Pressure Testing the BOP and the BOP FINAL

System Section: 4.4.

1. SPECIAL TOOLS AND EQUIPMENT

•Martin-Decker recorder •Pipe dope
•Perforated sub / drillpipe
•Safety lines or Chains
•Pin x Pin sub (IF connection)
•Crossover sub
•Setting / Retrieving Tool
•Chain tongs
•T.I.W. Valve with Wrench
•Pup joint
•Plug type tester
•Wear bushing
•Cup type tester
•Blind sub
•Chiksan lines
•Kelly test sub
•Test pump
•Hazard tape
•Circulating T Sub
•Hand-held radios
•Lo-Torc valve
•Kelly cock (with valve)
Note: “Permit to Work” must be obtained prior to commencing these procedures.

2. SAFETY INFORMATION

WARNING: The pressure rating of each item to be tested must be verified. The
lowest pressure rating of the components to be tested determines
the maximum test pressure to be used.
WARNING: No one is to tighten or loosen any connection under pressure.
WARNING: Ensure that all chiksan lines are fitted with a safety line or chain.
CAUTION: Ensure that no person is in the immediate vicinity of components
under test pressure.
CAUTION: The test area is to be cordoned off with Hazard Tape.
CAUTION: Clear communications are essential during testing procedure.
CAUTION: All personnel are to be informed when testing is to take place.

CAUTION: Ensure all test gauges and recorders have valid Dead Weight Tester
calibration certificates.
CAUTION: Annular BOP's are not to be tested over 70% of their rated operating
pressure.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

3. OPERATIONAL / TECHNICAL REFERENCES

• Government / Mining Regulations
• I.A.D.C. Manual, Chapter on “Well Control Equipment and Procedures”
• The Drilling Programme
• Equipment Manufacturer’s Bulletins

4. STANDARD OPERATIONAL CONSIDERATIONS ( DO’S AND DON’TS)

(1) Ensure that the BOP test is carried out under the direct supervision of the
Toolpusher.

(2) Hold a Toolbox Talk and ensure that the correct test pressures are used.

(3) The Driller is to carry out a function test of the BOP before the pressure test
commences.

(4) All BOP tests must be carried out with water, unless the Drilling Programme
dictates otherwise.

(5) Ensure that all air has been expelled from the test lines before the test
commences.

(6) The Driller will maintain chart recordings of all pressure tests.

(7) The Driller is to ensure that the wellhead valves are open before the pressure
test of the BOP stack begins.

(8) Ensure that salt water is used for testing if freezing weather conditions exist.

(9) All pressure tests should be maintained for 15 minutes.

(10) The test shall be accepted provided that after 15 minutes there is no pressure
drop.

(11) If any pressure drop is observed, the test shall be accepted only if :
(a) the pressure drop is less than 10% of the initial test pressure, and
(b) after the observed drop in pressure, the test pressure remains constant
over the next 15 minutes.

(12) If any component fails to hold the test pressure, that component will be repaired
or replaced, and re-tested.

(13) Manually operated chokes are not shut-off devices, therefore they always should
be left in the open position.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

5. INSTRUCTIONS

5.1. Pre-test Check List

(1) The Toolpusher and the Driller are to ensure that all testing equipment is on
location, have test code certifications, and are in good working order.

(2) The Toolpusher and the Driller are to ensure that all test plugs are the correct
size and pressure rating.

(3) The Toolpusher and the Driller are to review the applicable Regulations and the
Drilling Programme requirements ahead of the scheduled test.

(4) The Driller must have detailed drawing of the specific BOP and casing head /
spool on the rig floor.

(5) The Driller is to ensure that there are spare BOP rubbers, valve parts, and new
ring gaskets.

(6) The Driller is to ensure that the pipe used in testing is the correct size and grade,
and able to withstand the applied internal pressure.

(7) When using the "Multi-Setting tool" ensure the 1/2" pipe plug is installed in this
tool.

5.2. Frequency of Testing

(1) The BOP, wellhead, choke manifold, and related equipment are to be tested on a
weekly basis.

(2) The period between tests may be extended to 14 days, maximum, depending on
the well operations and the specifications in the Drilling Programme and the
applicable Regulations.

(3) The accumulator is to be tested prior to the first test of the BOP, or any time after
repairs are made to the accumulator unit.

(4) The accumulator bottles pre-charge pressure shall be checked before drilling out
the casing shoe or every 4 weeks.

5.3. Daily Function Tests

(1) The upper and the lower pipe rams shall be function tested during a trip and
recorded in the tour book.

(2) Any exceptions to the daily function test will be recorded in the tour book.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

5.4. Testing the Hydraulic Accumulator System

(1) Verify and record the hydraulic unit operating pressures:

Hydraulic unit: should be:

Accumulator operating pressure 3000 psi / 207 bar
Accumulator manifold pressure 1500 psi / 103 bar
Annular BOP closing pressure 1200 psi / 83 bar (for all Hydril Models)
Annular BOP closing pressure 1500 psi / 103 bar (Cameron Type D)

(2) If these pressures are not attained, investigate cause and repair.

(3) Commence test by slowly bleeding down the pressure of the hydraulic unit to
zero pressure.

(4) Observe and verify that:

When ... then ...

Hydraulic accumulator operating
pressure is reduced to 2700 psi
or 190 bar
Hydraulic accumulator operating
pressure is reduced to 2600 psi
or 183 bar
the electrical charge pump is automatically
activated (the charge pump must kick in at
90% of operating pressure of 3000 psi or
207 bar).
the air pumps to charge the unit are
automatically activated

(5) Switch off the electrical power to the hydraulic unit and close the air valve to the
air pumps after bringing hydraulic unit back up to pressure.

(6) Using the hydraulic unit, close and open the BOP rams, the annular BOP and the
HCR valve.
During this process:
(a) Note the time taken to close and open each with a stop watch and record.
(b) Note the remaining pressure on the Hydraulic unit and record.

(7) Close and open the annular BOP and one set of pipe rams a second time, note
and record the time taken and the pressure remaining on the hydraulic unit.

(8) The electrical power and the air supply are turned back on the hydraulic unit.

(9) Observe and record the time needed to pressure up the hydraulic unit to 3000 psi
or 207 bar operating pressure.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

(10) At the conclusion of the above tests verify that:

(a) All the handles on the Hydraulic unit are correctly marked.
(b) All the lights on the buttons of the remote control panel are operative.
(c) The manual levers at the Hydraulic unit are left in the correct position.

(11) Any deficiency noted during the above testing must be corrected prior to
resuming normal operations.

5.5. Testing the Choke Manifold

(1) Line up the chiksan line from the test pump to the choke manifold.

(2) Flush water through the choke manifold before starting the test.

(3) To prevent air entrapment, the valves to be tested will be closed slowly while
flushing. As soon as a pressure increase is observed, stop pumping.

(4) Check the level of fluid at the test unit and ensure that there is ample fluid for
testing.

(5) At the Driller’s instructions, the correct sequence of valves on the choke manifold
are to be closed.

(6) The sequence of choke manifold pressure tests, based on the valve locations
shown in Figure 1 must be as follows:

Test sequence with the only valves closed test to full rated pressure:
first number 15 5000 or 10,000 psi / 345 or 690 bars
second numbers 16, 17, and 18 5000 or 10,000 psi / 345 or 690 bars
third numbers 9,13,14 5000 or 10,000 psi / 345 or 690 bars
fourth numbers 10 and 12 5000 or 10,000 psi / 345 or 690 bars
fifth number 11 5000 or 10,000 psi / 345 or 690 bars

(7) Maintain test pressure on each test for 15 minutes.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

(8) At the Driller’s instruction, the test pump Operator slowly and progressively builds
up the test pressure as follows:

When pressure reaches ... then stop and observe for...

500 psi / 35 bar one minute.
1000 psi / 70 bar 30 seconds.
2000 psi / 140 bar 30 seconds.
the next 1000 psi / 70 bar increment 30 seconds.
the full test pressure 15 minutes.
(9) The test pump operator then will bleed off the test pressure through the choke.

(10) The test pump Operator will advise the Driller when the pressure has been
reduced to zero.

(11) The choke manifold is returned to its normal set up for drilling as follows (refer to
Figure 1):

Valves Open: 2 3 11 12 14 18 -- --
Valves Closed: 1 4 9 10 13 15 16 17

(12) The Driller will complete a BOP test report and submit to the rig manager and
client representative, enclosing the pressure graphs.

5.6. Testing the High-pressure Mud System

Note: The reduced pressure rating of the Buffer Manifold must be used.

(1) Close the valve at the standpipe manifold to the rig pumps.

(2) Test the high pressure mud line in pressure increments as per procedure 5.5. ,
above, work step (8) . Observe the test pressure for 15 minutes.

(3) The Test pump Operator will then the pressure off at the rig pumps.

(4) The Test pump Operator will advise the Driller when the pressure has been
reduced to zero.

5.7. Testing the Standpipe Manifold (SPM) and the Kelly

(1) Close the standpipe valve to isolate the kelly hose and the TDS.

(2) Open the bleed-off valve and flush the SPM.

(3) The Driller is to check and ensure that the pressure gauge reading is zero.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

(4) The Floormen connect the Lo-Torc valve and the chiksan line from the test pump
to the fill up line or the spare line on the SPM.

(5) Test the SPM valves in pressure increments as per instructions 5.5. , above, step
(8) . Observe the test pressure for 15 minutes.

(6) Install the kelly test sub beneath the kelly and connect the test line from the test
unit to the kelly test sub.

Note : If the rig is equipped with a top drive, the Driller will pick up a stand of drillpipe
and make it up to the top drive and install the test sub to the stand of drillpipe
and pressure test the top drive IBOP.

Note: Always pressure test the lower and upper kelly cocks from beneath.

(7) Test the kelly in pressure increments as per procedure 5.5 , above, step (8) .
Observe the test pressure for 15 minutes.

(8) The Driller will complete a BOP test report and submit to the Rig Manager and
the Client Representative, enclosing the pressure graphs.

5.8. Testing the BOP Stack

(1) Back off the packing nuts and unscrew the tie-down bolts to release the wear
bushing.

(2) Retrieve the wear bushing from the wellhead.

(3) If using a plug type tester, the seals on the plug type tester shall be checked,
cleaned and lubricated prior to running.

(4) The connection above the plug type tester shall be hand tight only, all other
connections are to be made up to the required torque.

(5) The plug type test assembly shall be made up as follows:

Item: Components:
1 2 stands HWDP or 1 stand DCs
2 kelly cock (Open)
3 4 1/2 inch IF sub, pin / pin
4 plug type tester
5 DP to surface
6 TDS
(6) If using a cup type tester, the seals on the cup type tester shall be checked,
cleaned and lubricated prior to running in.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

(7) The connection above the special cup type tester (left hand threaded) shall be
made up hand tight only, all other connections to the required torque.

(8) The Driller and the Floormen shall make up the cup tester assembly as follows:

Item: Components:
1 2 stands HWDP or 1 stand DCs
2 kelly cock (Open)
3 4 1/2 inch IF sub, pin / pin
4 cup type tester
5 perforated single
6 DP to surface
7 crossover sub and Lo-Torc valve)

(9) The Driller will lower in the test assembly and land the test plug or the cup tester
in the wellhead.

Note: For a given wellhead (i.e., Ingram Cactus or Cameron), utilise the special test
plug provided by the wellhead manufacturer. When using the "Multi-Setting tool"
ensure the 1/2" pipe plug is installed in this tool.

(10) The drillpipe is to be spaced so that no tool joint is across the BOP stack (use a
pup joint if necessary).

(11) Ensure that all the riser tie-down bolts are secure and that the stand-off over
each packing nut from the riser flange is approximately 5 cm, or 2 inches (± 1/8”).

(12) Open the casing spool valves to avoid pressurising the casing.

(13) Connect the circulating head crossover to the BOP. Install the Lo Torc valve and
connect the chiksan line to the test pump.

(14) Unseat the kill line check valve.

(15) Test the chiksan lines as per W.I. Section 1.13.

(16) Instruct the Test pump Operator to establish circulation and flush the system to
ensure removal of all air from the lines.

(17) Test the BOP and wellhead system in pressure increments as per procedure 5.5 ,
above, step (8) . Observe each test pressure for 15 minutes.

(18) The initial test after nippling up, should be to the maximum casing spool working
pressure or BOP working pressure, whichever is lower.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

(19) If using a 21-1/4 inch, 2000 psi BOP stack, the test sequence is as follows:

Test: Description; Pressure

(1) Surface lines against Lo-Torc valve • 500 psi / 35 bar
• full rated pressure
(2) Pipe rams and outer kill and choke valves • 500 psi / 35 bar
• full rated pressure
(3) Pipe rams and inner kill and choke valves • 500 psi / 35 bar
• full rated pressure
(4) Hydril, kill line check valve, and valve no. 1 on the • 500 psi / 35 bar
choke manifold • full rated pressure
Note: If using a cup type tester, the perforated single shall be backed off from the
test tool, and picked up above the BOP stack, to allow the Blind Rams to
be shut-in.
(5) Blind rams • 500 psi / 35 bar
• full rated pressure
(20) If using a 13-5/8 inch, 10,000 psi BOP stack, the test sequence is as follows:

Test: Description; Pressure

(1) Surface lines against Lo-Torc valve • 500 psi / 35 bar
• full rated pressure
(2) Upper pipe rams and outer kill and choke valves • 500 psi / 35 bar
• full rated pressure
(3) Upper pipe rams and inner kill and choke valves • 500 psi / 35 bar
• full rated pressure
(4) Lower pipe rams • 500 psi / 35 bar
• full rated pressure
(5) Hydril, kill line check valve, and valve no. 1 on the • 500 psi / 35 bar
choke manifold • full rated pressure
Note: If using a cup type tester, the perforated single shall be removed from the
test tool, and picked up above the BOP stack, to allow the Blind Rams to
be shut.
(6) Blind rams • 500 psi / 35 bar
• full rated pressure
(21) Bleed off the pressure.

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 Pressure Testing the BOP and the BOP FINAL
System Section: 4.4.

(22) Close the casing side outlet valves.

(23) Re-seat the kill line check valve.

(24) Back off packing nuts from the riser flange.

(25) The Driller will ensure that all BOP rams are open.

(26) Lower the cup tester 3-5 meter ton unseat the cup, remove and lay down the test
tool assembly.

(27) Install the wear bushing and tighten the packing nuts on riser flange.

(28) The Driller will complete a BOP test report and submit to the Rig Manager and
the Client Representative, enclosing the pressure graphs.

5.9. Testing the BOP on the Test Stump

(1) With the BOP on the test stump, install the blind sub and test pipe inside the
BOP Stack.

(2) Fill up the BOP stack with water.

(3) Test the BOP as per procedure 5.8. , steps (15) through (19) .

(4) After the BOP is installed on the wellhead, run test tools, and test the wellhead
and the mating flange to the BOP.

(5) The Toolpusher and the Driller will complete a BOP test report and submit to the
Rig Manager and the Client Representative, enclosing the pressure graphs.

6. ASSOCIATED WORK INSTRUCTIONS

W.I. Section 1.13.: Rigging Up and Testing Chiksan Lines
W.I. Section 4.1.: Nipple Up and Nipple Down BOP
W.I. Section 4.2.: Change out BOP Rams
W.I. Section 4.3.: Changing Valves on BOP
W.I. Section 4.5.: Running and Retrieving Wear Bushing

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 CUTTINGS TANK
SEPARATOR
TRIP TANK
25

FLARE
26
REMOTE CHOKE 19
PIPE RAMS
HALF OPEN
16 20
23
BLIND/SHEAR RAMS

1 9
2 3 4

TEST SEPARATOR
27 28
CHOKE LINE
10 14
PIPE RAMS
11 17 21 29
5 6 7 8

15
30 31
12
32

13
18 22 24 33 34

MANUAL CHOKE OPEN LEAD OFF SUMP

Figure 1: BOP and Choke Manifold Arragement

 Data sheet for pressure testing
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Testing of accumulator unit, preventers, manifold, high pressure lines, etc B.V.

DATE: WELL: RIG:PT III. Are the following pieces of equipment ready for use and
operational
yes no

I. CLOSING UNIT Inside BOP`s

Type:____________________________ Volume:____________________________litres Second kelly cock
Tank level indicator (recorder
Storage pressure:_________________________bar/psi Workingpressure:_____________________bar/psi and alarm)
Electrical pump cut in/out pressure: ___________________bar/psi Flo-Sho indicator and alarm
Airpump cut in/out pressure:_________________________bar/psi Trip tank / level indication
Trip tank used for RIH & POOH
TYPE WORKING TEST PRESS TEST TIME CLOSING PRESS. Pressure-gauge on standpipe, choke
SIZE PRESS. manifold, pumps
II. PRESSURE TESTS: Mud pump relief valves correctly
adjusted
Annular preventer BOP remote control tested
BOP spare parts (seal, rubbers)
Pipe rams Degasser
Variable pipe rams Poorboy
Preventer shear rams All instrumentation
Gas detector
Preventer blind rams Choke spare parts
Variable pipe rams Choke size
Pipe rams Striptank & bottle installed and
functioning
Choke line valves upper
" " " lower Have leakage or defects occured in any way in the above mentioned
HCR valve (hyd valve) or other areas, and how have they been repaired ?
Choke line
Kill line valves upper
" " " lower
Kill line
Kill line check valves Remarks:
High pressure lines
Pump manifold
Rotary hose
Swivel/Topdrive
Standpipe
Standpipe valves FUNCTION & PERFORMANCE TEST
ACCUMULATOR MONTLY
Kelly/Topdrive
Upper kellycock/IBOP With the accumulator at full pressure and both air
Lower kelly cock/TD and electrical pumps isolated
close and open all preventers and hydraulic valve
and additionally close the annular and one ram
preventer

Remaining pressure on accumulator bar/psi

yes no Recharge time with all pumps on min.

All the valves easy to open and close:

Have any leaks been found in the closing lines: IMPORTANT: Take care not to remain in
pressure hazard areas
Are all unrequired lines and valves closed
Choke test pressure / buffer manifold ENTP Diller ____________________
Have manifold valves been tested seperately
Were adjustable choke bodies tested with chokes open ENTP Drilling
Have all axtensions and mandrel been installed Supervisor __________________
Are all the nameplates located on the preventers
Company Supervisor ______________

CASING WEIGHT MATERIAL

Size:_____________ inch Grade:___________ 75% of csg burst___________bar How much weight material on hand type____________ ton________
Mud/Brine type____________ ton________
Casing test pressure up to:_______________bar/psi _________________mtr/ft How much liquid on hand SD ____________ m3________
SD ___________ m3________
Last casing string size:________________ Testpressure:________________bar/psi Cement how much on hand class ___________ ton________
Test time:_________ Min:Mudgradient SD:__________ Press.constant:_________ class____________ ton________

Figure 2. BOP Test Report Form