8 Subsea Well Control 1 PDF

Section 8.
Subsea Well Control
PVD Training
October 25, 2012
Authored by: Pham Van Thien
PVD Training
Section 8. Subsea Well Control
Table of Contents ............................................................................................................................................................................. 1

8.1 Overview of Subsea Drilling ....................................................................................................................................................... 4
8.1.1 Use of Marine Risers .......................................................................................................................................................... 4
Marine Riser Systems (General) ............................................................................................................................................. 4
Remotely Operated Connector................................................................................................................................................ 4
Marine Riser Sections ............................................................................................................................................................. 5
8.1.2 Riser Collapse ................................................................................................................................................................... 5
8.1.3 Reduced Fracture Gradients-Formation Strength ............................................................................................................. 6
Formation Fracture Pressure: ................................................................................................................................................. 6
8.1.4 Drilling with Riser and Diverter ........................................................................................................................................... 8
8.1.5 Choke Line Friction Determinations.................................................................................................................................... 8
8.1.6 Pressure Loss Change as Gas Hits the Choke Line ......................................................................................................... 9
8.1.7 Clearing Trapped Gas below the BOP‘s ............................................................................................................................. 9
Gas Removal........................................................................................................................................................................... 9
Riser Margin .......................................................................................................................................................................... 13
8.1.8 Subsea Stack Procedures ............................................................................................................................................... 13
General - Subsea Well Control Procedures .......................................................................................................................... 13
Shallow Gas .......................................................................................................................................................................... 13
Hazard Survey Report ........................................................................................................................................................... 14
Handling Shallow Gas in Conductor Hole ............................................................................................................................. 18
Drilling Riserless.................................................................................................................................................................... 18
Diverting at the Sea Floor...................................................................................................................................................... 20
Handling Shallow gas in Surface Hole .................................................................................................................................. 22
Well Control Considerations in Surface Hole ........................................................................................................................ 22
Loss of Buoyancy in a Gas Plume ........................................................................................................................................ 23
Recommended Practices for Diverting on Floating Rigs ....................................................................................................... 24
Diverter Equipment................................................................................................................................................................ 24
Seabed Diverter Equipment .................................................................................................................................................. 25
Choke Line Friction ............................................................................................................................................................... 28
Measuring Choke Line Friction in Cased Hole ...................................................................................................................... 28
Measuring Choke Line Friction in an Open Hole................................................................................................................... 28
Shut-in Procedures .................................................................................................................................................................... 29
General.................................................................................................................................................................................. 29
Shut-In Procedure While Drilling ........................................................................................................................................... 30
Shut-In Procedure While Tripping ......................................................................................................................................... 31
Considerations while Circulating ................................................................................................................................................ 31
Water in Choke Line vs. Mud in Choke Line ......................................................................................................................... 31
Water in Choke and Kill Lines: .............................................................................................................................................. 31
Compensating for Choke Line Friction .................................................................................................................................. 32
Monitoring Kill Line Pressures ............................................................................................................................................... 33
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8.1.9 Emergency Disconnect .................................................................................................................................................... 34
Disconnecting Introduction .................................................................................................................................................... 34
Emergency Disconnect ......................................................................................................................................................... 35
Re-entering the Well after Disconnecting .............................................................................................................................. 35
8.2 Subsea Equipment ................................................................................................................................................................... 37
Introduction ................................................................................................................................................................................ 37
BOP Equipment and Control Systems Overview .................................................................................................................. 37
BOP Stack ............................................................................................................................................................................. 37
8.2.1 Diverter ............................................................................................................................................................................. 39
8.2.2 Slip Joint (Telescopic Joint) ............................................................................................................................................. 40
Flex – Joint ............................................................................................................................................................................ 41
8.2.4 Ram Blowout Preventers ................................................................................................................................................. 42
General.................................................................................................................................................................................. 42
Stack Component Codes ...................................................................................................................................................... 43
Ram and Outlet Placement ................................................................................................................................................... 44
8.2.5 Testing and Inspection...................................................................................................................................................... 45
8.2.6 BOP Reliability .................................................................................................................................................................. 45
8.3 Subsea BOP Control Systems ................................................................................................................................................. 46
Introduction ................................................................................................................................................................................ 46
8.3.1 Indirect Hydraulic System ................................................................................................................................................. 46
8.3.2 Multiplex Electro-Hydraulic System .................................................................................................................................. 47
Overview ............................................................................................................................................................................... 47
Operating Sequence ............................................................................................................................................................. 50
Close Function ...................................................................................................................................................................... 50
Block Function ....................................................................................................................................................................... 54
Open Function ....................................................................................................................................................................... 55
Central Control Point ............................................................................................................................................................. 55
Control Fluid Circuit ............................................................................................................................................................... 55
Pilot Fluid Circuit ................................................................................................................................................................... 57
Hydraulic Power Unit ............................................................................................................................................................. 59
Mixing System ....................................................................................................................................................................... 60
High Pressure Pumps ........................................................................................................................................................... 60
Accumulator Requirements ................................................................................................................................................... 60
Subsea Accumulators ........................................................................................................................................................... 62
Subsea Control Pods ............................................................................................................................................................ 63
Control Panels ....................................................................................................................................................................... 67
Subsea Control Pods ............................................................................................................................................................ 73
SPM ( Sub Plate Mounted) Valves ........................................................................................................................................ 74
Regulators ............................................................................................................................................................................. 76
Redundancy/Shuttle Valves .................................................................................................................................................. 76
Flowmeters ............................................................................................................................................................................ 76
Subsea Bottle Dump Provisions ............................................................................................................................................ 77
Direct Accumulator Functions ............................................................................................................................................... 77
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Backup Control Systems ....................................................................................................................................................... 77
8.2.4 Choke Manifolds ............................................................................................................................................................... 78
Variance from Surface Installations....................................................................................................................................... 78
Installation Guidelines ........................................................................................................................................................... 79
Maintenance .......................................................................................................................................................................... 80
Choke and Kill Lines – Subsea Installations ......................................................................................................................... 81
8.3.6 Marine Riser Systems....................................................................................................................................................... 84
Marine Riser Tensioning System .......................................................................................................................................... 84
Buoyancy............................................................................................................................................................................... 85
Riser Running and Handling ................................................................................................................................................. 85
Marine Riser Inspection and Maintenance ............................................................................................................................ 85
Lower Marine Riser Package (LMRP) ................................................................................................................................... 86
Annular Preventers................................................................................................................................................................ 86
Emergency Control Funnels .................................................................................................................................................. 87
Choke / Kill Line Connection ................................................................................................................................................. 88
Marine Riser Flexible Joint (Ball Joint) .................................................................................................................................. 88
Ball Joints .............................................................................................................................................................................. 88
Hydraulic Wellhead Connectors ............................................................................................................................................ 89
Vetco H-4 Connector ............................................................................................................................................................. 90
Cameron Collet Connectors .................................................................................................................................................. 92
Hydrates ................................................................................................................................................................................ 94
Dril-Quip DX connector ......................................................................................................................................................... 94
Vetco Connectors .................................................................................................................................................................. 94
Shallow Water Flow Silt Contamination ................................................................................................................................ 95
System Maintenance ............................................................................................................................................................. 98
Pod Receiving Blocks/Lower Female Receptacles ............................................................................................................... 99
8.3.7 Other Subsea BOP Considerations .................................................................................................................................. 99
Cathodic Protection ............................................................................................................................................................... 99
Cold Weather Considerations ............................................................................................................................................... 99
Two Stack System & Split Stack Considerations: ................................................................................................................. 99
Choke Manifold ................................................................................................................................................................... 101
Hydraulic Quick-Response Systems ................................................................................................................................... 102
Solenoids............................................................................................................................................................................. 103
8.4 Workshop Exercise No. 7....................................................................................................................................................... 105
8.5 Workshop Exercise No. 7 – Answers ..................................................................................................................................... 116

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Floating drilling operations from semi submersibles and drill ships present special problems in well control.
Complications occur due to weather conditions, water depth, geology, and the design and operation of the
Subsea BOP stack and control system.
Two of the most serious operational scenarios are controlling a kick when only a shallow casing string has
been set and when drilling a long open-hole section before setting a protective casing string. Blowouts
have occurred in shallow wells when gas quickly arrived at surface with little warning.
8.1.1 Use of Marine Risers

Marine Riser Systems (General)
A marine riser system is used to provide a return 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.
Components of this system include remotely operated connectors, flexible joints (ball/flex joints), riser
sections, telescopic joints, and tensioners.
For a drilling vessel, the marine riser system should have adequate strength to withstand:
A. Dynamic loads while running and pulling the BOP stack:
B. Lateral forces from currents and acceptable vessel displacement:
C. Cyclic forces from waves and vessel movement.
D. Axial loads from the riser weight, drilling fluid weight, and any free standing pipe within the riser; and
axial tension from the riser tensioning system at the surface (which may be somewhat cyclic) or from
buoyancy modules attached to the exterior of the riser.
Unless otherwise noted, internal pressure rating of the marine riser system (pipe, connectors and flexible
joint) should be at least equal to the working pressure of thediverter system plus the maximum difference
in hydrostatic pressures of the drilling fluid and seawater at the ocean floor. In deeper waters, riser
collapse resistance, in addition to internal pressure rating, may be a consideration if circulation is lost or
the riser is disconnected while full of drilling fluid.
For bottom-supported units, consideration should be given to similar forces and loads as noted above, with
the exception of vessel displacement, vessel movement and high axial loads. Operating water depths for
bottom-supported units are often shallow enough to permit free standing risers to be used without
exceeding critical buckling limits, with only lateral support at the surface and minimal tension being
required to provide satisfactory installation.
Information presented in this section applies primarily to floating drilling vessels, since more demanding
conditions normally exist for these marine riser systems than those for bottom-supported units.
Remotely Operated Connector

A remotely operated connector (hydraulically actuated) connects the riser pipe to the BOP stack and can
also be used as an emergency disconnect from the BOP stack should conditions warrant. Connector
internal diameter should be at least equal to the bore of the BOP stack. Its pressure rating can be equal to
either the other components of the riser system (connectors, flexible joint, etc.) or to the rated working
pressure of the BOP stack (in case special conditions require subsequent installation of additional
preventers on top of the original BOP stack).
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Connectors with the lower pressure rating are designated CL while those rated at the BOP stack working
pressure are designated CH. Additional factors to be considered in selection of the proper connector
should include ease and reliability of engagement/disengagement, angular misalignments and mechanical
strength.
Engagement or disengagement of connector with the mating hub should be an operation that can be
repeatedly accomplished with ease, even for those conditions where some degree of misalignment exists.
Mechanical strength of the connector should be sufficient to safely resist loads that might reasonably be
anticipated during operations. This would include tension and compression loads during installation, and
tension and bending forces during both normal operations and possible emergency situations.
Marine Riser Sections

Specifications for riser pipe depend upon service conditions as outlined previously. It should be noted,
however, that drilling vessels normally encounter a wide variety of environments during their service life;
consequently, the riser should have minimum yield strength and fatigue characteristic well in excess of
those required not only for the present but for reasonably anticipated future conditions.
Riser pipe steel should confirm to ASTM Designation A-530: General Requirements for Specialised
Carbon and Alloy Steel Pipe and be fabricated and inspected in accordance with API Spec 5L:
Specification for Line Pipe. Specifications that provide riser pipe with a reasonable service life for operation
in most parts of the world include steel having minimum yield strength of between 50,000 psi and 80,000
psi.
Risers with lower minimum yield strength (35,000 psi) have proven satisfactory if used in those areas
where only light to moderate service conditions are encountered.
Computer programs are available for determining riser stresses under various operating conditions, and
should be used for installations where previous experience is limited or lacking. Permissible operating
stresses are normally expressed as a percentage of minimum yield strength and depend upon the
preciseness of the data input. For any combination of service conditions (i.e. environmental, vessel offset,
drilling fluid weight, riser weight, etc.), there is an optimum riser tension for which static and dynamic riser
stresses are minimum.
The internal diameter of the riser pipe is determined by size of the BOP stack and the wellhead, with
adequate clearances being necessary for running drilling assemblies, casing and accessories, hangers,
packoff units, wear bushings, etc.
Marine riser connectors should provide a joint having strength equal to or greater than that of the riser
pipe. For severe service, quench and tempering and shotpeening the connector pin end are sometimes
done. The joint when made up and tested under reasonable maximum anticipated service loads, should
have essentially no lateral, vertical, or rotational movement. After release of load, the joint should be free of
deformation, galling, or irregularities. Make up practices, including bolt torque requirement, should be
specified by the manufacturer.
Auxiliary drilling fluid circulation lines are sometimes required and included as an integral part of large
diameter riser systems. Drilling fluid can be pumped into the small diameter holes. The number of lines,
size, and pressure rating will be determined by flow rates and pressures required.
8.1.2 Riser Collapse

A marine riser fill-up valve is designed to prevent the riser from collapsing if the level of drilling fluid drops
due to intentional drive-off, loss of circulation, or accidental disconnection of the line.

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During normal drilling operations, the pressure head created by the mud column inside the riser keeps the
valve's internal sleeve closed. When riser pressure drops, ocean pressure pushes the sleeve up, initiating
a sequence which fully opens the valve to allow sea water to enter the riser, equalizing the pressure and
preventing riser collapse. The riser fill-up valve is activated by the pressure sensory sleeve when the
pressure inside the riser is from 250 - 350 psi below the ambient ocean pressure.
When activate, the valve fully opens to rapidly fill the riser. When pressure is equalized, the pressure
sensor returns to its normal position and the internal sleeve closes. Although the unit is totally self-
contained and independent of any control lines, the valve can also be manually operated through control
lines to the surface.
Fig 8.1.1 - Marine Riser Fill-up Valve
It would be useful to have a riser fill - up valve while drilling in areas with a high risk of lost circulation, or if
shallow gas were to evacuate mud from the riser.
8.1.3 Reduced Fracture Gradients-Formation Strength

Formation Fracture Pressure:
In order to plan to drill a well safely it is necessary to have some knowledge of the fracture pressures of the
formation to be encountered. The maximum volume of any uncontrolled influx to the wellbore depends on
the fracture pressure of the exposed formations.
If wellbore pressures were to equal or exceed this fracture pressure, the formation would break down as
fracture was initiated, followed by loss of mud, loss of hydrostatic pressure and loss of primary control.
Fracture pressures are related to the weight of the formation matrix (rock) and the fluids (water/oil)

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occupying the pore space within the matrix, above the zone of interest. These two factors combine to
produce what is known as the overburden pressure. Assuming the average density of a thick sedimentary
sequence to be the equivalent of 19.2 ppg then the overburden gradient is given by:
0.052 x 19.2 = 1.0 psi/ft
Since the degree of compaction of sediments is known to vary with depth the gradient is not constant.
Fig 8.1.2
Onshore, since the sediments tend to be more compacted, the overburden gradient can be taken as being
close to 1.0 psi/ft. Offshore, however the overburden gradients at shallow depths will be much less than
1.0 psi/ft due to the effect of the depth of seawater and large thicknesses of unconsolidated sediment. This
makes surface casing seats in offshore wells much more vulnerable to break down and is the reason why
shallow gas kicks should never be shut-in as shown in Figure 8.1.3.

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Fig 8.1.3
8.1.4 Drilling with Riser and Diverter

Due to pressure limitations at the casing shoe, it is not recommended to shut in a flowing shallow well.
Usually these wells are drilled riserless, or are diverted. In areas with a high risk of shallow gas a small
diameter pilot hole is drilled. No BOP is run.
Any kick is allowed to flow into the sea to reduce the pressure on the casing. When the BOP is first run,
any flow of formation fluids would be diverted away from the drill floor to save the personnel.
8.1.5 Choke Line Friction Determinations

Each choke and/or kill line piping assembly should contain two hydraulically operated valves. At least one
valve in each assembly should be ―failsafe‖ close. The lower valve in each assembly should be attached
directly to the BOP stack outlet with no spools, elbows, or tee connection between the valve and the BOP

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outlet. All right angle bends should be made with targeted tees or target type angle valves. The piping
between the upper valve and the choke/kill connectors or stab subs should be as straight as possible.
Slight changes of direction in this piping should be made with bends in the pipe itself, not using ells or
other weld fittings.
8.1.6 Pressure Loss Change as Gas Hits the Choke Line

When circulating out a gas kick at a slow circulating rate from the well, Choke Line Friction (CLF) will be
affected when gas reaches the area of the choke line. CLF will reduce as the lighter fluid fills the choke line
and the choke operator will need to close the choke in order to maintain a constant bottom-hole pressure.
As the small capacity choke line fills with formation fluid, the hydrostatics in the choke line will also change.
The choke operator will also need to compensate for this change by closing the choke. When the gas is in
turn displaced by the drilling mud behind it, the choke operator will need to open the choke to keep the
bottom-hole pressure constant.
When kill mud reaches the choke line CLF will again change and with the choke fully open, bottom-hole
pressure will increase by CLF corrected for kill mud.
8.1.7 Clearing Trapped Gas below the BOP’s

Free gas in the riser represents one of the most dangerous situations to rig floor personnel. The problem
intensifies in proportion to the water depth. Free gas in the riser could lead to riser collapse. As the well is
circulated to remove formation fluids, free gas will migrate upwards to fill the void space under the BOP
between the entrances of the choke line. The space could occupy one barrel in an 18 ¾‖ BOP with a pipe
ram closed.
Elementary volumetric calculations show that a small volume of gas under pressure will expand as the
pressure reduces, producing a significant volume at surface.
Experience has shown that if this is ignored, and the pipe ram is later opened to allow the trapped gas to
rise to the surface, a reduction in Bottom Hole Pressure (BHP) will occur allowing more formation fluid to
enter the well.
Gas Removal
In order to displace a gas kick completely from the wellbore several circulations of the well might be
needed. During this time some of the gas may have become trapped under closed rams in the BOP stack
as shown in Fig 8.1.4 (A). This has the potential to cause a serious problem if the gas is not removed in a
controlled manner.
If the rams were opened without removing the trapped gas, the gas would be released into the riser. As the
gas migrated, it would expand rapidly and cause the riser to unload mud onto the rig floor.
The most thorough method of gas removal is to leave the well shut on the lower rams whilst displacing the
choke and kill lines to water. By closing the kill line valves, pressure can be bled off up the choke line and
―U-tubed‖ up the choke line by opening the pipe rams. This sequence is shown below in Figures 8.1.4 (B)
thru (E).
The surface diverter should be closed during the operations so that any residual gas from the riser can be
safely dealt with. Once the riser has been displaced to kill weight mud the lower rams can be opened and
the well flow-checked. Calculate any new riser margin or trip margin that might have to be added to the
mud weight.

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Trapped Gas in Bop Stack - Figure 8.1.4 (A)
Removing Trapped Gas from BOP Stack
Trapped Gas in Bop Stack - Figure 8.1.4 (B)
1. Isolate the well from the BOP stack by closing the lower pipe rams.

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Trapped Gas in Bop Stack - Figure 8.1.4 (C)
1. Slowly displace kill line to salt water.

2. As the kill line is displaced to water increase the kill line circulating pressure by an amount equal to the
difference in hydrostatic pressure between kill mud and salt water at stack depth.
3. This will maintain the gas at original pressure with clean salt water returns at surface. Stop pumping and
close choke.
Trapped Gas in Bop Stack - Figure 8.1.4 (D)
1. Displace riser to kill mud using the upper kill line.

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Trapped Gas in Bop Stack - Figure 8.1.4 (E)

1. Close the subsea kill line valves
2. At this point the pressure is still trapped in the gas bubble.
3. Bleed off pressure through the choke to allow the gas to displace water from the choke line.
4. The gas bubble should now be as close to atmospheric pressure.
Trapped Gas in Bop Stack Figure 8.1.4 (F)

1. Close the diverter and line up to fill riser.
2. Open the pipe rams and allow the riser to U-tube, taking the returns up the choke line
3. Fill the riser as necessary.
4. Open the lower pipe rams and diverter element
5. Flow check the well.

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Bubble Expansion Example:-
DEPTH - 1000 ft
Choke Line Length = 1000'
Volume of Gas Trapped = 3 bbls
Kill Mud = 15 ppg
15 ppg x 0.052 x 1000‘ = 780 psi
Atmospheric Pressure = 14.7 psi
Gas Volume at Surface = = V2 = = 159 bbls
Riser Margin
Standard operating procedures (and in many areas, government regulation) have required a mud weight in
excess of formation pressure in the event of emergency disconnect so that the mud weight remaining in
the hole will balance formation pressure.
The additional mud weight designed to compensate for the loss of hydrostatic pressure of the mud column
from the wellhead back to the rig when the BOP is closed and the riser disconnected is known as the riser
margin.
The riser margin can be calculated as follows:
Reduction in BHP (psi) =
[Riser Length (ft) x Mud Gradient (psi/ft)] – [Water Depth (ft) x Sea Water Gradient (psi/ft)]
Riser Margin (ppg) = ÷ 0.052= (ppg)
In deepwater drilling, where the difference between formation and fracture pressures are very small, the
well cannot handle any extra pressure without losses occurring.
For this reason, enhanced well monitoring and training in well control and reconnecting methods becomes
essential.
8.1.8 Subsea Stack Procedures

General - Subsea Well Control Procedures
When drilling from a floating rig, well control methods are only slightly different than those employed when
drilling from a bottom supported rig. The major difference on a floater is that the blowout preventer
equipment is a long distance from the choke manifold, accumulator system, and rig floor. Conditions are
further complicated by the fact that the BOP stack is under water, which puts it in a poor working
environment. Some of the problems associated with well control on a floating rig and variations in well
control methods are presented in this section.
Shallow Gas
Shallow gas is a frequent hazard in offshore drilling for bottom supported rigs and floating drilling vessels.
Worldwide studies of blowouts indicate that shallow gas is the most serious cause of kicks leading to

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blowouts, and that these blowouts have caused more rigs to be severely damaged or entirely lost, than any
other well control problem. Attempts to divert shallow gas flows fail, on average, 50% of the time, and
result in loss of equipment and/or lives. Therefore, it is crucial to be prepared for encountering shallow gas
unexpectedly.
Hazard Survey Report

Prior to any offshore drilling program, a hazard survey should be conducted to identify the existence of
shallow gas horizons at primary and secondary drilling locations. The Hazard Survey Report is one of the
most important pieces of information available to drilling personnel. A copy of this report should be made
available to drilling supervisory personnel on the rig and in the office. It should be reviewed with the drilling
contractor prior to rig mobilization. The scope of the survey depends on local regulations, proximity to
areas of public interest, and experience in the area of operation.
Hazard survey raw data is collected by a spread of instruments pulled behind a survey vessel. These
vessels are typically 80-220 feet in length, and run (survey) at 4-5 knots. Surface running tools are used in
seastates less than 5 feet. When the seastate is greater than 5 feet, subsurface tools should be used to
avoid contamination of the data due to tool movement in rough seas. A schematic of a typical survey
vessel and instrument spread is presented in Hazard Survey Vessel illustration.
The seismic tools used in a Hazard Survey to detect shallow gas read sonic energy reflected by physical
interfaces (density changes) such as seafloor anomalies, bedding planes, unconformities, faults, and
gassy sediments. The tools are similar to those used in exploring for hydrocarbons at depth, but, there are
two basic differences: 1) the energy used is 0.5-24,000 joules for a hazard survey vs. 100,000 joules for
standard geophysical exploration tools, and 2) the frequency used is 10-200 Hz for a hazard survey vs. 50
Hz in geophysical exploration tools. Hazard Survey Tools Table lists various tools used to collect the raw
data, and the type of data collected.
The survey is conducted over a grid, as depicted in the Survey Grid illustration. Local regulation may
govern the spacing between tracks. In U.S. OCS waters, the maximum spacing between tracks is 1,000 ft -
3,000 ft. Closer spacing than that specified by local regulation may be used depending on geology and/or
experience in an area.
Because the Hazard Survey must tie into the geophysical survey maps, precise vessel navigation is
crucial. Ordinarily, two different navigation systems are employed to confirm each other. Types of
navigation (positioning) systems used, include:
• Line–of–sight: accurate to ±20 ft.
• Active radio navigation systems (Argo & Sylides): accurate to ±50 ft.
• Loran ―C‖: accurate to ±300 ft.
• The Global Positioning System (GPS) uses satellite passes to deter-mine location. The more satellite
passes, the more accurate the fix. One pass is accurate to ±50 ft.

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Fig 8.1.5 - Hazard Survey Vessel
The data collected should be verified and interpreted by experienced personnel. The report, too, should be
generated by professionals experienced in preparing such reports. Ideally the Hazard Survey Report is
available before the well plan is prepared, allowing shallow gas contingencies to be written into the drilling
program. The report might impact rig selection as well.
Generally the report may be considered valid for 18 months, less if the drilling location is in an active
geologic area, or in a geo-technical area such as at the mouth of a river. Also, many drilling contractors
require hazard surveys to be conducted within 6 months of spud to detect recent debris.
If the hazard survey indicates the existence of shallow gas at the intended drilling location, a decision must
be made to either avoid it by moving to an alternate, shallow gas-free location within the hazard survey
area, or prepare to divert if necessary.

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Fig 8.1.6 - Survey Grid

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Table 8.1.1 - Hazard Survey Tools

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Handling Shallow Gas in Conductor Hole

Generally, formations penetrated in the conductor hole (26‖) section are likely to break down if a well is
shut in on a kick. Therefore, in areas prone to shallow gas, plans must be made to rig–up to drill the
conductor hole in a way that prevents inadvertently shutting in on a shallow gas flow. On bottom supported
rigs this is accomplished by nippling-up a diverter. A diverter may also be used on a floater by placing it at
the top of the marine riser. However, unlike bottom supported rigs, where running a surface diverter is the
norm (there is a subsea diverter system available for bottom supported rigs, although its use is
uncommon), on floating rigs there is an alternative: drill the conductor section without running a riser and
take returns to the seafloor. Any shallow gas flow is ―diverted‖ to the seabed. This last option, to drill
conductor hole ―riserless‖ while taking returns to the sea floor, is considered recommended best industry
practice.
Drilling Riserless
The conductor hole (26‖) should be drilled without a hydraulic connector and associated riser. There are
several reasons why drilling riserless is preferable, including:
• When a riser is in use, the mud and cuttings contained in the riser put an increased hydrostatic
pressure on the exposed formations. This hydrostatic pressure could cause broaching or lost
circulation.
• If a shallow gas zone is entered with a riser installed, the riser serves as a conduit to bring the
potentially explosive and/or lethal gas to the rig floor.
• The hydrostatic pressure of the sea water is always exerted on a flowing formation.
One disadvantage of drilling riserless is that it is difficult to detect a gas flow. A subsea video camera,
either the rig‘s camera or one carried by an ROV, must be used.
Frequently, when drilling riserless, the only indication that a well is flowing is bubbles breaking the surface
of the sea.
The key point is to react as soon as a flow is noted.
While every floating rig has specific procedures for drilling in a shallow gas prone area, a contingency plan
ought to be developed and reviewed with the drilling contractor prior to rig mobilization. The following
guidelines should be considered in developing both the contingency plan and the drilling plan:
1. Serious attention should be given to drilling a pilot hole to conductor (20”) setting depth. This
pilot hole is drilled before setting structural casing (30”).
Pilot hole advantages include:
• Less expense is incurred if an uncontrolled shallow gas flow takes place and the pilot hole is lost.
• A dynamic kill may be possible in holes 8-1/2‖ or smaller. The back pressure on the flowing formation
due to the friction of drilling fluids being pushed up the hole may be great enough to kill the well, or at
least to slow gas flow substantially.
2. Pilot hole disadvantages include:
• Records show that many shallow gas flow occurrences have been initiated by swabbing. By design,
pilot holes have a restricted annulus, which increases swabbing tendencies. The swabbing potential is
worse in areas where BHA balling is a problem.

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• The pilot hole annulus volume is smaller, permitting mud displacement by smaller kick volumes and at
a faster rate.
• Control drill to avoid overloading the annulus with cuttings. This is a concern if a pilot hole is drilled,
because of the relatively small annular clearance.
Note: Consider recommending drilling pilot hole to the depth of 1 st casing string intended to permit
conventional well control (which might be, but usually isn‟t, the 20”). Otherwise, you lose much of the
benefit of a pilot hole. Since most subsea BOP‟s go on the 20” wellhead, the above practice often results in
possibly encountering relatively shallow gas with a BOP and riser in place – thereby missing the benefits of
riserless drilling.
3. Sweep the hole frequently to assure hole cleaning.

4. Mooring Lines & Winches
• Establish the move–off direction during initial anchor-up or before, if possible.
This will be based on wind and current direction. The appropriate mooring winches to be released
(slackened) should also be determined.
• Pretension the anchor lines to allow the rig to be moved off location (If moving off location becomes
necessary, it would be accomplished by releasing the anchor tension on the leeward anchors and
winding in the windward anchors).
• Keep winches on brakes, not dogged off.
• If possible, man each winch continuously with experienced personnel while drilling is underway.
5. Use an ROV or rig camera to watch for gas bubbles at the wellhead. Note that the sonar on
some ROVs may be more effective than the camera, in detecting gas bubbles.
6. Maintain a constant watch of the moonpool area.
7. Station personnel on the bridge or topside with full view of the area during the time riserless
drilling is under way, and until casing has been cemented.
8. Minimize the number of non-essential personnel on board.
9. Do not allow any hot work.
10. On semi-submersibles, restrict personnel entering columns and pontoons.
11. Close all vents and water tight doors.
12. Have an anchor handling/standby boat circling the rig while the conductor hole (26”) section
is drilled. It should not be tied up to the rig or on anchor.
13. Conduct a shallow gas drill. Hold a safety meeting to discuss detection and handling
procedures. Reiterate authority levels spelled out in the contingency plans.
Suggested Procedures for Responding to Shallow Gas Flow while Drilling Riserless:
When drilling the conductor hole (26‖) riserless, the following steps are to be taken immediately upon
detection of a flow:
a) Sound the alarm and notify the control room.

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b) Immediately increase pump speed and pump as fast as possible.

c) Switch over to kill mud ready in the reserve pits.
• The change over to kill mud must be accomplished without stopping or slowing pump(s).
• When approximately 3/4 of the kill mud volume is pumped (be careful to not pump all of the kill mud
away and risk loosing pump suction), stop pumping and check for flow. If the well is still flowing,
switch to sea water. Continue pumping seawater until one of these conditions exists:
a) the shallow gas zone has been depleted,
b) additional kill mud is ready to pump, or
c) The situation becomes too dangerous and an emergency move-off is initiated.
d) Begin evacuation of nonessential personnel.
e) Prepare to move the rig off location. On ship–shaped floaters, the decision to move off location must
be made quickly if gas erupts beneath or near the ship.
Note: Pulling off location could result in pulling the string apart. It may be necessary to drop the string to
avoid this occurrence.
Diverting at the Sea Floor

While drilling the conductor (26"/20") hole there are some situations when it is necessary to bring returns
back to the rig, and a riser must be run. Situations requiring a riser to be run include:
• Higher hydrostatic pressure produced by bringing a weighted drilling fluid back to the drilling rig is
necessary for borehole stability.
• The borehole requires mud chemistry to remain stable. Expensive treated mud should be returned to
the rig. It would be prohibitively expensive to dump it at the sea floor.
• The geologists require formation sampling (cuttings).
When a riser is run, a safe method of handling shallow gas flow must be employed.
While a surface diverter system might be considered a reliable solution, there are factors which render it a
poor choice.
Shallow gas zones ordinarily flow large volumes of gas and carry formation debris at a high velocity. The
large internal diameter of the riser provides a very efficient conduit up to the rig. Consequently, a surface
diverting system must contend with high rates of erosive, explosive and/or lethal gas. Historically, 50% of
shallow gas divert events fail, resulting in uncontrolled gas flowing to the moonpool area or to the rig floor
through the telescopic joint. These failures usually result in the loss of equipment, life, or both. Diverting
events fail for a variety of reasons, including:
• Flowlines fail due to erosion and/or vibration.
• Valves fail because trash prevents full opening or closure. Valve erosion is also a problem.
• Slipjoints fail due to:
1) Packer element failure caused by excessive well pressure and/or heave induced motion reversal;
2) When they are physically driven through the rotary table by high thrust forces created when
excessive wellbore flowing pressure acts over the large cross sectional area of a closed diverter
sealing element.

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Only 1 of every 2 surface diverts are successful. Statistically, half of all attempts to divert a shallow gas
flow at the surface will fail.
Fig 8.1.8 - Effect of Water Depth on Fracture Gradients
Considering this information, it is obvious that a much better way to divert a gas flow is to do so at the
seabed (mud line). Seabed diverting provides more advantages than surface diverting, as follows:
• Keeps hazardous flow remote from rig.
• Diffuses the flow and diminishes its effect.
• Throughout a diverting event, the hydrostatic head of the sea water is exerted against a flowing
formation to help reduce the flow.
• If blind/shear rams are installed in the seabed diverter system, it's possible to quickly shear the drill
string, disconnect, and move the rig off location.

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Note: When a seabed diverter is installed, a surface diverter is also installed to provide a means of
diverting any gas which may get into the riser due to the late detection of a kick or a leaking seabed
sealing element.
(Refer to Section 7.3 for surface diverting procedures)
Handling Shallow gas in Surface Hole

The riser with a diverter is always in place when drilling the surface hole. Well control problems are
magnified in this section as the formations penetrated are deeper and bottomhole pressures are higher. A
leak off test should be conducted after drilling out below the conductor (26"/20") shoe to determine the
hydrostatic pressure that the formation will support. See illustration ‗Effect of Water Depth on Fracture
Gradients‘ which points out the effect of water depth on the maximum mud weight that the formation below
the conductor (26"/20") shoe can support. Thus, while it is possible to circulate 11.3 ppg mud in 500 ft. of
water, mud density would have to stay below 9.7 ppg in 3,000 ft. of water or there is a risk of breaking
down the formation and possibly broaching back to the mud line.
Well Control Considerations in Surface Hole

Two well control options are available for handling flow from the wellbore while drilling the surface hole.
One option is to divert the well at the surface. However, surface diverting is a poor choice because
successful diverting operations are rare and usually result in the loss of equipment and life. The second
option is to shut–in the well using the annular preventer on the lower marine riser package. This latter
option is considered the Industry best recommended practice. By shutting in at the sea floor and
preventing uncontrolled gas flow up the riser, the rig and rig crew are not exposed to the catastrophic
dangers of high flow rates, erosive gas and thrust forces commonly encountered during a surface divert
occurrence.
While shutting in the well risks breaking down the formation at the shoe and possible broaching to the
surface, it will usually not result in the loss of equipment or life. In any case, the risk of breaking down the
shoe is relatively low, and is therefore acceptable. Recent studies and published reports from other
operators cite instances where wells have been successfully shut in on less than 1,000 feet of conductor
(26"/20") casing, with no evidence of broaching at the shoe.
Shutting in before a large gas influx exists in the wellbore or before all mud is voided from the hole is
critical. Shut–in procedures detailed later in this section are employed, and once the well is shut in, kill
procedures outlined in section 6 may be initiated. For surface hole kicks, the Driller‘s Method (refer to
section 6.3) is preferred because it can be started immediately, to reduce gas migration complications and
because it is not necessary to first determine drillpipe pressure. However, the Drilling Supervisor should
apply whichever method best suits the situation. The drillpipe should be hung off as soon as possible after
shutting-in the well. By following this procedure, if the rig is in danger from the shoe broaching and gas
surfacing then disconnect and move–off procedures are greatly simplified and can be accomplished
sooner.
When the well is shut-in on the annular, the surface diverter should also be closed.
Because the exact location of the influx in the well may be unknown (it may already be above the annular
preventer) the closure of the surface diverter will permit dumping any gas in the riser overboard. Once it is
determined that there is no gas in the riser, it should be opened to allow the detection of a leaking BOP
element.
The key to a successful kill is early detection and shutting-in the well before the influx size creates shut–in
pressure high enough to fracture the shoe. If the shoe does fracture, and the rig is not in danger,
conventional control methods may still be used to save the well.

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Note: Avoid bringing gas flow to the rig through the riser / diverter system. Shut-in on surface hole kicks.
While circulating out a shallow gas influx, a high degree of readiness to react to additional complications
should be maintained. Some considerations regarding kill operations include:
• Mooring lines/winches:
a. Pre-establish the move–off direction. This will be based on wind and current direction. The
appropriate mooring winches to be released (slackened) should also be determined.
b. Pretension the anchor lines to allow the rig to be moved off location. If moving off location becomes
necessary, this would be accomplished by releasing the anchor tension on the leeward anchors and
winding in the lines on the windward anchors.
c. Keep winches on brakes, not dogged off.
d. Man each winch continuously with experienced personnel while drilling is underway.
• Use an ROV or rig camera to watch for gas bubbles at the wellhead or from the seabed in the vicinity
of the wellhead.
• Have an anchor handling boat sailing around the rig until the surface hole section is drilled. The boat
should not be tied up to the rig, or on anchor.
• Post and rehearse, rig crew assignments and duties.
• Consider evacuating non-essential personnel.
If the well broaches while circulating out an influx, and the rig is not endangered by an erupting gas plume,
then it may be possible to displace the open hole section with high density mud. Rapidly displacing the
open hole section with a high density fluid may kill the well, or at least prevent continued broaching, and
cratering. Therefore, a reserve pit of high density mud should be ready to pump.
Case histories of many shallow gas kicks indicate that swabbing is a major cause of these incidents.
Therefore, if a pilot hole is drilled, remember that the reduced annular space may exacerbate swabbing
tendencies, particularly in areas prone to BHA balling.
Loss of Buoyancy in a Gas Plume

A valid concern is the danger a vessel is in by remaining in or near a gas plume erupting at sea level.
However, if the rig is operating in a water depth greater than 250', the danger is not due to a loss of
buoyancy. Computer models (confirmed by field observations of actual occurrences), give evidence that a
floating vessel can remain in a gas plume without a significant loss of buoyancy. Gas plume induced
buoyancy reduction is most pronounced very near sea level. A floating rig may suffer a 4%-7% loss of
buoyancy, which might result in 2'-6' loss of freeboard. The loss of freeboard is less pronounced for a
semi-submersible than a ship-shaped floater, as the semi's columns and pontoons are mostly below the
zone of pronounced buoyancy reduction.
The danger results from gas accumulations around the rig those are potentially explosive and/or toxic. This
is particularly dangerous when the wind is calm. If a gas plume erupts beneath or near the rig, the rig
should be ready to move off the location.
When the rig is operating in water depths less than 250', it should be ready to move off location on short
notice.

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Recommended Practices for Diverting on Floating Rigs

• Use a surface diverter only to clear gas which is in the riser because of late shut–in or leaking
preventer sealing elements, or when clearing stack–gas.
• Drill conductor hole (26‖) riserless, taking returns to the sea floor.
• Run the BOP stack after conductor casing (typically 20‖) is cemented.
Once the BOP stack is run, shut–in on any kick taken. Circulate the kick out of the well through the choke
line using the Driller‘s or Wait & Weight Engineer‘s Method, whichever is more appropriate.
a. In a shallow gas area, the conductor (20‖) shoe should be set deep enough to allow shutting–in on
kicks.
It is understood that there is a risk of the well broaching at the shoe.
• While drilling conductor hole, if returns must be brought back to the rig, run a seabed diverter and
divert kicks to the sea floor.
Diverter Equipment
The diverter that is part of the riser equipment on floaters has a different function than a similar component
found on a bottom supported rig. The main function of the diverter on a floating rig is to handle gas that
may inadvertently enter the riser during a well control operation. This could occur if gas migrates into the
riser before a kick is recognized and preventers are closed, if preventers leak, or when gas is being
circulated out from between two closed preventers after the well is killed (clearing stack–gas). See Sub-
section 8.1.7.
Fig 8.1.9 - Surface Diverter Equipment

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By far the most common surface diverter found on floating rigs is the ABB-Vetco Gray (formerly Regan)
KFDS. Vetco Gray has improved on the KFDS with the KFDS-1000 CSO, illustrated in Regan KFDS-1000
Surface Diverter illustration. This new design uses a spherical sealing element rather than the insert type
used in earlier generation Regan diverters.
The ―CSO" (Complete Shut Off) designation denotes the capability of this diverter to close and seal on
open hole without pipe. Other than the spherical sealing element, the operation of this diverter is identical
to that of the insert type KFDS.
Fig 8.1.10 - Hydril FS 21-500 Diverter

As an alternative to the insert type diverter mentioned above, Hydril developed the FS 21-500 Marine Riser
Diverter depicted in Hydril FS 21-500 Diverter illustration. The FS diverter has an annular BOP type sealing
element. When the piston moves up to energize the sealing element around pipe, it simultaneously closes
off the flowline and opens the diverter to the overboard lines. The system uses a targeted ―never closed‖
selector valve for diverting port or starboard (see Hydril Flow Selector illustration in Section 7). The
philosophy behind the design of the FS 21-500 was to eliminate as many points of potential operator error
and hydraulic malfunction as possible. This diverter will seal on open hole.
Seabed Diverter Equipment

The Hydril SXV/MSP Seabed Diverter is attached to the subsea guide base by a 30‖ hydraulic connector.
In this system, a conventional annular blowout preventer is used to shut–off the flow of gas. It can also seal
off open hole. A specially designed drilling spool with an integral vent–port valve is opened to divert the
gas flow laterally. This valve opens simultaneously with the closing of the annular preventer.
The large area vent–port (12‖–16‖ diameter) minimizes back pressure on the flowing formation. A flex joint
is built into the head of the annular BOP, providing up to ±10º of global flexure, with tension load capability
to 1,000,000 lbs. As an option, a blind/shear ram may be included to facilitate severing the drillpipe and
sealing the wellbore (see following two illustrations).

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Fig 8.1.11 - Hydril SXV/MSP Seabed Diverter

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Fig 8.1.12

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Choke Line Friction

When drilling with a subsea stack, the choke is usually a great distance from the BOP stack, depending on
the water depth. Any friction occurring in the annular section of the well bore will be reflected in the
bottomhole and shoe pressures. Thus, it becomes important in well control to take into consideration the
additional friction generated while circulating through the choke line. If ignored, the friction pressure could
become great enough to fracture the formation at the casing shoe or deeper downhole.
Two methods are discussed below to determine the amount of choke line friction that occurs while drilling
with a subsea stack.
Measuring Choke Line Friction in Cased Hole

1. Record the standpipe pressure while circulating through the riser at three pump rates.
Note: As will be discussed in detail later in this section, the maximum pump rate used should not exceed
the highest pump rate that can be tolerated when the kick reaches the choke line.
2. Close the annular preventer on the LMRP and open the choke line valves and all valves and chokes
on the surface manifold.
3. Circulate through the choke manifold at the same rates used in Step #1. If applicable, circulate out all
water in choke and kill lines.
4. Record the circulating rates and associated standpipe pressures on the back side of the Pre-
Recorded Data Sheet and calculate the amount of choke line friction. An example calculation is
shown below.
Fig 8.1.13
Measuring Choke Line Friction in an Open Hole

In an open hole, the method previously discussed is not recommended as it exposes the open hole section
to the full amount of choke line friction while circulating through the choke. In this situation, the method to
be used is as follows:
1. Connect rig pumps to the bypass line on the choke manifold and pump down the choke line at the
predetermined rates while taking returns from the riser.
2. Pressures at the various pump rates can be read directly from the choke manifold gauge.
3. As the friction pressure while circulating at reduced rates through the riser is negligible, the readings
from the choke manifold pressure gauge will be the value for choke line friction at the corresponding
pump rate.
Slow pump pressures (and choke line friction values, if mud is in lines) should be recorded once per tour,
after a change in mud weight occurs, and after setting each string of casing. If you did not determine a new
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value for choke line friction after changing mud weights, use Equation 8.1 to closely approximate the new
value for choke line friction:
Equation 8.1 Adjusting Choke Line Friction for New Mud Weights
New Choke Line Friction, psi =
Shut-in Procedures
General
When a kick is detected, the well should be closed-in on the uppermost annular preventer. After shut-in,
drillstring reciprocation through the annular preventer is not recommended as significant wear may occur
on the sealing element, especially if a tool joint is reciprocated through the element. To avoid this, the
drillstring should be hung-off on a pipe ram as soon as possible. Additionally, a trapped gas bubble will be
left in the BOP stack between the annular preventer and the choke line outlet used to circulate the well.
This trapped bubble may be hazardous to handle at the surface, depending on its size and pressure. To
minimize the risk of annular wear and the size of the trapped bubble, the following is recommended:
a. The well should be shut-in on the annular preventer in the LMRP and operations begun immediately
to hang off the drillpipe on the pipe rams. Pipe reciprocation should be sacrificed in order to minimize
the size of the trapped bubble and annular element wear. It is acceptable (but not recommended) to
hang off on VBRs only if a tool joint will rest on ram blocks, not on the fingers.
b. When circulating out the influx, returns should be taken through the choke or kill line outlet directly
beneath the closed pipe rams. Once the influx is circulated from the wellbore, remove the trapped gas
from the BOP stack. Fill the riser with kill weight mud. The diverter controls and overboard line should
be manned before the well is opened. When circulation begins up the riser, any residual gas bubble
will then be diverted overboard through the diverter lines as necessary.
c. In the event of trapping significant quantities of gas in the BOP stack for any of the following reasons:
i) Not hanging off the drill pipe on the pipe rams.
ii) Not closing the well in until gas reaches the BOP stack.
iii) Pipe rams leaking with the annular closed.
iv) Not being able to utilize a choke or kill line outlet directly beneath the hang-off rams.
Special procedures must be used to control the expansion of the trapped bubble when the well is opened
up. This topic is discussed in detail later in this section.
NOTE: The quantity of gas trapped in the BOP stack which will become significant at the surface is
dependent upon water depth and mud weight. Two barrels of trapped gas in 150' of water with 10 ppg mud
will expand to just over 10 barrels at the surface. The same two barrels in 1000' of water with 15 ppg mud
will expand to over 100 barrels
The three advantages of hanging-off versus reciprocating through the annular preventer are:
a. Minimizes wear on the annular
b. Minimizes the amount of trapped gas in the stack after the kick has been circulated out.
c. Facilitates a quick disconnect if the need should arise.

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Shut-In Procedure While Drilling

The annular preventer on the LMRP (upper annular) is used as the initial closing element, absorbing
whatever damage is done, until the drill pipe is supported on the ram-type preventers. Keeping
reciprocation brief through the annular preventer should minimize the damage (the annular preventer on
the stack, i.e. lower annular, is still available for well control). The Operator Company Drilling
Representative must know the relative positions of tool joints in relation to the annular and ram-type
preventers at all times.
The Recommended Procedure for Shutting-in and Hanging-Off:

a. Sound Alarm.
b. Pick up kelly and position the tool joint clear of the sealing element (and with lower kelly cock above
the rig floor) and stop the pumps.
c. Close upper annular preventer. Regulate closing pressure so pipe moves freely.
d. Open the upper kill line valves and monitor the SICP while hanging off.
e. Space drill pipe to insure no tool joint will interfere with closing pipe rams. This might be done by
pulling the tool joint up into the closed annular to positively locate the tool joint relative to the rams.
f. Close pipe rams with normal operating pressure (approximately 1500 psi).
g. Close ram locking device if not automatic.
h. Lower drill pipe slowly until it is supported on closed pipe rams. The lower kelly cock should be
accessible with heaving conditions.
i. Bleed well pressure from between annular and ram preventers via kill line. Observe well to verify rams
are holding. Open annular preventer.
j. Adjust the compensator to mid-stroke and support the string weight above the hang off rams plus a
nominal overpull (15 - 20 thousand lbs.)
k. Close the upper kill line valve, open the choke outlet just below the hang-off rams, read and record
the SICP.
l. Bump the float, read and record the SIDP pressure, bleed off any trapped pressure on the annulus
and continue with the kill procedure as you would for a surface stack.
NOTE: The Driller must have record of proper tool joint spacing and be aware of tidal changes. In order to
keep tool joint at a working height above the rig floor and clear of the annular sealing element after shut-in,
a pup joint may be required in the drillstring between rotary and stack while drilling ahead. A “kick control
joint” is not recommended because of the time required to break-out the kelly and attach the joint. There is
a method which can be used to positively locate a tool joint relative to the rams: carefully pull the tool joint
up into the closed annular element
The recommended procedure for shutting-in and reciprocating is similar to the procedure for hanging
off except for the following:
1. After closing in the well, reduce the closing pressure on the annular to a point where the pipe moves
freely, but does not allow the annular to leak.
2. Ensure that no tool joints are working through the annular.
3. Have the kelly positioned so that the lower kelly cock does not pass below the rotary table.
4. Use the choke outlet as close to the annular as possible to minimize the size of the trapped bubble in
the stack.
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Shut-In Procedure While Tripping

The recommended shut-in procedure for Tripping is as follows:
1. Sound Alarm.
2. Install the fully opened safety valve in the drillstring. Close the safety valve.
3. Close upper annular preventer. Regulate closing pressure so that the pipe moves freely.
4. Open the upper kill line outlet to monitor the SICP.
5. Read and record the SICP. Strip to bottom as for a surface stack.
Considerations while Circulating

Water in Choke Line vs. Mud in Choke Line
Either gelled fresh water or drilling mud may be kept in the choke and kill lines.
Although mud is the preferred fluid, using water is not a problem as long as it is displaced with the mud in
use prior to circulating out a kick. Listed below are the advantages and disadvantages of using each type
of fluid and the recommended procedure for dealing with them.
Water in Choke and Kill Lines:

The use of gelled fresh water in the choke and kill lines has an advantage. It eliminates barite settling while
the fluid is static and possibly plugging off the lines. However, there are several disadvantages to having
water in the lines, such as:
1) The SICP read after taking a kick will be in error due to the difference in hydrostatic pressure
between the mud in the hole and the water. This will require adjusting the SICP value back to the true
value by using Equation 8.2:
Equation 8.2 Adjusting SICP for Water in the Choke Line
True SICP,psi = SICP Read, psi - (MW, ppg - SW Weight, ppg)(0.052)*(RKB to ML, ft.)
2) If the water is not circulated out of the lines prior to beginning circulation of a kick, then when bringing
pumps up to speed and keeping casing pressure constant, the hydrostatic pressure in the choke line
will be increasing as the mud enters the line. This, in turn, will require that the surface pressure be
decreased to compensate for the increase in hydrostatic pressure in the choke line, to hold
bottomhole pressure constant. Clearly, this is not a preferred method.
3) In deep water, water in the choke and kill lines greatly increases the risk of gas hydrates forming.
If water is to be kept in the choke and kill lines, then prior to beginning a kill procedure the water must be
displaced. Listed below is the recommended procedure:
a) If the drillstring is not already hung-off, ensure that it is spaced out properly to close one set of pipe
rams which isolates one set of choke and kill outlets.
b) Close the rams and open the isolated choke and kill outlets.
c) Circulate the "old" mud weight (NOT KILL WEIGHT) fluid down the kill line and out the choke line
until the lines are completely displaced.
d) Close the kill outlet, open the rams and check the new SICP, then continue with the kill procedure.
If there are not sufficient outlets to perform the above procedure, the alternatives are:
1) Monitor kill line pressures until the choke line is displaced with mud; or
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2) Close the pipe rams below the choke and kill outlets and circulate the "old mud" above the closed
pipe rams and displace the choke line; or
3) Use the slowest pump rate possible and hold the drillpipe pressure constant until the choke line is
displaced.
Compensating for Choke Line Friction

As discussed previously in this section, adjustments must be made for choke line friction or there is a risk
of breaking down the formation at the shoe or at a deeper weak point. Practically speaking, you should
compensate for choke line friction if it is greater than 50 psi. Listed below is an example of the steps to be
taken to compensate for choke line friction.
As discussed previously in this section, it is recommended that a kick not be circulated out at a rate greater
than what can be handled when the kick reaches the choke line. For this example, assume that the well
can be killed at 50 spm. The initial SICP is 600 psi and the initial SIDPP is 500 psi.
1. Hold casing pressure at 600 psi while bringing the pump rate up to 20 spm. The drillpipe pressure
should increase to 850 psi.
2. Reduce the casing pressure to 550 psi to compensate for the addition of 50 psi of choke line friction
by opening the choke slightly. The drillpipe pressure should then drop by 50 psi to 800 psi.
3. Hold the casing pressure at 550 psi while bringing the pump rate up to 30 spm. The drillpipe pressure
should increase to 1,050 psi.
4. Reduce casing pressure to 500 psi to compensate for the addition of 50 psi of choke line friction by
opening the choke slightly. Drillpipe pressure should drop by 50 psi to 1,000 psi.
5. Hold casing pressure at 500 psi while bringing the pump rate up to 50 spm. Drillpipe pressure should
increase to 1,850 psi.
6. Reduce the casing pressure to 350 psi to compensate for the addition of 150 psi of choke line friction
by opening the choke slightly. Drillpipe pressure should drop to 1,700 psi.
7. At this point the pumps are up to speed. The drillpipe pressure can be monitored the same as for a
surface BOP application.
By "backing out" the choke line friction, drillpipe pressure is now 1,700 psi, which is the same as the initial
SIDPP + the slow pump rate circulating pressure through the riser (500 + 1200 = 1700). Thus, when
calculating the initial and final circulating pressures for the Wait and Weight Engineer's Method drillpipe
pressure schedule, use the circulating pressure through the riser, and not the circulating pressure through
the choke line.
Choke line friction must also be accounted for whenever the pumps are slowed down or stopped
completely during a kill operation.
Using the previous (compensation for choke line friction example) shown in Figure 8.1.13, the following
procedure should be used to stop the pumps:
Assume a circulation rate of 50 spm with kill weight mud around the bit, with casing pressure 700 psi and
drillpipe pressure 1,300 psi (final circulating pressure).
1. Increase the casing pressure to 850 psi by adjusting the choke. The drillpipe pressure should
increase to 1,450 psi.
2. Reduce pump speed from 50 spm to 30 spm while holding casing pressure constant at 850 psi.
Drillpipe pressure should decrease to 540 psi.

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3. Increase casing pressure to 900 psi by adjusting the choke. The drillpipe pressure should increase to
590 psi.
4. Reduce the pump rate to 20 spm while holding the casing pressure constant at 900 psi. Drillpipe
pressure should decrease to 325 psi.
5. Increase casing pressure to 950 psi by adjusting the choke. The drillpipe pressure should increase to
375 psi.
6. Stop the pumps while holding the casing pressure constant at 950 psi. The drillpipe pressure should
be 0 psi after the pump is stopped since kill weight mud is at the bit.
When kill weight mud is circulated back to the surface, choke line friction will increase due to higher density
fluid being circulated through the choke. In some situations, the increase in choke line friction can be
significant and may become critical, e.g. deep water with a long choke line, a large increase in kill mud
density, or the kill weight mud density is close to the shoe test. In these situations, it may become
necessary to open the choke, or perhaps open a second choke, in order to reduce the drillpipe pressure to
its proper value. If the drillpipe pressure is still too high, the only alternative would be to slow down the
pump. The amount of choke line friction increase can be predicted using Equation 8.1, by subtracting off
the value of choke line friction for the "old" mud weight.
Monitoring Kill Line Pressures

On some rigs, choke and kill lines can be monitored independently at surface, and if suitable outlets are
available on the BOP stack, then the casing pressure can be monitored through the kill line. Since there is
no circulation through the kill line, there is no friction in the line to contend with. Thus, if kill line pressure is
held constant while bringing the pumps up to speed or slowing them down, the Bottom Hole Pressure
(BHP) will be constant. Since the kill line is static, it does not matter what type of fluid is in the line (i.e. sea
water or mud).
For these reasons, it is recommended always having a kill line pressure gauge available.
The advantages to this method are:
1) The pump does not have to be brought up to speed in stages, which eliminates the possibility of error
while compensating for choke line friction; and
2) If the choke and kill lines contain water instead of mud, this method would eliminate the need for
displacing the choke line with mud prior to circulating out the kick.
Note: If the kill line is being used to monitor casing pressure, the kill line valves on the BOP stack should
be closed before the gas reaches the BOP stack. This will prevent the possibility of gas migrating into the
kill line.
One of the most critical points in a subsea well killing procedure is when gas enters the choke line. (See
sub-section 8.1.6). At this point, the hydrostatic pressure in the choke line begins to drop due to a low
density fluid (i.e., gas) displacing a higher density fluid (i.e, drilling mud). At this time, the choke will have to
be closed-in to increase the surface pressure and maintain a constant bottomhole pressure. A similar
situation occurs when mud begins to enter the choke line and displaces gas, except that this time
hydrostatic pressure in the choke line begins to increase and the choke will have to be opened to reduce
surface pressure to maintain a constant bottomhole pressure.
Obviously, the more reaction time available to make the choke adjustments, the easier it is to make these
adjustments. Since the capacity (bbl/ft.) of the choke line is much smaller than the annulus capacity of the
well, the rate of change in hydrostatic pressure when the gas enters the choke line is dependent on the
pump rate used to circulate the kick out of the hole. Thus, the slower the pumps are run, the more reaction
time is available.

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The procedure once used was to slow the pumps down after pumping 65% of the annulus volume.
However, this resulted in several complications as follows:
1. After 65% of the annulus volume has been pumped, a gas bubble is rapidly expanding and the mud
ahead of the bubble is flowing at a rate faster than that being pumped. Therefore, when the pumps
are slowed down and the proper amount of choke line friction is put back into the system, the amount
of choke line friction is incorrect due to the higher flow rate through the choke line. Thus, after slowing
the pumps down, there will be more choke line friction in the system than necessary, which could
result in formation breakdown and lost circulation.
2. Adjusting the choke line friction and slowing down the pumps causes the bubble pressure to change
significantly. Because gas is very sensitive to changes in pressure, it acts like a shock absorber
downhole and may require a long period of time to stabilize. Until the bubble pressure and volume
stabilize, changes in drillpipe pressure will make it difficult to keep bottomhole pressure constant. This
in turn may result in either lowering bottomhole pressure to a point where a second kick is taken, or
raising bottomhole pressure to a point that formation breakdown could occur.
Thus, the recommended procedure is to choose a circulating rate that allows controlling the kick when it
arrives at the choke line and maintain that rate for the entire circulation.
A second complication of gas in the choke line is that PcMax at the surface will be higher than that
calculated using the charts. The charts are designed to calculate PcMax at the wellhead, which is at the
mudline for a subsea stack. Thus, to calculate the PcMax at the surface, which is the pressure imposed on
the choke manifold and surface equipment, PcMax must be corrected using Equation 8.3:
Equation 8.3 PcMax at the Surface
PcMaxCorr = PcMaxCalculated + [(Old Mud Wt,ppg)*(0.052) - SG Gas][RKB - ML,ft]
Example:
A kick is going to be circulated out PcMax is calculated to be 3,000 psi (using the charts), old mud weight
is 14.5 ppg, and RKB to Mud LIne is 1,000 feet. Assume a gas gradient of 0.1 psi/ft. The corrected PcMax
would be:
PcMaxCorr = 3000 psi + [(14.5)(0.052) - 0.1]*[1000 ft) = 3000 + 654 = 3654 psi
8.1.9 Emergency Disconnect

Disconnecting Introduction
Subsea stacks are designed to allow a floating drilling vessel to disconnect from the well while the well
remains shut-in. Weather, an out of control well, or other situations could require isconnecting. Listed
below are the recommended procedures for disconnecting in non-emergency and emergency situations.
Non - Emergency Disconnect:
1. Circulate bottoms up and pull into casing.
2. Figure space out to land hang-off tool in the wellhead.
3. Make up hang-off tool in the string and run it into the hole (making sure that the bit is still inside the
casing).
4. Land hang-off tool inside the wellhead with the compensator stroked open. Position compensator in
mid-stroke and adjust the compensator to support the pipe weight above the rams.
5. Close the appropriate pipe rams and locks.
6. Back off the right hand release sub on the hang off tool.

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7. Pick up drillpipe above the BOP stack. Check for flow and close the blind shear rams. Close the
wedge locks if ram is a Cameron ram.
8. Displace the riser with sea water and adjust riser tensioning. Dump the subsea accumulator bottles, if
applicable. Deballast part or all of the air buoyancy tanks on the riser, if applicable.
9. Pull the remainder of the drillpipe out of the riser. Disconnect the LMRP and pull the riser.
Emergency Disconnect
Situations that might require an emergency disconnect include: the loss of well control, a sudden change in
weather, or waiting too long to do a "non-emergency" disconnect. In these situations, the following
procedure is recommended:
1. Pick up and space out to hang off on the designated hang-off ram.
2. Close hang-off ram with 1,500 psi closing pressure. Close wedge locks if ram is a Cameron ram.
3. Close lower pipe rams for a backup.
4. Adjust compensator to support string weight above rams, plus overpull of 10,000 lbs (time
permitting).
5. Shear drillpipe with full operating pressure (3,000 psi). Some BOP manufacturers have had trouble
with new drillpipe. On some new drillpipe, the tapered section next to the tool joint has been
lengthened. If some of this type of drillpipe is in the string, the BOPE manufacturer should be
contacted to determine shearing capability.
6. Check the riser tensioning then disconnect the LMRP and pull the riser if possible. If unable to pull
the riser, move the vessel off location while dragging the riser. Stay clear of shallower water and away
from the BOP stack.
Note:
Studies conducted by Operator Companies and ram manufacturers indicate that complete shear of some
grades of drillpipe will not be obtained using 1,500 psi closing pressure. Five inch grade G drillpipe may
require up to 3,000 psi closing pressure for a complete shear. Also, note that high strength drillpipe that
has been sheared can explode, long after shearing. A sheared stub should be handled carefully and
removed from the rig as soon as possible.
Re-entering the Well after Disconnecting

While disconnected from the well, gas may "seep" into the wellbore and then migrate to the BOP stack.
Also, the wellbore is cooled by circulating, but circulation has stopped. The wellbore temperature therefore
begins to increase, which may cause the wellbore pressure to increase. When reentering the well, care
must be taken to remove the trapped gas from under the BOP stack. The following procedure is
recommended:
1. After reconnecting the LMRP, open the lower pipe rams (if closed), upper kill line valves and the
lower choke line valves. Check pressure on the choke line for indication of trapped gas. Attempt to
bleed off any pressure.
2. Circulate the proper mud weight down the kill line while taking returns through the choke. Displace
the riser with mud using the drillpipe.
3. After clearing the well of any trapped gas, open the blind/shear rams.
4. Screw into the hang-off tool. If the pipe was sheared, dress-off the top of the drillpipe stub and latch
with an overshot.

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5. Open the middle pipe rams and monitor the well for flow.
6. Pull the hang-off tool (or overshot, if pipe was sheared) out of the hole.
7. Trip to bottom, circulate and condition mud as required.
Note: If S-135 drillpipe has been sheared, "shattered" pieces of the drillpipe will be on top of the shear
rams. Pick up these pieces with a magnet prior to opening the shear rams

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Introduction
BOP Equipment and Control Systems Overview
Much of the BOP equipment found on floating drilling rigs duplicates that which is used for surface
locations. With only slight modifications, surface-style‖ annular preventers, pipe rams, and hydraulic
valves are incorporated onto a four posted subsea BOP guide frame. Like surface operations, pressurized
hydraulic fluid operates this equipment. Both a choke and kill line are available for well control, with bottom
hole pressure being regulated via an adjustable choke and manifold assembly. Differences include a pilot
operated control system, the number and types of preventers (complete with - remote locking
mechanisms), the need for hydraulic connectors and motion compensation, and even the physical location
of the stack. The purpose of positioning the BOPs on the seafloor is to allow for vessel motion and to
facilitate a swift departure procedure after disconnect of the hydraulic connector without pulling the well
over. Also, with the stack on bottom, the marine riser doesn‖ t have to contend with high wellbore
pressures. Therefore, a significant reduction in the riser pipe burst strength is realized.
In this section, the subsea BOP equipment and control systems will be divided into the following five major
components (as shown in Figure 8.1.1):
1. BOP Stack
2. LMRP (Lower Marine Riser Package)
3. Marine Riser and Diverter Assembly
4. Choke Manifold
5. Control System
Note: The remaining BOP equipment, which is identical for both environments, is reviewed in Sections 7
& 8.
BOP Stack
As depicted in Figure 8.1.2, the BOP Stack consists of a hydraulic wellhead connector, ram type
preventers, choke and kill line valves, and pod receiving blocks/lower female receptacles. An annular
preventer may or may not be included on the BOP Proper. Notice the absence of drilling spools between
preventers, a design intended to minimize the overall height, thereby increasing the assembly‖s stiffness
and reducing the bending moment transferred to the wellhead.
Typically the subsea stack has consisted of 4 rams and possibly an annular (alternately the annular is on
the LMRP). However, today‖s new generation rigs and the increasingly difficult drilling conditions have
changed the thinking on a ―typical‖ BOP configuration. Many new generation rigs are now equipped with 6
ram stacks with either single or double annulars both on the stack and on the LMRP. A detailed well
program should help the planning engineers to determine the BOP configuration required for specific
operations. Additionally, extensive thought must be given to the configuration of rams within the ram
bodies (i.e., where to put the shears, VBRs. Etc and why).
PVD Training | 8.2 Subsea Equipment 37

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Fig 8.2.1

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Fig 8.2.2 – BOP Stack
8.2.1 Diverter
When a diverter system is to be used in connection with a subsea installation, there must be a short string
of casing or drive pipe installed below the mud line. A marine riser is attached to this casing or drive pipe.
The diverter system is then connected to the top of the marine riser above the telescopic joint (slip joint)
and secured to the rig substructure.
The diverter system vent lines are usually large diameter (12‖ or larger) and are designed to divert wellbore
fluids away from the rig floor with minimum back pressure on the wellbore. They are usually directed to the
opposite extremities of the vessel. The live vent line would be determined by wind direction to carry
wellbore fluids away from the rig. Any valves in the diverter vent lines must be full-opening and either
automatic or selectively controlled or sequenced, so that flow from the well bore cannot be closed in.
The diverter and valves should be actuated when installed and at appropriate times during operations to
determine the system will function properly.

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Fig 8.2.3 - Typical Diverter System Installed on a Floating Rig
8.2.2 Slip Joint (Telescopic Joint)

The slip joint (telescopic joint) 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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The outer barrel (lower member), connected to the riser pipe and remaining fixed with respect to the
seabed, is attached to the riser tensioning system and also provides connections for the choke and kill
lines. A pneumatically or hydraulically actuated resilient packing element contained in the upper portion of
the outer barrel provides a seal around the outside diameter of the inner barrel.
The inner barrel (upper member), which reciprocates within the outer barrel, is connected to and moves
with the drilling vessel and has an internal diameter compatible with other components of the marine riser
system. The top portion of the inner barrel has either a drilling fluid return line or diverter system attached,
and is connected to the underneath side of the rig substructure.
The telescopic joint (slip joint), either in the extended or contracted position, should be capable of
supporting anticipated dynamic loads while running or pulling the BOP stack and should have sufficient
strength to safely resist stresses that might reasonably be anticipated during operations. Stroke length of
the inner barrel should provide a margin of safety over and above the maximum established operating
limits of heave for the vessel due to wave and tidal action.
Selection of a telescopic joint (slip joint) should include consideration of such factors as size and stroke
length, mechanical strength, packing element life, ease of packing replacement with the telescopic joint
(slip joint) in service, and efficiency in attachment of accessories (i.e. tensioner cables, choke and kill lines,
diverter system, etc.).
Flex – Joint
A flexible-ball joint is used in the marine riser system to minimise bending moments, stress concentrations
and problems of misalignment engagement. The angular freedom of a flexible joint is normally 10 degrees
from vertical. A flexible joint is always installed at the bottom of the riser either immediately above the
remotely operated connector normally used for connecting/disconnecting the riser from the blowout
preventer stack (BOP stack), or above the annular preventer when the annular preventer is placed above
the remotely operated connector.
For those vessels having a diverter system, a second flexible joint is sometimes installed between the
telescopic joint (slip joint) and the diverter to obtain required flexibility, or some type of gimbal arrangement
may also be used. For deep water operations or unusually severe sea conditions, another flexible joint may
be installed immediately below the slip joint.
Mechanical strength requirements for flexible joints are similar to those for the remotely operated
connector. They should be capable of safely withstanding loads that might reasonably be encountered
during operations, both normal and emergency. In addition, the angular freedom of up to approximately 10
degrees should be accomplished with minimum resistance while the joint is under full anticipated load.
Hydraulic ―pressure balancing‖ is recommended for ball-type flexible joints to counteract unbalanced forces
of tensile load, drilling fluid density and sea water density. This pressure balancing also provides
lubrication for flexible joints.
Technical investigations and experience have shown the importance of close monitoring of the flexible joint
angle to keep it at a minimum. One method of accomplishing this is by the use of an angle-azimuth (slope)
indicator. The flexible joint angle, vessel offset and applied (riser) tension are indications of stress levels in
the riser section. For continuous drilling operations, the flexible joint should be maintained as straight as
possible, normally at an angle of less than 3 degrees: greater angles cause undue wear or damage to the
drill string, riser, BOPs, wellhead or casing.
For riser survival (to prevent overstressing) the maximum angle will vary from about 5 degrees to
something less than 10 degrees, depending upon parameters such as water depth, vessel offset, applied
tension and environmental conditions. Drill pipe survival must also be considered if the pipe is in use
during those critical times of riser survival conditions.

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The following limits are recommended for the lower ball joint angle:
Ball Joint Angle Range Comments
00 – 10 The ―goal‖ during operations is to maintain the ball joint angle within
these limits if at all possible.
10 – 30 Maximum limit for normal operations. Preferably should be in this

range only on a temporary basis.
At 30 and increasing Start operations for drill pipe hang-off.
At 50 and increasing Drill pipe hung-off. Preparations started for riser disconnect.
Utilizing the lower ball joint angle ranges indicated above, the following operational limits are recommended:
8.2.4 Ram Blowout Preventers

General
Blowout Preventers (BOPs) and associated equipment (refer to section 7.0) provide the means of
controlling a well after primary control has been lost. The basic requirements for effective BOP equipment
include:
 A properly designed and cemented casing string to contain pressures encountered while drilling.
 A properly designed and installed wellhead assembly to support and seal between the casing string
and BOP stack.
 A BOP stack capable of closing off the annulus against an open hole or any tools run into the hole.
 A closing system to operate the BOPs with adequate redundancy and closing times.
 A choke system to maintain backpressure on the well being circulated.
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 A flexible kill system to pump into the hole through the annulus or drillstring.
 Instrumentation to control the well killing operation.
Subsea BOP stacks are similar in component arrangement to surface installations, with the following
differences:
a. Choke and kill lines are normally connected to ram preventer body outlets.
b. Spools may be used to space preventers for shearing tubulars, hanging off drill pipe, or stripping
operations.
c. Choke and kill lines are manifolded for dual purpose usage.
d. Blind/shear rams are normally used in place of blind rams.
e. Ram preventers are usually equipped with an integral or remotely operated locking system
f. More accumulator volume is required and some of the accumulator bottles may be mounted on the
BOP stack.
Stack Component Codes

The recommended component codes adopted for designation of subsea BOP stack arrangements use the
same nomenclature as surface installations (refer to section (BOP stack arrangements - Surface
installations.) with the addition of remotely operated connectors:
CH = remotely operated connector used to attach wellhead or preventers to each other. Connector
should have a minimum working pressure rating equal to the BOP stack working pressure rating.
CL = low pressure remotely operated connector used to attach the marine riser/ lower marine riser
package to the BOP stack.
 Type TL - This latest version of Cameron Ram type Blowout Preventer offers a more compact ram
preventer, for use in deep water and severe environments. Currently, it is only available in 18-3/4"
15M for subsea applications (see Figure 8.2.4). It too has the hydraulic bolt tensioning system, but
features a metal-tometal bonnet gasket seal, termed the ―TX. (Due to the involved nature of
changing out this style of door gasket). Horizontal ram block removal reduces stack height, and
simplifies access and handling. The preventer is available with either wedgelock or ST lock.
The ST locking mechanism utilizes an overhauling nut and brake system and is similar to the wedgelock
concept. The ―ST is mounted perpendicular to the ram door, with the tailrod cut at an angle that matches
the locking wedge.

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Figure 8.2.4
In the 1980‘s, Cameron experienced seal difficulties with the 2 7/8‖ x 5‖ and the 3 ½‖ x 5‖ VBR‘s for type U
18 ¾‖ preventers. This lead to the development of a Flex Packer, which consists of multiple metal inserts
bonded into the elastomer. As the rams are closed and energisezed, the appropriate set of inserts is forced
against the pipe. (The top plate of the packer fits the largest pipe diameter). This design incorporated metal
pins through the plates which provides a system for positive retention, even if the bonding fails as shown in
Figure 8.2.5
Ram and Outlet Placement

The specific ram block size placement is often dictated by the BOP configuration and outlet location. A
suitable hang-off ram position has to be identified, since having the ability to shear pipe and disconnect the
LMRP from the BOP Proper is necessary. (Hanging off during a well control situation will simplify
emergency disconnects, prevent rig heave from wearing away at the closing element and minimize gas
accumulation under a closed preventer).

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Fig 8.2.5
Typically, there is not enough distance between the #3 (upper pipe) ram and #4 (blind/ shear) ram to fit a
tool joint. Since the capability to shear pipe is lost, this may not be a prudent hangoff location. Placing the
hang-off ram in the #2 position (middle pipe ram) allows for shearing operations and the #1 (bottom pipe)
ram to act as a back-up.
Choke and kill valve outlet placement becomes a function of the procedures planned and an assessment
of what contingencies are to be given priority. Consideration is given to where valve failures can be
tolerated and how placement affects a corresponding back-up plan, what the likelihood is of a disconnect
during a well control procedure, and whether it is possible to re-establish onto a well after returning from a
disconnect. Most of these scenarios can be handled by having one outlet below and one outlet above the
hang-off ram. If a third outlet is present, it should be below the hang-off ram as well. (If fortunate to have a
forth outlet, position it above the hang-off ram).
A consequence of certain outlet placements is a lack of consistent BOP pressure testing on every outlet.
For example, a weekly pressure test of blind shear rams requires backing off a test plug, which can be
undesirable. (If test pressure leaks by the - backed off‖tool, it can go to the formation, since the subsea
wellhead has no casing valve that can be opened. Also, any damage to the test tool while running, setting,
or retrieval may dictate a fishing job). If the blind/shear rams are only pressure tested before drilling out
casing strings, any valves on outlets directly under these rams will experience the same infrequent
intervals (and only tested to casing pressure). Ensure this is thoroughly addressed in the Application to
Drill.
8.2.5 Testing and Inspection

(Refer to Section 7.9)
8.2.6 BOP Reliability

Reliability studies for subsea BOP systems have compiled data from 1981 to the present. These reliability
studies focused on failures during normal operations and testing. Failures during well control situations are
not addressed, as these occurrences are analyzed on an individual basis. (The majority of failures under
well control conditions are directly attributable to human error).
Analysis of the reliability studies clearly indicates that the majority of failures occurring during normal
operations or testing can be attributed to the control system. Additionally, the studies reveal that the
average downtime per failure (all types) was 1.2 days. It should be noted that since the majority of control
system failures could be repaired without pulling the stack the associated average downtime is fairly low.
However, repairs, which required the recovery of the BOPs to the surface, incurred significantly longer
downtimes.
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Besides the safety / environmental implications of BOP equipment failure, there can be huge costs
associated with such failures. Operators must actively participate with the Contractor on all aspects of BOP
inspections, testing, maintenance, and repair. Probably the single most important aspect that the Operator
can influence (positively as well as negatively) is in the planned maintenance programs (PMP). Operators
and their rig site representatives must play a pro-active role in these programs not only during the actual
operations but also during the well / project planning stages. All too often the well work program takes no
account of the requirements for planned maintenance and critical items are deferred in preference to the
―job at hand‖.
It is recommended that Operators review planned maintenance programs to ensure all critical items are
included and that the programs are followed. An excellent way to ensure the programs are followed is to
compare PMPs to purchase orders. For example, if the PMP calls for the replacement of particular seals
on a six monthly basis there should be a record of purchase orders for those items every six months. This
can prove to be a valuable way to ensure that the programs are being followed.
Introduction
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.
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 sea-bed. 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.
8.3.1 Indirect Hydraulic System

This reduces the size of the control umbilical by splitting the hydraulic control functions into two:
• Transmitting hydraulic power to the BOP down a large diameter line.
• Transmitting hydraulic signals down smaller lines to pilot valves which in turn direct the operating
power fluid to the appropriate BOP function.
The pilot valves are located in control pods on the BOP stack. In order to provide a complete back-up of
the subsea equipment there are two control pods - usually referred to as the - blue and the yellow pod‘s.
PVD Training | 8.3 Subsea BOP Control Systems 46

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No attempt is made to recover the hydraulic power fluid once it has been used to operate a function since
this would increase the number of lines required in the umbilical. Instead the fluid is vented subsea from
the control pod.
8.3.2 Multiplex Electro-Hydraulic System

As greater water depths were encountered the problems of umbilical handling and reaction times became
significant. In order to overcome them the hydraulic lines controlling the pilot valves were replaced by
separate electrical cables which operate solenoid valves. These valves then send a hydraulic signal to the
relevant pilot valve which in turn is actuated and directs power fluid to its associated BOP function.
The time division multiplexing system provides simultaneous execution of commands and results in a
relatively compact electrical umbilical. This typically consists of four power conductors, five conductors for
signal transmission and additional back-up and instrumentation lines. With the armored sheath the
umbilical has a resulting diameter of some 1.5 inches with a weight of about 3 Ib/ft in air.
An electro-hydraulic system should have a central control point which interfaces various signals
electronically and sends one set of signals electrically to the subsea solenoid valves, which direct the flow
of power fluid to operate the preventer function. In this system, a flow meter should be used to provide an
indication of the proper flow of hydraulic fluid and a proper operation of the blowout preventer.
Overview
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.
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 in Figure 8.3.1.
Figure 8.3.2 is a block diagram of the hydraulic flow system for a stack function. 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

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to power the various BOP functions.
Figure 8.3.1

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Fig 8.3.2 - Subsea Control System (Block Diagram)
The power fluid is routed to the subsea control pod selected by the 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
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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 summary of this operating sequence is shown in Fig 8.3.3 following. 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
diagram in Figs 8.3.4 (A) (B) and (C). 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.
Close Function
In Fig 8.3.4 (A) one of the BOP rams is being closed using the drillers master control panel. Pushing the
―close‖ button on this panel actuates 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.
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.
At the same time power fluid at its regulated pressure is allowed past the bottom of the spindle and into the
valve block in the male and female sections of the control pod. 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 th RAMS OPEN SPM valve vents the hydraulic fluid from the ―open‖ side of the BOP
ram.

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Fig 8.3.3 – General Operating Sequence

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Fig 8.3.4 (A): Operating Sequence – Close Function

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Fig 8.3.4 (B) Operating Sequence – Block

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Fig 8.3.4 (C) Operating Sequence – Open Function
Block Function
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 centering and venting all the valves when

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the accumulator unit is first being pressurized unintentional and inadvertent operation of the various other
positions and functions can be eliminated.
Referring to Figure 8.3.4 (B), when the ―block‖ button is pressed, both the solenoid valves are actuated in
such a way as to apply pressure to both sides of the air operator. This causes the pilot control valve to be
centered which then allows both the pilot ―open‖ and ―close‖ lines to be vented. The springs in both the
SPM valves then push the spindles down so that they seal against the bottom seats and block the flow of
any power fluid through the valves. At the same time this also vents both sides of the BOP ram operating
cylinders.
Open Function
This sequence is the parallel opposite of the CLOSE function. As shown in Figure 8.3.4 (C), when the
―open‖ button is pressed, the solenoid valves on the hydraulic control manifold are actuated and allow air
pressure to move the operator on the pilot control valve to the ―open‖ position. The solenoid valve on the
left in the diagram vents the ―close‖ side of the operating piston.
The pilot fluid can then flow down to the subsea control pod where it lifts the spindle in the RAMS OPEN
SPM valve thus blocking the vent and allowing power fluid to flow through the valve. From the pod the
power fluid travels through the ―open‖ shuttle valve to the ―open‖ sides of the BOP ram operating cylinders.
Simultaneous reciprocal action in the RAMS CLOSE SPM valve allows the fluid from the ―close‖ side of the
operating cylinders to be vented.
Central Control Point

A subsea closing unit control system should have a central control point. For a hydraulic system, this
should be a manifold capable of controlling all the hydraulic functions on the BOP stack. The hydraulic
control system should consist of a power section to send hydraulic fluid to subsea equipment and a pilot
section to transmit signals through pilot lines. When a manipulator valve on the closing unit control
manifold is operated, a pilot signal is sent subsea to a SPM control valve, which when opened directs
power fluid to the blowout preventer.
Pressure regulators on the surface control manifold send pilot signals to the subsea regulators to control
the pressure of the power fluid at the preventers. The surface control system should also include a flow
meter which, by a measure of the volume of fluid going to a particular function, will indicate if that function
is operating properly. The hydraulic manifold should be located in a safe but readily accessible area.
Control Fluid Circuit

In addition to the control fluid circuits used to operate stack functions such as ram or annular preventers,
the control system must also perform other functions such as control of subsea regulators, provide
readback pressures, latch/unlatch the subsea control pods and charge the subsea accumulators.
Figure 8.3.5 shows a typical control fluid circuit. The hydraulic fluid is mixed, pressurized and stored in
accumulator bottles by the hydraulic power unit. A pilot operated accumulator isolator valve is provided to
allow the pumps to charge the subsea accumulators. When control fluid is used, it passes through a
totalizing flow meter in the hydraulic control manifold and then through the pod selector valve which directs
it to the chosen subsea pod.
After passing through the jumper hose and the subsea hose bundle to the control pod, the fluid supplies
the hydraulically operated subsea regulators. These reduce the fluids pressure to that required to operate
the particular BOP function desired. The fluid is also routed to a SPM valve in the pod which is controlled
by the accumulator isolator valve on the hydraulic control manifold. In the open position this SPM valve

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allows the control fluid to charge the stack mounted accumulator bottles. Shuttle valves allow the bottles to
be charged from either pod.
Fig 8.3.5 Subsea Control System – Hydraulic Schematic

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Pilot Fluid Circuit

The pilot valves in the subsea pods are controlled from the surface by means of control valves located in
the hydraulic control manifold. These control valves can be operated either manually from the control
manifold itself or remotely from an electrical panel via pneumatic solenoid valves.
Any BOP stack function such as a failsafe valve, which requires pressure only to open or close it is called a
2-position function. There is an operate position and a vent position. The latter position is used to release
pressure from the operating side of the pilot valve.
Figure 8.3.6 shows a typical 2- position function pilot circuit. The control valve, a ¼ ―, four-way manipulator
valve, can be controlled from a remote panel via the two solenoid valves which can place the valve either
in the open or vent positions. A pressure switch connected to the discharge line of the control valve is
activated when a pilot signal is present and lights up the appropriate lamp on the control panel.
In the open position the pilot signal is transmitted to the subsea control pods where it operates its
associated pilot valve which then allows the power fluid to flow through the selected pod to the BOP
function. A BOP stack function requiring pressure to both open and close is called a 3-position function.
The hydraulic pilot fluid circuit for a 3- position function is shown in Figure 8.3.7. It requires the use of three
solenoid valves, the block solenoid valve being used in conjunction with two shuttle valves in order to
centre the control valve.
A pressure switch is connected to each discharge line of the control valve and will transmit a signal to the
appropriate control panel lamp whenever a pilot signal is present. The operation of the 3-position pilot
circuit is as described above. The main components of the control system and some of the other operating
sequences are now described in more detail.

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Fig 8.3.6 Pilot Fluid Circuit (Two-Position Function)

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Fig 8.3.7 - Pilot Fluid Circuit (Three-Position Function)
Hydraulic Power Unit

This unit contains the mixing system, high pressure pumps and accumulator banks as shown in Figure
8.3.8.

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Mixing System
The hydraulic power unit supplies hydraulic fluid to the entire control system. It requires fresh water,
soluble oil, glycol (for freeze protection), compressed air and electrical power for operation. Two small
reservoirs contain the soluble oil and glycol which are automatically blended with fresh water to make up
the hydraulic fluid which is then stored in a large reservoir known as the mixed fluid tank. Since the control
system is an open one in that the used hydraulic power fluid is vented into the sea, the type of soluble oil
used must be completely biodegradable. Additives to prevent bacteria growth and to inhibit corrosion are
also frequently included in the mix water.
The soluble oil reservoir has a capacity of at least 110 gal whilst the mix fluid tank should be capable of
holding sufficient fluid to charge the system accumulators from their pre-charge condition to their maximum
operating pressure. All the tanks are fitted with sight glasses and a low-level alarm system which activates
a warning light and horn on the control panels.
The proper mixing fluid ratio is maintained by air operated hydraulic pumps, a water pressure regulator, a
double acting motor valve and a water flow rate indicator. A reservoir float switch is used to control
operation of the mixing system in order to maintain the correct level of fluid and to ensure a continued
supply for the control system.
Water/additive concentrations can be adjusted by setting the mixing pump to run at the appropriate rate. A
minimum rig water supply pressure of 25 psi is typically required for the correct operation of the mixing
system and to provide a fluid supply at least equal to the rate at which mix fluid is drawn from the tank by
the high pressure pumps.
High Pressure Pumps

These are the pumps which take the fluid from the mix tank and transfer it to the accumulator bottles,
under pressure, where it is stored ready for use by the system. Typically, three air powered and two
electrically powered pumps are used. During normal operation the electric pumps are used to recharge the
system. However if these cannot keep up with demand, or fail in some way, then the air powered pumps
can assist or take over completely.
The electric pump assemblies consist of a heavy duty triplex reciprocating plunger pump with a chain and
sprocket drive and powered by an explosion-proof motor. Pump capacity should be such that they can
charge the system accumulators from their precharge condition to their maximum operating pressure in
less than 15 minutes. The pumps should be installed so that when the accumulator pressure drops to 90
per cent of the preset level, a pressure switch is triggered and the pumps are automatically turned on.
Accumulator Requirements
Volumetric Capacity
As a minimum requirement, closing units for subsea installations should be equipped with accumulator
bottles with sufficient volumetric capacity to provide the usable fluid volume (with the pumps inoperative) to
close and open the ram preventers and one annular preventer.
Usable fluid volume is defined as the volume of fluid recoverable from an accumulator between the
accumulator operating pressure and 200psi above the pre-charge pressure. The additional pre-charge
pressure required to offset the hydrostatic head of the seawater column and the effects of subsea
temperature should be considered when sizing subsea mounted accumulator bottles,
Response Time
The closing system should be capable of closing each ram preventer within 45 seconds. Closing time

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should not exceed 60 seconds for annular preventers

Requirements for Accumulator Valves
Multi-bottle accumulator banks should have valving for bank isolation. The isolation valves should have a
rated working pressure at least equivalent to the designed working pressure of the system to which they
are attached. The valves must be in the open position except when the accumulators are isolated for
servicing, testing or transporting.
Accumulator Types
Both separator and float type accumulators may be used.
Fig 8.3.8 Accumulator Sizing
Calculation of Accumulator Size

The volume of the accumulator system as calculated by using ―Boyle‖s law‖:
P1 = P2V2
Where :
P1 = Maximum pressure of the accumulator when completely charged
P2 = Minimum pressure left in accumulator after use. (Recommended minimum is1200 psi)
V = Total volume of accumulator (fluid and nitrogen)

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V1 = Nitrogen gas volume in accumulator at maximum pressure P1.

V2 = Nitrogen gas volume in accumulator at minimum pressure P2.
V2 = V, plus usable fluid maximum to minimum pressure.
V2 – V1 = Total usable fluid with safety factor usually 50% included.
3000 psi system precharged to 1000 psi; V = 3V1
Subsea Accumulators
The nitrogen precharge pressure must be increased in the subsea accumulator bottles in order to account
for the hydrostatic pressure of the hydraulic fluid in the power fluid supply hose, when calculating the
amount of usable fluid volume. As an added safety factor the sea water gradient is used for this purpose,
i.e. .445 psi/ft.
If operating in 1500 ft of water, the hydrostatic pressure would be:
1500 ft x .445 psi/ft = 667.5 or 668 psi (rounded off).
Thus the nitrogen precharge would need to be increased by 668 psi.
i.e. 1000 psi + 668 psi = 1668 psi.
Therefore:
P1 = nitrogen precharge pressure of 1668 psi (1000 psi + 668 psi)
P2 = minimum operating pressure of 1868 psi (1200 psi + 668 psi)
P3 = maximum operating pressure of 3668 psi (3000 psi + 668 psi)
V1 = bladder internal volume at precharge pressure (11 gal - 1 gal)
V2 = bladder internal volume at minimum operating pressure, P2 (in gals)
V3 = bladder internal volume at maximum operating pressure, P3 (in gals)
Therefore:- 1668 psi x 10 gals = 1868 psi x V2 and 1668 psi x 10 gals = 3668 psi x V3
Giving: V2 = 1668 psi x 10 gals = 8.93 gals and V3 = 1668 psi x 10 gals = 4.55 gals
1868 psi 3668 psi
The usable volume of hydraulic fluid per subsea bottle in 1500 ft of water would be the difference between
these two volumes.
V2 – V3 = 8.93 gals - 4.55 gals = 4.38 gals.
Application of the above calculation now makes it possible to determine the total number of accumulator
bottles required both on the surface and subsea, given the following opening and closing volumes of
hydraulic fluid for a typical 18.75 inch subsea BOP stack.
Annular preventer 44 gals to close 44 gals to open
Ram preventer 17.1 gals to close 15.6 gals to open
Failsafe valves 0.6 gals to close 0.6 gals to open
Assuming that company policy is to have sufficient subsea accumulator capacity to close:
1 annular
1 ram preventer

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4 failsafe valves
Then the usable volume required will be 44 gal + 17.1 gal + (4 x 0.6 gal) = 63.5 gals and since each bottle
can deliver 4.38 gals then:
= 14.49 or 15 bottles will be required subsea.
If the BOP stack consists of:

2 annular preventers
4 ram preventers
8 failsafe valves
Then the total volume of hydraulic fluid required to open and close all of the BOP functions together will be:
CLOSE OPEN
2 x annular preventers 2 x 44 gal = 88 gal 2 x 44 gal = 88 gal
4 x ram preventers 4 x 17.1 gal = 68.4 gal 4 x 15.6 gal = 62.4 gal
8 x failsafe valves 8 x 0.6 gal = 4.8 gal 8 x 0.6 gal = 4.8 gal
TOTAL 161.2 gal 155.2 gal
Including a 1.5 safety factor will give a grand total of:

(161.2 gal + 155.2 gal) x 1.5 = 474.6 gals.
Since 63.5 gals are available subsea, the surface accumulators will have to supply (474.6 gal - 63.5 gal) =
411.1 gals. As calculated above, the usable fluid from each surface accumulator bottle is 5 gals therefore:
= 82.22 or 83 bottles will be required on surface.
Subsea Control Pods

There should be two completely redundant control pods, normally referred to as the blue and yellow pods,
on the BOP stack after drilling out from below the surface casing. Each control pod should contain all
necessary valves and regulators to operate the BOP stack functions. The control pods may either be
retrievable or non-retrievable. The hoses from each control pod should be connected to a shuttle valve that
is connected to the function to be operated. A shuttle valve is a slide valve with two inlets and one outlet
which prevents movement of the power fluid between the two redundant control pods.
Example:
Surface Pre-charge = 1000psi, Water Depth = 1000 feet, Sea Water gradient = 0.445psi/ft.
1000‘ x 0.445 = 445psi, 1000psi+445pi = 1445psi.

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Fig 8.3.9 - Rotary Shear Seal Type Valves

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Fig 8.3.10 - Pilot Circuit
Regulator Control
Since the power fluid arrives at the subsea control pod at 3000 psi and the BOP functions have a
maximum normal operating pressure of 1500 psi, regulators are needed in the pods - one is provided for
the annular preventers and one for the ram preventers. Figure 8.3.11 shows how the subsea regulator is
controlled from the surface. A 1/2" air operated pilot regulator in the control manifold transmits pilot
pressure to the subsea regulator in order to adjust its setting.
The air operator can be manipulated either manually using an air regulator on the control manifold or
remotely from another control panel. When operated from a remote panel a solenoid valve is used to
increase the air pressure by allowing rig air to flow into a 1 gallon receiver connected to the air pilot line.
The receiver acts as a surge protector for the pilot regulator. Decreasing the air pressure is achieved by
using a solenoid valve to vent the line to atmosphere.
Pressure Readback
In order to ensure that the subsea regulator has set the desired operating pressure the manifold
incorporates a readback system. The output of each subsea regulator is connected through a 1/8" hose in
the umbilical back to a pressure gauge in the control manifold. Pressure transducers transmit the readback
pressures to remote panels. A shuttle valve also in the manifold unit connects the lines from both
umbilicals and isolates the active and inactive pods.
All the electrical components are housed in separate explosion proof housings on the control manifold unit.
One housing contains the solenoid valves and another contains the transducers and pressure switches.
The pressure switches are typically set to be activated ‗on‘ when pressure in the pilot line to the ram or
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failsafe SPM reaches 1000 psi and to switch ‗off‘, when the pressure falls to below 700 psi.
Fig 8.3.11 - Subsea Regulator Control Circuit

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Control Panels
These panels permit the operation of the manifold unit from remote locations. Usually two remote panels
are used - a master one on the drill floor, and a mini-panel in a relatively safe location such as a rig office.
Other mini-panels can be integrated into the system if desired.
The drillers‖ master panel is normally explosion proofed or air-purged since it is located in a hazardous
area. It contains a set of graphically arranged push-button/indicating lights for operation and status
indication of each stack function. The regulator pressures are controlled by increase/decrease push-
buttons and there are gauges for monitoring pilot and readback values. A digital readout of the flow meter
located on the control manifold is also provided.
Many types of drillers panel also include controls for the operation of the rig diverter system which is
controlled in a similar way to a surface BOP system. The mini-panel is usually not required to be explosion
proof. It operates in the same way as the master panel but does not include the pressure gauges. Both
panels include lamp test facilities to check for burnt out lamps. They also contain alarms for low hydraulic
fluid level, low accumulator pressure, low rig air pressure and an alarm to indicate that the emergency
battery pack is in use.
The remote panels contain all the necessary electrical switches to operate the solenoid valves on the
hydraulic control manifold which in turn control the air operators of the pilot control valves. Lights on the
panels (red, amber, green) indicate the position of the 3-way valve (open, block, close) and there is a
memory system so that when a function is in block with the amber light on, the actual position of the
function (the red or green light) will also be displayed.
Figure 8.3.12 (A) (B) & (C) shows in more detail the operation of a BOP function from a remote panel.
Although the lights on the panels show the position of the BOP functions, the control buttons are not active
until a ―push and hold‖button is depressed in order to allow the supply of electrical power to the panel.
The sequence of events that occur is as follows:
Close
1. The ―press and hold‖ button is held in to activate the panel.
2. The ―close‖ button is pressed.
3. Current flows to the ‗close‘ solenoid valve which lifts to supply air to the 3- position air operator.
4. The air operated piston moves the pilot control valve to the ―close‖ position and pilot pressure is sent to the
subsea control pod.
5. Successful pressurization of the pilot line to the control pod actuates a pressure switch on the control manifold.
6. Current flows through an electronic card which illuminates the lamp of the ―close‖ button indicating that the
function is now closed.
7. The ―press and hold‖ button is released; the ―close‖ lamp remains illuminated.

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Fig 8.3.12 (A) Remote Operation – Close Function
Open
2. The ―open‖ button is pressed.
3. Current flows to the ‗open‘ solenoid valve which lifts to supply air to the 3- position air operator.
4. The air operated piston moves the pilot control valve to the ―open‖ position and pilot pressure is sent to the
subsea control pod.
5. Successful pressurization of the pilot line to the control pod actuates a pressure switch on the control manifold.
6. Current flows through an electronic card which illuminates the lamp of the ―open‖ button indicating that the
function is now closed.
7. The ―press and hold‖ button is released; the ―open‖ lamp remains illuminated.

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Fig 8.3.12 (B) Remote Operation – Open Function
Block
2. The ―block‖ button is pressed.
3. Current flows to both the ‗close‘ and ‗open‘ solenoid valve which lifts to supply air to both sides of the 3- position
air operator piston.
4. The air operated piston moves to a central position which places the pilot control valve in the middle ―block‖
position so that no pilot pressure is sent down either the ―close‖ or ―open‖ pilot line.
5. Since no pilot line is pressurized, neither pressure switch is activated.
6. The electronic card senses that no pressure switch has been operated and illuminates the ―block‖ lamp.
7. The ―press and hold‖ button is released; the ―block‖ lamp remains illuminated.
The ‘block’ position can be used to assist with the location of a hydraulic leak in the system by
systematically isolating the various BOP stack functions. It is also used to depressurize the pilot lines when
attaching junction boxes to the umbilical hose reels.
Note: The illumination of a push button lamp only indicates that a pilot pressure signal has been generated
and not that a function has been successfully operated subsea.
Indications of a successful subsea function movement are

a. The flow meter shows that the correct amount of power fluid has been used.
b. There are fluctuations in manifold and readback pressure readings.
c. There is a noticeable drop in accumulator pressure.

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Fig 8.3.12 (C) Remote Operation – Block Function

The BOP functions can be controlled from any panel at any time during normal operations. If one panel or
a cable to a panel is damaged, destroyed or malfunctions then it will not interfere with the operation of the
system from any other panel.
An emergency battery pack supplies the electric panels with power for a period of up to 24 hours
(depending on use) in case of failure of the rig supply. The power pack typically consists of ten 12 volt
lead-acid batteries. A battery charger is also included to maintain the batteries in a fully charged condition
ready for immediate use. Electrical cable connects the remote panels and the battery pack to the junction
boxes on the hydraulic control manifold.
Hose Reels
The hose bundle as shown in Figure 8.3.13 is mounted on heavy duty reels for storage and handling and
are connected to the hydraulic control manifold by jumper hoses. The reels are driven by reversible air
motors and include a disc brake system to stop the reel in forward or reverse rotation.
Once the BOP has been landed and latched on to the wellhead, the control points on the side of the reel
are shut down and isolated to prevent interference with the full control system. The regulators on the reel
which control the manifold and annular pressures must also be isolated in case they dump pressure when
the jumper hose RBQ plate is attached as shown in Figure 8.3.14.
When the subsea control pod is run or retrieved, the junction box for the jumper hose is disconnected from
the hose reel. However in order to keep selected functions ―live‖ during running or retrieval operations, five
or six control stations are mounted on the side of the reel. These live functions include at least the riser
and stack connectors, two pipe rams and the pod latch. Figure 8.3.13 is a schematic of the hydraulic
system through which the power fluid flows to the controlled functions during reel rotation.
With the supply pressure isolated the 3-position, 4-way valves are used to vent any pressure that may
remain trapped in a pilot line holding an SPM valve open. This is necessary, as the reel is fitted with a

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different type of valve to the control manifold manipulator valves. These valves look similar but do not vent
when placed in the ―block‖ position, see Figure 8.3.12(C).
Hose Bundles and Hose Reels

A hydraulic hose bundle may consist of up to 64 pilot hoses which have an inside diameter of 1/8‖ or 3/16‖
or both, and a power fluid hose which is 1‖ (one inch) inside diameter. The pilot hoses, as previously
described, carry signals to the SPM control valves on the BOP stack, while the power fluid is supplied
through the one inch hose or rigid line to the pod and accumulator bottles on the BOP stack.
The working pressure rating of the hose bundle should exceed the working pressure rating of the control
system. For an electro-hydraulic system, electrical cables are run subsea to the solenoid valves. The
hydraulic power supply line may be integrated into an electrical cable bundle or run separately.
The hose reels should be equipped so that some functions are operable while running or pulling the BOP
stack or lower marine riser package (LMRP). Recommended functions to be operable at these times are
the stack connector, riser connector, one set of pipe rams, pod latches, and, if applicable, ram locks.
Fig 8.3.13
Fig 8.2.14

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Fig 8.2.15 Hose Reel Control Manifold

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Subsea Control Pods

The subsea control pods contain the equipment that provides the actual fluid transfer from the hose bundle
to the subsea stack. A typical pod assembly as shown in Figure 8.3.16 consists of three sections:
 a retrievable valve block
 an upper female receptacle block permanently attached to the lower marine riser package
 a lower female receptacle permanently attached to the BOP stack
Control fluid enters the pod at the junction box and is routed either direct to an SPM valve or to one of the
two regulators (one for the BOP rams and one for the annular preventers) from where it is sent to the
appropriate SPM. When a SPM pilot valve is actuated it allows the control fluid to pass through it to one of
the exit ports on the lower part of the male stab and into the upper female receptacle attached to the lower
marine riser package.
For those functions which are part of the lower marine riser package the fluid is then routed out of the
upper female receptacle and directed via a shuttle valve to the functions operating piston. For those
functions which are part of the main BOP stack, the fluid is routed through the upper female receptacle and
into the lower female receptacle from where it goes via a shuttle valve to the appropriate operating piston.
Not all the functions on the BOP stack are controlled through pod mounted pilot valves. Low volume
functions such as ball joint pressure are actuated directly from surface through 1/4" lines. These are
generally referred to as straight through functions.
The integrity of each fluid route between the different sections is achieved by using a compression seal
that is installed in the retrievable valve block section of the pod. Compression between the three sections
is achieved by hydraulically locking the pod into the lower receptacle (which is spring mounted on the BOP
stack in order to facilitate easier engagement).
Locking is accomplished by hydraulically extending two dogs that locate under the bottom of the upper
female receptacle. A helical groove on the outside of the lower skirt of the pod ensures correct alignment of
the fluid ports. To retrieve the pod independently of the lower marine riser package, the locking pressure is
bled off and the dogs are retracted mechanically when an overpull is taken on the retrieving wire.
A more recent design utilizes the same concept but consists of a cube shaped retrievable valve block
which latches over two tapered blocks mounted on a base plate permanently attached to the lower marine
riser package. A single tapered block mounted on a spring base is permanently attached to the BOP stack.

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Figure 8.2.16 Subsea Control Pod
The packer seals on the retrievable valve block are pressure balanced in a breakaway condition so that
there is no tendency for it to be blown out of the pocket if the pod has to be released under pressure.
Besides the latching system, packer seals and piping, the principal components of the retrievable valve
blocks are the SPM pilot valves and regulators.
SPM ( Sub Plate Mounted) Valves

As described above these valves direct the regulated power fluid to the desired side of the preventer, valve
or connector operating piston and vent the fluid from the other side of the piston to the sea. The annular
preventers typically use large 1 1/2" SPM valves in order to provide sufficient fluid flow, the ram preventers
use 1" valves and the other functions such as failsafe valves and connectors use 3/4" valves. Fig .15
shows a NL Shaffer 1 inch SPM valve.
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The valve is a poppet type in which a sliding piston seals at the top and bottom of its travel on nylon seats.
In the normally closed position a spring attached to the top of the piston shaft keeps the piston on the
bottom seat and prevents the power fluid from passing through the valve to the exit port. Power fluid
pressure, which is permanently present, also assists in keeping the valve closed by acting on a small
piston area on the spindle. In this position fluid from the valve‖s associated operating piston is vented
through the sliding piston at ambient conditions.
When pilot pressure is applied to the valve the sliding piston moves up and seals against the upper seat
which blocks the vent ports and allows regulated power fluid to flow through the bottom section of the valve
to function the BOP. Note that the pilot fluid therefore operates in a closed system whilst the hydraulic
power or control fluid is an ―open‖circuit with all used fluid being vented to the sea.
As illustrated previously in Figures 8.3.12 (A), (B) & (C), two SPM pilot valves are required to operate a
BOP function.
Shown below is an illustration of a single SPM Valve.
Fig 8.2.17 NL Shaffer 1” SPM Valve

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Regulators
Each subsea control pod contains two regulators - one to regulate pressure for the ram preventers and one
to regulate the pressure for operating the annular preventers. Some control systems incorporate a third
regulator so that the operating pressure of each annular preventer can be individually manipulated.
Typical regulators are 1 l/2" hydraulically operated, stainless steel, regulating and reducing valves. As
shown in Figure 8.2.11 the output line of each regulator is tapped and the pressure roused back to a
surface gauge through the umbilical. This readback pressure is used to confirm that the subsea regulator is
supplying the power fluid at the pressure set by the pilot surface regulator.
Redundancy/Shuttle Valves
The two subsea control pods are functionally identical. When a pilot control valve (rams close for example)
is operated on the hydraulic control manifold a pilot signal is sent down both umbilicals so that the
associated SPM valve in each pod ―fires‖. If the pod selector valve is set on yellow then power fluid is sent
only to this pod and it is only through the SPM valve in this pod that the fluid will reach the ram operating
piston. The pod selection has no effect on the pilot system.
Once the yellow pod SPM valve ―fires‖, the power fluid passes through it to a shuttle valve, the shuttle
piston of which moves across and seals against the blue pod inlet. The fluid then passes through the
shuttle valve to move the ram to the close position. Fluid from the opposite side of the operating piston is
forced out through the ―ram open‖ shuttle valve and vented through the ―ram open‖ SPM valve and into the
sea.
Note that if the blue pod was now selected to open the rams; then the power fluid would flow to the ram
through the ―open‖ SPM on the blue pod but the fluid from the ―close‖ side of the piston would be vented
through the yellow pod SPM since the ―close‖ shuttle piston would still be sealing the blue pod inlet port.
The shuttle valve (s) should be located as near as possible to their relevant ports on the BOP stack since
the system is redundant only down as far as the shuttle valves. Figure 8.3.18 shows a NL Shaffer shuttle
valve.
Fig 8.3.18 N LN Shaffer Shuttle Valve
Flowmeters
Flowmeters are generally mounted in the surface accumulator the bottles remain on line. Isolation of
bottles should only be done when a very close determination of the actual fluid supplied to a function must
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be known (e.g., in the event of a problem while testing the BOP stack).
Subsea Bottle Dump Provisions

As water depth varies, so does the subsea accumulator pre-charge. Along with stack mounted bottles, an
additional function should be supplied - a subsea accumulator dump. As mentioned, these bottles are a
part of the entire 3,000 psi control system. When opened and on line with the surface bank, they retain an
internal pressure higher than the surface reading. This is the control fluid hydrostatic head. Without a dump
provision, retrieving the stack reduces the differential pressure and the bottle shells experience the higher
actual pressure. For example, if the stack was pulled from 3,000' subsea and no fluid dumped, the
accumulator gauge pressure when reaching the surface would be 3,000 psi plus 0.43 psi/ft x 3,000 ft or
4,290 psi. With a shell test pressure of 4,500 psi, the bottle is well above working pressure and just below
test pressure. Therefore, dump valves are essential in deep water.
On any rig, a check valve must be installed in the power fluid line to the surface, so that a power fluid leak
subsea does not bleed down all accumulators, both surface and subsea. With the check valve in line, a
surface pop-off valve cannot be relied upon to dump excess subsea pressure.
Direct Accumulator Functions

Access for some straight through or direct functions supplied only from the surface accumulator may be
provided for each pod. Examples of such functions are the ball joint pressure balance, pod latch, etc. With
these functions, pressure flows from the pod directly to that function. These direct functions usually take a
very small fluid volume for operation and are not changed that often, therefore the long time to complete
the operation does not cause a problem.
Backup Control Systems

Additional methods to operate certain pre-selected functions may be present on the BOP stack. In the
event of a total pressure loss, an inability to access the surface accumulators, complete severing of the
control bundle or cable, rupture of a supply line or even riser separation, control of critical BOP functions
must still be possible.
These operations may include closing the blind shear rams, closing one set of pipe rams and releasing the
LMRP connector. The functions typically will not be possible in both operator directions.
Three items are required on every back up control system: 1) power fluid plumbing modifications, 2) a
method to select the operation, and 3) a power fluid source. The methods to select an operation and
provide power fluid differs for each back up control system; the basic plumbing modifications do not. On
each function selected, one additional shuttle valve is necessary. See Fig 8.3.19.
The blue/yellow pod shuttle valve is removed from the operator fluid entry port and a piggyback shuttle
valve is installed. The outlet of the original shuttle valve is attached to one inlet of the new shuttle valve.
The other inlet of the second shuttle is attached to the control fluid source for the back up system. Fluid
can be supplied via acoustic controls, diver stabs, or emergency control funnels.

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8.2.4 Choke Manifolds

Variance from Surface Installations
The choke manifold assembly for subsea installations (Ref API RP 53, P18 ) has the same purpose as for
surface installations: viz., holding back pressure on the formation by means of adjustable, fixed, or
remotely operated chokes. The illustration below shows an example choke manifold assembly for a subsea
installation for 5M, 10M, or 15M psi rated working pressure service. This assembly differs from a surface
installation in that the choke and kill lines are manifolded to permit pumping through either line. Other
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features are: a remotely controlled adjustable choke and adjustable choke systems (manual) to permit
control through either the choke or kill line, double valves upstream of each choke, an accurate pressure
gauge, and tie-ins to both drilling fluid and cement unit pump systems.
Fig 8.3.21 Example Choke and Kill Manifold for 5K, 10K, and 15K Rated Working Pressure Service Subsea
BOP Installations
Installation Guidelines
Recommended practices for planning and installation of choke manifolds for subseainstallations include:
a. The assembly connections, full-opening valves, fittings, piping, etc., subject to well or
pump pressure should be flanged, clamped, or welded and have a rated working
pressure at least equal to the rated working pressure of the blowout preventers.

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b. All components should be selected in accordance with applicable API Specifications,

taking into consideration pressures, volumes, temperatures and conditions under which
they may be operated (i.e., gas, oil, drilling fluid, hydrogen sulphide, the environment,
etc.).
c. The main header should be 3-in. nominal diameter or larger. All other components
should be 2-in. nominal diameter or larger. The assembly should have a minimum
number of turns and be securely anchored. Turns in the assembly should be targeted.
d. The choke control station, whether at the manifold or remote from the rig floor, should
be as convenient as possible and should include all monitors necessary to furnish an
overview of the well control situation. The ability to monitor and control from the same
location such items as standpipe pressure, casing pressure, pump strokes, etc., greatly
increases well control efficiency.
e. 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.
f. Initial testing of the entire choke manifold system assembly to the rated working
pressure of the preventers should be performed when the BOP stack is on the test
stump (prior to running subsea). Subsequent pressure tests of the choke manifold
assembly should be conducted when the blowout preventers are tested subsea and
limited to 70% of the rated working pressure of the BOP stack or to the maximum
anticipated surface pressure, whichever is greater.
g. Lines downstream of the choke manifold are normally not required to contain rated
manifold pressure, but should be tested during the initial installation test. An initial
pressure test should be conducted on all preventer installations prior to drilling the
casing plug. Conduct each component pressure test for at least FIVE minutes. Monitor
secondary seal ports and operating lines on each preventer while testing to detect
internal seal leaks.
h. Lines downstream of the choke manifold should be securely anchored, be of sufficient
size to minimise friction and permit flow direction either to a mud gas separator, vent
lines, or to production facilities or emergency storage.
i. Buffer tanks are sometimes installed downstream of the choke assemblies for the
purpose of manifolding lines together. When these tanks are employed, provision
should be made to isolate a failure or malfunction without interrupting flow control. Any
sharp bends in the piping arrangement should be targeted.
Maintenance
Preventative maintenance of the choke assembly and controls should be performed regularly checking
particularly for wear and plugged or damaged lines. Frequency of maintenance will depend on usage.
Spare Parts
An adequate supply of spare parts is important for components subject to wear or damage or whose failure
seriously reduces the effectiveness of the manifold. Standardization of components is recommended to
minimize the inventory required. Although the inventory will vary from rig to rig, a generalized
recommended spare parts list includes:

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a. one complete valve;

b. critical parts for adjustable chokes such as flow tips, inserts, packing, gaskets, O - ings, disc assemblies,
and wear sleeves.
c. Critical parts for the remotely controlled choke; and
d. Miscellaneous items such as hose, flexible tubing, electrical cable, pressure gauges, small control-line
valves and fittings, and critical electrical components.
Choke and Kill Lines – Subsea Installations

Purpose
Kill lines for subsea installations are similar in purpose to those for surface installations. Comments
relevant to kill lines and valves also apply to choke lines and valves since for subsea installations they are
connected (through the choke manifold) to permit pumping or flowing through either line.
Installation Description
Choke and kill lines for subsea installations are installed opposite one another on the exterior of the marine
riser and are of three types: integral, track or funnel.

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Fig 8.3.22 Example Riser Mounted Kill and Choke Lines for Subsea BOP Installations
The integral type has the lines permanently installed on each marine riser joint, with pin and box
connectors stabbed and made up simultaneously with the riser connector. The track type has two guide
rails permanently installed on the marine riser which offers guidance to ―skates‖ attached to choke and kill
lines; Choke and kill lines are run after the riser has been installed. The third type has funnels attached to
the marine riser, which also permit choke and kill lines to be run after the riser is installed. Choke and kill
lines are normally 3 inches in nominal diameter or larger.
Installation Guidelines
Some of the more important considerations concerning subsea choke and kill lines are:

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A. Connector pressure sealing elements should be inspected, changed as required, and tested
before being placed into service. Period pressure testing is recommended during installation.
Pressure ratings of all lines and sealing components should equal or exceed the rated working
pressure of the ram preventers.
B. Selection of choke and kill line connectors must take into consideration the ease of
connect/disconnect operations and the dependability of sealing elements for those emergency
situations where it is necessary to unlatch the riser from the BOP stack and then
latch/reconnect again prior to resuming normal operations.
C. Each choke and kill line should have two full opening valves adjacent to the preventers. These
valves are hydraulically operated and at least one on each line should be ―failsafe‖ in the
closed position. Periodic pumping through the valves is necessary since they are normally
closed and may become plugged if not occasionally flushed.
D. Locations of the choke and kill lines openings on the BOP stack depends on the particular
configuration of the BOP stack and the operator‖ s preferred flexibility for well control
operations. Sharp turns in the piping arrangement should be targeted where practical.
E. Flexible connections required for choke and kill lines both at the top and bottom of the marine
riser, should have a pressure rating equalling or exceeding the rated working pressure of the
ram preventers
Fig 8.3.23 Example types of flex connection on Tp of marine riser for choke/kill

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F. Selection of the top connection should include consideration of criteria such as relative
movement between vessel and riser, the environment, type and temperature of fluids handled,
pressure integrity, service life, ease of connect/disconnect operations and replacement costs.
G. Bottom flexible connections (circumventing the flexible (ball) joint) have the same requirements
as the top connection but are even more critical due to their relative inaccessibility and the
environmental conditions under which they must operate. For deeper water operations,
particular considerations should be given to internal–external pressure integrity and reliability.
Fig 8.3.24 Example Types of Flex Connectors at Bottom of Marine Riser for C/K Lines
8.3.6 Marine Riser Systems

Marine Riser Tensioning System
The marine riser tensioning system provides for maintaining positive tension on the marine riser to
compensate for vessel movement. The system consists of the following major components:
a. Tensioner cylinders and sheave assembly.
b. Hydro pneumatic accumulators/air pressure vessels.
c. Control panel and manifolding.
d. High pressure air compressor units, and
e. Standby air pressure vessels
Tensioning at the top of the riser is one of the most important aspects of the riser system, as it attempts to
maintain the riser profile as nearly straight as practicable and reduces stresses due to bending. As tension
is increased, axial stress in the riser also increases. Therefore, an optimum tension exists for a specific set
of operating conditions (water depth, current, riser weight, drilling fluid density, vessel offset, etc.).
Wire lines from the multiple hydraulic tensioner cylinders are connected to the outer barrel of the telescopic
joint (slip joint). These cylinders are energised by high pressure air stored in the pressure vessels. Tension

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on the wire lines is directly proportional to the pressure of stored air. In general, as the vessel heaves
upward, fluid is forced out of the hydraulic cylinders thereby compressing air. As the vessel heaves
downward, pressure of the compressed air will cause the hydraulic cylinders to stroke in the opposite
direction.
Selection of tensioner should be based on load rating, stroke length, speed of response, service life,
maintenance costs, and ease of servicing. Maximum load rating of individual tensioners depends on the
manufacturer, typically ranging from 45,000 to 80,000 pounds and allowing maximum vertical vessel
motion of 30 to 50 feet. Design of the wireline system that supports the riser must take into consideration
the angle between the wireline and the axis of the telescopic joint and its influence on stresses.
The number of tensioners required for a specific operation will depend on such factors as riser pipe size
and length, drilling fluid density, weight of suspended pipe inside the riser, ocean current, vessel offset,
wave height and period, and vessel motion. Computer programs are available for riser analysis, including
tensioning requirements. Consideration should also be given to operating difficulties that might occur
should one of the tensioners experience wireline failure.
Periodic examination of riser tensioning system units should be made while in service, since the system
can cycle approximately 6000 times per day. Particular care should be taken to establish a wireline and
replacement program based on ton cycle life for the particular rig installation. Users should consult the
equipment manufacturer for general maintenance procedures and specifications recommendations.
Buoyancy
For deeper waters, it may be impractical from an operating viewpoint to install sufficient units capable of
providing adequate tensioning. In these cases, some types of riser buoyancy may be the solution (flotation
jackets, buoyancy tanks, etc.). Buoyancy reduces the top tensioning requirements but loses some of its
effectiveness as a result of the increased riser diameter exposing a greater cross sectional area to wave
forces and ocean currents. Selection of the optimum method and/or material for obtaining buoyancy
requires careful consideration of a number of factors, including water absorption, pressure integrity,
maintenance requirements, abuse resistance, and manufacturer‖s quality control. Several of these factors
are time and water-depth dependent. As water depth increases, these factors become more critical. A part
of any analysis for an optimum system should include consideration of the consequences of buoyancy
failure during operations.
Riser Running and Handling

Well trained crews and close supervision are needed for maximum efficiency and to preclude any failure
from improper handling or makeup of marine riser connectors. Some special equipment and tools for
handling, running, and makeup/breakout may also be beneficial, both in protecting the riser and improving
efficiency. These tools include a flare-end guide tube (riser spider) for guiding the riser through the rotary
table and a joint lay down trough installed in the V-door. Care should also be taken in protecting riser joints
stored on the vessel.
Marine Riser Inspection and Maintenance

As marine joints are removed from service, each joint and connector should be cleaned, surfaces visually
inspected for wear and damage, damaged packing or seals replaced, and surface re-lubricated as
required. Buoyancy material and/or systems, if installed, should also receive close inspection. Prior to
running a riser, thorough inspection of all components may also be warranted, particularly if the riser has
been idle for some time or previous inspection procedures are unknown. For those operations where
environmental forces are severe and/or tensioning requirements are high, consideration should be given to
maintaining records of individual riser joint placement in the riser string and periodic testing (non-

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destructive) of the connector and critical weld areas to reduce failures. Refer to API RP 2K: Recommended
Practice for Care and Use of Marine Riser Drilling Systems for specific information.
Lower Marine Riser Package (LMRP)

The LMRP consists of a riser connector, annular preventer(s), a flex joint/ball joint assembly, choke/kill
lines stab (or mini collet connectors) and pod receiving blocks/upper female recepticles for the control
pods. An isolation valve for the choke and kill lines may also be included on the LMRP. The LMRP
provides the means to disconnect from the BOP should weather, an emergency abandonment, or a well
control situation dictates such action. It can be pulled to surface with the marine riser, leaving the well shut
in on the BOP. The riser connector is of the same design as the wellhead connector, which is discussed in
the previous section. Details on the pod receiving block/upper female recepticles are covered in the section
on Control Systems
Fig 8.3.25 LMRP Components
Annular Preventers
At least one annular preventer will be located on the LMRP. Other than the size, its design is the same as
that used on surface locations. One prudent addition often found is a ―surge bottle‖, which is a pre-charged
accumulator style bottle tied into the close chamber of the annular. The bottle acts as a buffer for tool joints
that are stripped through, allowing the pressured closing fluid to be momentarily stored rather than
dumped. This is required because the pressure regulator on the subsea pod cannot respond quickly
enough to the fluctuations caused by the passing tool joint. The surge bottle should be pre-charged to 500
to 700 psi plus hydrostatic adjustment (approx .445 psi/ft).

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Emergency Control Funnels

Emergency control funnels serve as a means to close the blind/shear rams and release the LMRP
connector, in the event of a riser separation. A drillpipe stab assembly is run to function the rams and
connector and then retrieve the LMRP.
Emergency control funnels are mounted on the LMRP guide frame in pairs, situated 180 degrees apart.
Either funnel is accessed by the ported stab assembly . This stab is stung and locked into the funnel
housing, landing out on a shoulder. A dart is then dropped through the drillpipe and pressured up . This
exposes a port, through which control fluid can be routed to the blind/shear rams. With the blind/shear
rams closed, the dart is removed by an overshot. A second dart is run, exposing ports routed to the LMRP
hydraulic connector release. Pumping fluid down the drillpipe then releases the LMRP.
These funnels also have heavy steel cables attached to the LMRP, enabling LMRP retrieval by the
drillpipe. Once the LMRP connector is released, the funnel is removed from the guideframe by picking up
on the drillpipe. Since the cables are able to support the LMRP‖s entire weight, it can be pulled to surface.
Note that the hydraulic connector release pressure is maintained through a pilot operated check valve,
which is discussed in Control Systems.
Additionally, subsea BOP stacks can be fitted with ROV / Diver hot stabs for emergency functions. The
installation of ROV hot stabs is at the discretion of the operator as well as the functions chosen for hot stab
access.
Fig 8.3.25 - Ported Stab Assembly

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Fig 8.3.26 - Dart inside ported stab assembly
Choke / Kill Line Connection

The majority of LMRP configurations use ―stabs‖ to connect the choke and kill lines between the LMRP
and the BOP. These stabs are the same as those used on the riser sections. Some rigs utilize a mini
connector to make this connection. The most common is a Cameron HC mini-collet connector. This
connector is similar in operation to the HC wellhead connector but with a 3-1/16‖ bore. A weight set version
is also available which uses the mechanical motion of the LMRP to latch and unlatch the connector.
Marine Riser Flexible Joint (Ball Joint)

A flexible joint is used in the marine riser system to minimise bending moments, stress concentrations and
problems of misalignment engagement. The angular freedom of a flexible joint is normally 10 degrees from
vertical. A flexible joint is always installed at the bottom of the riser system either immediately above the
remotely operated connector normally used for connecting/disconnecting the riser from the BOP stack, or
above the annular preventer when the annular preventer is placed above the remotely operated connector.
Ball Joints
A ball joint consists of a ball and socket assembly, similar to a human hip joint. The hydrostatic head of
fluids inside the marine riser impart a downward force against the inside of the ball, while the overpull of
the riser tensioners create an upward force on the socket. Both forces act upon the interface of ball to

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socket. As such, a pressure balance system is required on a ball joint to reduce the bearing forces that
result from high tension loads across the face. Therefore, a hydraulic line must be run. In very deep water
or where high mud weights are used, the pressure required to compensate the ball joint may limit the
capacity of the seals.
Fig 8.3.27 - Ball Joint
For those vessels having a diverter system, a second flexible joint is sometimes installed between the
telescopic joint and the diverter to obtain required flexibility, or some type of gimbal arrangement may also
be used. For deep-water operations or unusually severe sea conditions, another flexible joint may be
installed immediately below the telescopic joint.
Mechanical strength requirements for flexible joints are similar to those for the remotely operated
connector. They should be capable of safely withstanding loads that might reasonable be encountered
during operations, both normal and emergency. In addition, the angular freedom of up to approximately 10
degrees should be accomplished with minimum resistance while the joint is under full anticipated load.
Hydraulic ―pressure balancing‖ is recommended for ball-type flexible joints to counteract unbalanced forces
of tensile load, drilling fluid density and seawater density. This pressure balancing also provides lubrication
for flexible joints.
Technical investigations and experience have shown the importance of close monitoring of the flexible joint
angle during operations to keep it at a minimum. One method of accomplishing this is by the use of an
angle–azimuth indicator. The flexible joint angle, vessel offset and applied (riser) tension are indications of
stress levels in the riser section.
For continuous drilling operations, the flexible joint should be maintained as straight as possible, normally
at an angle of less than 3 degrees: greater angles cause undue wear or damage to the drill string, riser,
BOPs wellhead or casing. For riser survival (i.e. to prevent overstressing) the maximum angle will vary
from about 5 degrees to something less than 10 degrees, depending on parameters such as water depth,
vessel offset, applied tension and environmental conditions. Drill pipe survival must also be considered if
the pipe is in use during those critical times of riser survival conditions.
Hydraulic Wellhead Connectors

The hydraulic wellhead connector attaches the BOPs to the wellhead and is designed to latch and unlatch
on to specific wellhead profiles. It is designed to withstand the bending stresses and separating forces
imposed by currents, wave and vessel movement, and wellbore pressures. The connector will have a

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pressure rating that matches the ram preventers.

Two basic types are available, the multiple piston type (Vetco H-4) and the annular piston type (Cameron
HC & Dril-Quip DX). Due to the large surface area, the annular type has a higher preload at lower hydraulic
pressures. The angle of locking dogs, or fingers, with regard to engagement of the wellhead profile also
has a significant influence on preload.
Operating features of the two most common manufacturer‖s models are listed below.
(Note that a second riser connector attaches the LMRP to the BOP Proper).
Vetco H-4 Connector

The Vetco H-4 Connector consists of two major assemblies, the lower connector body (which houses the
mechanical and hydraulic operating components) and the top adapter section (see Figure 8.3.27). The
operating components consist of multiple locking dog segments, a sliding cam ring that engages the dogs,
hydraulically actuated pistons to move the cam ring, and an indicator rod that provides visual confirmation
as to whether the connector is locked or unlocked. (This rod is connected to the cam ring). When operating
fluid is introduced to the ―lock‖ chambers, the pistons pull the cam ring downwards, driving the dogs into a
grooved profile on the wellhead. Various styles of H-4 connectors are currently marketed, ranging from 13-
5/8" 5M to 18-3/4" 15M and 21 1/4" 10M.
The H-4 provides both a primary and secondary locking system. Half the pistons are ported to the
―primary‖ lock chamber, with the rest ported to the ―secondary‖ lock chamber. This set up is identical for
the unlocking system, making a total of four ports. The locking systems are normally plumbed together
externally by Vetco or the drilling contractor, routing fluid to all locking chambers simultaneously. The
unlock systems are always separate, providing a standby system, should the primary unlock fail. The
pistons are designed so that a given operating pressure results in a larger unlocking force being generated
in comparison to locking force.
Depending on the year of manufacture, all pistons may or may not be attached to the sliding cam ring. (If
not attached, the secondary pistons provide no locking force, but still push up against the cam ring to
unlock). It has become Vetco‖s intent to attach all pistons, but this ultimately depends on contractor
request. The status of the connector should be verified with the contractor.
H-4 connectors carry their ring gasket subsea by holding it with retaining pins. Four types of pins are
available: 1) spring latch, 2) solid screw, 3) hydraulically retractable and 4) oriented two-piece. Three types
of ring gaskets are available: 1) standard, 2) single resilient seal, and 3) double resilient seal. (These are
the VX style). Gaskets made from cadmium plated carbon steel or stainless steel are used for 10M
applications, but Vetco recommends only stainless steel for H2S 15M operations.
With the introduction of the Vetco Gray MS-700 wellhead system, Vetco Gray offers two metal-to-metal
wellhead to H-4 connector seal options - the standard VX gasket and the a secondary VT-1 gasket. All MS-
700 subsea wellhead housings, manufactured for H-4 connectors, have a dual-taper VX / VT gasket profile
with two independent sealing surfaces. The secondary VT sealing surface is used when impact, corrosion,
or washout has damaged the primary VX sealing surface in the wellhead. The VT-1 gasket lands and seals
in the secondary taper in the wellhead bore. VT-1 gasket design provides 15,000 psi sealing integrity. They
can be installed into existing H-4 connectors and are retained by the seal ring retainer screws in the same
manner as the standard VX gasket.
Consideration should be given to using only non-resilient seal rings for testing and during operations.
When resilient seals are used, point loading occurs (due to test pressure and weight) on the
connector/profile at the resilient seal. This causes the shape of the resilient seal to change, resulting in a
permanent deformation to the surface of the ring groove. Consequently, resilient seals are generally

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considered a ―last option‖ when pressure integrity can not be achieved with metal-to-metal seals.
A high angle release model is also available (see Section 8.3.28) termed the HAR-H4. Its purpose is for
LMRP connection to the BOP Proper where higher angles of inclination (between the BOPs and riser
column) are conceivable, especially deepwater prospects. A much shorter swallow design permits
disconnects at up to 15 degree offsets. (However, realize that the rig may not be capable of disconnecting
above 8 degrees because of pod interference or moonpool binding). This high angle connector only
―swallows‖ about 13 inches of the locking mandrel, whereas the standard H-4 ―swallows‖ about 27 inches.
Fig 8.2.27 - Vetco H-4 Connector

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Fig 8.2.28 - H-4 High-Angle Release Connector
Note: All H-4 greasing operations should be performed with the connector removed from the test stump.
Otherwise, a hydraulic grease lock may develop
Cameron Collet Connectors

Cooper Cameron Corp (formerly Cameron Iron Works) Collet Connectors — These items are carried under
a division of Cooper Cameron which is still called Cameron. Therefore, the equipment noted below is
designated Cameron.
Two basic styles of Cameron connectors are available for wellheads, the Model 70 and the Model HC.
Both designs attach the connector to the wellhead by a series of pivoted locking segments shaped like
tapered fingers (forming a ―clamp‖ segment) rather than dogs. These segments create a funnel to guide
the connector to it‖s final landing position.
When unlocking pressure is applied, the segments rotate into the fully open position prior to wellhead
release, allowing for large angle disconnects (up to 30 degrees). An advantage to this connector design is
that the clamp segment fully releases when retracted, where as trash build-up behind the ―dog‖ style Vetco
may prevent a total unlatch.

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Both styles of Cameron connectors normally use an AX ring gasket to mate with the wellhead. Model 70 —
The clamp segment is engaged by a series of hydraulic pistons (see Figure 8.3.29). A common plumbing
arrangement has all 9 pistons dedicated to lock: six pistons to primary unlock, and three pistons to
secondary unlock. Unlike Vetco‘s ―fluid band‖, all pistons are individually hosed. Each piston is designed
to provide an unlocking force that is 80% greater than the locking force. One other feature is that the ring
gasket can be hydraulically locked in place while running or retrieving the BOP stack. Manual override is
standard.
Fig 8.2.29
 The difference in this connector is that the clamp segment is engaged by an annular preventer
type of piston (see Figure 8.3.30). No hydraulic pistons are necessary, therefore no hoses. This
actuator piston design provides substantially higher clamping pre-loads than the hydraulic pistons.
 HCH4. This model is based on the standard HC connector but is modified toconnect onto a Vetco
H4 wellhead profile
 DWHC. This model was designed specifically for deep water applications. This connector is
designed to mate with the Cameron DW wellhead profile or the standard Cameron wellhead hub.
Segment and hub geometry and a large actuating piston area create a greater clamping force for
the higher load requirements of deep water drilling.

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Fig 8.2.30
Hydrates
Severe problems have occurred due to gas percolation causing hydrates to form inside the wellhead
connector. Hydrates that form within the internal pockets (that are open to the sea) can prevent the
connector from being unlatched. As all connectors internal mechanisms have internal pockets that are
open to the sea, this is a problem that must be considered for every connector type.
The means of hydrate prevention has been to employ a method of ―diverting‖ the gas away from these
components. The primary method is to install a ―hydrate seal‖ between the base of the connector and the
wellhead housing. Additionally, some contractors and/or operators have modified the wellhead connectors
with a flushing port. This port allows access to the void areas by use of an ROV stab. The ROV can then
pump methanol to dissolve a hydrate plug. Another (secondary) method of diversion is to use diverting
plates on the subsea guidebase to deflect any percolating gas away from the entire wellhead connector
area.
Dril-Quip DX connector
Has a "hydrate diversion seal" at the base of the connector as standard design. A flushing port is not
standard in the design. However, the connector could be modified to allow such a function by utilizing one
of the excess ports that are available for indicator rods.
Vetco Connectors
Employ a bolt-on type"hydrate excluder seal". Machine modifications to the connector and the test stump
are required to facilitate installation of this seal. There has been some problems with the original design of
the seal and changes have been made. A full description of the modifications required can be found in
Appendix 4 ABB Vetco Gray Engineering Bulletin H-990750. H-4 Wellhead Connector Excluder Ring for

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Hydrate or Shallow Flow Silt Contamination Cameron connectors employ a bolt-on type diverting seal at
the base of the connector. Bolt on seals can be used on all of the Cameron designs without modification
but the seal is not standard with the connector. Inclusion of a flushing port would require the connector to
be modified.
Shallow Water Flow Silt Contamination

Silt contamination due to shallow water flow coming up under the wellhead connectors has caused the
same type of problems as highlighted above in Hydrates. The silt gets into the open spaces of the
wellhead connector and makes it difficult or impossible to unlatch. The connector manufacturers utilize the
same sealing mechanism as used for hydrates to divert and protect the wellhead from silt contamination.
Guide Structure
The guide structure, a four-post tubular structure attached to the BOP assembly, is the primary guidance
means for guiding the complete BOP stack for primary alignment onto the permanent guide base
The upper section of the guide structure acts as primary guidance for the lower marine riser package. The
guide structure also acts as the structural mounting for the various components of the remote control
system and the choke/kill connectors or stab subs. The guide structure should have sufficient strength to
protect the BOP stack from damage during handling operations.
Tilt-Azimuth Indicator
Tilt-azimuth devices are attached to the flexible (ball) joint and/or marine riser to indicate the amount and
direction of deflection. With this information, proper corrective measures can be taken to minimise the
deflection.
Underwater Television
An underwater television system for visual inspection of the wellhead, BOP stack, marine riser, and other
allied components generally consists of a television camera and high intensity lights attached to a
telescoping guide frame. This guide frame normally attaches around two of the guide lines. The assembly
can be lowered by special umbilical cable which supports the package plus furnishes all electrical circuits
for the TV camera and lights. Surface equipment includes a powered reel for the umbilical cable and a TV
monitor with allied electronic equipment and camera remote control.
“Failsafe Valves”
―Failsafe‖ valves are required by the regulatory authorities in the UK and Norway, but not in other operating
areas of the world.
An operating scenario to consider is an emergency disconnect sequence or difficulties with the multiplex
BOP control system.
Prudent operating procedures suggest that the outer valve be closed first in the event full closure is not
achieved or erosion occurs preventing a seal. The outer gate will then act as a choke and increase the
likelihood that the inner valve will successfully close and obtain a seal.
All choke and kill valves on a subsea stack are hydraulically actuated gate valves, containing the same
seats, gates, stems, etc. as their surface counterparts. They vary from a surface stack ―HCR‖ valve in that
they contain a spring to assist gate closure (under most operating conditions). Hydraulic pressure applied
to the open port forces the valve stem down, compressing the spring. When this pressure is removed, the
spring assists in closing the gate. The term ―failsafe‖ valves is more recognizable, but recent tests with
mud and simulated deep water production conditions have shown the spring does not always close the

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valve, especially where a plug in the opening port may occur. Manufacturers now stress the term ―spring
assist‖. Two subcategories exist for spring assist valves, ―line pressure closure‖ and ―system closure‖. Both
styles permit bi-directional sealing.
Line Pressure Closure

Line pressure closure valves do not require an external source of hydraulic fluid to close the valve. For
Cameron AF type actuators, the valve closes by spring action plus line pressure from the bore of the valve
acting on the balancing stem (see Figure 8.3.31). The balanced stem design prevents fluid displacement in
the valve body during valve opening and closing, and prevents the valve from opening when line pressure
is less than the hydrostatic pressure.
Shaffer‘s ―HB Long Sea Chest‖ model varies slightly, where line pressure assists spring closing through a
pressure-balancing tail rod that is 1/4" smaller than the valve‖s stem (see Figure 8.3.32). Also, hydrostatic
pressure affects on valve closure are negated through a ―sea chest‖system. Oil fills the spring side of the
actuator piston, which is ported to the sea chest. As the gate valve opens, oil is displaced to the sea chest
via a bypass system. Hydrostatic pressure is transmitted to the oil remaining in the spring side of the
actuator piston, as well as the tail rod diameter. This overcomes the hydrostatic forces trying to keep the
valve open. Other ―line pressure closure‖ valves include ―McEvoy EU‖ and ―EDU‖ nomenclatures.

PVD Training
Fig 8.2.31 - System Closure
System closure valves have a hydraulic control fluid supply plumbed to both open and close ports.
However, if a hydraulic pressure failure occurs, the actuator spring should ensure the valve closes. Some
actuators (Cameron DF see Figure 8.3.33) have an exposed tailrod that the hydrostatic pressure can acts
on, enhancing in the hydrostatic pressure already acting on the close side hydraulic fluid. This serves to
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counteract the hydrostatic forces imparted by the column of fluid acting on the open side hydraulic fluid,
which try to open the valve. Shaffer‘s ―HB Short Chest‖ is another example of a system closure valve.
Subsea valves can also have a pressure assist bottle tied into the closing chamber (accumulator style
bottles, pre-charged for water depth). When the valve opens, fluid from the closing chamber charges the
bottle, storing it to assist with the next closure.
It is required to always have two valves on each choke/kill outlet, providing redundancy. The actuators
require only 1500 psi to operate, but are rated to 3000 psi, should the higher operating pressure be
required. When possible, the valves should be mounted directly to the ram preventer outlets, eliminating
spools (and possible additional leak paths).
System Maintenance
Grease insert sealing failures on choke and kill line valves have occurred on a number of semi-
submersibles, or both old and new valves. It is recommended all ―high pressure‖ grease inserts be
replaced with certified ―high pressure‖ plugs prior to stump testing. However, it is critical that the valves are
greased. After each well these grease inserts should be reinstalled and each valve greased with OEM
recommended lubricant. These lubricants greatly enhance valve gate and seat life. A 3‖ valve will hold
approximately 4 lbs of grease.
Most subsea BOPs have eight failsafe valves. Typically one valve or one set (two valves) should be
disassembled, inspected and serviced after an average well (assuming 12-20 weeks for a well). API
recommends one spare valve of each size and type be kept onboard (RP53 9.4) so a swap out is usually
more efficient between wells, with the service performed while the stack is on bottom.
Fig 8.3.32 Fig 8.3.33

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Pod Receiving Blocks/Lower Female Receptacles

The control pods receive hydraulic operating fluid from the surface accumulator unit via hose bundles or
rigid conduit, and transmit it to the BOP functions through either ―stack mounted blocks‖ or the ―lower
female‖ receptacles (depending on which type of pod system is in place). Regardless of the system used,
two ―blocks‖ or ―Receptacles‖ will be located at the top of the BOP Proper guide frame. When given the
opportunity, the individual seals and bore holes should be inspected for scarring/wear and blockage. (Both
systems are described in the Control Systems section).
8.3.7 Other Subsea BOP Considerations

Cathodic Protection
The subsea BOP and LMRP assembly requires cathodic protection to minimize the corrosive degradation
caused by electrolytic action. This protection is normally achieved through the installation of sacrificial
anodes on the guideframe and around the control pods. It is important to evaluate the current protection, to
assess the condition and space-out of the anodes.
Cold Weather Considerations

Operations in sub-zero temperature environments dictate additional stack considerations. Specifically, a
glycol-water mixture is warranted for use as the preventer‖s operating fluid. Lubricants and grease should
contain low temperature additives. Sharp impacts or loads on elastomers should be avoided, as their brittle
nature could cause them to shatter. (A storage temperature range for rubber goods is 40 to 80 degrees
Fahrenheit.)
Two Stack System & Split Stack Considerations:

Two Stack System
Some of the earlier designs for floating drilling vessels did not have the capabilities to handle the larger
BOP stacks (16-3/4" and 18-3/4" 10 M and 15M) that have been the focus of this section. Due to space
and lifting restrictions, they utilized a system consisting of two smaller stacks instead. The two stack BOP
system consists of a large bore, low pressure stack (211/4", 2000 psi to 3000 psi) and a smaller bore, high
pressure stack (13-5/8" 10M or 15M). An important aspect to consider if considering the use of a two stack
system rig is that the wellhead system must also be specific to the two stacks. A two stack system can
have a significant impact of the days required to complete a well program.
There are only two rigs still operating today which utilize the two stack system.
Spilt Stack
Past experience with split stacks (BOP & LMRP must be separated to move under the rotary) has been
quite poor. The stack is completely tested and ready to operate out with the critical path of rig operations.
However, when the LMRP is re-landed on the BOP below the rotary it must be re-tested and all functions
checked before it can be run subsea.
Significant time and money has been lost due to problems getting these tests.
Rig evaluations have typically given insufficient thought to the possibility of significant downtime due to
problems with a split stack system.
Sub-Salt Considerations
Drilling of sub-salt formations with saturated salt mud systems has caused some problems with salt crystal
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build up on BOP components, particularly valve gates and seats. Proper maintenance (greasing) programs
of the valves must be adhered to.
However, on wells that will drill through large sections of sub-sea, this standard procedure may not be
sufficient. It should be considered that all valves should undergo a complete service prior to use on a well
which will utilize a salt saturated mud system and drill large sections of sub-salt. Additionally, extra
diligence for the choke manifold valves maintenance is warranted.
Hydrate Considerations
Hydrates have formed and caused severe problems while killing gas influx kicks. In a well control situation,
the kick fluid leaves the formation at a high temperature, with an extended shut-in period of time it can cool
to seabed temperature. With high enough hydrostatic pressure at the mudline, hydrates could form in the
BOP and choke / kill lines.
Hydrates are created by the reaction of natural gas with water and occur under certain pressure and
temperature conditions. They form substances that consist of ± 10% hydrocarbon and ± 90% water that
range in texture from a "jelly-like" mush to a solid "ice-like" substance. Although the solids are similar in
appearance and shape to the physical properties of ice, they incorporate light hydrocarbons, carbon
dioxide, hydrogen sulphide, nitrogen and some other small compounds. Each hydrocarbon (guest)
molecule is surrounded by a number of water (host) molecules that create a cage. There are roughly 17
water molecules for each gas molecule, so water is the predominant component of these solids.
The danger of hydrates comes from several basic physical properties, the plugging nature of the hydrate
phase itself and its tendency to adhere to metal surfaces. And the large gas content of the hydrate phase
which, upon melting, can release up to 170 scf of gas per cubic foot of hydrates. Furthermore, hydrate
formation can cause the breakdown of a mud system by fresh water extraction from the mud to form the
hydrate structure.
Hydrates formation in drilling fluids is a relatively new experience offshore.
Temperature, pressure and gas composition determines the conditions for hydrate formation. Solidification
of the hydrate occurs as the temperature decreases and/or pressure increases with the proper amount of
gas and water present. In a drilling situation hydrates can format temperatures well above freezing
temperature of water due to the pressure exerted by the hydrostatic head. That statement should not be
construed to mean that hydrates are only a concern in deep water. Hydrates are a serious concern any
time that cold temperatures meet high pressure. The common condition in all hydrate formation
experienced offshore has been extended shut-in periods. The well control operations should start as soon
as possible after recording the shutin pressure parameters.
The significant effects of the hydrate formation in drilling operations are:
 Plugging of choke and kill lines
 Formation of a plug at or below the BOP, preventing monitoring of pressures below the BOP.
 Formation of a plug around drillstring in riser, BOP or casing
 Formation of a plug in ram cavity of a closed BOP- preventing it from fully opening.
In order to prevent hydrate formation during a kick situation, mineral oil base fluid can be spotted across
the BOP and in the choke / kill lines. In the event of a gas kick when a water based mud system is being
used, be prepared to spot a glycol / salt pill in the BOP, choke / kill lines.
Deep water and/or cold water locations, which will explore for gas should take into consideration the
prediction and prevention of hydrates during the planning phase.

PVD Training
Prediction evaluations must take into account:

 Hydrostatic head plus maximum anticipated shut-in pressures at the coldest point in the system
(i.e., mudline)
 Final maximum anticipated mud weight
 Mud line temperature
Some items that may be impacted in the well plan due to possible hydrates are:
 BOP modifications to allow inhibitor injection at the BOPs
 Inhibitor type, volume and concentration
 Drilling fluid type to be used through the prospective zone of interest
 Choke manifold modifications to allow inhibitor injection at the choke.
Prevention is always the best method. Remedial actions are always time-consuming, costly and could
possibly risk the safety of the rig and/or personnel.
Choke Manifold
A floating vessel‖s choke manifold is often more elaborate than it‖s surface counterpart (as depicted in
Figure 8.3.34). Often times, two hydraulic chokes with at least one manual type choke are present.
Depending on the choke placements, various flow path combinations can be available, should either a
washout or plug occur during well control operations. Both the choke and kill lines terminate at this
manifold, where fluids can be circulated through either one (The mud pumps can be routed into the
manifold, and most rigs have provisions to tie in the cement unit as well). Also, depending on kill line outlet
placement on the BOP, pressure at the BOPs can be monitored via the kill line during well control
operations, reducing the need for ―choke line friction determinations. The remaining manifold
components, including gate valves, pressure gauges and choke actuators, are the same as those found on
- surface operations
Note: Grease insert sealing failures on choke manifold valves have occurred. It has been recommended
all „high pressure‟ grease inserts be replaced with certified „high pressure‟ plugs prior to testing and system
maintenance.

PVD Training
Fig 8.3.34 - Choke Manifold for Sub Sea Drilling
Hydraulic Quick-Response Systems

The standard hydraulic system can be upgraded with a - quick-response‖pilot operated system to achieve
faster BOP operating times. With additional, relatively inexpensive pilot hoses installed, BOP response
times as low as 12-15 seconds on a ram and 20-25 seconds on a bag-type annular in 3,000 feet of water
can be achieved.
The quick-response system is an adaptation of standard hydraulic controls. It employs an additional bank
of quick-release valves mounted upstream of the main control pod, which maintain the 3000 psi pilot fluid
behind them. Once the quickrelease valves are activated, they allow the pilot fluid to flow to the
standard SPM valves, which in turn direct the regulated power fluid.
The overall operating time is reduced, as all pilot lines (now attached directly to the quick response valves)
are pre-pressured and maintained between a 800 -1000 psi bias. The pressure bias eliminates an initial,
slow expansion of the pilot lines from 0-500 psi. (Just prior shifting a preventer from - open to - close, a
standard system has zero pressure on the - close pilot line. With a quick-reponse system, the - close pilot
line has 800 - 1000 psi already on it).
Note:
Spring performance decreases with fatigue. Therefore, spring tension settings on the quick-response
SPMs should be greater than 1000 psi, to avoid accidental firing.
When the quick-reponse valve line pressure reaches 1,300 -1,500 psi, the quickrepsonse valve
trips.
PVD Training
This allows 3,000 psi pilot fluid, located at the pod, to flow into the function – controlling SPM valve almost
instantaneously.
The SPM valve moves off seat immediately and the overall operating time is reduced by half or more.
All other features of the standard hydraulic control apply. A schematic of the quick response system is
shown in Figure 8.3.35.
Fig 8.3.35
A MUX processor is mounted above each pod/solenoid rack in a one atmosphere bottle. A multiplex
control bundle size is generally 1 to 1-1/2" OD. (The electronic signal and solenoid valve arrangement is
analogous to a pre-pressured control line and extra pilot operated valve in a quick-response system.) EH
and MUX pods are larger than hydraulic pods and are typically not remotely retrievable.
Solenoids
Solenoid valves are used to send SPMs hydraulic signals. See Figure 8.3.36. With two additional equip-
ment packages, these control systems are obviously much more complex. The advan-tage of each is a
lower response time (i.e., the function signal is delivered to the pod much faster). Rams will respond in 6-8
seconds, bag-type annulars in 12-18 seconds. MUX has an additional advantage over a straight EH
system with the control cable options. Since only one pair of signal wires is required, extra features such
as riser angle indicator read-back or coaxial cables for stack mounted TV can be added without a
significant bundle OD increase. Additional stack functions may be added easily since all signals travel via
one pair of wires.

PVD Training
Fig 8.3.36 - Solenoid valve

PVD Training
1. On a floating rig with an indirect hydraulic control system manifold regulators are used in the Subsea
control pods to regulate power fluid.
Which of the following hydraulic BOP functions are operated using this regulated power fluid?
(Select SIX answers)
a) Annular BOPs.
b) Ram BOPs.
c) Riser Connector.
d) Wellhead Connector.
e) Wedge Locks.
f) Fail safe valves.
g) Mini collet connectors.
h) Diverter.
4 points
2. What is the maximum allowed response time for a subsea annular preventer according to API RP 53?
a) 30 seconds.
b) 45 seconds.
c) 1 minute.
d) 2 minutes.
e) Less than 15 minutes.
2 points
3. Which of the following statements describe the functions performed by the pilot control lines in the pod
control hose?
(Select FOUR answers)
a) Pilot lines allow regulation of the subsea regulators inside the control pods.
b) Pilot lines can be activated by the four way manipulator valves on the hydraulic closing unit.
c) Pilot lines operate SPM valves which allow hydraulic fluid to flow to the relevant BOP function.
d) Pilot lines are activated by manifold pressure.
e) Pilot lines are operated by annular pressure.
f) Pilot lines are operated by pilot pressure which is supplied by the accumulators.
4 points
4. Which of the following statements best describe a manipulator valve?
a) A manipulator valve is a 3 position 4 way valve that when activated allows regulated power fluid to be directed
to the relevant SPM valves in the control pods.
b) A manipulator valve is a 3 position 4 way valve that when activated directs unregulated power fluid to the
active pod on the subsea stack.
c) A manipulator valve is a 3 position 4 way valve that when activated directs regulated pilot pressure to the
relevant SPM valves in the active control pod.
PVD Training | 8.4 Workshop Exercise No. 7 105

PVD Training
d) A manipulator valve is a 3 position 4 way valve that when activated allows pilot pressure to be directed to the
relevant SPM valves in the control pods.
2 points
5. When a ram BOP is activated to the close position from the remote and/or central hydraulic control unit
on a floating rig, certain functions occur. Identify the correct functions from the list below.
(Select TWO answers)
a) An SPM valve fires in the active pod only.
b) SPM valves fire in both the active and redundant pods.
c) The ram open SPM valve or valves will be vented.
d) The ram closed SPM valve or valves will be vented.
4 points
6. Figure SS7- 001 below illustrates a Sub Plate Mounted valve (SPM) used in the In-direct hydraulic control
system in a Subsea BOP system.
Identify whether the valve is in the open or closed position.
a) The SPM valve is in the open position, allowing hydraulic fluid to flow to the BOP function.
b) The SPM valve is in the closed position allowing power fluid from the BOP function to be vented.
Figure SS7-001 Sub Plate Mounted (SPM) Valve

7. What is the function of the „memory button‟ found on subsea BOP remote panels?
a) To identify the correct position of the BOPs if the remote panel lights fail.
b) To identify which position a BOP was in prior to being put into block.

PVD Training
1 point
8. Power fluid travelling through a SPM valve is?
a) Regulated.
b) Un-regulated.
1 point
9. Subsea accumulator bottles should be pre-charged to:
a) The same as surface accumulator bottles.
b) The same as surface accumulator bottles plus the seawater hydrostatic pressure at the BOP stack.
1 point
10. Which of the following statements are true or false regarding riser flood valves?
a) The riser flood valve is pressure sensitive and will automatically open when the pressure inside the riser drops
to 200 to 300 psi below the ambient seawater hydrosatic pressure.
True/False
b) The riser flood valve can be remotely operated and reset through surface control lines.
True/False
c) The riser flood valve prevents the riser system from collapse.
True/False
1 point of each correct answer
11. From the list below match the following BOP manufacturers to the corresponding automatic ram BOP
locking systems.
1. Cameron
2. Hydril
3. Shaffer
4. Val-Con
Place the corresponding number (1 to 4) in box next to the correct locking device.
a) Multi Position Lock (MPL).
b) Ultra Lock.
c) Wedge Lock.
d) Pos Lock.

PVD Training
Figure SS7-002 - Koomey Indirect Control System

PVD Training
14. When a Subsea BOP is put into the „Block‟ position:

a) Actuating pressure is removed from the SPM valves.
b) The SPM valves vent any pressure supplied to the BOP functions.
c) The rams remain closed or opened depending on their position prior to being put into block.
d) Power fluid is prevented from entering the BOP operating chambers.
e) All of the above.
2 points
15. The following ten events take place as a sub-sea ram BOP is functioned to the close position from the
Drillers remote panel.
1. Unregulated pilot pressure arrives at the control pods lifting the relevant SPM valves on both Pods.
2. The ―push to operate‟ button is depressed at the same time as the ―Ram close‟ button is depressed.
3. Regulated Power fluid passes through a shuttle valve to the close chamber of the BOP.
4. The ram close solenoid allows air to flow to the air piston on the manipulator valve at the hydraulic control unit.
5. The 4-way manipulator valve moves to the close position.
6. The lights on the remote panel change from green (open) to red (close).
7. Manifold and Accumulator pressure decrease.
8. Power fluid fills up the closing chamber of the BOP, the power fluid in the opening chamber is directed to the
relevant closed SPM valve and is vented at the Pod.
9. The BOP is closed and manifold pressure returns to 1500 psi.
10. Unregulated Power fluid from both surface and subsea accumulators starts to travel through the manifold
regulator, and allows regulated power fluid to travel through the relevant SPM on the active pod.
From the above list of events please arrange the list of events shown below into the correct order from first to
last.

PVD Training
Event Numbers: 1, 2, 4, 5, 6, and 7.

a) First event ___
b) Second event ___
c) Third event ___
d) Fourth event ___
e) Fifth event ___
f) Sixth event ___
5 points
16. What is the maximum response time for a Sub-sea Shear Ram BOP according to API RP 53?
a) 30 seconds.
b) 45 seconds.
c) 60 seconds.
1 point
Figure SS7-004 - Cameron "D" type annular
18. Which of the following locking systems requires separate hydraulic control lines?

PVD Training
a) Wedge Lock.
b) Ultra Lock.
c) Pos Lock.
d) MPL.
1 point
19. On a ram type preventer, on a surface stack, in which position will the 4-way valve be put to assist with
the removal of the bonnet after backing off the bonnet bolts?
a) Open.
b) Close.
c) Neutral (Block).
d) Any position, it does not matter.
1 point
20. Which of the following are disadvantages when using a float valve?
(Select THREE answers)
a) If reverse circulation is required.
b) For obtaining drill pipe shut in pressure reading.
c) To prevent flow back while tripping.
d) Minimising surge pressure.
4 points
21. Which piece of equipment on a floating rig is considered to be the weakest point when diverting a
shallow gas kick?
a) The seals between marine riser joints.
b) The ball joint on the lower marine riser package.
c) The ball joint on the diverter housing.
d) The slip joint packers.
e) The insert packer (annular packing element).
2 points
22. An accumulator cylinder at surface has a pre-charge pressure of 1000 psi.
The pressure gradient for sea water is 0.445 psi/ft.
What will be the correct pre-charge pressure if the cylinder is used subsea in 1000 feet of water?
a) 555 psi
b) 445 psi
c) 1445 psi
3 points
23. Figure SS7-005 illustrates the main components of the Lower Marine Riser Package (LMRP) used for
subsea drilling operations.
Place the corresponding number in box next to the correct locking device.
a) Connector.
b) Annular Preventer.

PVD Training
c) Flex Joint.
d) Control Pod.
Figure SS7-005 - Lower Marine Riser Package

24. Figure SS7-006 illustrates a style of diverter commonly used when drilling with a Subsea BOP.

PVD Training
25. Figure SS7-007 illustrates a Hydril GL annular BOP. Which of the following statements are correct when
this preventer is used in a Subsea operation?
(Select TWO answers)
a) The secondary chamber allows balancing the opening force of the piston created by drilling fluid hydrostatic
pressure in the marine riser.
b) Lowest required hydraulic closing pressure when closing chamber and secondary chamber are connected.
c) Lowest required hydraulic closing pressure when opening chamber and secondary are connected.
3 points

PVD Training
26. Which one of the following statements about the “Memory Function” on a Subsea BOP Driller‟s panel is
true?
a) Memory Function indicates the previous position of the stack function before the ―Block position‖ was
selected.
b) Memory Function indicates a malfunction by giving a permanent light on the alarm panel after an alarm has
been acknowledged and the audible alarm has stopped.
c) Memory Function reminds the Driller to add anti-freeze fluid when the temperature drops below a set level.
d) Memory Function reminds the Driller to engage wedge locks before hanging off the drill string on the ram
BOPs.
3 points
27. On a subsea BOP installation, what is the advantage of using a kill line gauge to monitor changes in
pressure during a well kill operation?
a) The kill gauge is always more accurate.
b) The effect of choke line friction is reduced to a quarter when monitoring of the kill line gauge during the kill
operation.
c) Maintaining a constant pressure on the kill line gauge when starting or stopping the pump compensates for
the effect of choke line friction.
d) The effect of choke line friction is reduced to a half when monitoring on the kill line gauge during the kill
operation.
2 points
28. Figure SS7-008 illustrates part of the hydraulic “principle of redundancy” utilised to control functions on
the subsea BOP stack.

PVD Training
Which statement about the Shuttle valves on a subsea BOP stack is correct?
a) The Shuttle valves require 3000 psi to operate.
b) The Shuttle valves are directly controlled by pilot fluid.
c) The Shuttle valves are 3 position/4 way valves.
d) The Shuttle valves isolate the control fluid system between the active and the redundant pods.
e) The Shuttle valves isolate the hydraulic pilot system from the hydraulic control system.
3 points
29. When is the accumulator bank isolation valve closed on a hydraulic BOP control unit according to API
RP 16E?
a) During drilling ahead.
b) During the testing of the BOP‘s.
c) During any testing of accumulator unit, transportation and servicing.
d) When filling the reservoir with soluble oil.
3 points

PVD Training
1. B, C, D, E, F, G e) 2, Piston
2. C f) 6, Tail Rod
3. A, B, C, F 14. E
4. D 15. 2, 4, 5, 6, 1, and then 7
5. B, C 16. B
6. A 17. a) 1, Quick Release Top
7. B b) 8, Piston
8. A c) 7, Pusher Plate
9. B d) 9, Hydraulic Closing Port
10. a) True e) 5, Ring Groove
b) True 18. A
c) True 19. B
11. a) 2, Hydril 20. A, B, D
b) 3, Shaffer 21. D
c) 1, Cameron 22. C
d) 3, Shaffer 23. a) 7, Connector
12. a) 6, Control Pod b) 5, Annular Preventor
b) 7, Telescoping Joint c) 1, Flex Joint
c) 3, Annular Preventer d) 6, Control Pod
d) 4, Hose Reel 24. a) 9, Drill Pipe
e) 5, Choke and Kill lines b) 7, Standard (Outer) Packer
f) 8, Wellhead Connector c) 5, Diverter Packer Closing Port
g) 2, Hydraulic Unit d) 4, Flow Line Seals
h) 9, LMRP connector e) 8, Insert Packer Lockdown Dogs
i) 1, Drillers remote panels 25. A, B
13. a) 3, Locking Wedge 26. A
b) 4, Locking Port 27. C
c) 5, Extension Tail Rod 28. D
d) 1, Unlocking Port 29. C
PVD Training | 8.5 Workshop Exercise No. 7 – Answers 116

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Section 8.

Subsea Well Control

Table of Contents ............................................................................................................................................................................. 1

PVD Training | Table of Contents 1

PVD Training | Table of Contents 3

8.1.1 Use of Marine Risers

Remotely Operated Connector

Marine Riser Sections

8.1.2 Riser Collapse

PVD Training | 8.1 Overview of Subsea Drilling 5

Fig 8.1.1 - Marine Riser Fill-up Valve

8.1.3 Reduced Fracture Gradients-Formation Strength

PVD Training | 8.1 Overview of Subsea Drilling 6

PVD Training | 8.1 Overview of Subsea Drilling 7

8.1.4 Drilling with Riser and Diverter

8.1.5 Choke Line Friction Determinations

PVD Training | 8.1 Overview of Subsea Drilling 8

8.1.6 Pressure Loss Change as Gas Hits the Choke Line

8.1.7 Clearing Trapped Gas below the BOP’s

PVD Training | 8.1 Overview of Subsea Drilling 9

Trapped Gas in Bop Stack - Figure 8.1.4 (A)

Removing Trapped Gas from BOP Stack

Trapped Gas in Bop Stack - Figure 8.1.4 (B)

PVD Training | 8.1 Overview of Subsea Drilling 10

Trapped Gas in Bop Stack - Figure 8.1.4 (C)

1. Slowly displace kill line to salt water.

Trapped Gas in Bop Stack - Figure 8.1.4 (D)

1. Displace riser to kill mud using the upper kill line.

PVD Training | 8.1 Overview of Subsea Drilling 11

Trapped Gas in Bop Stack - Figure 8.1.4 (E)

Trapped Gas in Bop Stack Figure 8.1.4 (F)

PVD Training | 8.1 Overview of Subsea Drilling 12

Bubble Expansion Example:-

Gas Volume at Surface = = V2 = = 159 bbls

Riser Margin (ppg) = ÷ 0.052= (ppg)

8.1.8 Subsea Stack Procedures

PVD Training | 8.1 Overview of Subsea Drilling 13

Hazard Survey Report

PVD Training | 8.1 Overview of Subsea Drilling 14

Fig 8.1.5 - Hazard Survey Vessel

PVD Training | 8.1 Overview of Subsea Drilling 15

Fig 8.1.6 - Survey Grid

PVD Training | 8.1 Overview of Subsea Drilling 16

Table 8.1.1 - Hazard Survey Tools

PVD Training | 8.1 Overview of Subsea Drilling 17

Handling Shallow Gas in Conductor Hole

PVD Training | 8.1 Overview of Subsea Drilling 18

3. Sweep the hole frequently to assure hole cleaning.

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b) Immediately increase pump speed and pump as fast as possible.

Diverting at the Sea Floor

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Fig 8.1.8 - Effect of Water Depth on Fracture Gradients

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Handling Shallow gas in Surface Hole

Well Control Considerations in Surface Hole

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Loss of Buoyancy in a Gas Plume

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Recommended Practices for Diverting on Floating Rigs

Fig 8.1.9 - Surface Diverter Equipment

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Fig 8.1.10 - Hydril FS 21-500 Diverter