KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
1 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 arrangements are as
follows:
G = rotating head.
A = annular type BOP.
R = single ram type BOP with one set of rams, either blank or for pipe, as operator prefers .
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.
K = 1000 psi rated working pressure.
Cw = wellhead connector used to attach wellhead and preventers to each other (connector should have a minimum
rated working pressure equal to the BOP stack rated working pressure).
2 RAM LOCKS
RAM type preventers should be clearly and documented that it is equipped with extension hand wheels or
hydraulically operated locks.
3 SPARE PARTS
As per API The following recommended minimum BOP spare parts should be carefully stored, maintained and readily
available at any given time :
a) A complete set of ram rubbers for each size and type of ram BOP being used.
b) A complete set of bonnet or door seals for each size and type of ram BOP being used.
c) Plastic packing for BOP secondary seals.
d) Ring gaskets to fit end connections.
e) A spare annular BOP packing element and a complete set of seals.
f) A flexible choke or kill line if in use.
4 DRILLING SPOOLS
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 nominal diameter and be
flanged, studded, or hubbed.
b) 10K, 15K, and 20K arrangements should have two side outlets, one 3-inch and one 2-inch nominal diameter
as a minimum, and be flanged, studded, or hubbed.
c) Have a vertical bore diameter the same internal diameter as the mating BOPs 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.
5 PRESSURE RATING
All valves, fittings, and other components, such as pressure switches, transducers, transmitters, etc., should have
a working pressure at least equal to the rated working pressure of the control system .
KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
6 TYPES OFTESTS
6.1 INSPECTION TEST
6.1.1 Visual Inspection of the Annular Preventer
6.1.1.1 Packer unit
6.1.1.2 Annular bore
6.1.1.3 Ring grooves
6.1.1.4 Bolt holes
6.1.1.5 Control hose connector
6.1.1.6 Wear sleeve (if applicable)
6.1.1.7 Inner body with head and packer unit removed
6.1.1.7.1 Piston, seal assemblies and cylinder walls
6.1.1.7.2 Wear plate (if applicable)
6.1.2 Visual Inspection of the Rams
6.1.2.1 BORE
6.1.2.2 RING GROOVES
6.1.2.3 FLANGE BOLTS AND NUTS
6.1.2.4 BONNET DOORS
6.1.2.5 BODY FACE
6.1.2.6 BONNET BOLTS
6.1.2.7 RAM CAVITIES
6.1.2.8 RAM BLOCKS
6.1.2.9 RAM OPERATING SHAFT
6.1.2.10 EMERGENCY PACK OFF
6.1.2.11 LOCKING DEVICES
6.1.2.12 CONTROL HOSE CONNECTORS
6.1.3 Visual Inspection of Valves and Chokes (Will Be Done After Finish Bop )
6.1.4 Visual Inspection of Accumulators (Will Be Done After Finish Bop )
KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
6.2 FUNCTION TEST
6.2.1 See appendix 1 for detailed test sheet
6.3 PRESSURE TEST
All blowout prevention components that may be exposed to well pressure should be tested first to a low
pressure of 200 to 300 psi and then to a high pressure.
make sure the document for shell test is available and 1½ times bop pressure rating (150% of pressure
rating) is applied .
6.3.1 When performing the low pressure test, do not apply a higher pressure and bleed down to the
low test pressure. The higher pressure could initiate a seal that may continue to seal after the
pressure is lowered and therefore misrepresenting a low pressure condition.
6.3.2 A stable low test pressure should be maintained for at least 5 minutes.
6.3.3 The initial high pressure test on components that could be exposed to well pressure (BOP stack,
choke manifold, and choke kill lines) should be to the rated working pressure of the ram BOPs
make sure the rated working pressure of the stack installed on can withstand such pressure.
6.3.4 Annular BOPs, with a smallest size anticipated joint of drill pipe installed 3 ½”, may be tested to
the test pressure applied to the ram BOPs
6.3.5 The pressure test performed on hydraulic chambers of annular BOPs should be to at least 1,500
psi Initial pressure tests on hydraulic chambers of ram BOPs and hydraulically operated valves
should be to the maximum operating pressure recommended by the manufacturer but not to e
less than 1500 psi
The tests should be run on both the opening and the closing chambers.
Pressure should be stabilized for at least 5 minutes.
Summary of the pressure test
Component to be Tested Pressure Test- Pressure Test-
Low Pressure, psi' High Pressure, psi,
Annular Preventer 200-300 Minimum of 70% of annular BOP
working pressure.
Operating Chambers Minimum of 1500
Ram Preventers Fixed Pipe 200-300 Working pressure of ram BOPs.
Ram Preventers Variable 200-300 Working pressure of ram BOPs.
Bore
Ram Preventers 200-300 Working pressure of ram BOPs.
Blind/Blind Shear
Ram Preventers Operating N/A Maximum operating pressure
Chamber recommended by
ram BOP manufacturer.
Choke Line & Valves 200-300 Working pressure of ram BOPs.
Annular BOPS should be tested with the smallest OD pipe to be used.
Variable bore rams should be initially pressure tested on the largest and smallest OD pipe sizes that may be used during
the well operations.
KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
Prior to testing each ram BOP, the secondary rod seals (emergency pack off assemblies) should be checked to ensure the
seals have not been energized. Should the ram shaft seal leak during the test, the seal shall be repaired rather than
energizing the secondary packing.
Ram BOPs equipped with ram locks should be pressure tested with ram locks in the closed position and closing pressure
bled to zero. Manual locks either screw clockwise or counter-clockwise, to hold the rams closed. Hand wheels should be
in place and the threads on the ram locking shaft should be in a condition that allows the locks to be easily operated.
The BOP elastomeric components that may be exposed to well fluids should be verified by the BOP manufacturer as
appropriate for the drilling fluids to be used and for the anticipated temperatures to which exposed. Consideration should
be given to the temperature and fluid conditions during well testing and completion operations.
Manufacturers’ markings for BOP elastomeric components should include the durometer hardness, generic type of
compound, date of manufacture, part number, and operating temperature range of the component.
6.4 HYDRAULIC OPERATOR TEST
6.4.1 Annular preventer hydraulic operator test
1. The annular should be closed on the pipe size that is to be used, with 1500 psi closing pressure.
2. Allow the element to stabilize. Due to the large amounts of rubber in the element, it will take a few minutes
for the element to stop "creeping".
3. Once "creeping" has ceased, lock the pressure on the closing chamber using the "hot line" assembly. The
pressure should be monitored using a chart recorder.
4. Carefully remove the opening line and monitor the fluid draining out. Ensure the fluid is free of sand and
other abrasives and that the fluid is the proper type for the BOP (i.e. hydraulic fluid).
5. If there is no pressure drop in 10 minutes, the seals are holding and proceed to step 9.
6. If the pressure drops, there are two possible leak paths:
Closing chamber to the opening chamber
Closing chamber to the well bore
7. If fluid continues to flow out the opening chamber then the seals between the closing and opening chambers
are in need of repair.
8. If the fluid stops running out of the opening chamber, then the leak is into the well bore and those seals
need repair.
9. The opening line should be reinstalled and the annular opened with 1500 psi. Lock the pressure on the
annular and monitor it using a chart recorder.
10. Carefully remove the closing line and inspect the fluid as in step 4.
11. If the pressure remains constant for 10 minutes, the seals are holding and the test is completed.
12. If the pressure drops there two possible leak paths:
Opening chamber to the closing chamber
Opening chamber to the well bore
13. If fluid continues to flow out the closing chamber, then the seals between the opening and closing chamber
need repair.
14. If the fluid stops flowing out of the closing chamber, the leak is into the well bore and those seals need
repair.
KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
Two additional leaks are possible involving the hydraulic chambers are possible:
From the well bore to the closing chamber
From the well bore to the opening chamber
Both of these leaks can result in a blowout through the accumulator. Identification of these leaks can be determined
by a "shell test".
i. Install a blind flange on top of the annular. This will also test the condition of the ring groove and bolt holes
on the annular head. As previously stated, a competent seal on top of the annular is needed if a lubricator or
snubbing unit is installed.
ii. Remove the opening and closing lines and pressure test the annular. As with any pressure test, low pressure
should be done first, followed by high pressure. Care should be taken to ensure that the area in front of the
hydraulic operating line outlets is clear of personnel while the annular IS pressurized.
iii. Any fluid leaking out of the opening or closing chambers indicates a leak in the respective seal assemblies.
iv. If a top blind flange is not incorporated, only the bottom set of seals will be tested. The annular should be
closed around a test mandrel, using the lowest possible closing pressure required to get an effective seal.
This closing pressure should be locked on the annular with the "hot line" assembly. The annular should then
be pressure tested to a pressure higher than the closing pressure, typically 70 % of the working pressure.
Monitor the closing pressure trapped on the annular (by the "hot line" assembly). If this pressure increases,
then the seals isolating the closing chamber from the well bore are leaking and require repair.
v. (It should be noted that if the annular is "well bore assisted" the pressure trapped by the "hot line" assembly
will decrease when well bore pressure is applied.) If any leak occurs during the hydraulic operator test, all
seals, the piston and cylinder walls should be closely evaluated, and repaired as necessary.
6.4.2 Ram preventer hydraulic operator test
1. The rams should be closed on the proper pipe size (no pipe for blind rams) and closing pressure increased to 3000 psi
2. Lock the pressure on the closing chamber and monitor using a chart recorder.
3. Carefully remove the opening line and inspect the fluid draining from the chamber, as is done with the annular.
4. If there is no pressure drop in 10 minutes, the seals are holding and proceed to step 6.
5. If the pressure drops, there are several possible leak paths:
From the closing chamber to the opening chamber.
Continuous flow out of the opening chamber indicates the seals between the closing and opening
chambers are in need of repair.
Around the locking mechanism
Between the bonnet door and the BOP body
6. The opening line should be reinstalled and opening pressure increased to 3000 psi Lock the pressure and monitor it using a
chart recorder.
7. Carefully remove the closing line and inspect the fluid as before.
8. If the pressure remains constant for 10 minutes, the seals are holding and the test is completed.
9. If the pressure drops, there are several possible leak paths:
From the opening chamber to the closing chamber.
Continuous flow out of the closing chamber indicates the seals between the opening and closing
chambers are in need of repair.
The weep hole.
Flow out the weep hole indicates the seals on the operating shaft need repair.
Between the bonnet door and the BOP body.
The hinge, if applicable.
10. If any leak occurs during the hydraulic operator test, the ram bonnet door assembly should be closely evaluated, and repaired as
necessary.
KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
6.4.3 HCR valve hydraulic operator test
This procedure is very similar to the ram test. The test pressure should be 3000 psi and the test should be run from both the opening and
closing chambers. If any pressure drop occurs the leak should be isolated and repaired in a manner similar to that of the rams.
7 BOP Sealing Components
7.1 FLANGES AND HUBS
MAKE SURE ALL flanges and hubs, including sizes, service conditions, dimensions, and other design requirements for blowout
preventers are in LINE WITH the latest edition of API Specification 6A and API Specification 16A.
7.2 RING-JOINT GASKETS
Type RX and BX ring-joint gaskets should be used for flanged and hub type blowout preventer connections in that they are self-
energized type gaskets. API Type R ring gaskets are not a self-energized type gasket and are not recommended for use on well
control equipment.
7.3 BOLTING
Flange and clamp stud bolt and nut specification requirements should be in accordance with API Specification 6A and API
Specification 16A. Identification marking of bolting components should be in accordance with API Specification 6A and API
Specification 16A.
8 Check-list
After checking all of the above 6 points please arrange to fill the following table :
BOP and Control System
BOP-Stack
Contractors BOP stacks should have been inspected, shop tested and certified.
Check last inspection, test reports and certification.
NDT reports on: Ram piston hubs, shear ram blades, bonnet bolts. If not available
please refer to inspection test and its appendix-2
Ensure hydraulic connections are welded to the BOP body (not threaded). Check
that there are no threaded connections on pressure systems above 3,000 psi(API
RP 53 8.2.b).
Ensure maintenance tools (e.g. spanners) and handwheels (with extensions, if
required) are available (API RP 53 17.5.8).
Function all manual locking spindles.
Check stripping bottle on size (13-5/8" BOP: 5 gallon), rating, last test, certification,
proper installation, proper functioning/calibration of specific fittings (valves, p-
gauges, connections). Check pre charge.
Is the stripping tank calibrated for the drill pipe in use?
9 Check all documentation/certification of spools, DSA'a
etc.
CIW type clamps to be MPI inspected as per CIW product alert.
10 Check both choke and kill line are adjustable suspended
from the stack to avoid bending forces at connections.
11 Remove bonnets and inspect ram cavities and ram blocks.
KHALDA PETROLEUM COMPANY
DRILLING DEPARTMENT
KPC master Rig checklist – BOP section
Take wear measurements.
12 Pressure test operating system ( opening and close
sides) to maximum operating pressure.
13 Remove annular bag for internal inspection.
Check bell nipple of BOP, check for space out, trip tank hook up, bleed off line hook
up. Proper bell at top.
Check riser, for quick connection & valve/space out and hook up of flow line and
trip tank.
Check teststump/condition of ring groove. Practicality of testing offline.
Test BOP to full SWP on the stump.
Check BOP test procedures.
Check testpump, calibration, charts. Spares, including charts.
