For well-completion operations, ensuring the integrity and safety of your Blowout Preventer (BOP) system is crucial. This guide offers a comprehensive overview of the necessary blowout-preventer testing, maintenance, and record-keeping practices according to industry standards. By adhering to these guidelines, you can improve operational safety and efficiency while meeting standard requirements.
BOP Pressure Testing
Timeframes – Installation and Frequency
You must pressure test your BOP system when it is installed and before 14 days have passed since your last test. Begin your next test before midnight on the 14th day after the last test.
BOP Test Pressures
There are two types of pressure tests. Conduct both low-pressure and high-pressure tests for each BOP component, ensuring the pressure holds long enough to verify the component can withstand the required pressure.
Low-Pressure Tests
Must be between 200 and 300 psi. If the initial pressure is above 300 psi, reduce it to the 200-300 psi range before testing. Pressures exceeding 500 psi must be reset to zero before retesting. Perform the low-pressure test prior to the high-pressure test.
High-Pressure Tests
For ram-type BOPs, choke manifolds, and other equipment, the high-pressure test should match the equipment’s rated working pressure. For annular-type BOPs, the high-pressure test should be 70% of the equipment’s rated working pressure.
Duration of Pressure Test
Test Duration
Each pressure test must maintain the required pressure for five minutes. Surface BOP systems and surface equipment of subsea BOP systems can have a three-minute test duration if the test pressures are recorded on the outermost half of a four-hour chart, a one-hour chart, or a digital recorder.
Failed Tests
If the equipment fails to hold the required pressure, resolve the issue and retest the component.
Additional BOP Testing Requirements
- Surface BOP Systems: Use water for testing.
- Subsurface BOP Systems: Conduct a stump test with water before installation. Subsequent tests can use drilling or completion fluids.
- Control Stations and Pods: Alternate tests between these stations. Suspend operations if a station or pod is non-functional until it is operable.
- Routine Tests:
- Pressure-test the blind or blind-shear ram at least every 30 days.
- Function-test annulars and rams weekly.
- Pressure-test variable bore-pipe rams against all pipe sizes used, excluding drill collars and bottom-hole tools.
- Test BOP components after disconnection or repair of well-pressure containment seals.
- ROV Intervention: Test all ROV functions during the stump test and at least one set of rams during the initial seafloor test. Ensure ROV hot stabs can actuate at least one set of pipe and blind-shear rams and unlatch the LMRP. Document all test results for BOEMRE.
- Safety Systems: Function-test auto shear and deadman systems during the stump test and the deadman system during the initial seafloor test. Submit test procedures for District Manager approval and document all results.
Postponing BOP Tests
Tests may be postponed due to well-controlled issues but must be conducted as soon as possible after resolving the problem. Record the reason for any postponement in the driller’s report.
Weekly Crew Drills Frequency
Conduct weekly drills to familiarize all personnel with safety measures during well-completion operations.
BOP Inspections
Inspection Standards
Inspections for blowout preventers must meet or exceed API RP 53 standards. Document procedures and results, making them available to BOEMRE. Keep records on the rig for two years or since the last major inspection -whichever is longer.
Daily Inspections
Visually inspect the BOP system and marine riser daily, weather permitting. Alternate methods and frequencies can be approved by the District Manager.
BOP Maintenance
Maintenance must comply with API RP 53 guidelines. Document procedures and results, keeping records for two years or since the last major inspection -whichever is longer.
BOP Test Records
Record Keeping
Record all pressure tests, actuation, crew drills, and inspections in the driller’s report, including:
- Pressure test readings on charts
- Certification of test charts and reports by an onsite representative
- Sequential order, pressure, and duration of each test
- Control station or pod identification
- Noting and addressing any issues or irregularities
Record Retention
Maintain all records at the facility throughout the completion activity and for two years post-well completion.
Taking It to the Next Level
Proper testing and maintenance of your BOP system are essential for ensuring the safety and efficiency of well-completion operations. We recommend following these guidelines to significantly reduce the risk of accidents and downtime at your oil rig. For more information about BOPs and other products, reach out to us today!
