Surface BOPs

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1
 Surface Well Control Equipment

• Secondary Well Control

• If formation pressure exceeds BHP for
any reason due to drilling into a
formation with a higher pore pressure,
swabbing on trips, gas cut mud etc,
Primary Well Control is lost and an influx
may occur.
• BOP equipment must then be used to
enable the “kick” to be controlled by one
or more kill procedures.
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2
 Secondary well Control (continue)

• To avoid single components to create total

failure of the system a contingency (back

up) function should be build into the

system.

• All well control equipment must be

maintained, function- and pressure tested

according to company policy and

procedures to assured correct function and

integrity when required.

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3
 Secondary well Control:
Drill String Barriers
• With the well closed in and the drill
string in the well bore, formation
SIDPP
pressure can be obtained through SICP
the drill string by adding SIDPP
with pressure hydrostatic.
Mud
• To secure the drill string and obtain
CSD
integrity the following barriers can
be used:
• FOSV (full opening safety valve)
• One way valves (IBOP, Dart sub) Gas
• Check valves (Drill pipe floats) Pf
TD

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4
 Secondary well Control
Annulus Barrier
• To secure the annulus and
obtain integrity the following
barriers can be used:
• Annular Preventer
• Ram Preventer
• Shear/Blind Ram
• Rotating head

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5
 Basic BOP Set Up

Here we see a typical stack-up

of the Blow Out Preventers.
Top Down:

1. Annular Peventer
2. Rams (pipe rams)
3. Rams (blind/shear rams)
4. Drilling spool with the
hydraulic operated valves
(HCR)
5. Rams (Pipe or variable
bore rams)
6. Casing head or casing
spool
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 Rated Working Pressure
• 2K 2,000 psi (13.8 MPa)

• 3K 3,000 psi (20.7 MPa)

• 5K 5,000 psi (34.5 MPa)

• 1OK 10,000 psi (69.0 MPa)

• 15K15,000 psi (103.5 MPa)

• 20K20,000 psi (138.0 MPa)

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7
 Stack Component Codes

• Every installed ram BOP should have,

as a minimum, a working pressure
equal to the maximum anticipated
surface pressure to be encountered.

• The recommended component codes for

designation of BOP stack arrangement
are as follows:
G = Rotating head.
A = Annular type BOP.
R = Single ram type BOP with one set
of ram, either blank or for pipe, as
operator prefers.

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 • RD = Double ram type BOP with
two sets of rams, positioned in
accordance with operator's choice.
• RT = Triple ram type BOP with
three sets of rams, positioned in
accordance with operator's choice.
• S = Drilling spool with side outlet
connection for choke and kill lines.
• C = Hydraulic well head connector with
a minimum rated working
pressure equal to the BOP stack
rated working pressure.
• K = 1000 psi rated working pressure.

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 BOP components

• BOP components are typically described upward

from the uppermost piece of permanent wellhead
equipment, or from the bottom of the BOP stack. A
BOP stack may be fully identified by a very simple
designation, such as:
• 15K - 13 5/8 - RSRRAG
• This BOP stack would be rated 15,000 psi (103.5
MPa) working pressure, would have a through bore
of 13-5/8” (34.61 cm), and would be arranged as in
RSRRAG.
• Annular BOP’s may have a lower rated working
7/12/08
pressure than the ram BOPS.
10
 Surface Well Control
Equipment

Standpipe
Drillers Remote Manifold
BOP Panel

Remote Choke

Annular
Preventer

Central Hydraulic control Choke /Kill

Double Pipe
Manifold (Koomey Unit) Manifold
Ram Preventer
Kill Line
Drilling Spool

Control Lines from

Koomey Unit to BOP Single Pipe Choke Line
HCR Valve Choke Line
Ram Preventer
Casing Head

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 Stack Configurations
9
Fill Up
Line 8
1. Flanged gate valves – 2” minimum ID,
same working psi as “A” section. The
Annular
BOP
outside valve is the working valve during
well control operations. This valve is
removed and reused after completion.
Outlet Flange 2. Tee with tapped bullplug, needle valve and
Used Only for
Blind Ram pressure gauge.
Ram Combination
Stripping 3. Flanged gate valve – 2” minimum ID –
same as working pressure as “B” section.
4. Flanged gate valve – 2” minimum ID –
Upper Pipe Ram same working pressure as BOP stack.

Choke Line 5. Drilling Spool – two flanged outlets – 3”

5 Choke choke and 2” kill line minimum IDs.
Drilling Manifold
4 4 Spool 7 6 6. Flanged hydraulically controlled gate valve
– 3” minimum ID – same working pressure
as BOP stack.
Lower Pipe Ram 7. Flanged gate valve – 3” minimum ID –
same working pressure as BOP stack.
2
3 3 8. Top of annular preventer must be equipped
Section B with API flange ring gasket. All flange
studs must be in place or holes filled in
with screw-type plugs.
Section A
9. The ID of the bell nipple must be less than
1 1
2 the minimum ID of the BOP stack.

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 Standpipe Manifold

To Derrick Standpipe To Derrick

For 10,000 psi and 15,000 psi BOP Standpipe

systems, it is acceptable to use

5000 psi standpipe manifold, but the
isolation valve should be the same Pressure Gauge
pressure rating as the BOP stack, as
should the connecting pipework.
To Vent Line
From Cement
Pump

The primary purpose of a “manifold”

is to allow flexibility with regard to
circulation paths.
To Choke Line To Kill Line

Hole Fill-Up
The manifold shown at right allows From Mud Pump
one mud pump to be lined up on the From Mud Pump

annulus (through kill line) and the

second to kelly or circulating head.

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 Surface Well Control
Equipment

Drilling Spool
Kill Line

Manual Valve
(inner valve) HCR Valve
(outer valve) Choke Line

Casing Head

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 Casing
Heads
and
Spools

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15
1. Like all other Stack
equipment the Spool should
be Studded, Flanged or
Clamp-on connected.

2. The picture has been

labelled with ID, pressure
rating and Ring Gasket
type.

DRILLING SPOOLS
1. A Drilling Spool is a connector placed within the BOP Stack to which are
attached the choke and kill lines. Certain Rams have integral choke and kill
line connections.
2. The reasons for using Drilling Spools are to localise erosion in the cheaper
spool and to give additional space between rams; useful when stripping.
3.
Spools must have pressure ratings equal to the rest of the Stack and a vertical
7/12/08 bore to allow the largest diameter equipment to be lowered.
16
 Drilling Spool
• Choke and kill lines may be
connected either to side outlets of
the BOP’s, or to a drilling spool
installed below at least one BOP
capable of closing on pipe.
• Utilization of the BOP side outlets
reduces the number of stack
connections and overall BOP stack
height.

• However, a drilling spool is used to

provide stack outlets

(to localize possible erosion in the less expensive spool)

and to allow additional space between preventers to
facilitate stripping, hang off, and/or shear operations.
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 Drilling spools for BOP stacks should meet the following
minimum qualifications:

a. 3K and 5K arrangements should have

two side outlets no smaller than a 2-inch
(5.08 cm) nominal diameter and be
flanged, studded, or hubbed.
b. 1OK, 15K, and 20K arrangements should
have two side outlets, one 3-inch (7.62
cm) and one2-inch (5.08 cm) nominal
diameter as a minimum, and be flanged,
studded, or hubbed.
c. Have a vertical bore diameter the same
internal diameter as the mating BOP’s
and at least equal to the maximum bore
of the uppermost casing/tubing head.
d. Have a rated working pressure equal to
the rated working pressure of the installed
ram BOP
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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Typical Annular Preventer

Typical Annular
Preventer:
1 Rubber element
2 Top seal ring
3 Secondary closing
chamber
4 Piston Seals
5 Primary closing
chamber
6 Piston
7 Opening Chamber

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 Annular Preventers
• In the industry there are three different manufactures of
Annular Preventers used both for SubSea or Surface
application:

1. Hydril :
Model “GK”
• Model “GL”
• Model “GX”
• Model “MSP”
2. Cameron Cooper:
• Type “D”
• Type “DL”
3. Shaffer:
Shaffer Spherical

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 Surface Well Control
Equipment

Hydril GK
Annular
Preventer

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 Surface Well Control
Equipment

Hydril GK
Annular
Preventer

Land
Operation

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 Hydril Annular Type GK Preventer

Animation
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26
 Surface Well Control
Equipment

•THE UNIQUE FEATURE OF

HYDRIL ANNULAR
PREVENTERS IS WELL-
PRESSURE ASSIST ON THE
BOTTOM OF THE
OPERATING PISTON.

WELL PRESSURE APPLIED

FROM BELOW HELPS
KEEP THE ANNULAR
CLOSED.

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27
 Annulars: WHAT ARE THEY DESIGNED TO DO?

 Seal around smooth objects in the wellbore e.g. drill collars,

drill pipe, casing, tubing, square kelly and wireline.

 Seal off an open hole although not necessarily at full R.W.P.

(this will shorten the working life).

 Allow stripping of drill pipe under pressure while maintaining

a seal.

 Allow reciprocating of the drill string during well control

operations.

 Allow rotation of the drill string during well control

operations.
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 Surface Well Control Equipment

HYDRIL
GL type .

Used for
subsea and
deep
land
operations

Two closing
chambers

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 Surface Well Control
Equipment
HYDRIL GX ANNULAR PREVENTER

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 Surface Well Control
Equipment

5” Drillpipe

Adjusted pressure
300/400 psi

SICP pressure
7/12/08 1000 psi
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 EXERCISE

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33
 EXERCISE)

A. What is the recommended initial hydraulic closing pressure

for stripping operation for a 13 3/8” pipe in the BOP if the well
pressure is 1500 psi?.
300 – 400 psi
B. What is the recommended initial hydraulic closing pressure
for stripping operation for 9 5/8” pipe in the BOP if the well
pressure is 2000 psi?.
900 – 1000 psi
C. What is the recommended initial hydraulic closing pressure
for stripping operation for 5½” pipe in the BOP if the well
pressure is 3000 psi?.
1000 – 1200 psi

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 Surface Well Control
Equipment
Tubular
Annular Element
•ANNULAR
PREVENTER IN
OPEN
POSITION

500 to 1500 psi on

opening side of piston

Closing side of piston

vented back to tank
Operating Piston
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 Surface Well Control
Equipment

•ANNULAR
PREVENTER
FUNCTIONED

CLOSED

Operating fluid vents

from opening side of
piston

500 to 1500 psi on

closing side of piston
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 Surface Well Control
Equipment

ANNULAR
PREVENTER
FULLY
CLOSED

Operating fluid vented

from opening side of
piston

500 to 1500 psi on

closing side of piston +
wellbore pressure
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 ANNULAR PREVENTER TYPES

 Normal Operating Press : 600 – 900 Hyd.GK

1500 Cameron D

 Closing Time : Should not exceed 30seconds

for preventers smaller than 18¾” .

: Should not exceed 45 seconds for

preventers 18¾” and larger.

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 Hydril and Shaffer Element

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40
 Surface Well Control
Equipment
• Annular Preventer
 The most vulnerable part of the
annular preventer is the rubber
packer unit, which is subject to
wear. The annular should never be
closed on open hole during function
testing as this will shorten the life of
the packing element.
 When packing element leakage
occurs during kick control, a pipe ram
preventer should be closed and if
necessary, a second set of ram
preventers should be equipped with
pipe rams before the killing operation
is resumed.

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 Surface Well Control
Equipment
Cameron
Cooper:

Type “D”

Type “DL”

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7/12/08
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 Cameron Element

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 Shaffer type Annular
Prevente
Element
Wedged Head

Adapter Ring
Shaffer
type
Annular Opening Chamber
preventer

Operating Piston Closing Chamber

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Pipe Rams

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50
 Pipe Rams

1. Pipe Rams are installed to close around one specific pipe size.
2. Also they should be able to carry the entire load of the drill string when the drill
pipe tool joint is set on the top of the rams.
3. A locking device at the end of the piston, provides a piston lock- up to prevent
an accidental opening of the rams.
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51
7/12/08
52
 Pipe Rams
1. Pipe rams are designed to close
and seal on one specific size of
pipe, and
2. are also used for "hang-off.
 With hang-off, the ram is used to
suspend pipe or casing by closing
underneath a tool joint.
 The recommended procedure for
emergency hang-off of drill pipe is
to close the rams, lock the ram
using the normal procedure, and
then transfer slowly the drill pipe
weight onto the rams.

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53
 Closing Ratio
A dimensionless factor equal to the wellbore pressure divided by the operating
pressure necessary to close the ram BOP against wellbore pressure.

1. Closing ratios are generally in the range from 6:1 to 9:1.

This means that it takes 1 psi of closing hydraulic
pressure per 6 to 9 psi wellbore pressure to close the
preventer.
2. Stated in another way, on a preventer with closing ratio
of 6:1, if the wellbore pressure is 3.000 psi it should
take 500 psi hydraulic pressure to close the preventer.

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54
 Typical Pipe Rams body block

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 Surface Well Control
Equipment

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56
 Surface Well Control
Equipment
CAMERON FIXED BORE
RAMS

Cameron rams are self-

feeding, with a large
reserve of packer rubber.

The packers are locked in

place and are not
dislodged by well flow, the
packer rubber is bonded
to steel plates which
confine it to the sealing
area.

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 Surface Well Control
Equipment

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58
 Surface Well Control
Equipment
•SHAFFER FIXED BORE PIPE RAMS

Ram Block Retaining Screw

Ram Holder
Ram Rubber

Retracting Screw

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59
 Surface Well Control
Equipment
Tubular

Extrusion Plate
Top Seal

Piston Ram
Ram
Rod Block
Rubber
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60
 SHEARING BLIND RAMS
Shearing blind rams (SBRs) are dual-purpose rams.
Under normal operating conditions, they are used as blind rams to
shut-of an open hole.
When used as a blind ram, the blade packer in the upper shear ram
seals against the front face of the lower shear ram.
In an emergency, SBRs are used for shearing.

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 Surface Well Control
Equipment

•CAMERON BLIND/SHEAR RAMS

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 Surface Well Control
Equipment
•CAMERON BLIND/SHEAR RAMS
Top Seal

Side Packers
Upper Ram
Block

Blade Packer

Upper Ram
Lower Ram Assembly
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 Surface Well Control
Equipment

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 Surface Well Control
Equipment
Shear Blade

Shear Blade

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65
 Shaffer Shear Rams
Rams

Exploded View of Shear Rams

1. Upper Holder 2. Lower Holder

3. Upper Ram Block 4. Lower Ram Block
Shear Rams
5. Upper Rubber 6. Lower Rubber
7. Lower Shear Blade 8. Retainer Screw
9. O-Ring 10. Retainer Ring
11. Allen screw 12. O-Ring
13. Washer

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66
 Well Control Equipment

CAMERON
VARIABLE BORE
RAMS

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67
 Variable Bore Rams
1. The Variable Bore Ram, or VBR, seals on several sizes of pipe within
its specified size range. A typical range for Careron Iron Works
variable bore rams, is from 5" to 3-1/2". Other size ranges, such as 7"
to 4-1/2", are available.
2. VBR’s are not intended for stripping use purposes.

Typical Cameron Iron Works variable bore ram

7/12/08
blocks and sealing elements.
68
 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

•Once the bonnet bolt have been released reduce the Manifold
Pressure to minimum, move the manipulator valve to the CLOSE
position and slowly increase the Manifold Pressure until the
bonnets slide out on the ram change pistons.

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 Surface Well Control
Equipment

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 Opening & Closing Lines

Opening Line

Opening Chambers

Piston

Closing Chambers

Closing Line

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 MATCH THE ITEMS LISTED TO THE NUMBER AS FOUND
IN THE FOLLOWING DIAGRAM

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79
 Side Packers =2

Blade Packer =3

Top Seal =1

Top Ram Assembly =4

Lower Ram Assembly =5

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 Surface Well Control
Equipment

Emergency Mud Seal

Intermediate Flange

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 Surface Well Control Equipment

Intermediate Flange Weep Hole

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82
If during an emergency operation the seals on
a Ram leak there are a secondary set of seals
that can be activated. . The secondary seal is
activated by screwing down on the piston
which forces plastic through the check valve
and into the space between the two swab cup
seals. Further piston displacement causes
pressure to build up between the swab cups,
forcing them to flare out and provide a seal.
When the pressure exerted by the plastic
packing reaches the proper valve, additional
displacement of the piston will overcome the
spring tension in the relief valve and plastic
packing will begin to extrude from it.
The secondary seal should only be activated
if the primary connecting-rod seal leaks during
an emergency operation. The secondary seal
is designed for static conditions and
movement of the connecting rod causes rapid
seal
7/12/08
and rod wear.
83
 Secondary Ram Shaft Seal

On many ram preventers there is a “weep hole”

located on the under side of the preventer body.
This hole is lined up with the “travel” of the ram.
The weep hole is actually in line with secondary
rod shaft seals and is there to indicate leaks in
those seals. If needed, the cap screw is removed
and using an allen wrench, plastic sealant is
injected through a check valve and around the
ram shaft between seals to temporarily stop the
leak.

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84
 Surface Well Control
Equipment
•SECONDARY OR
•EMERGENCY MUD SEAL

•The figure shows the secondary mud

•seal on a NL Shaffer ram type BOP.
•The secondary seal is a plastic
packing
•injected into an exterior groove around
•the ram shaft. As more plastic is
•injected and seals off between the ram
•shaft and the interior body off the
•preventer. The secondary mud seal
•should only be used in an emergency
•and is only usable once.

7/12/08 85 85
 •If the Weep hole leak while testing BOPs… Immediate
repair
•If the Weep hole leak while Killing Operation… energize
with Plastic sticks, Use Secondary Packing

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86
 Surface Well Control
Equipment

Bonnet Bolt

Locking Screw Housing

Locking Screw

Bonnet Assembly

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87
 Refer to the diagram below of a Pipe ram preventer on a surface stack:

(a) During a BOP pressure test, water is observed coming from the weephole.
What action should now be considered?
--------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------- 3 points
b) If hydraulic fluid is observed coming from the weephole, what position is the
four way valve most likely to be in?
( a ) Open
( b ) Closed
( C ) Neutral or Block 3 points

(a) Replace the mud seal

(b) Open
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88
 Surface Well Control
Equipment Secondary Mud Seal

Ram Change Cylinder

Primary Mud Seal
Ram Change Piston

Bonnet Stud

Intermediate Flange

Operating Piston
Bonnet

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89
 Surface Well Control
Equipment

Bonnet Bolt

Locking Screw Housing

Locking Screw

Bonnet Assembly

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 Surface Well Control
Equipment

Upper Pipe Ram

HCR Valve

Manual Valve
Check Valve

API 6BX Flange

Lower Pipe Ram

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7/12/08
92
 Motion of the piston and tail rod during closing or opening
the ram causes the lock nut to rotate. The fast lead, six path
helical thread rotates the nut three turns per foot of travel.

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 Surface Well Control
Equipment

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Surface Well Control 94 94
 Surface Well Control
Equipment

Wedge Lock Assembly

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment
Tail Rod Slot

Wedge Piston
Locking Piston

Opening Port
Closing Port

Operating Piston Tail Rod Extension

Ram Bonnet

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 Surface Well Control
Equipment
CAMERON WEDGELOCK

The Wedge Lock System is a hydraulically

operated mechanical locking mechanism,
thus demanding a separate hydraulic
system to be activated and deactivated.
The Wedgelock system will lock the rams
in their closed position and maintain the
rams mechanically closed and locked also
when actuating pressure is released.
The hydraulic operating system can be
interlocked using sequence valves to
ensure that the Wedgelock is retracted
before pressure is applied to open the
rams. For subsea applications, a pressure
balance chamber is connected to the
Wedgelock housing to eliminate the
possibility of the Wedgelock becoming
unlocked due to hydrostatic seawater
Pressure.

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment
According to API RP 53, what is the
meaning of the
term "closing ratio for a ram type BOP”?

The ratio of wellhead pressure to the

pressure to close the BOP.

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

Well pressure
10,000 psi
Manifold
pressure
1500 psi

BOP closing ratio: 10.6 to 1

10,000 psi ÷ 10.6 = 943 psi
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 Surface Well Control
Equipment

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 Surface Well Control
Equipment
Drill string
sheared with
rams

Drill string
Hung-off on
lower pipe rams

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 Surface Well Control
Equipment
Bonnet Seal
Threads on Ring Groove
Internal & Groove
Locking Hinge Pin
Screw Bore

Sealing
Face

Piston Rod

Ram Outlet

Sealing
Face Ram Foot
Ram Cavity

Stud Holes Bonnet

Cavity
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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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108
 BOP TEST

 Factory shell test.

 Low pressure Test:
All components should be tested to 200 – 300psi for at least
5minutes.
 Initial high pressure Test:
OR Acceptance Test
OR Prespud Test
OR Test on Test Stump
Should be performed on location before the well is spudded or
before the equipment is put into operations service.
Ram 100 %
Annular 70 %
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109
  Subsequent high pressure Test:

(Not to exceed 21 Days)

Greate than max. anticiplated surface pressure, but not exceed

working pressure of ram BOP’s

 Function Test:

(Once Per Week)

All operational components should be functioned to verity the

components.

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110
 Pressure Test Frequency

• According to the API RP 53 Pressure test on well

control equipment should be at least:

1. Prior to spud or upon installation.

2. After disconnection or repair of any component

3. Not to exceed 21 days

4. Manufacturer test the body of new well control

equipments to 150% of the Rate working Pressure RWP

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111
 5. Closing time RAM Annular
Smaller than 18 ¾” 30 sec max. 30 sec max.

18 ¾” and larger 30 sec max. 45 sec max.

6. Pressure Test Frequency

Pressure test on well control equipment should be at least:

1. Prior to spud or upon installation.

2. After disconnection or repair of any component

3. Not to exceed 21 days.

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112
 7. Shell or Body Test at manufacturer Shop
1 ½ times BOP rating I.e. 150% of pressure rating.

8. Closing Ratio
Ratio of well head pressure to pressure required to close the
BOP.
10. Choke Lines
1. Minimum recommended size for choke line is 2 inches for 3K and
5K arrangements and 3 inch for 10K and 15K.
2. Minimum recommended inside diameter for lines downstream of
choke should be equal to or greater than the connecting lines of
the choke (choke line).
3. The bleed line should be at least equal in diameter to the choke
line . This line allows:
a) Circulation of well with preventors closed while
maintaining a minimum back pressure.
b) Permits high volume bleed off of well fluids to relieve
casing pressure with the preventers closed.
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 Diverter Hook Up

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment

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 Surface Well Control
Equipment
•API Standard Diverter

•1: Drillpipe
•2: Diverter housing
•3: Closing line
•4: Insert packer
•5: Diverter vent line
•6: Insert packer
lockdown dogs
•7: Diverter
lockdown dogs
•8: Standard packer
(outer packer)

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•Diverter Procedures for Land
•Rigs, Swamp Barges, Jack-ups.

At first sign of flow:

1: Do not stop pumping.

2: Open the diverter line to divert/close

diverter (both functions should be
interlocked).

•3: Increase pumps strokes to maximum

(do not exceed maximum pump speed
recommended by the manufacturer or
maximum pressure allowed by relief
valve).

4: Switch suction on mud pumps to

heavy mud in the reserve pit. Zero
stroke counter.

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Diverter Procedures for Land

Rigs, Jack-ups.

5: Raise alarm and announce

emergency using the PA system
and/or inform the Toolpusher.

6: Post personnel to look for gas

(jack-up, swamp barges).

7: If the well appears to have

stopped flowing after the heavy mud
has been displaced, stop pumps
and observe well.

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Diverter Procedures for
Land Rigs and
Jack-ups.

8: If the well appears to continue to flow after the heavy

mud has been pumped, carry on pumping from the active
system and prepare water in a pit for pumping and/or
consider preparing pit with heavier mud.

When all mud has been consumed, switch pumps to water.

Do not stop pumping for as long as the well continues to
flow.

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Typical Diverter
System
Installed on a
Floating
Rig

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