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RUL E&P REGLAS (COMPANY RULES)

APROBADO
NOMBRE

FECHA

Direccin E&P
Pierre Senequier

Julio 2004

Divisin OPS
Miguel ngel Jimnez

Julio 2004

FIRMA

El documento original, que est firmado y aprobado por la persona y en la


fecha arriba indicadas, se encuentra bajo custodia de E&P, de acuerdo con la
normativa vigente.

RUL-WLP-165 PRESSURE & FUNCTIONAL TESTING REQUIREMENTS


OF CONTROL EQUIPMENT - GEN

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INDEX
1.

PURPOSE .................................................................................................................................. 3

2.

APPLICATION ............................................................................................................................ 3

3.

REFERENCE DOCUMENTS ....................................................................................................... 3

4.

FOREWORD- GENERAL DEFINITIONS ...................................................................................... 3


4.1. Indicator ............................................................................................................................... 3
4.2. Glossary............................................................................................................................... 3

5.

OPERATIONAL CONSIDERATIONS ........................................................................................... 4


5.1. General Consideration........................................................................................................... 4
5.2. Organization......................................................................................................................... 5
5.3.
5.4.

Function Tests ...................................................................................................................... 5


Pressure Tests ..................................................................................................................... 5

6.

FUNCTION TESTING PERIODICITY............................................................................................ 6

7.

LEVEL AND PERIODICITY OF PRESSURE TESTING ................................................................. 7


7.1. Routine Pressure Testing ...................................................................................................... 7
7.2. Non Routine Pressure Testing ............................................................................................... 8

8.

LOCKING DEVICES ................................................................................................................... 8


8.1. Surface Bop Stack ................................................................................................................ 8
8.2. Subsea Bop Stack ................................................................................................................ 9

9.

BOP CLOSING/OPENING CONTROL LINES PRESSURE TEST .................................................. 9

10. OVERALL ACCUMULATORS TEST............................................................................................ 9


11. DRILL STRING SAFETY VALVES AND KILL SYSTEMS ........................................................... 10

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RUL E&P REGLAS (COMPANY RULES)
RUL-WLP-165 PRESSURE & FUNCTIONAL TESTING REQUIREMENTS OF CONTROL
EQUIPMENT- GEN

1.

PURPOSE

The purpose of this Company Rule is to define the rating & frequency of pressure and functional tests
to be performed on well control equipment used in drilling, testing, well completion and work -over
operations.
2.

APPLICATION

This document represents CEPSA E&P policy and should be part of the Standing Instructions established
by any Asset or Subsidiary for conducting well operations
The provision of this rule apply to all Operated E&P Subsidiaries or Assets, whenever national rules and
regulations either fail to cover the subject or are insufficiently explicit or less stringent.
Any significant deviation from the rules stipulated in this document shall only be agreed following
submission of a formal request to CEPSA E&P/OPS.
3.

REFERENCE DOCUMENTS

Unless otherwise stipulated, the applicable version of the reference documents listed below, including
relevant appendices and supplements, is the latest revision published.
Standards
Reference

Title

API RP 53

Recommended Practices for Blowout Prevention Equipment Systems for Drilling


Wells

CEPSA E&P Documents


Reference

Title

RUL-WLP-160
RUL-WLP-225
RUL-WLP-310

Well control equipment


Casing Design
Tubing Design

RUL-WLP-265

Well Integrity

4.

FOREWORD- GENERAL DEFINITIONS

4.1.

Indicator

Mandatory rule - any deviation requires authorization


4.2.

Glossary

BOP
BSR
CL

Blowout Preventer
Blind Shear Rams
Choke Line

DICV

Drop-In Check Valve

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FSOC
KL

Fast Shut-Off Coupling


Kill Line

MEWHP
OBM
RSES

Maximum Expected Wellhead Pressure


Oil Base Mud
Site Safety and Environment Manager

WBM
WH:
WP

Water Base Mud


Wellhead
Working Pressure

5.

OPERATIONAL CONSIDERATIONS

5.1.

General Consideration

Rule 1:
Even if complete redundancy exists for a BOP component, if any such part cannot fulfill its function and/or
fails a pressure test or a functional test, the operation shall be stopped, the well secured and the BOP
repaired before entering any potential hydrocarbon bearing zone
Rule 2:
A pressure test is considered satisfactory if recorded pressure is stabilized for 10 minutes at the pressure
test value with a pressure drop of less than 5%, limited to 300 psi.
All tests shall include a low-pressure test of 200 to 300 psi for 5 minutes before proceeding to the high
pressure test.
All pressure tests shall be recorded on a chart.
The volume of test fluid pumped shall be monitored and logged.

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The compression volume to reach the programmed pressure should be known and checked; the following
values should help:

For mud 3 liters per cubic meter and 1000 psi ( 7 Mpa )

For water 4 liters per cubic meter and 1000 psi ( 7 Mpa )

For diesel oil 7 liters per cubic meter and 1000 psi (7 Mpa).

5.2.

Organization

Rule 3:
The rating and sequences of the BOP testing program are discussed and agreed with the Drilling
Contractor and incorporated in the Management System Bridging Document. Forms shall be developed to
record all tests of well control equipment.
Pressure tests of well control equipment need a permit to work and are risk assessed by the Company
Man and CONTRACTOR Tool Pusher. The equipment and the lines under pressure shall be identified and
access shall be restricted.
A pre-job meeting is done to ensure that the risk mitigation measures, the roles and responsibilities are
clearly defined and allocated and are clearly understood by all parties involved.
In all cases, BOP tests are witnessed by the Company Man together with the CONTRACTOR Tool Pusher,
recorded and filed in the Rig Safety Register.
5.3.

Function Tests

All ram type preventers should be function tested at the normal control system pressure.
Rule 4:
When performing a function test, the control panel used, the opening and closing volumes (if flow-meter is
available) and times of all tested functions shall be monitored and logged.
During drilling operations, it is recommended to perform a function test during tripping operations.
Annular bag preventer should not be fully closed during a function test
If a glycol or equivalent injection system is installed upstream of chokes, it should be tested during the
function tests.
Rule 5:
When performing a pressure testing, a function test is considered as being performed.
When performing a function test on floating rigs, both pods shall be tested.
It is recommended to issue a form adapted to each rig and to use it to log data when performing a function
test.
5.4.

Pressure Tests

Rule 6:
To be relevant, a BOP pressure test shall be performed:

For subsea BOP: on bottom after BOP connection on wellhead.

For surface BOP: BOP on test stump or on wellhead.

Note that only the connection between the BOP and the wellhead is to be pressured tested after BOP
installation on the wellhead, if the pressure test on test stump is still valid.
For subsea BOP a pressure test on test stump is recommended prior to start running the BOP.
The BOP pressure-testing program must verify all components in sequence while:

Minimizing successive pressurization operations of each component

Applying pressure in the direction in which the components will be working

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Except on Deep-Water applications, the BOP and piping should be flushed with clean water (if WBM) or
base oil (if OBM SG > 1.3) or mud (if OBM SG < 1.3) prior to the pressure tests being carried out. To
ensure that they are not blocked the kill and choke lines will then be flushed with clean fluid at the end of
the test.
On Deep-Water applications, the lines should be circulated prior to the pressure test being carried out to
ensure that they are not blocked and low freeze-point fluids should be used.
No pressure test should be performed against closed chokes.
To prevent excessive pressurization of the kill and choke lines, the BOP stack can be tested through the
string by using a perforated test sub, or test joint connected to the plug type tester
The annular preventers should always be closed on a Drill Pipe body for pressure testing. The regulating
pressure of this preventer should be adjusted in accordance with the expected test pressure
(manufacturers charts)
The variable rams should be pressure tested at all DP body diameters at which it can be used during well
operations.
When pressurizing, the pressure should be increased by increments.
When testing wellhead components, due consideration should be given to burst and collapse rating of
relevant casing components.
While a cup tester is in use it should be checked that:

The maximum pressure is within 90 % of the burst resistance of the top casing joint,

The overload of the used drill pipe is within 80 % of the combined stress ( tension / collapse )
resistance,
If this can not be achieved a plug type tester should be chosen.
When the periodic pressure tests will be made using a tester plug set in the WH, the wellhead side outlets
just below the plug should be open to prevent pressurizing the casing
If casing is tested at bump, the WH/casing sealing should be tested at MEWHP using a tester cup. Type of
string used should match the generated tensile load.
Annular valves opened during pressure testing or any other type of operation should not be left open
without monitoring.
6.

FUNCTION TESTING PERIODICITY

Rule 7:
When in operation, all well control equipment (rams, bag preventer, remote and manual valves and chokes
of BOP and choke manifold,) shall be function tested (cycled) once a week. The main and remote control
panels shall be used alternately.
At the same time a circulation at a reduced rate should be carried out to ascertain a correct flow path.
The emergency disconnect system should only be tested once a well preferably when disconnecting the
BOP stack from the wellhead.
Function testing is also recommended to be performed at rig commissioning, at rig acceptance, after repair
or installation of new equipment, etc.
The exact BOP closing time for each function should be assessed at the rig commissioning.

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7.

LEVEL AND PERIODICITY OF PRESSURE TESTING

7.1.

Routine Pressure Testing

Rule 8 (routine pressure testing):


Periodicity
All well control equipment (rams, bag preventer, kill and choke lines, remote and manual valves and
chokes of BOP and choke manifold) excluding blind rams (1) shall be pressure tested at least every two
weeks (14 days).
The local Drilling and Completion Manager and the Drilling Contractor Representative may extend the 14day interval under exceptional circumstances, after an appropriate risk assessment and formal
endorsement. In any event, the interval shall not exceed 21 days.
(1) The blind rams are only tested prior to drill out each casing string.
Level of pressure:
The periodic pressure testing shall be done at the maximum expected wellhead pressure (MEWHP) when
its value is known or estimated with confidence or either at the rated working pressure of the BOPs or the
drilling wellhead, whichever is the less (2).
(2) Bag type preventer test pressure shall be limited to:

50% of their nominal WP in the case of a pressure testing at MEWHP

70% of their nominal WP in the case of a pressure testing at WP

It is recommended to pressure test the BOPs equipment at the beginning of each drilling phase before
drilling out the casing shoe.

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7.2.

Non Routine Pressure Testing

Rule 9 (non-routine pressure testing)


All well control equipment (rams, bag preventer, kill and choke lines, remote and manual valves and
chokes of BOP and choke manifold) shall be pressure tested:

A part of the well equipment shall be pressure tested:

Bag type preventer test pressure shall be limited to:

50% of their nominal WP in the case of a pressure testing at MEWHP

70% of their nominal WP in the case of a pressure testing at WP

8.

LOCKING DEVICES

8.1.

Surface Bop Stack

Locking screws are designed:

to block any ram in a fail-safe closed position in the case of a severe situation (heavy DP string
hung on BOP ram, high pressure in the well, etc)

to close the BOP ram, should the hydraulic power supply fails to operate

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Rule 10:
Surface BOP stacks equipped with locking screw system shall be pressure tested (with locking screws
tighten and all control lines bled off) on the first well after the spudding date and after once a year.
The hand wheel should be left on the locking screw throughout the drilling phase, as it will be necessary to
lock the pipe rams before shearing in case of emergency.
8.2.

Subsea Bop Stack

Rule 11:
Subsea BOP stacks equipped with hydraulic wedge or ram locks or hydraulic locks shall be pressure
tested with the hydraulic locks in closed position and closing pressure vented. BOP pressure tests are to
be performed with all control lines vented.
9.

BOP CLOSING/OPENING CONTROL LINES PRESSURE TEST

The possible use of the emergency by-pass with surface BOPs dictates to check the open and close
hydraulic lines up to 3000 psi.
Rule 12:
On surface BOPs, control system lines shall be tested at the maximum rated working pressure at least
once per well or every quarter whichever is the longer.
It is recommended to perform the test of control lines at BOP nippling-up phase and to pressure test with
plugs at control line ends (unless push-pull fittings exist) to avoid over stressing the BOP mechanisms.
10.

OVERALL ACCUMULATORS TEST

An overall accumulator function and pressure test (as per RUL-WLP-160 requirements) includes:

Switch on/off test: The objective is to ensure correct functioning of the manometric switch on the
accumulator pumps and to adjust the settings if necessary

Depletion test: The objective is:


o
o

to confirm the reserve capacity of the accumulators to supply hydraulic power to the BOP in
case of complete black-out
to check the residual pressure after operation of the last function.

o to check the time required to restore pressure after a complete depletion test
(The stack shall be full of water or special soluble oil to perform these tests when on the test
stump).

Emergency test: The objective is to ensure that each pump system (electric and air) is able to close the
BOP (as per RUL-WLP-160 requirements) in the event of a problem with the accumulator bank.
(Surface stack only).

Rule 13:
An overall accumulator function and pressure test shall be performed at the spudding date and after every
three months or after any repair of the accumulator system.

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11.

DRILL STRING SAFETY VALVES AND KILL SYSTEMS

Rule 14:
All drill string safety valves and kill systems (from HP pump to drill pipe string) shall be pressure tested as
follows:

At full working pressure at rig commissioning and each time a new component is put into service,

With the BOPs periodic pressure tests.


All drill string safety valves and kill systems shall be function tested with BOPs periodic functional tests.
The Drop In Check-Valve (DICV) sub and dart shall be pressure tested with one stand in hole when
running in before drilling out the casing shoe, once a well or every quarter which ever is the longer.
Test subs for testing the drill string safety valves should be available on the drilling site.

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