched. If the BOP needs to be pulled to
surface then the bottom connector is unlatched.

Flex (Ball) joints: There may be two or more flex joints. One is installed on
top of the Upper Annular and the other could be near surface. These are
installed to compensate for lateral movement of the drilling vessel.

Slip or Telescopic joint: The slip or telescopic joint is installed near

surface. It is installed to compensate for vertical movement in the drilling
vessel. The slip joint is the weakest when diverting shallow gas due to the
seals between the outer and inner barrel.

219
 Discrete hydraulic
control system
 Electro-hydraulic (EH)
/ Multiplex (MUX)
control system

220
 Hydraulic umbilical hoses carry
pilot signals and power fluid to
subsea BOP stack
 Pilot operated valves,
controlled from the surface,
direct hydraulic power fluid to
functions

221
 Electric/optical signals to
reduce response times in
deepwater operations
 Rigid conduits carry power
fluid to subsea BOP stack
 Signals activate solenoid
operated pilot valves
 Solenoid valve activates a pilot
operated control valve to direct
power fluid to a particular
function

222
 Pre-charge pressure
increased due to HH of control
fluid 0.445 psi/ft or 0.101
bar/m
 Stack mounted accumulators
assist surface system and
reduce function time
 If water depth is equal 1000 ft.
How much do we need to
increase the pre-charge
pressure ?
 445 psi

223
 The Driller can regulate the operating pressure
and must know how to operate and check
 Annular, ram BOP and bypas
 Accumulator pressure = 3000 psi
 Manifold pressure + read back = 1500 psi
 Annular pressure + read back = 500 – 1500
psi
 Air pressure = 75 - 125 psi

224
 Time between activation and complete operation of a
function is based on BOP or valve closure and seal off
 Ram preventers: ≤ 45 sec
 Annular preventers ≤ 60 sec
 Unlatch LMRP ≤ 45 sec
 Choke and kill valve: not to exceed minimum observed
ram close response time

225
 Panel lamp strack status
 Green: function is in normal drilling
position
 Red: function is in abnormal
position
 Red or green is on when block
(amber) is on to indicate the
functions last selected position

226
 Hydraulic Control System
 Umbilical carries power fluid
and pilot signals
 EH/MUX Control System
 Rigid conduits carries power
fluid
 MUX cable supplies power and
communications

228
OVERVIEW
figure shows the general arrangement. Fluid used to
operate the functions on the BOP stack is delivered from
the hydraulic power unit on command from the central
hydraulic control manifold. This contains the valves which
direct pilot pressure to the pilot valves in the subsea control
pods and which are operated either manually or by solenoid
actuated air operators.
In this way the manifold can be controlled remotely via the
actuators from the master electric panel (usually located on
the rig floor) or from an electric mini panel (located in a safe
area). The system may include several remote mini-panels if
desired. An electric power pack with battery back-up
provides an independent supply to the panels via the central
control manifold.
The pilot fluid is sent to the subsea control pods through
individual, small diameter hoses bundled around the larger
diameter hose which delivers the power fluid. In order to
provide complete redundancy for the subsea portion of the
control system there are two independent hydraulic hose
bundles and two independent control pods.
Every component in a blowout preventer assembly is operated
hydraulically by moving a piston up and down or back and
forth. Thus the function of a BOP control system is to direct
hydraulic fluid to the appropriate side of the operating piston
and to provide the means for fluid on the other side of the
piston to be expelled.
On land, jack-up or platform drilling operations the control of
the BOP is easily achieved in a conventional manner by
coupling each BOP function directly to a source of hydraulic
power situated at a safe location away from the wellhead.
Operation of a particular BOP function is then accomplished
by directing hydraulic power from the control unit back and
forth along two large bore lines to the appropriate operating
piston.

230
This system uses the minimum number of controlling valves to
direct the hydraulic fluid to the required function. It also enables
the returning fluid to be returned to the control unit for further
use.
For subsea drilling operations, it is necessary to control larger,
more complex BOP assemblies which are remotely located on
the seabed. In this instance, direct control cannot be applied
since the resulting control lines connecting the BOPs to the
surface would be prohibitively large to handle. Reaction times
would also be unacceptable due to the longer distances to the
BOP functions and the consequent pressure drop.
In order to overcome these problems indirect operating systems
have been developed. There are two types — hydraulic and
multiplex electro-hydraulic of which the indirect hydraulic system
is by far the most common
The hydraulic hose bundles (or umbilicals) are stored on two hose reels, each of which is
equipped with a special manual control manifold so that certain stack functions can be
operated whilst the stack is being run. Hydraulic jumper hose bundles connect the central
hydraulic control manifold to the two hose reels. Each umbilical is run over a special
sheave and terminates in its control pod.
For repair purposes each pod along with its umbilical can be retrieved and run
independently of the BOP stack. In order to do this, the pod and umbilical is run on a
wireline which is usually motion compensated. In some designs of control system, the
umbilical is run attached to the riser in order to give it more support and reduce fatigue at
hose connections. The pod is still attached to a wireline for retrieval purposes. This design
has the advantage of not having to handle the umbilicals whenever the pod is pulled but
has the disadvantage of requiring more subsea remote hydraulic connections. Guidance
of the pod is provided by the guidewires and guideframe as shown.
The hydraulic fluid is prepared and stored under pressure in the accumulators. Some
accumulators (usually two) are dedicated to storing fluid for use in the pilot line network
and the remaining accumulators contain the fluid that is used to power the various BOP
functions.
The power fluid is routed to the subsea control pod selector valve which is
located in the central hydraulic control manifold. The line to the non-
selected pod is vented. When power fluid reaches the pod, it is combined
with fluid stored at the same pressure in subsea accumulators, located on
the BOP stack. The pressure of the combined fluid is then reduced, to that
required to operate the stack function, by a subsea regulator situated in the
control pod. Adjustment of this regulator is performed from the surface via
dedicated pilot and read-back lines in the hose bundle.
Pilot fluid is always directed to both pods at the same time. When the pilot
fluid for a particular function reaches each pod it lifts the spindle of its
associated SPM (sub plate mounted) pilot valve. In the pod to which the
power fluid has been sent this will allow the fluid to pass through the SPM
valve and be routed to the stack function via a shuttle valve.

OPERATING SEQUENCE
A more detailed description of the sequence of events that occur when a
function is operated will now be given with reference to the flow diagrams .
Each piece of equipment on the BOP stack has a corresponding pilot control
valve on the central hydraulic control manifold which actuates the
appropriate SPM valve. The control valve is a four-way, three-position valve
and can be functioned manually or by an air operator.
 Point of Distribution
 For redundancy
reasons: 2 control
pods
 Yellow and Blue
 One pod is selected
as main pod and the
other used as backup
pod

234
 Hydraulic control pod
 Power fluid only sent to
active pod
 Pilot signals sent to both
pods
 Backup pod mimics the
active pod continuously
 Pods contain annular and
manifold regulators
 Regulated pressure value
fed back to readback
gauges via pilot lines

235
 Hydraulic control pod
 SPM (subplate mounted
valves) installed
downstream of regulators
 Fluid from SPM exits pod via
male stab that locks into
female LMRP and BOP
stack receptacle

236
 MUX control pod
 Upper electronic; Lower:
hydraulic
 Upper part: Contains 2 SEM
(main and backup)
 Main SEM communicates with
surface and activates solenoids
(shear-seal)
 Lower part: Contains regulators
and
 SPM valves

237
 Directs regulated power fluid to
function
 Corresponding SPM vents
opposite side of function
 Pilot signal lifts spindle
 Blocks vent
 Allows regulated power fluid to
pass

238
 Directs flow of regulated power fluid
 No redundancy downstream of shuttle valve

239
Emergency Disconnect System
(EDS)
 Programmed sequence of events
 Autoshear System
 Automatically shuts-in well i.c.o.
LMRP disconnect
 May use dedicated accumulator
system

Deadman System
 Automatically shuts-in well i.c.o.
absence of hydraulic supply and
control of both pods
 May use dedicated accumulator
system
240
ROV Intervention
 Operate critical functions
(shear, pipe ram, ram locks
and LMRP unlatch)
 Acoustic Control
 Operate critical functions when
primary control is inoperable

241
• Between BOP & LMRP
• Between BOP and wellhead
• Unlocking force > locking
force

242
244
SUBSEA BOP STACK Diverter

Slip Joint
Riser

Choke Line
Kill Line
Flex Joint

Upper Annular

Lower Annular

Collet Connector
Blind/Shear Rams

Pipe Rams
Fail Safe Valves

Wellhead Connector
 Divertor
STACK PODS
Slip/Telescopic Joint

Riser Joints

Flex Joint
Upper
Annular
Yellow Blue
Pod Pod

Lower Connecto
Annular r
Ram Choke
Kill line line
Ram
Fail
Ram Safe
s
Ram
Connecto
r
The main objective of the BOP control system is to operate any of the functions in as short a time as
possible. There are three systems. The Hydraulic system, Electro-hydraulic system or the Multiplex system.
The difference between them is the way the command signal is transmitted from Surface to the Pods on the
BOP Stack. For simplicity the hydraulic system will be discussed.

Components of a Hydraulic System

Manipulators
The manipulators are three position four way valves. The three positions of the manipulator are OPEN,
CLOSE and BLOCK(neutral). These manipulators can be functioned from a remote location or manually. On
a Subsea Hydraulic system manipulators direct pilot fluid to the Sub Plate Mounted (SPM) valves in the
pods, when the manipulator is in the Open or Close position and Block pilot fluid when the manipulator is in
the Block position.

Pods
There are two pods in a Subsea control system. The Blue pod and the Yellow pod. These pods are mounted
on the Lower Marine Riser Package. The reason for having two is for redundancy. The pods could be
retrieved separately in a Guide line system only. In a guide line less system they cannot be retrieved
separately. The Driller has to select either one of the pods to be active. By active, it means that power fluid
to function the BOP goes only to the active pod.

247
Sub Plate Mounted (SPM) valves

In each pod there are open SPM valves and close SPM valves for each
function on the Subsea BOP. These valves are actuated by pilot pressure.
Once actuated, power fluid from the active pod is direct to a function via a
shuttle valve. SPM valves when not activated, are venting.
Shuttle Valves

The shuttle valve is installed as close as possible to the function. The

shuttle valve directs power fluid from the active pod to the function and
isolates the non-active pod.

248
Pod Selection YELLOW BLOCK BLUE
RESERVOIR

YELLOW BLOCK BLUE

Manipulator

YELLOW POD BLUE POD

Pod Selection YELLOW BLOCK BLUE
RESERVOIR

YELLOW BLOCK BLUE

Manipulator

YELLOW POD BLUE POD

Step 1: The Driller pushes the Blue Pod Selector Button and a signal is sent to
the manipulator.
Pod Selection YELLOW BLOCK BLUE
RESERVOIR

YELLOW BLOCK BLUE

Manipulator

YELLOW POD BLUE POD

Step 2: The manipulator shifts to the Blue Pod selection and permits Power
Fluid to go to the Blue Pod only. The Blue Pod is now Active, where
as the Yellow Pod is Not Active.
 OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

HYDRAULIC SYSTEM COMPONENTS

CLOSING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 1: The Driller pushes the close button to close the

ram and a signal is sent to the manipulator
 CLOSING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 2: The manipulator shifts to the close and allows Pilot fluid
to go to the close SPM valves in both pods.
 CLOSING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 3: The close SPM valves in both pods actuate but power
fluid to close the ram only goes through the active pod.
CLOSING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 4: The ram closes. Power fluid from the opening

chamber vents at the open SPM valve.
 OPENING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 1: The Driller pushes the ram open button.

OPENING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 2: A signal is sent to the manipulator.

 OPENING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 3: The manipulator shifts to the open position. Pilot fluid

from the close line bleeds back into the reservoir.
 OPENING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 4: Pilot fluid goes to the open SPM valves in both pods.
 OPENING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 5: The open SPM valves in both pods actuate but power
fluid to open the rams only goes through the active pod.
 OPENING A RAM OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 6: The ram opens. Power fluid from the closing chamber
vents at the close SPM.
 RAM BLOCK OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 1: The Driller pushes the block function.

RAM BLOCK OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 2: A signal is sent to the manipulator.

 RAM BLOCK OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 3: The manipulator shifts to the open position. Pilot fluid

from the open line bleeds back into the reservoir.
 RAM BLOCK OPEN BLOCK CLOSE
RESERVOIR

Pod Selector
BLOCK
OPEN CLOSE

Manipulator
Open Close
SPM SPM

To
Yellow
Pod
Manifold
Regulator

Close
Shuttle
Open
Shuttle

Step 4: The power fluid from the opening chamber vents at the
open SPM.
267
268
Choke Lines
• Minimum recommended size for choke line is 2 inches for 3K and 5K
arrangements and 3 inch for 10K and 15K.
• Minimum recommended inside diameter for lines downstream of
choke should be equal to or greater than the connecting lines of the
choke (choke line).
• The bleed line should be at least equal in diameter to the choke line
the bleed line allows:
– Reducing back pressure if needed.
– Permits high volume of kick to bypassed MGS and bleed off of to
lower circulating pressure and avoid exciding shoe pressure
during kick circulation

269
270
271
272
To provide a return fluid flow path from the wellbore to either a floating
drilling vessel (semi submersible or hull type) or a bottom supported
unit, and to guide the drill string and tools to the wellhead on the ocean
floor.

 Remotely operated connectors

 Flexible joints (ball joints)
 Riser sections
 Telescopic joints
 Tensioners

273
• Used to maintain flex/ball joint angles within specs as
mud weight and marine conditions change.
• Provides for similar function as a surface stack type
diverter system.
• Slip joint allows for vessel heave so that flow lines and
surface connections remain stationary. The flexible
hose connectors for the choke and kill lines terminate
here
• The marine riser is the primary flow path for the mud
circulated from the wellbore to the surface.
• The riser is not capable of high pressure mud sealing
since it has to connect to the seafloor BOPs and
compensate for rig motion. 274
• High pressure choke and kill lines are
run integral along the riser and provide
for high pressure circulation of the
drilling fluid.
• The subsea BOPs include an “upper”
package consisting of a connector, flex
joint, and annular BOP (called the
Lower Marine Riser Package, LMRP)
as well as the main BOP stack and
hydraulic wellhead connector and BOP
control system.
• The hydraulic/electric control system
distribution PODs are located with the
lower marine riser package.
275
SUBSEA BOP STACK Diverter

Slip Joint
Riser

Choke Line
Kill Line
Flex Joint

Upper Annular

Lower Annular

Blind/Shear Rams Collet Connector

Pipe Rams
Fail Safe Valves

Wellhead Connector
276
 Riser
Kill and Choke Isolation Valves Guideline
Flex/Ball Joint
Prevent choke and kill line Choke/Kill Lines
Guideline
evacuation when planned or Pod

unplanned disconnects occur. Annular

Preventers

Riser Boost Line and Valve Pod

To assist in hole cleaning when

Subsea
drilling smaller diameter holes Accumulator
Bottles

caused by the reduced annulus Ram Preventers

Guidepost
velocity of the mud in the larger ID
Wellhead
riser. Can also be used to flush Connector

gas or “kill” the riser.

277
Gas Vent Line
Used to remove gas that may have
accumulated beneath a closed annular
during kick pump-outs. Gas can
accumulate beneath the preventer due
to the “separator” effect when gas
influxes are circulated through the Gas vent line
Not showed here
BOP and choke line.

278
Multiple Pipe Shear Rams
Dynamic positioning drill vessels have a greater need
for the ability to rapidly shear and disconnect. Usually
redundant shears or shears for multiple drillpipe sizes
are included.
Casing Shear
Casing shears are generally provided on subsea
stacks rigged for deepwater use. Additional “booster”
pistons are necessary for super shearing capabilities.
Pressure and Temperature Sensors
Electronic pressure and temperature sensors can be of
great help when circulating kicks and performing LOT,
etc.

279
• High pressure choke and kill lines are run
integral along the riser and provide for high
pressure circulation of the drilling fluid.
• The subsea BOPs include an “upper”
package consisting of a connector, flex
joint, and annular BOP (called the Lower
Marine Riser Package, LMRP) as well as
the main BOP stack and hydraulic
wellhead connector and BOP control
system.
• The hydraulic/electric control system
distribution PODs are located with the
lower marine riser package.

280
281
282
283
284
Lower Marine Riser Package, (L.M.R.P.)
• The LMRP connector should have a pressure rating at
least equal that of the annular BOP.

• The pressure rating of the wellhead connector should be

at least equal to that of the ram preventers.

• LMRP and wellhead connectors should have ring gaskets

designed to provide for metal-to-metal sealing.

Control Hose Bundles

Choke / Kill Lines

Control Pod

Ball Joint

Annular Preventer

Connector

Subsea Accumulators

285
286
The Indirect Hydraulic
System

 Every Component in the Subsea Blow Out Preventer is operated

hydraulically by moving a piston up & down or back & forth.

 Therefore the function of a BOP Control System is to direct

hydraulic fluid to the appropriate side of the operating piston & to
provide a means of expelling fluid from the other side.

 This system uses the minimum number of control v/v’s to direct

hydraulic fluid to the required function.

287
 The indirect hydraulic system reduces the size of umbilical control hoses by
splitting the hydraulic control functions into two.
1. Transmitting hydraulic Power Fluid to the BOP down a 1” diameter line.
2. Transmitting hydraulic signals down 3/16” or 1/4”lines to Pilot V/V’s, which in turn direct the
operating Power Fluid to the appropriate BOP function.

 The Pilot V/V’s are located in the Control Pods on the BOP. In order to have
a back up there are two Pods - usually referred to as the Blue & Yellow
Pods.
 No attempt is made to recover the Hydraulic Power Fluid once it has been
used as this would increase the number of lines required, instead it is
vented to sea.
 Hydraulic Pilot Fluid utilizes a closed loop system and as such is recovered
to surface.
288
 Pilot Fluid Circuit

 The Pilot Fluid goes to Both Pod SPM V/V’s, but

only the selected Pod operates.
 The Pilot V/V’s in the Subsea Pods are controlled
from surface by means of control V/V’s located on
the Hydraulic Control Manifold & can be operated
manually from the Manifold or Remotely from the

289
 Electric panel via Pneumatic Solenoid
V/V’s A pressure switch is connected to
each discharge line of the control valve
& will transmit a signal to the appropriate
control panel lamp whenever a pilot
signal is present.
 Shuttle V/V’s on the BOP move back &
forth depending on the direction of the
fluid, isolating one pod from the other.
They are located on the BOP not inside
the Pods. 290
1. Pushing the 'close' button
will activate the solenoid
valves on the hydraulic
manifold thus allowing air
pressure to move the pilot
control valve to the 'close'
position. The solenoid valve
on the right in the diagram
vents the other side of the
air cylinder

291
With the pilot control valve in the
'close' position, pilot fluid at 3000
psi is sent down the umbilical to
the RAMS CLOSE SPM valve in
the subsea control pods. The
pressure lifts the spindle in this
valve so that it seals against the
upper seat, thus blocking the
vent.

292
 From the bottom of the female
section, the power fluid then
travels through the shuttle
valve to the 'close' side of the
BOP ram cylinder.
 Simultaneous reciprocal
action in the RAMS OPEN
SPM valve vents the hydraulic
fluid from the 'open' side of the
BOP ram.

293
 The block function is used to
vent a pilot control valve. By
doing this individually on each
valve a leak in the control
system or the preventers can
be located and isolated. By
centring and venting all the
valves when the accumulator
unit is first being pressurised
unintentional and inadvertent
operation of the various other
positions and functions can be
eliminated.
294
295
Power
Fluid

296
Regulator Control

 Since the Power Fluid arrives at Subsea Control Pod @ 3000psi &
normal operating pressure is 500/1500psi for Annulars & 1500psi for
Manifold Pressure, regulators are needed in both Pods. One for the
Annulars & one for Manifold Pressures. The Pilot Control fluid
transmits regulated pilot pressure to the subsea regulators in order to
adjust the settings.
 Readback pressure gauges are also incorporated within the system
downstream of the regulators & back up to the Remote Panel.
 Subsea Accumulator bottles are tied in with Surface Accumulator
bottles & Pre-Charged to 1000psi + Hydrostatic of S/Water Depth.
 Accumulator bottles can charge Pilot bottles, but not visa-versa
297
SPM valves direct the
regulated power fluid to the
desired side of the preventer,
valve or connector operating
piston & vents the fluid from the
other side.

298
On a Sub Sea BOP, two
mechanisms close SPM
valves

1. Spring mechanism
2. Sea water hydrostatic
pressure

299
When a function button on the panel is pushed an electrical signal is
sent to the associated solenoid valve on the Central Hydraulic Manifold.

300
The solenoid activates the movement of high pressure air to pass through the ¾ valve and actuate its
corresponding pilot control valve. The position of the pod selector valve on the Central Hydraulic
Manifold determines to which of the two subsea control pods the hydraulic POWER FLUID is directed.

301
An eclectic signal is sent to the solenoid
and the valve moves to allow high
pressure air to pass through it and
actuate its corresponding pilot control
valve. The position of the pod selector
valve on the Central Hydraulic Manifold
determines to which of the two subsea
control pods the hydraulic POWER
FLUID is directed to.

302
When the pilot control valve is actuated, hydraulic fluid is allowed to flow from the pilot accumulators
(where it is stored at 3000 psi) to the 3 position 4 way valves and down the appropriate pilot lines in
each of the umbilical hose bundles. Power fluid is also stored at 3000 psi in the main accumulators
and is sent to the active subsea pod through a 1” hose in the umbilical bundle.

303
The pilot line terminates in the subsea pod at the SPM (Sub mounted Plate) valve. When activated by
the pilot pressure, this valve lifts to allow power fluid (at its regulated pressure) to flow to its
associated BOP function.

304
Hydraulic fluid on the opposite side of the BOP function is vented.

305
 Pilot fluid is directed to both Pod’s ‘Open’ SPMs Valve and
Power fluid is regulated in the pods. The regulators are operated by pilot fluid from
the hydraulic Koomey unit

Solenoid inside the panel

3/4 way valves set in

Open position

Pilot fluid in closed

loop and 3000 psi
sendt to SPM valve

Regulated Power fluid

306
Send electric signal to the
solenoid this will place the 3/4
way valve in close position.

Pilot fluid in closed

loop and 3000 psi
sendt to SPM valve

Regulated Power fluid

307
Send electric signal to the
solenoid this will place the 3/4
way valve in block position.

Pilot fluid is
blocked

Regulated Power fluid

are vented to the sea

308
 HPU, Reels ,UPS/PDP
Surface Control Panels, CCU, Surface
Equipment Accumulators, & test units

Cables & hotline Marine Riser System

Clamps.

Subsea BOP with MUX

Equipment Control Pods
on the LMRP,
acoustic back
up systems, &
subsea
Standard accumulators
Wellheads

309
310
311
312
313
314
 Sub Sea Sub Sea Sub Sea
MUX Cable Electronics Transformer
Connector

Pressure
Compensated Shear Seal
Solenoid Housing Pilot Valves

Solenoids
Pressure
Transducers

One Atmosphere Hydraulic Seal

Base Sub J-Plates

321
322
 Connects the riser pipe to
the blowout preventer stack
and can also be used as an
emergency disconnect from
the preventer stack, should
conditions warrant

323
 Used in the marine riser system to
minimize bending moments, stress
concentrations, and problems of
misalignment engagement

 Angular freedom of a flexible joint

is normally 10 degrees from
vertical

 Always installed at the bottom of

the riser system either immediately
above the remotely operated
connector, or above the annular
preventer when the annular
preventer is placed above the
remotely operated connector

324
 Ball joint
Flex joint

325
 Serves as a connection between
the marine riser and the drilling
vessel, compensating principally
for heave of the vessel

 It consists of two main sections,

the outer barrel (lower member)
and the inner barrel (upper
member).

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 It is likely the explosion took out both MUX
cables, preventing communication to the
subsea BOPs Manual activation of either the
High-Pressure Blind Shear Rams or the
EDS would have been prevented.
 Testimony indicated that the EDS was
pushed and the panel reacted like it should
,but "It never left the panel ”At this point,
only the AMF (Automatic Mode Function)
and ROV intervention remained

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 Although the pressure responses indicated the subsea
BOP sealed eventually, flow continued after the initial
explosion based on the intensity of the fire. This flow
may have come from several sources, including:
 Rig drifting or traveling equipment movement moved
pipe enough to damage the VBR and allow flow again
 Damage to the drill pipe allowed flow into riser or onto
rig floor area
 Surface equipment failures (swivel packing, kelly hose)
 Pressure relief valves on mud pumps allowed flow into
pit area

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 Had the 14” overboard line been utilized, as it should
have been for any significant gas event, the outcome
may have been different. The slip joint packer may still
have been at risk, but a significant portion of the gas
would have been vented safely away, reducing the
chance for ignition. Manual activation of the high-
pressure BSR or the EDS would have been much more
likely

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Manual emergency functions had been
rendered inoperable by the explosion and
fire The AMF (Automatic Mode Function,
more commonly called the Deadman
System) then became the second to last
line of defence. At a minimum this
function would have activated the high
pressure BSR. The Deadman System
requires a loss of communication,
electrical power and hydraulics (all three)
at both pods to activate. Communication
and electrical power would have been lost
with the MUX cable damage Although
more protected, the hydraulic supply
conduit and surface system would have
been destroyed as well, if not by the
explosion, then by the fire. The Deadman
System failed to function

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 On this model BOP Stack, the Deadman System relies
on lithium battery packs in the subsea control pods to
operate the solenoid valves. When these pods were
recovered to the surface during the response effort, the
Deadman System functions in both were found
inoperable. In the Blue Pod, the battery power remaining
was significantly below that required to operate the
solenoid valve. In the Yellow Pod, there was probably
sufficient battery power, but the solenoid valve was
inoperable.

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 ROV Intervention also failed to secure the well
 The shuttle valves on the Cameron BOP Stack require a minimum flow rate to fully
shift and direct fluid to the intended function.
 ROV Intervention capability is routinely tested at surface, but it is typically done with
a hot line pulling fluid directly from the rig’s accumulator system. It is seldom done
with or at a rate equivalent to what the ROV pump can generate.
 The rate the ROV could generate was insufficient to shift the shuttle valves on this
stack. This was due to the design of the shuttle valves and hydraulic leaks
subsequently discovered in the system.
 The ROV successfully activated the auto shear function (if armed, this function
activates the high pressure BSR when the LMRP is disconnected) by cutting the
indicator rod. This was done 07:40, 21 April 2010.
 The high pressure BSR failed to secure the well, and this was the last line of
defence. Additional attempts were made to actuate components with the ROV
intervention panel. It was assumed that attempts to close the “pipe rams” meant the
middle VBR, but it was discovered that the bottom, inverted test ram was the one
actually plumbed to the ROV intervention panel.

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 Failure of the auto shear function, which closes the high-
pressure BSR, to secure the well may have been due to:
 Insufficient hydraulic power to shear the 5-1/2” 21.9 ppf,
S-135 which was across the stack at the time of the
incident
 Seal failure due to prevailing flow conditions in the BOP
 Presence of non-shearable components across the BSR

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 Insufficient hydraulic power to shear the 5-1/2” 21.9 ppf, S-135
which was across the stack at the time of the incident Period of
approximately 30 hours existed where the subsea accumulators
were not being charged from surface (explosion to ROV auto shear
activation)
 During subsequent control efforts, a control system leak of “no
greater than” 0.32 gph was determined between pod retrieval and
reinstallation.
 The investigation team stated that a leak of approximately 3 gph for
30 hours would have been required to drop the subsea accumulator
pressure below that required to shear the drill pipe.

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 BSR seal failure due to prevailing flow conditions in the BOP at the
time of actuation.
 BSR successfully tested during the positive pressure test on the
morning of the incident
 The exact flow rate at the time of actuation is not known, but the
effect of closing the BSR under what may have been high flow rates
is unknown. Much later in the response a rate of 53,000 BOPD was
observed, but this was under different conditions at surface (and
probably TD).
 The investigation team stated that with the leak observed in the
hydraulic circuit, the shearing operation would have taken 17
seconds to complete. Without the leak, it should have taken 14
seconds.

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 Non-shearable components were across the BSR at the time of
actuation
 Pictures from later in the response effort showed two distinct drill
pipe stubs in the riser section that was cut. This immediately raised
questions regarding what exactly was across the stack when the
BSR were activated.
 Through examination of the recovered stubs, the investigation team
concluded only one string was across the stack at the time of the
BSR activation. Erosion, rig drift and hoisting equipment movement
likely resulted in pipe movement and parting of the string above the
BOP.
 The location of tool joints relative to the BSR at the time of actuation
is not known exactly.
 Results from the physical inspection of the subsea BOP have not
yet been released, but may shed more light on this subject.
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374
 In the weeks and months following the Macondo Incident, the
industry focused on Prevention. The government then demanded
similar focus on Spill Containment and Spill Response.
 The immediate focus on Prevention is both understandable and
warranted. We have all heard that “An ounce of prevention is worth
a pound of cure”. An ounce of prevention would have been worth at
least 62 lbs of cure in the case of the Macondo incident.
 The same philosophy holds true when focused entirely on the
multiple layers of Prevention that we rely upon. The earlier in the
layers of defence that an issue is recognized and aggressively
addressed, the more efficient and reliable the response will be.

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 Barrier Philosophy Maintaining control of fluids, both produced
and injected, throughout the life-cycle of a well is of primary concern
and is a basic expectation. The design, installation or use, and
proper verification of barriers is critical to meeting this expectation.
Examples:
 If cement is going to be relied upon as a barrier, then achieving this
becomes the primary objective in the design and execution. If trying
to meet other needs that may jeopardize the barrier objective, the
ability of the cement to perform as an effective barrier should be
rigorously verified, or another barrier should be installed and tested.
 Safety-critical tests should be as simple and straight forward as
practical, not encumbered by steps that could contribute to the
misinterpretation of deviations from the expected. The reasons for
deviations from the expected should be adequately investigated,
the risks assessed if needed, and mitigation efforts implemented
before proceeding.

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 Secondary and Emergency Control systems should be understood and tested. Deficiencies
or failures in these systems should be either remedied or risk assessed. If the risk assessment
concludes it prudent to proceed, the implications should be well understood by those potentially
relying on the system. If another use or configuration exists for a safety-critical system, but this
use or configuration may create additional hazards, the circumstances under which the alternate
use can be employed must be well defined and understood. Examples:
 How much attention is given to the lines of defence that are considered “last” or “next to last”,
especially when there are several barriers before these are needed (Deadman, autoshear and
ROV intervention)? At least in the GOM, this is soon to be mandated.
 A diverter system is designed to divert flow safely away from personnel and the facility while
minimizing the pressure on components with low pressure ratings. With the prevalence of SBM
usage in the deepwater environment, the ability to route the diverter to a MGS became common.
The diverter should direct flow directly overboard through a large ID line to avoid over pressuring
the slip joint packer, diverter element and marine riser components. Since SBM can’t be
discharged, and gas has the ability to go into solution (oil phase of the mud) and then be liberated
near surface, the use of the MGS to control relatively minor solution-gas events (bottoms up after
a trip, extensive sampling operations, or controlling a kick) has been widely accepted. Routing
returns to the MGS during a major event, however, poses significant hazards. In the case of the
Macondo incident, this action may have resulted in the death of 11 people and the
elimination of some critical barriers that are typically relied upon.

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Culture
 In the days following the Macondo incident, most companies
immediately searched for assurances that this could not happen to
them. I won’t speculate on how many assurances were made. The
established processes that BP had in place (documented reviews
,management of change, basis of design) are impressive.
Unfortunately ,these failed top revent 11 deaths and a spill of
national significance. Although harder to define and measure,
and even more difficult to regulate, we pointed to our culture
as the single most important differentiating attribute when
comparing us to BP. In a recent meeting with an individual who
has numerous dealings with BP, he observed that regardless of the
purpose of the gathering (planning session to morning rig call),it is
almost impossible to determine who is ultimately responsible
and accountable for the operation being discussed. Evidence
of this exists in the very report this presentation was derived
from.

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