C HAPTER

5
 5-1

P ROCEDURES
T
his chapter covers various procedures
and topics and is presented to offer
examples of typical rig activities. Please
note that generalities are covered, not specifics.
Procedures must Procedures must be written on a per-well basis
and detailed for the type of rig and operation.
be written on a Crew assignments may also change on different
wells or activities and must be individually
per-well basis and addressed.

detailed for the

SHUTTING THE WELL IN
type of rig Once a kick has been detected, the well
should be controlled according to correct
and operation. procedures. Shut-in procedures require common
sense. At times of excitement or emergency,
there must be strong control and discipline on
the rig floor. Drills, planned procedures and

5-2
strong supervision are the keys to successfully
controlling the well. Once a kick has been
detected, the well should be shut in as quickly
as possible. The reasons for shut-in procedures
include:
w To protect the crew and rig
w To stop the influx of formation fluid into
Flow check: the wellbore
observing a well
w To allow shut-in pressures to be determined
with pumps shut
w To provide an opportunity to organize the
off to determine
whether or not
kill procedure.
it is flowing. There is no such thing as a small kick
or a small flow. Either can rapidly develop
into a blowout. All flows must be recognized
as potential blowouts. When in doubt as to
whether the well is flowing or not – shut it
in.
Shut-in procedures may vary considerably,
depending on company policy, the type of rig
and the size of the crew. However, the basics of
shutting a well in do not change. A preventer
must be closed to stop the flow. There are
debates as to which method is the proper one
to use, a hard or soft shut in, or a modification
of either. It is not the intention of this manual
to advocate one or the other of these methods.
All wells are different, and procedures should
be decided upon, posted, known and practiced
on an individual well or activity basis.
GENERAL FLOW CHECK PROCEDURES
FLOW CHECK WHILE DRILLING
1. Alert the crew
2. Pick up off the bottom and
clear uppermost tool joint
above the rig floor
3. Stop the rotary
4. Shut off pump
5. Observe the well for flow
If the well is flowing, shut-in procedures should begin immediately.
C HAPTER 5
FLOW CHECK PROCEDURES
A flow check consists of observing a well
with pumps shut off to determine whether it is
flowing. Sometimes flow checks are performed
as standard company policy, perhaps prior to
pulling pipe off bottom, at casing shoe or prior
to pulling collars. They are also performed at
the driller's discretion from changes in drilling
parameters, or at the request of supervisors,
the mud logger or crew members noting
kick indicators. Flow checks are performed by
direct observation, flow sensor equipment or
volumetrically. If the well is flowing, shut-in
procedures should begin immediately.
Depth, fluid type, formation permeability,
degree of underbalance and other factors affect
how long to observe the well during the flow
check. The check should be long enough to
determine if the well is flowing or static.
SHUT-IN PROCEDURES
WITH PIPE ON BOTTOM
The chart and accompanying illustrations
assume a kick while drilling is noted from the
flow check sequence and shut in is required.
FLOW CHECK WHILE TRIPPING
1. Alert the crew
2. Set slips so the last tool joint is at
normal working level above rig floor
3. Install full open safety valve
in open position
4. Observe the well for flow
Note: Make flow check prior to pulling BHA
through BOPs.
P ROCEDURES
5-3
Shut-In
Hard Shut Procedures

Shut-in
with Pipe on
In Bottom

Close
2 Close

1
Open
3 Monitor & record
Well

Modified
Shut In
Close
1 Close Closed Closed

Shut-in
3 Monitor & record
Open procedures
2 Open
vary from job
to job but the
basics do not
change:
• protect the
Soft Shut crew
In • stop the flow
• gain time
Close while
monitoring pressure • read pressures
2 Close 3

4 Once choke closed

Open monitor & record
1

HARD SHUT IN MODIFIED SHUT IN SOFT SHUT IN

(CHOKE CLOSED) (CHOKE CLOSED) (CHOKE OPEN)

1. Open choke line valve on stack
2. Close designated BOP
3. Notify company personnel
4. Read and record SIDPP
and SICP each minute
1. Close designated BOP
2. Open choke line valve on stack
3. Notify company personnel
4. Notify company personnel
and SICP each minute
1. Open choke line valve on stack
2. Close designated BOP
3. Close choke, watching casing
4. Read and record SIDPP pressure
to ensure limitations are
not exceeded or pressure trapped
5. Read and record SIDPP
and SICP each minute
 C HAPTER 5
5-4
Shut-In
Procedures
Hard Shut In
1

Shut-in
While Tripping

Close
3 4 Monitor &

Well
Close
record

Open
2

Modified Shut
1 In

Close
2 Close Closed Closed

Open
3 Open

Soft Shut In
1

Close while
monitoring
3 Close 4 4 Monitor &
Top drive record
systems employ 5 Once choke
Open closed monitor
a remotely 2
operated FOSV & record
which is always
made up on
the drive.

SHUT-IN PROCEDURES MODIFICATIONS TO SHUT IN

WHILE TRIPPING
The illustration above and the chart on
the facing page both assume a kick during
a trip has been noted from the flow check
sequence and shut in is required.
Under certain circumstances, modifications
will need to be made to the standard shut-in
procedures. Examples of some of these
circumstances follow.
P ROCEDURES
5-5

SHUT IN ON TRIP WITH TOP DRIVE SPACING OUT

The kelly is not used on rigs equipped with
top drive systems. Once the well has been shut
in, it is recommended that a pup joint or a
single be installed between the top drive and
full opening safety valve (FOSV) stabbed on the
string. Then open the valve. If flow through
the string prevented installation of the safety
valve, the top drive may be stabbed and made
up directly on the drillpipe.
Top drive systems employ a remotely
operated FOSV which is always made up on
the top drive. If a kick is suspected, the pipe
can be set in the slips, the top drive lowered
and spun up on the string. The FOSV is
then closed. At shallow depths, where time
is especially critical, this technique offers
great advantages over conventional rotary kelly
systems.
Surface Stacks: It is not desirable to close a
ram preventer around a tool joint. Preventing
this requires knowing the distance from RKB
(Rotary Kelly Bushing, rig floor) to components
in the BOP stack. The average length of pipe
Water depth,
in use should also be known. The driller and
tidal changes
crew should know the approximate length of
and sea
pipe above the rotary table in order to prevent
conditions can
the annular and rams from closing around
complicate
a tool joint. Exact lengths should be used if
spacing out
the pipe is to be hung off on a set of ram and hanging
preventers.
off on floating
Subsea Stacks: Spacing out on floating operations.
operations can be more of a problem. Great
water depths, tidal changes and sea conditions
complicate spacing out and hanging off, especially
since many subsea BOP systems are taller
than the average length of pipe used. Accurate
measurement of each joint and stand is a must.

HARD SHUT IN MODIFIED SHUT IN SOFT SHUT IN

(CHOKE CLOSED)
1. Install FOSV in the open
position, close valve
2. Open choke line valve on stack
3. Close designated BOP
4. Notify company personnel
5. Pick up and install kelly or
circulating swage, open FOSV.
If no float is in use, make
sure surface equipment is
full before opening FOSV
6. Read and record SIDPP
and SICP each minute
(CHOKE CLOSED)
1. Install FOSV in the
open position, close valve
2. Close designated BOP
3. Open choke line valve on stack
4. Notify company personnel
5. Pick up and install kelly or
circulating swage, open FOSV.
If no float is in use, make
sure surface equipment is
full before opening FOSV
6. Read and record SIDPP
and SICP each minute
(CHOKE OPEN)
1. Install FOSV in the
open position, close valve
2. Open choke line valve on stack
3. Close designated BOP
4. Close choke while watching casing
pressure to ensure pressure
limitations are not exceeded or
pressure trapped
5. Notify company personnel
6. Pick up and install kelly or
circulating swage, open FOSV. If
no float is in use, make sure
surface equipment is full before
opening FOSV
7. Read and record SIDPP
and SICP each minute.

5-6
Typically the upper annular is used to shut
in the well. Once shut in, if exact spacing is
unknown due to a trip or above factors, pull
pipe slowly and monitor the weight indicator
and accumulator flow meter. Weight should
increase slightly as the tool joint is stripped
through the annular. As it goes through, the
If a well is shut annular will use more fluid to maintain closure
in with drill pressure against the pipe body. Spacing can
collars in the then be calculated.
Once spacing has been verified, close the
rotary, it is
hang off rams. Hang off using the drillstring
possible that
well pressure compensator and close the ram locks. If
will force the possible, bleed off pressure between the closed
pipe out of ram and annular, then open the annular.
the well.
SHUT IN ON COLLARS
One of the more critical shut-in situations
develops when collars are pulled through the
rotary. The annular preventer is typically used,
but situations complicating the shut-in process
must be considered, such as the use of spiral
collars or the lack of a float or backpressure
valve. In addition, there is the possibility the
influx may be close to surface; if pressure on
shut in acting upwards is greater than the
weight of the collars acting downward, the well
may try to eject the collars when shut in is
attempted.
Often the collars have a different thread
size and/or type. The proper crossover subs
must be available on the rig floor, made up
with a safety valve and ready for installation.
The procedures for making and picking up this
assembly must be addressed.
A plan of action should be decided upon and
questions, such as the following, answered.
w Is it safer to pull the remaining collars or
install the crossover/safety valve assembly?
w On shut in, if the collars begin to be ejected
from the well, will a choke be used to relieve
pressure below the annular? (Remember that
this may also allow more influx to enter the
well.)
w If drill collars must be dropped, how will this
be done?
C HAPTER 5
An important consideration on any trip
is the location of collars in the derrick. They
should be racked in a manner not blocking
the drillpipe in the event pipe must be run
back in the hole.
KICKS WHILE OUT OF HOLE
There are many philosophies as to what to
do with regard to kick detection when out of
the hole. Possibilities include closing the blind
ram (choke closed or open), closing a pipe ram
and covering the rotary. All present different
problems in kick detection while out of the hole,
but these problems can be solved by monitoring
the hole or pressure gauges and implementing
contingency procedures. Generally:
1. If the blind rams are closed and choke
open: monitor the choke for flow.
2. If the blind rams and choke are closed:
monitor the casing (annulus) pressure gauge
for pressure buildup. Some operators have
a policy, when the bit clears the rotary,
of opening the HCR, closing the remote
choke, filling the hole and closing the blind
rams. If gas was swabbed into the well
during a trip, then there will be an increase
in surface pressure after a period of time
depending on migration rates.
3. If the pipe rams are closed: monitor the
flowline for flow.
Note: Just because there is no flow from
the wellbore does not mean that there is not a
kick in the well. If technique 2 above is used in
areas where temperatures drop below freezing,
lining up on a choke could freeze the mud and
plug the choke, giving a false reading. Prior
to opening the blinds in techniques 1 and 2
above, ensure that the choke is open to vent
the stack and check that personnel are clear
of the wellbore. Gauges have been known to
be inaccurate or not register low pressure. If
technique 3 above is used, closing pipe rams on
an open hole may keep large junk from falling
into the well and allow you to see if the well is
flowing, but may also damage ram front-packer
seals or reduce the operating life of the pipe
rams.
P ROCEDURES
5-7

If a kick is
detected while
out of the hole,
most operators
Kicks taken
will use stripping
while running
casing are techniques to
extremely run pipe to
dangerous.
bottom.

When flow is detected while out of the
hole, the well should be shut in. This stops
the influx, allows pressures to be determined
and provides time to decide the next course
of action. Most operators will use stripping
and volumetric techniques to run pipe to
bottom while maintaining bottomhole pressure
control.
Where formation characteristics are well
known (i.e., a tight formation not exhibiting a
high flow rate), and where the danger of gas
to the surface is minimal, the decision to run
several stands of pipe back into the hole may
be considered. It must be understood that
running pipe back into an open and active well
is dangerous and has lead to several disasters.
It can result in significantly higher surface
pressure than if the well were shut originally. If
an underbalanced condition exists, additional
influx will continue entering the well and
will accelerate the rate of flow as more mud
is displaced. Also, gas migration and upward
displacement of the kick by stinging the
pipe into the influx may reduce the effective

5-8
Flaring gas
on a floating
operation.
hydrostatic pressure, thereby accelerating or
allowing additional influx to enter. And, if the
well has to be shut in while running pipe, there
may not be enough pipe weight to overcome
the force of the kick. Pipe rams should be
closed to prevent the well from forcing pipe
out of the hole. If collars were run, pipe rams
will not prevent the collars from unloading
from the well. Under no circumstances should
pipe be run into the well (BOPs open) if a
Under no significant flow is present or if there is gas
circumstances
at surface.
should pipe
be run into an
open well if
a significant SHUT IN WHILE RUNNING CASING
flow is present.
The main objective in a closing sequence
is to close off the smallest and most vulnerable
flow path first. The inner diameter of the string
is typically the smaller diameter compared with
C HAPTER 5
the annulus, and is usually shut off first. The
opposite situation exists while running casing,
when the annulus should be shut in first.
Prior to running casing, BOPs should be
equipped with casing rams and pressure tested.
A circulating swage with a high pressure/low
torque valve must be made up, positioned
near the rotary table and installed immediately
after the BOPs have closed, in case the float
equipment fails during a well control event.
Floating rigs should have a crossover from
the casing to drillpipe to allow the string to
be hung off if necessary. Closing pressure on
annular preventers should be checked against
the collapse pressure of the casing and adjusted
if necessary before running casing. An alternate
to this on surface stack rigs is to lower a joint of
casing into the annular, bleed all pressure off
the annular pressure regulator and gradually
increase the closing pressure 100 psi (6.89 bar)
P ROCEDURES
at a time until closure around the casing is
obtained. From this point an additional 100 to
200 psi (6.89 to 13.79 bar) should be sufficient
to form a seal. Again, before adding the seal
pressure, check against the collapse pressure. If
additional pressure is required to obtain a seal,
adjust the pressure regulator.
SHUT IN WITH
BRAIDED WIRELINE
Wireline operations typically employ a
lubricator if there is a possibility of pressure at
the surface during the operation. The lubricator
assembly typically consists of a stuffing box,
grease injectors, lubricator joints or tube bodies,
blowout preventers and a bleed or pump-in valve
(high pressure/low torque). The equipment
may be nippled differently, depending on the
application. Equipment may be:
w Flanged up to an annular preventer
w Secured inside annular preventer or rams
w Made up to a gauge flange (crown valve)
on a Christmas tree.
Close cooperation between the rig crew
and the wireline crew is essential if kicks are to
be detected and handled properly. A suggested
shut in sequence follows.
1. Notify the wireline operator to cease
operations.
2. The driller closes the bleed or pump in
valve.
3. Wireline BOPs are closed manually or by
a hydraulic hand pump. The driller should
designate the floorhand(s) to perform this
task. It should be noted that two wireline
ram type BOPs can be used, the bottom
preventer inverted. The bottom ram in
this situation is used as a high-pressure seal
against grease that will be injected between
the two closed rams to provide a viscous
grease seal against the braided wireline.
4. Notify supervisors that the well is shut in.
5-9
5. There must be a means to cut the
wireline should the need arise. This can
be accomplished with wireline shear rams
and a hydraulic hand pump (on the rig
floor) or a set of shear or blind/shear Close
rams in the BOPs. Safety valves (FOSV and cooperation
Master) should not be used, as they are not between the
designed for this type of service. rig crew and
the wireline
crew is important
if kicks are to
HANDLING GAS be handled
AT THE SURFACE properly during
wireline
Until the nature of the kick has been operations.
determined, the entire rig should be alerted to
the possibility of the presence of toxic and/or
explosive gases. All assigned personnel should
check gas detectors, breathing and warning
devices for proper operation. Once the well
has been shut in, the responsible personnel
should immediately check out the wellhead,
BOPs, manifolds, choke and kill lines, etc.,
for possible leaks. Offshore rigs should post a
watch for signs of gas around the rig. Should
leaks be detected, report them immediately.
In addition, during the kill operation the
above items need to be checked frequently. If a
gas leak is observed, report it immediately – do
not try to stop it before notifying supervisors.
Make sure that the gas is not toxic. If tightening
a connection to repair leaks, a brass hammer
should be used to prevent sparks.
On shut in, align the choke to the gas
separator. Make certain that the separator
is functioning properly. During circulation,
monitor the separator for pressure buildup and
blowby. Ascertain that the degasser is operating
correctly and the pits are aligned correctly.
Confirm that the downwind vent and flare
lines are open and the igniter is operational. If
a derrick flare line must be used, then caution
must be exercised to ensure that any liquids
or heavy gases, which could be toxic and/or
explosive, do not settle on the rig.
Extinguish all potential sources of ignition,
including welding activities, engines and
equipment not necessary to the operation.
 C HAPTER 5
5-10

DIVERTER PROCEDURE
WHILE DRILLING
Diverters are BOPs (usually of the annular
type) which are designed to protect the rig
from shallow blowouts by closing off the well
under the rig, while allowing the influx to
evacuate safely through the blooey line(s) below
Diverter the preventer. Diverter procedures must be
procedures implemented quickly because the time from
must be kick detection until the kick reaches surface
implemented may be minimal. The warning signs of a
quickly. shallow gas kick include:
w An increase in flow (usually quite dramatic)
w Mud coming over the bell nipple and/or
the rig floor
w Loss of standpipe pressure and increase in
pump strokes.
Remember that all of the signs will happen
rapidly, so the diverter procedure must be
known and undertaken quickly.
EXAMPLE PROCEDURE
1. Do not shut pump(s) down. (Loss of
mud volume as the well unloads will
result in loss of equivalent circulating
density [ECD] and will reduce bottomhole
pressure, causing the well to unload at a
higher rate.)
2. Chain down the brake.
3. Open downwind diverter line.
4. Close the diverter packer. Most rigs have
coupled the diverter line and diverter
packer together to ensure a correct closing
sequence.
5. Pump at maximum rate with drilling
fluid, seawater or heavy mud from reserve
pits. Should you decide to continue using
drilling fluid, remember that it may soon
be depleted, forcing the switch to seawater
or another source of fluid.
6. Set a watch observing the diverter system
for signs of failure. Set a watch for signs of
broaching around the rig.

Wind direction is
an important
consideration
when gas is
vented at the
surface.
P ROCEDURES
At the pre-spud meeting the diverter
procedure should be thoroughly discussed and
understood by the drillers, roughnecks and
derrickmen to insure that everyone knows
the procedure as well as their duties and
responsibilities. Drills should be practiced until
the crew is proficient at this procedure.
DIVERTER PROCEDURE
WHILE TRIPPING
EXAMPLE PROCEDURE
1. Open downwind diverter line.
2. Install FOSV in open position, close valve.
3. Close preventer. (A ram may be used
instead of the annular to prevent pipe from
traveling upwards.)
4. Install kelly, chicksan or top drive.
5. Open safety valve.
6. Pump at maximum rate with mud, or switch
to seawater, heavy mud or reserve pit.
Note: Steps 1, 2 and 3 should be done as
quickly as possible. As soon as the crew sets
the slips and the driller chains the brake, the
FOSV should be stabbed and closed by the
crew as the driller closes the ram.
ROTATING HEAD PROCEDURE
The rotating head is often used for air
drilling and in areas where a large amount of
background gas is present. The rotating head
allows us to drill or circulate while flaring gas
and returning the mud to the pits. A procedure
to divert the well might be:
1. Increase closing pressure (depending on the
type of well).
2. Speed up pumps to increase ECD, but
use caution not to produce too much
back-pressure which could exceed pressure
limitations of the system.
5-11
PRE-PLANNING AND DRILLS
Pre-planning and drills on the rig are
necessary to prepare for expected and
unexpected events. Pre-planning should take
all expected operations into account and set a
well control plan of action. Unexpected events
frequently occur. Forethought must be given to
unusual situations and a plan of action should
be defined. Once a plan of action is established,
the crew should familiarize themselves with
it. Drills should be designed to ensure that
everyone knows their responsibilities. Many
drills cannot be performed without
complications, and the drills are often different
from the actual procedure. For example, a
diverter drill might require the driller to go to
the diverter console where he would not shut
in the well, but rather explain the procedure
of opening the downwind diverter line and
closing the diverter packer. Then he would
to go to the pump control, and explain the
process of bringing the pump to full rate.
Other drills can be initiated by raising the float
in the mud pits or the flowline sensor paddle.
The elapsed time for the drill is measured
until everyone is in position to shut in the
well. Drills should be practiced as if the event
were real.
Drills may be announced or unannounced
and typically take place at times that will not
interfere with the current activity. Evacuation Drills may be
drills rarely include the driller if the bit is in announced or
the well and are often announced so personnel unannounced
will not overreact, panic or injure themselves. and usually
Trip drills are frequently practiced, but not take place at
until the BHA has been pulled into the casing. times that will
not interfere
with current
activity.
CREW RESPONSIBILITIES
Many factors may affect the size of the crew
required for a given job. Each crew member
should know his station and job responsibilities
for well control activities. Specific activities can
require specialists, such as casing, cementing,
or logging crews, who add to the active on-duty
personnel roster, thereby altering the general
assigned responsibilities.

5-12
Remember that the primary responsibility
of each member is to keep the lines
of communication open. The individual
responsibilities shown below are representative
of what must be done, and the person who
typically performs the tasks during well control
events. The following list provides an example
only and does not in any way recommend or
represent policy.
DRILLER
w Primary responsibility is kick detection
and verification
w Shut in the well
w Notify supervisor
w Organize crew for kill operation
w Remains at drilling console to run rig and
rig pump during kill operation
TOOLPUSHER/RIG MANAGER
w Responsible for rig and personnel
w Verifies proper on and off tour crew
deployment, notifies barge engineer or
vessel captain of well control operations
w May be responsible for operating the choke
or to designate choke operator
w Coordinates kill operation with company
representative
COMPANY REPRESENTATIVE
w Organizes kill operation
Each crew w Has overall responsibility unless rig has
member must offshore installation manager (OIM)
know his station w Briefs crew, oversees operations and makes
and duties for sure crew knows their responsibilities
well control
w Notifies and keeps communications open
activities and with office
keep the lines of
w May be responsible for operating the choke
communication
or designating a choke operator
open.
BALLAST/BARGE ENGINEER
w Notifies support vessels of operations
w Stands by in control room for instructions
w Monitor fluid transfers
DERRICKHAND/ASSISTANT DRILLER
w Goes to pit area, aligns gas separator,
degasser and pits
C HAPTER 5
w Works with mud engineer to supervise
mixing crew and to ensure rig and mixing
pumps are functioning and aligned properly
ROUGHNECKS (DEPENDENT ON THEIR DESIGNATION)
w Report to assigned well control station
(rig floor, pumproom, choke console, etc.)
w Follow instructions of driller
ELECTRICIAN/MECHANIC
w Assists mechanic/motorman if required
w Stands by for orders
MUD ENGINEER
w Goes to pits
w Supervises weighting operations
w Maintains constant properties and
fluid density
ROUSTABOUTS
w Go to mud or pump room and follow
instructions of supervisor
MOTORMAN
w Shuts off all non-essential equipment
w Ensures rig power throughout operation
w Goes to assigned station for well control
operations
w Stands by for orders and to shut down rig
CEMENTER
w Reports to cement unit
w Lines up to pump cement
w Stands by for orders
SUBSEA ENGINEER (FLOATING OPERATIONS)
w Reports to rig floor to inspect subsea panel
w Checks for possible problems
w Stands by for orders from rig manager
SERVICE PERSONNEL
w Go to assigned stations for well control
operations
w Stand by for orders
P ROCEDURES
COMMUNICATIONS
Perhaps one of the most important aspects
of any activity is communications. This
seemingly simple subject is actually very
complex. It may be broken into three distinct
components, each with responsibilities and
plans of action and how to communicate:
Before the job: Safety meetings are common
to communicate to all crew members what
activities and goals will be performed and
accomplished during the workday. The safety
meetings should discuss risk analysis and detail
areas of concern as well as corrective plans of
action and how to relay information that you
are responsible for. Remember that you are
part of the team and you need to know what
is expected of you. If you have questions
regarding the operation, this is a safe time to get
them answered. Non-routine activities should
be discussed, and any additional personnel
brought in to become familiar with what is
expected of them, as well as how they will
affect your responsibilities. When in doubt,
ask questions.
Carefully planned close-in procedures are an essential component of well control operations.
5-13
During the Job: There is a basic chain
of command to follow orders to perform the
day's activities. Each team member has certain
responsibilities and must report to a supervisor.
However, if anything out of the ordinary is
noted, it should be immediately reported. Risk analysis
For effective communications, someone has and good
to transfer information, and someone has communications
to listen and acknowledge that it has been minimize
received! Poor communications in your work problems and
environment can lead to disaster. increase safety.
Changeover and documentation: When Work as a team.
relief arrives, they should be thoroughly
briefed on everything that transpired during
the workday. Changeover or handover notes
should include information about what you
accomplished, where the job is standing at
this point, any problems or complications that
occurred as well as the normal parameters (e.g.,
depths, tools run, pump rates and pressures,
bit/mill rpm, depths, weight, torque, drag,
gains or losses, fluid properties, etc.) that were
experienced during your tour. Remember that
is not just the driller or unit operator that has a
relief. Inform your relief what happened, what
you are watching for and what to expect. After

5-14
changeover, personnel in supervisory roles are
usually required to document or report on the
day's activity.
Crew change is an especially important time
for good changeover notes. Many companies
have a staggered crew change policy to ensure
If the that someone is on hand and familiar with the
accumulator prior week's events at all times.
system is not
functioning
correctly, BOP
closure may not ACCUMULATOR AND BOP TEST
be possible.
The accumulator system is the key to
success in the control of a kick. Unless the
system is functioning correctly, the BOP closure
sequence and operation of other well control
equipment may not be possible. Therefore a
thorough and successful test is essential. The
following procedures (excerpts from API RP
53) are a general guideline only and should
not be confused with any government, state
or company policy. For specific test procedures
always refer to the manufacturer's procedures
and to appropriate regulations.
On surface preventers, the closing system
should be capable of closing each ram preventer
within 30 seconds and should not exceed 30
seconds for annular preventers smaller than
20 inches (508 mm) or 45 seconds
for ones larger than 20 inches (508
mm). For subsea preventers each
ram should close within 45 seconds
and annular preventers within 60
seconds.
CLOSING UNIT From
REQUIREMENTS
Cement Unit
The closing unit pump capability
test should be conducted on each
well before pressure testing the BOP
stack. A typical test would entail:
1. Position a joint of drillpipe/
tubing in the BOP stack.
2. Isolate the accumulators from
closing unit manifold by closing
the necessary valves.
C HAPTER 5
3. If the pumps are powered by air, isolate
rig air system from the pumps. A separate
closing unit air storage tank or a bank of
nitrogen bottles should be used to power
the pumps during this test. If a dual power
source system is used, each power supply
should be tested separately.
4. Simultaneously turn the control valve
for the annular preventer to the closing
position and turn the control for the
hydraulically controlled (HCR) valve to
the open position.
5. Record the time in seconds for the pumps
to close the annular preventer, to open
the hydraulically controlled (HCR) valve
and record the pressure that is remaining.
API recommends that this time should not
exceed two minutes.
6. Close the hydraulically controlled (HCR)
valve and open the annular preventer. Open
the accumulator system to the closing unit,
charge the accumulator system to its proper
operating pressure, and record the time
required to do this.
Testing the casing string
From
Mud Pumps
Annular
Pipe
RAM
Blind
RAM
Pipe
RAM
P ROCEDURES
5-15

ACCUMULATOR CLOSING TEST

This test should be performed on a per
well basis prior to testing the BOP stack. A
typical test procedure follows.
Test pressure
through drill
From From
1. Position a joint of drillpipe/tubing in the Cement Unit Mud Pumps

BOP stack.
2. Close power supply to accumulator pumps. Annular

3. Record the initial accumulator pressures. Pipe

RAM
Adjust the annular regulator to 1500 psi
Blind
(103.42 bar) or designated pressure. RAM

4. Depending on policy, perform the Pipe

RAM
functions that are required (e.g., API
requires the minimum standard to close
the annular, one pipe ram and the
hydraulic choke line valve). Testing the blowout preventer on a typical surface stack

5. Record the time required for accumulators

to close. Record the final accumulator
pressure. It should not be lower than
200 psi (13.79 bar) above the precharge
pressure.
(Note: some regulatory agencies require that
a minimum of 200 psi (13.79 bar) above
precharge remain after closing all BOPs.)
6. After preventers have been opened,
recharge accumulator system to designed
operating pressure and record time
for complete power up.
BOP INSPECTION AND TESTING
Before hydraulically testing a preventer, check
the following:
1. Verify wellhead type, rated working
pressure.
2. Check for wellhead bowl protector (wear
bushing).
3. Verify the preventer type and rated working
pressure.
4. Verify drilling spool, spacer spool and valve
types and rated working pressures.
5. Verify ram placement in preventers and pipe
ram size.
6. Verify drillpipe/tubing connection size and
type in use.
7. Open casing valve during test, unless
pressuring the casing or hole is intended.
8. Test pressure should not exceed the
manufacturer's rated working pressure for
body or seals of assembly being tested.
For specific
9. Test pressure should not exceed the values equipment test
for collapse and internal yield pressures procedures,
tabulated for the appropriate drillpipe/ always consult
tubing used. Do not exceed tensile strength manufacturer’s
of pipe. guide as well
as local
10. Verify the type and pressure rating of regulations.
pump and preventer tester to be used.

5-16
All wellhead
equipment
tests should be
documented.
RAMS AND CIRCULATING SPOOLS
At a minimum the inspections and tests
should include the following:
1. Visually inspect the body and ring grooves
(vertical, horizontal or ram bore) for
damage, wear and pitting.
2. Check studs and nuts for correct size/type.
3. Check size/type of ring joint gaskets.
4. Visually inspect ram preventer.
a. Wear, pitting and/or damage to bonnet
or door seal areas or grooves, ram bores,
ram connecting rods and operating rods.
b. Packer wear, cracking, excessive hardness.
c. Measure ram and ram bore to check for
maximum vertical clearance according
A visual to manufacturer's specifications. The
inspection is clearance is dependent on type, size and
an important trim of the preventers.
part of d. If preventer has secondary seals, inspect
BOP tests. secondary seals and remove plugs to
expose plastic injection ports used for
secondary sealing purposes. Remove the
plastic injection screw and check valve
in this port. (Some rams have a release
packing regulating valve that will need
to be removed.) Probe the packing to
C HAPTER 5
ensure it is soft and not energizing the
seal. Remove and replace the packing if
necessary.
5. Hydraulically test with water as follows:
a. Connect closing line(s) to preventer(s).
b. Set preventer test tool on drillpipe/
tubing below preventers if testing
preventer with pipe rams.
c. Check for closing chamber seal leaks by
applying closing pressure to close rams
and check for fluid leaks by observing
opening line ports. Closing pressure
should be equivalent to manufacturer's
recommended operating pressure for
preventer's hydraulic system.
d. Release closing pressure, remove closing
lines and connect opening lines.
e. Check for opening chamber seal leaks
by applying opening pressure to open
rams. Check for fluid leaks by observing
closing line ports. Opening pressure
should be equivalent to manufacturer's
recommended operating pressure for the
preventer's hydraulic system.
f. Release opening pressure and reconnect
closing lines.
g. Low pressure test: check for ram packer
leaks at low pressure by closing rams with
1,500 psi (103.42 bar) operating pressure
P ROCEDURES
(or per manufacturer procedures) and
apply pressure under rams of 200 to 300
psi (13.79 to 20.68 bar) with blowout
preventer test tool installed (if testing
preventer containing pipe rams). Hold
for required time. Check for leaks. If
ram packer leaks, check for worn packers
and replace if necessary. If preventer
is equipped with an automatic locking
device, check it for proper adjustment
according to specifications. Continue test
until successful result is obtained.
h. High pressure test: check for ram packer
leaks by increasing pressure slowly to
the rated working pressure of preventer.
Hold for required time while checking
for leaks. If packer leaks, check worn
packers and replace as necessary. If
preventer is equipped with automatic
locking devices, check them for proper
adjustment in accordance with
specifications. Continue testing until a
successful result is obtained.
i. Test connecting rod for adequate strength
by applying pressure as recommended by
the manufacturer with rams closed and
BOP rated working pressure under rams.
j. Release opening pressure and release
pressure under rams.
k. Repeat steps a - j for each set of rams.
l. Test blind rams in the same manner as
pipe rams with test plug installed and
test joint removed.
ANNULARS AND DIVERTERS
Inspections and tests should include visual
inspections and hydraulic tests.
THOROUGH VISUAL INSPECTION
w Face of preventer head/cap for off-center
wear, pitting and damage, especially in ring
grooves and bolt/stud holes.
w Body for wear and damage.
w Vertical bore for wear and damage from
pipe and tools.
w Slotted body sleeve for pitting and damage.
Look through slots in base of inner liner
5-17
for accumulations of cuttings that might
prevent full movement of the piston.
w Packer element for wear, cracking, excessive
hardness, correct elastomer composition.
w Bolting – both studs and nuts for proper
type, size and condition.
w Where possible, inspect ring joint gaskets
for proper type, size and condition.
HYDRAULIC TEST Always perform
1. Connect closing line to preventer. low pressure
tests prior to
2. Set test tool on drillpipe/tubing below
high pressure
preventer.
tests.
3. Test seals between closing chamber and
wellbore and between closing chamber
and opening chamber by applying the
recommended closing pressure. If other
chambers are located between wellbore
and operating chamber, these seals should
also be tested.
4. If pressure holds, proceed to step 13.
a. If pressure does not hold and no fluid
is running out of the opening chamber,
the seal between the closing chamber
and the wellbore or other operating
chamber is leaking. Proceed to step 11.
b. If fluid is coming out of the opening
chamber, indicating the seal between the
closing chamber and opening chamber
is leaking, proceed to step 5.
5. Release closing pressure.
6. Install plug in opening chamber, or if
opening line is equipped with a valve,
install opening line and close valve.
7. Test seals between the closing chamber,
operating chambers, and wellbore by
applying recommended closing pressure.
Observe to see that pressure holds.
8. Release closing pressure.
9. Remove plug in opening chamber and
install opening line or open valve in
opening line.
10. Apply 1,500 psi (103.42 bar) closing
pressure.
11. Apply 1,500 psi (103.42 bar) wellbore
pressure. (Use lower pressure for lower
rated equipment.)
12. Bleed closing pressure to 1,000 psi
(68.95 bar).

5-18
13. To test the seal between the wellbore and
closing chamber, close the valve on the
closing line and disconnect the closing
line from the valve on closing unit side of
valve. Install pressure gauge on closing
unit side of valve and open valve. If this
seal is leaking, the closing line will have
pressure greater than 1,000 psi (68.95 bar).
Testing should Caution: if the closing line does not have
be methodical, a valve installed, the closing line should
performed to not be disconnected with pressure trapped
specifications and in the closing chamber.
documented. 14. Release wellbore pressure.
15. Release closing pressure.
16. To test the seals between the opening
chamber and the closing chamber and
between the opening chamber and the
piston, apply the recommended opening
pressure. If the pressure holds, proceed
to step 21.
a. If pressure does not hold and no fluid
is running out of the closing chamber
opening, the seal between the opening
chamber and piston is leaking. Verify
this visually. Proceed to step 21.
b. If fluid is coming out of the closing
chamber opening, indicating the seal
between the opening and the closing
chamber is leaking, proceed to step 17.
17. Release opening pressure.
18. Install closing line and block flow (close
valve in closing line, if available).
19. Apply 1,500 psi (103.42 bar) opening
pressure. If the pressures do not hold,
the seal between the opening chamber
and the preventer head is leaking. Verify
this visually.
20. Release opening pressure and replace
necessary seals. Refer to step 22.
21. Release opening pressure, replace closing
line, and replace necessary seals.
22. If the closing line has a valve installed,
make certain that the valve is open at the
end of the test. NOTE: This procedure
tests all seals except the seal between
the wellbore and the opening chamber.
This seal should be tested in the
C HAPTER 5
bottom annular preventer if two annular
preventers are being used when a stack is
nippled up on an annular preventer (for
snubbing, etc.). It can be tested to rated
working pressure by running a test joint
and plug, closing an upper preventer,
removing the opening line, and pressuring
the preventer stack up to 1,500 psi
(103.42 bar) maximum or by closing an
upper preventer and annular preventer,
removing the opening line, and pressuring
up between preventers.
Once systems have passed all the required
tests, make sure to check manifold and annular
pressure regulators. Most systems require 1,500
psi (103.42 bar) manifold pressure. The initial
closing pressure regulated to the annular
depends on several factors. If either pressure
is incorrect the regulators must be adjusted,
either remotely or manually.
CHRISTMAS TREE TESTING
Trees are classified according to various
factors, such as rated working pressure,
corrosion, H2S gas and their proximity to
other pressure equipment. Depending upon the
classification, hydrostatic or gas and hydrostatic
tests may be required prior to putting the well
on line. If mixed pressure rated components
are used, the tree should be tested to the
lower rated pressure. Testing usually consists
of several pressure holding periods with test
time requirements varying according to the
tree classification, as well as regulations and
policies. The tree body, inlets and outlets – as
well as all seals – must be tested. Both sides
of bi-directional valves should be tested, one
side at a time.
For plug valves, when test pressure is on
each side of the plug, the plug should be
moved at least two times. Unidirectional valves
should have pressure applied in the direction
indicated on the body, except for check valves
which would be tested on the downstream side
with the opposite end open to the atmosphere.
P ROCEDURES
SUMMARY
Once a kick is detected, the well must be
shut in according to correct rig procedures.
Procedures must be known prior to beginning
any well. Modifications to procedures may
be made on a case-by-case basis. Common
sense usually dictates the alternative solutions
as things change. Safety procedures must be
developed, known and practiced. Once the
BOPs are shut, other areas from the pumps
to manifolds and all lines in between should
be inspected to ensure the well is shut in and
there are no leaks. In cases where the BOP
stack is in an enclosed area, or in a cellar where
toxic gases may accumulate, respirators should
always be worn when working near equipment.
Weather conditions, crew changes, toxic fluids,
and equipment changes from job to job all may
dictate changes in shut-in procedures. These
changes must be practiced until the crew is
familiar with and proficient at their respective
tasks. The consequences of a blowout – fire,
pollution, toxic gases, loss of life or resources
– dictate that kick detection and shut-in
5-19
Wellhead
equipment
should be tested
according to its
lowest rated
component.
procedures be a priority during any operation.
Practice “What if” thinking. What if
someone is not present at his job assignment?
What if equipment will not function properly,
or fails altogether? What if other complications
arise? Alternate plans and courses of action
should be anticipated and practiced in well
control drills and discussed with the crew. Fear
of the unknown will cause panic. Fear of the
known leads to cautious, yet decisive, actions.
When operators move from rig to rig and An extra
the contractor works for different companies, moment taken
shut-in procedures, killsheets and general to shut a well
procedures may differ. Proper procedures for all in correctly may
activities should be discussed and understood result in more
by all parties. While the basic shut-in procedures influx, but this is
have been covered in this section, remember preferable to a
tragic accident
that extra procedural steps for safety, rig type
resulting from
and company policy are often added.
panic.
Too often, emphasis is placed on quickly
shutting in the well. If confronted with a
flowing well, act but do not overreact. An extra
moment taken to do things right the first time
may result in a little more kick taken, but this is
preferable to panic leading to improper shut-in
procedures, mistakes or accidents. t