Boricon BOP-TEST Guidelines

TEST PROCEDURES:
In general; a BOP test consumes a lot of rig time and often more than necessary.
The main reasons why these tests take longer than required are not related to
equipment problems. The reasons are related to:
a) Little understanding of the wellhead and test-tools.
b) The wrong set-up
c) The preparation, before the actual testing commences, is not thoroughly enough,
This leads to downtime.
The preparation of a BOP-test starts with a proper understanding of the wellhead, the
way the test-tools are situated in there and the BOP's itself.
A manual should be onboard/onsite and should be consulted.
Most (All) manuals have proper drawings of the test tools and the way they fit.
Two test-tools are generally available: Plug-type tester & Cup-type testers.
A Plug-type tester sits in the top of the wellhead and does not enter the casing.
Normally, the wellhead is rated higher than the casing and therefor the test-pressure
with a plug tester can be higher.
A Cup-type tester enters the casing. A standard F tester can be put anywhere in the
casing. The Test-pressure should not exceed 80% of the casing burst pressure.
There have been occasions, where the test pressure exceeded the rating of the Cuptester and the drill pipe parted or the cup failed. (In smaller size casings with a high
burst-pressure).
Therefore Shell-Cameron designed a Cup-tester which is wellhead supported and there
is no strain on the drill pipe.
To safeguard the casing against a too high a pressure; with a PLUG-type tester,
always have an outlet on the wellhead, below the Plug, open to atmosphere in case the
tester leaks past the seals. Calculate the volume required to get to test pressure.
Often not more than a few gallons.
With a CUP-type tester: Always have the drill pipe open to atmosphere in case the Cup
leaks into the casing. (The casing might be drilled out and the test pressure will go onto
the formation)
Never set the slips if a type F Cup-type tester is used.
When pressure is applied the CUP will move down and pull on the drill pipe.
The Martin-Decker will get an increased reading. The Driller can therefore check if he

stays within the maximum pull limits of his drill pipe.

Better is it to calculate the force before the pressure is applied to check if the set-up is
adequate.
Area of cup;
9-5/8 43.5-53.5 #= 42.4 sq./ 13-3/8 103 sq./18-5/8=230 sq. and 20 = 300 sq.
Example: A 3500 psi-test will produce a force of 33500 psi x 42.4 sq. =148400 lbs.
on a 9-5/8cup. One can also see the advantage of a Wellhead supported Cup-type
tester.
PREPARATION for TESTING:
1) Establish the test pressures. How high is the test-pressure going to be?
2) Check the wellhead and the Casing burst pressure! Do not exceed 80% of these.
Always have B annulus open and guarded, while testing.
3) have a Drawing available to know, where the individual testers will seat.
Depending on Casing hangers already present in the wellhead this might vary.
Secondly, a measurement from the Rotary table to the hang-off point can be
calculated.
4) Check the Test-tools on the deck and make sure the O-rings or Seals are in good
order- Check on spares.
5) Depending on the measurement from the R/Table to the Hang-off point, a test-string
will be made up- A full single through the BOP; Pup-joints as required.
6) Every rig will have (or should have) a Test-procedure.
The first test should be small-i.e. only a few items involved to check surface linesTester and one set of ramsThis eliminates delays later and will prove that the basics are sound.
Based on this test-we will extend our testing. A lot of Rig-time is lost due to testing
too many items at ones and you are not able to find which one is leaking.
7) The formula to establish the Volume needed for a test:
Volume (BBL) = Test pressure x Volume x .000003 (Water)(Five times zero)
.0000045 = Water based mud, .0000059 = Oil-based mud.
Example: Stack test-to 5000 psi.
Depth to wellhead to Annular= 50', 13-5/8 = ~8 bbl.
Volume required to get up to test-pressure= 5000 x 8 x .000003 = .15 bbl.

Not very much.

If this is known in advance, time is saved when the cementer has pumped 1-2 bbl.
and NO pressure is achieved.
If a casing test is needed-13-3/8 x 2500 ft. to 3500 psi. =
3500 x 381 bbl. x .000003 = 4 bbl. to be pumped.
THE ACTUAL TEST:
1) Pull Wear bushing- Always measure the bushing out from R/T- to Bottom
of the Bushing.
2) Drain Riser at wellhead.
3) Flush stack out with a water hose.
4) If radio's are available or the Remote is close:
Operate all the rams-Operate the Close-lever and open up, as soon as the rams
come out. This to clear the Cavities.
5) Flush out with water again.
6) Make up Plug type tester and check seals once more.
Grease lightly-Dirt etc. Sticks to grease and might score the wellhead.
7) Always measure in. If there is a Hang-up, you will know where!
8) Land Tester-The measurement should be close to the one of the wear bushing.
Open up one Outlet below the PLUG type tester. A person there to watch.
A) Assuming the test is performed through the pipe-Open all valves on the stack
and on the Choke-manifold. Fill up the stack with water and flush all air out of the
Choke-& Kill-line.
T1) Close the Bottom rams; Close the Inner-BOP-valves and Manual Kelly valve.
Apply the test pressure. This will be a very small volume. If the test is goodThe Plug tester is good, the Inner valves are good and the Bottom rams are.
T2) Open up the Inner valves and Test the outer valves.
T3) Open Bottom rams-Close Upper rams-Close Inner valves below U/RamsTest Upper rams and Inner valvesT4)Test Outer valves.

By making up such procedure, the changes are logical and small;

a leak can be pointed at quickly.
The previous test was good, so it must be one of the valves or a set of rams etc. This
can be checked quickly. By not following a logical procedure, lots of time is lost.
Once the BOP, Inner -Outer valves have been tested, the Choke and KILL line will
follow. A lot of rigs will then pull the test-string and test the Blind-rams. Once that is
done, the CUP type tester is run to test the Outlet below the Plug type tester. (AAnnulus valve).
The remainder of the Choke and Standpipe manifold can be tested once the Test plugs
have been recovered and the wear bushing is re-run.
Also here should there be a logical sequence and not too many valves at once.
At a glance, one will notice that there are more tests involved than in one big test,
which is true.
But experience shows that the time lost while searching for a leak with many valves
involved is enormous, because people than go back to the small, individual tests to find
out where it is leaking.
To find a leak;
first, develop a sequence-plan for your testing which involves small, individual steps
towards an overall test.
The leak can then be located quicker and often it will be a choice between two.
Closing a valve Down-stream of the suspected valve gives the clue.
If the Rams are suspect; do not open the bonnets up straight away.
Better is too make sure it is the rubbers, by draining the stack-level to below the ramsClose the rams to a 1Gap by operating the close-lever and put it in block-check the gapclose it a bit more-in block etc. Fill up the stack to a point where the level is just at the
rams. (This all, off course, if you can see the rams)
Close the rams and re-test. If they leak, it will be very clearly visible.
It has been the case that the Test-string leaked at a connection above the rams but
below the fluid-level in the well. When using a Plug-type tester, the valve below the
tester is open.
A Crew-member should be on watch. Also the annulus should be full below the tester.
Stick in a water hose and convince yourself the well is full.
Any leak past the Plug will be detected quickly.
When using a Cup-Tester-The drill pipe should be open, i.e. No top-drive installed.
It's wise to top up the drill pipe with a water hose to detect leaks quicker.
If the cup leaks-The drill pipe needs to fill up first before you see it.
The CUP are made for different grades of casing. On the top of the Cup, you will find
the grade-range, the cup is suitable for. This is also important when ordering new cups.
A bit of luck and common sense is needed.

To keep the BOP- stack in good shape, it is advisable to function test the Rams, Valves
and Annular-every couple of days.
Open the valves on the wellhead also once in a while to make sure they have not been
plugged with cuttings and/or cement. (When drilling out shoe tracks etc.)
It should not harm the Blind-rams when they get closed regular. On trips etc.
The life of Pipe-rams is shortened when closed in open hole. This should not be done
as a routine.
When testing the Choke manifold; do not test against a closed Choke. The choke is
made out of tungsten carbide and very hard and brittle. The choke-bean or stem might
break.
Accumulator testing/sizing:
The pre-charge pressure in the bottle is usually 1000 psi.N2. The size of the bottles is
usually 11 gallons. Effective size 10 gallons. When the hydraulic fluid is pressed in the
bottle, the Accumulator pressure will be 3000 psi.
Using the law of Boyle. P1 x V1= P2 x V2= 1000 x 10 = 3000 x X ----> X = 3.33.
This means that the N2-bladder will have shrunk from 10 gallons to 3.33 gallons and
thus .66 gallons of fluid is left in the bottle.
When we operate the BOP's, fluid will be taken out of the bottle. If we perform an
Accumulator test, all Preventers (Rams and Annular) will be closed and opened. There
should be enough pressure available to close one more Ram and One Annular
preventer. Generally a min. of 1200 psi is aimed for. (After above)
Per bottle, assuming 1200 psi final pressure, there will be (3000 x 3.33 = 1200 x X =
---->
8.33 gallons N2 ----> means 5 gallons of fluid available.
Check in the Operators manual, how much gallons are required to Close and Open the
Preventer and size the accumulator accordingly. (50 % excess is recommended.)
While performing the test, all pumps will be switched off and after the test, only one recharge system (either Air pumps or triplex) will be used.
Max. Time to recharge 15 minutes.
Max. closing time of Annular up to 18-3/4 is 30 seconds, Rams 30 seconds and Annular
bigger than 18-3/4 45 seconds.
The automatic re-charge switch will be set at 90 % of the working pressure. This should
be checked with only the electric pumps operative. A min. level indicator should be
present. Anti-freeze should be present in cold conditions.
Test frequency: At start of well and after repairs to accumulator Unit.
Supplement: To BOP document.
Shear forces on Ram type preventers:

Description:

Shear force:

2-7/8

N80

6.6 lbs/ft.

120.000 lbs.

3.5

P-110

10.2 lbs/ft

180.000 lbs.

G-105

19.5 ft/lbs

375.000 lbs.

S-135

19.5 ft/lbs.

375.000 lbs.

X-95

25.6 lbs/ft.

480.000 lbs.

Force required to shear ------------------------------= Closing pressure.

Closing Area (sq. inch)
Closing area of the BOP-shear ram- depends on the size of the Operating piston and
the size of the piston rod.
For a 13-5/8 Cameron Bop, bonnets of the Shear rams are usually bigger, the size of
the piston = 13.75. The rod is 3. The working area for the closing pressure = 136 sq.
inch.
Therefor the closing pressure = 375.000/ 136 = 2756 psi.
Available from the Koomey, 3000 psi. The average pressure, taking into account
leakage past the valves, is considered 2800 psi. Therefor the shear pressure should be
based on a maximum of 2800 psi.
The size of the bonnet, as can be seen from the calculation, needs to be big. The type
of Ram also plays a role. Cameron rams have an option to install a Tandem booster in
the bonnet which increases the Closing area and therefor reduced the required closing
pressure.
Things to watch for are the size of the Bonnet, thus the Closing area, and the type of
rams installed. There is a difference between Shearing Blind Rams and DS Shear rams.
DS Rams have a different seal design, an M/M seal plus rubber, and require no booster.
The Shearing blind ram does.
The Booster is a two part piston assembly. The extra piston is designed to disengage
after the shearing operation, but prior to energizing the packer in the ram. A One-piece
two cylinder assembly cannot disengage and might over-energize the packers.

Reducing the service life. A BOP with Tandem (two pistons) Booster can give max.
Shearing force and reduce wear and tear on the packers.
For 5- 19.5# pipe, Shear Bonnets with Tandem Booster will shear the pipe. Large bore
shear bonnets will shear the pipe without booster. (Bigger area)
More information via Cameron engineering.
Case history:
During a leak of the Diverter package, the string was pulled out of the hole and above
the 7liner. The string was hung off on the bottom rams. These were 4.5-7 Variable.
The top rams (2-7/8- 5) were also closed and the posi-locks were activated.
The string was disconnected and the repair executed. After the repair, a leak on the
hydraulic hose, leading to the posi-locks, was observed and the locks were opened.
This shocked the rams and the string slipped through the bottom rams. Luckily, the top
rams caught the tool joint again. Never install the bigger Variable rams in the bottom
rams.