EP 2002-1500

- 89 -

Restricted to Shell Personnel Only

4. 4.1.

WELL CONTROL EQUIPMENT SURFACE The Well Kill System

The Well Kill System is comprised of various rig components, many of which are permanently installed and in most cases have daily routine functions. This section highlights their involvement in the kill process and makes recommendations on their specification and dimensions. 4.1.1. Schematic (an example of many possible alternatives)
Kelly Cock IBOP FOSV To Flare To Vent

Reserv Pits
BOP Pump #1

Mud-Gas Separator

NRV

Active

Kill&Choke Choke Line Manifold Manifold

Pump #2 Cmt Pump

Trip Tank Stripping Tank

Drop-In Dart

Header Tank De-gasser

4.1.2.

Tankage

Mud Pit Management The guidelines given below refer to ideal situations where local circumstances, size of rig, type of well, design of well, equipment availability and other limitations are not an issue. The decision to say, increase the size of reserve tanks or mixing speed to comply with these guidelines should reflect local circumstances. The key element is to maintain control by utilising available resources to the best advantage by pre-planning and good mud pit management. A set of very specific procedures should be developed locally when a set of standard equipment components are not available. Factors to consider may include:

The total volume of mud after circulating out a kick without weighting up (Driller's method) will be the same as before the kick was taken. As a gas kick is circulated up the hole, it may expand, causing an increase in pit volume. As a gas kick is circulated out of the hole through the choke and vented, there will be a decrease in pit volume to the pre-kick volume. It is important to monitor these variations which, if irregular, may indicate losses.

Before circulating out a kick by the Driller's method, reduce the active system to effectively one pit. The total pit capacity should be capable of accommodating a potential pit gain due to gas expansion and accommodate a level drop due to volume replacement of vented gas or reservoir fluid.

EP 2002-1500

- 90 -

Restricted to Shell Personnel Only

If weighting up is required, the volume will increase by the volume of the weight material added. An efficient kill will be the one that initially weights up only the hole volume and a minimum surface circulating volume. Weighting up should proceed in reserve pits during the first circulation of the Driller's method only if they can be managed to advantage. It is best to prepare weighted mud in a reserve pit that has direct mud pump suction and can take returns direct from the degassed mud pit. It may be necessary to segregate tanks in the active system to achieve this set-up. Weighting up can proceed in the active suction pit during the wait period of the Wait & Weight method.

Before preparing weighted mud for either kill method, reduce the mud volume in the pit to the lowest practical level. This will facilitate faster initial weighting but will have no effect on the pump rate at which the kill can proceed. Pump rate will be governed by the rate at which weight material can be added to the mud returning from the hole. Active Pit

The Active pit should be large enough to hold an adequate working volume of fluid yet small enough so that a small influx can easily be detected due to an increase in mud level. Any pit to be used as the Active must be equipped with accurate fluid levelling devices. Wherever possible, the pit levelling devices should be alarmed (visual & audible to the driller) to indicate flow from the well. For floating rigs, consider a levelling device in each corner of the pit with averaged output, to compensate for rig pitch and roll. If a mud-logging contractor is to be used, an ultra-sonic levelling system is recommended. The reserve system should be large enough to accommodate all surface volumes required in the course of the well. Provision must be made for increases in volume due to weighting-up. The mud mixing system (hoppers, jet-guns etc.) should be adequate to allow fast density changes to large volumes of mud (i.e. a hole volume). The system of valves and transfer lines must be such that pit-management is simple and efficient. Normally confined to critical wells (HPHT etc.) where the risk of a kick is high. Normally large enough to hold a full well volume of mud weighted to maximum anticipated kill weight plus a safety margin.

Reserve Pits

Kill Pit

EP 2002-1500

- 91 -

Restricted to Shell Personnel Only

May also be used to hold Tripping Mud, on wells where low fracture margins require a dual system. Primarily use to monitor hole fill and returns while tripping. The trip tank shall be provided with an accurate fluid level indicator or a recorder/indicator, showing the amount of mud used to keep the hole full when pulling pipe, and the amount of mud returned when running in. It should also be possible to monitor hole fill/flow during static conditions such as electric logging operations. Used for accurate volumetric flow-checks, particularly on floating rigs. Must have a small cross-section so that volume changes are easily detected and accurately quantified. An indicating and recording mud pit level system, capable of providing early visual and audible warning of gain or loss of fluid in the well, shall be installed in those mud tanks which serve as active mud tanks. There should always be a redundancy in measuring trip tank levels i.e. Drillers should use their own (mechanical) devices as well as those from other systems (either acoustic or ultra-sonic). Apart from accuracy, the importance of understanding why discrepancies exists and how they should be interpreted should be stressed. Multiple levelling devices must not interfere with each others operation (i.e. a float giving a false signal to a sonic sensor). Volume changes must be easily monitored from the Driller's position. A small secondary tank to the trip tank used to measure fluid transferred from the trip tank while stripping. Must have a small cross section so that volume changes can be accurately measured. Pumps Prior to spudding, the drilling mud pumps, mud manifolds, valves and main discharge lines shall be pressure tested with water to 34,500kPa (5000psi) or the circulating system working pressure if it is higher e.g. (7500psi). In all cases, a minimum of two pumps must be available to allow for redundancy. Hydraulic output must be sufficient to circulate maximum anticipated kill weight mud at planned well profile and worst-case geometry. Functional stroke counters must be installed to monitor displacement.

Trip Tank

4.1.3.

Stripping Tank

Mud Pumps

EP 2002-1500

- 92 -

Restricted to Shell Personnel Only

Cement Pump

The emergency high pressure kill pump (and/or the cement pump), manifolds, valves and lines shall be tested to the maximum rated working pressure of the lowest rated part of the system. The cement pump may be required during kill operations as a back-up to the mud pumps. Ideally, the cement pump will have an independent power source (diesel) in the event of total power loss. Functional stroke counters or flow/volume measuring devices must be installed to monitor displacement. Drill String Shut off Devices The kelly cock is used to prevent flow up the drill pipe. On a kelly-rig, two kelly cocks are used, one above the kelly saver-sub (Full Opening Safety Valve (FOSV)) and the other, with LH threads, below the swivel (i.e. one at either end of the kelly itself). The left-hand threaded upper FOSV shall be in good operating condition at all times. A test sub for testing the kelly or top drive and kelly cocks shall be available on the drilling rig. The hexagonal wrench (Allen Key) used to operate the kelly cock must be available on the rig floor at all times. Top-drive rigs generally have one kelly cock (IBOP) positioned below the TDS and which is remotely operated from the Driller's position. The IBOP of a top drive should be hydraulically operated. It should be possible to break the connection above the IBOP of the top drive and remove the top drive when string entry below the top drive is required with the well under pressure. The stab in valve is used to shut-off flow up the string while tripping (i.e. the kelly is racked) Three Full Opening Safety Valves (FOSV) for each size of drill pipe in use shall be available. One shall be used below the kelly or top drive during drilling operations, One shall be on the drilling floor complete with removable handles for easy stabbing and connection and; One as a spare.

4.1.4.

Kelly Cock

Stab In Valve (FOSV)

The valve must be crossed-over to fit the pipe currently being run. Cross-overs must be available for all pipe and thread combinations being run. If this is not possible or practical, alternate methods to control the well should be available,

EP 2002-1500

- 93 -

Restricted to Shell Personnel Only

understood and practised (e.g. shearing the pipe or dropping the string). A method of shearing and dropping the string should be possible in all cases as a redundancy method, if the safety valve cannot be stabbed owing to location of connection (above the drill floor) or excessive flow.

The valve and cross-over assembly must be full bore to the pipe being run so that stabbing the valve does not present a restriction to flow from the well. The valve must always be in the full-open position until actually installed. The valve is closed after being made up and before the BOP is closed. The FOSV is opened after installing the IBOP before stripping. Stabbing of the valve and cross-over assembly must be facilitated by either limiting the size and weight to that that can be easily man-handled, or use of un-powered mechanical means such as a counterweight device. FOSV's have been known to fail under external pressure differential and hence may not be appropriate for high pressure stripping operations. The inside BOP is a non-return valve contained in a sub that can be made up in the drill string. A 'Gray-type' inside BOP (IBOP), with the appropriate connections for the drill string in use, shall be on the drilling floor at all times. It shall be ready for immediate use. It is always made up above the FOSV when stripping is required or may be stabbed directly onto the drill string in place of the FOSV. Practical considerations for use are similar to the FOSV with the exception that once it is installed there is no longer wireline access to the drill string below it, neither can pump-down devices be used. This term applies to a number of devices, which are dropped into the pipe at surface and locate in a dart-sub in the BHA. Their function is to prevent flow up the string, working as a one-way check valve. When drill string float valves are not run, two drop-in type back-pressure valves (NRV) must be available. These are to be complete with seating subs to fit the drill string in the hole. The drop-in valves must be able to pass the smallest bore in the drill string above the seating sub, and preferably be wireline retrievable. If a dart-sub is being run, the drift of the BHA and pipe above it must be checked to ensure that the dart can land. A Drop In Sub should be installed in the string when drilling with total losses or with a floating mud cap. The dart of the DIS should be dropped and pumped down/latched prior to each trip. In a well control situation, the string should never be broken specifically to drop a dart except in extreme circumstances where loss of containment at surface is likely. A drill pipe float valve run in the bit sub provides a 'permanent' non return function during trips and connections.

Inside BOP or IBOP

Drop-in Sub (DIS)

EP 2002-1500

- 94 -

Restricted to Shell Personnel Only

Circulating Head

A 69,000kPa (10,000psi) WP 76.2mm (3") rotating type circulating head with correct bottom subs for the drill string sizes in use shall be available on the drilling floor A casing circulating head with a pressure rating equal to the casing rating shall be available on the drilling floor throughout casing running operations.

Any item for shut off in an emergency shall match the tool joints in use and be tested on the same routine frequency as the BOP stack. 4.1.5. The BOP The function of the BOP is to seal-off the annulus to divert flow from the well to the choke manifold. The BOP rating and ram configuration will be determined by well conditions and the proposed activity. The equipment and example stack-ups are discussed in Section 4.2. Down Stream Equipment The choke is a device which allows gas and fluids to be released from the well at a controlled rate and pressure Ideally, two chokes should be available, particularly on critical wells. This will allow washed out or plugged choke devices to be changed without stopping the kill. A glycol injection point should be available to prevent hydrate build-up resulting from cooling caused by gas expansion through the choke. See Section 4.7. The Mud-Gas Separator (MGS), is the first device down stream of the choke during well control operations. It is not a part of the normal circulating system. It is essentially a gravity separation tank where the mud is briefly unconfined and flows across a series of baffles. This allows gas bubbles to breakout at the surface of the mud and pass up the vent line. Mud is effectively drawn off from the lowest part of the separating chamber of the tank through the mud leg (liquid seal, U tube) on route to the header tank. Gas is vented through a large diameter line usually secured to the derrick. Must be fitted with a low pressure gauge 100kPa (15psi) which should be visible from the choke control console and preferably alarmed. See Section 4.6. Although not strictly part of the kill system, the flow line is an important location for kick detection.

4.1.6.

Choke Manifold

Mud-Gas Separator (Poor Boy)

Flowline

EP 2002-1500

- 95 -

Restricted to Shell Personnel Only

The traditional mud-flow paddles are poor in angled flow-lines. Wherever possible they must be located at the downstream end of a horizontal section, to allow the flow to settle. Flow sensors in general, are unreliable on floating rigs due to vessel motion. Entrained gas downstream of the MGS is monitored at the header tank, normally by the mudlogging contractor. If on contract, mud weight, mud temperature and H2S sensors should also be located here. The primary function of these Vacuum or Centrifugal De-Gassers is the removal of dissolved or entrained gas from the mud system. They are part of the normal circulating system and can be used at any time to treat gas-cut or aerated mud In simple terms they work by subjecting the mud to a mechanically induced pressure gradient, which allows gas to break out of the mud. Mud can carry high levels of entrained and/or dissolved gas for many circulations through the MGS, therefore the De-Gasser is required to reduce levels prior to the mud returning to the active pit. See Section 4.6. Surface Well Control Equipment

Header Tank

Vacuum De-Gasser (or Mechanical Atmospheric De-Gasser)

4.2.

This section lays out the basic requirements of well control equipment for a typical surface installation and reviews the philosophy for BOP stack-up. 4.2.1. General Issues New BOP equipment shall have a rated working pressure (WP) in excess of maximum anticipated surface pressures. BOPs that have been fully refurbished and body pressure tested to 50% above the rated work pressure are considered "new"; Used BOPs (>5 years old) shall have a rated working pressure no less than 10% in excess of maximum anticipated surface pressures; The BOP shall consist of remotely controlled equipment capable of closing in the well with or without pipe in the hole. The remote control unit should diagrammatically represent the stack-up arrangement. Valves, handles and buttons, which are not in use, should be removed; Welded, flanged, or hub connections are mandatory on all pressure systems with a rated working pressure in excess of 13,800kPa (2000psi). Threaded connections are not acceptable; In wells where H2S may be encountered, well control equipment suitable for sour service is required; in such cases the complete high-pressure BOP system should be fabricated of materials resistant to H2S and sulphide stress corrosion cracking.

The following considerations should be made when selecting well control equipment:

EP 2002-1500

- 96 -

Restricted to Shell Personnel Only

Elastomers installed in BOPs must be appropriate for the mud systems used and temperatures / fluids expected. Dedicated kill lines must not be smaller than 50mm (2") nominal and shall be fitted with two valves and an NRV. Choke lines must not be smaller than 75mm (3") through bore and are to be connected with two valves to the BOP stack of which the outer valve shall be remote hydraulically operated. When dual purpose kill and choke lines are employed, both lines must not be smaller than 75mm (3") through bore and the outer valve of each line shall be remote hydraulically operated. They shall both be connected to a Kill & Choke Line Manifold that incorporates an NRV on the mud pump discharge line. During drilling and workover operations, shearing blind rams should be provided in the BOP stack whenever feasible. The shearing blind rams should be capable of shearing the drill pipe/tubing in use under no-load conditions and subsequently provide an effective seal (forces required to shear common sizes of drill pipe are shown in Figure 4.2.1). Closing systems of surface BOPs should be capable of closing each ram preventer within 30 seconds. The closing time should not exceed 30 seconds for annular preventers smaller than 508mm (20") and 45 seconds for annular preventers of 508mm (20") and larger (see also API RP53). All master and remote operating panel handles should, at all times, be in the full open or closed position, and be free to move into either position, i.e. the shear ram operating handles should not be locked but may be screened to prevent inadvertent operation. All four way valves in operation should be either in the fully open or fully closed position, as required; they should not be left in the blocked or centre position. All spare operating lines and connections, which are not use in the system should be blanked off with blind plugs at the hydraulic operating unit. Grade N-80 N-80 C-75 P-110 Grade E Grade E G-105 S-135 X-95 Weight 6.6. lb/ft 10.2 lb/ft 10.2 lb/ft 10.2 lb/ft 19.5 lb/ft std 19.5 lb/ft soft 19.5 lb/ft 19.5 lb/ft 25.6 lb/ft Shear Force 120,000 lbs 180,000 lbs 180,000 lbs 180,000 lbs 200,000 lbs 295,000 lbs 375,000 lbs 375,000 lbs 480,000 lbs

Pipe Size Diameter 2-7/8 3-1/2 3-1/2 3-1/2 5 5 5 5 5

Figure 4.2.1: Shearing Forces for Common Sizes of Drillpipe Closing pressure = (Force required to shear)/(Closing Area)

EP 2002-1500

- 97 -

Restricted to Shell Personnel Only

Note: Closing area of BOPs (with or without booster) can be obtained from the BOP manufacturers engineering data. Some typical BOPs are listed in Figures 4.2.2 through to 4.2.5 Closing areas of common BOPs Size 7-1/16 11 13-5/8 13-5/8 16-3/4 18-3/4 18-3/4 18-3/4 21-3/4 Type Type U Type U Type U Type T Type U-II Type U Type U-II Type T Type U Pressure rating 3/5/10M 3/5/10M 3/5/10M 10M 5/10M 5/10M 10/15M 15M 2/3M Weight lbs 145 lbs 300 lbs 510 lbs 600 lbs 920 lbs 1250 lbs 1200 lbs 1200 lbs 980 lbs H 4.5 5.5 6 7.5 8 11 11 11.5 8 W 7.5 12 15 16 17.5 20 20 20 17.5 L 13 17.5 22 27 28 27 27 27 30

Figure 4.2.2: Cameron Shearing Blind Rams (SBRs) Size 7-1/16 13-5/8 13-5/8 18-3/4 18-3/4 20-3/4 21-1/4 Figure 4.2.3: Hydril Shear Rams Size 7-1/16 11 13-5/8 13-5/8 16-3/4 18-3/4 18-3/4 18-3/4 21-3/4 Type Type U Type U Type U Type T Type U, U-II Type U Type U-II Type T Type U Pressure rating 3/5/10M 3/5/10M 3/5/10M 10M 5/10M 5/10M 10/15M 15M 2/3M Weight lbs 145 lbs 300 lbs 510 lbs 600 lbs 920 lbs 1200 lbs 1200 lbs 1200 lbs 980 lbs H 4.5 5.5 6 7.5 8 11 11 11.5 8 W 7.5 12 15 16 17.5 20 20 20 17.5 L 13 17.5 22 27 28 27 27 27 30 Type Pressure rating 5/10M 5M 10M 10M 15M 5M 3/5M Weight lbs 260 lbs 675 lbs 780 lbs 1530 lbs 1620 lbs 900 lbs 900 lbs H 5 6 7 9 11 7.5 7.5 W 8.5 16 19 23 24 22 22 L 16 26 30 36 38 40 40

EP 2002-1500

- 98 -

Restricted to Shell Personnel Only

Figure 4.2.4: Cameron DS Shear Rams Size 7-1/16 11 11 13-5/8 13-5/8 13-5/8 16-3/4 16-3/4 18-3/4 18-3/4 21-3/4 Type Type SL/LWS Type LWS Type SL Type LWS Type SL Type SL Type LWS Type SL Type SL Type SL Type SL Pressure rating 5/10/15M 5M 10M 5M 10M 15M 5M 10M 10M 15M 2/3M Weight lbs 150 lbs 330 lbs 365 lbs 330 lbs 510 lbs 520 lbs 255 lbs 530 lbs 590 lbs 565 lbs 550 lbs H 3.5 3.5 3.5 4 5.5 5.5 6 6 7 6.5 8 W 9.5 16 16 16 16 16 20 20 24 24 26 L 14 18 18 18 18 18 25 25 30 36 36

Figure 4.2.5: Shaffer Shearing Blind Rams 4.2.2. Stack-up

The relative positioning of the blind rams, pipe rams and the kill and choke line outlets for surface BOPs will depend on the well, the rig, the equipment available and the particular operating conditions. Each stack-up has both advantages and disadvantages which should be matched to the anticipated situation. The sketches in the following sections show some of the options available. In each case: Option a) would normally be preferred. Option b) would be suitable only for special circumstances.

EP 2002-1500

- 99 -

Restricted to Shell Personnel Only

4.2.3. A.

Stack-up Options for Two-cavity-BOP Two Single Ram Preventers

1. When blind ram cannot shear the drill string. a) Position BR in lower cavity, PR/VBR in upper cavity, Drilling spool or side outlets below both. Advantages: Allows change of PR to CR above closed BR. Allows installation of shooting nipple above BR. Disadvantage: Does not allow stripping tooljoints from annular to PR. (Resolved by placing a spacer spool between annular and PR.) b) Position PR/VBR in lower cavity, BR in upper cavity, Drilling spool or side outlets below both. Advantage: Allows stripping tooljoints from annular to PR. Disadvantages: CR installation only with PR blanking plug or drill pipe in the hole. CR installation removes BR from stack. Cannot install shooting nipple above BR. 2. When Shearing blind rams are available and they can shear the drill string. a) Position PR/VBR in lower cavity, SBR in upper cavity. Drilling spool or spacer spool and side outlet between rams, and drilling spool or side outlet below both. Advantages: Allows pipe hang-off and shear. Allows stripping tooljoints from annular to PR. Disadvantages: CR installation only with PR blanking plug or drill pipe in the hole. CR installation removes SBR from stack. Cannot install shooting nipple above SBR May Increase stack height. b) Position SBR in lower cavity, PR/VBR in upper cavity. Drilling spool or side outlets below both. Advantages and disadvantages same as for A1a) above. i.e SBR not positioned for maximum benefit.

PIPE/VBR BLIND SPOOL

CASING

ANNULAR

BLIND PIPE/VBR SPOOL

CASING

ANNULAR

SHEAR SPOOL PIPE/VBR OUTLET

CASING

ANNULAR

PIPE/VBR SHEAR SPOOL

CASING

EP 2002-1500

- 100 -

Restricted to Shell Personnel Only

B.

One Double Ram Preventer

1. When blind ram cannot shear the drill string. a) Position BR in lower cavity, PR/VBR in upper cavity, Drilling spool or side outlets below both.
PIPE/VBR CASING

Advantages and disadvantages same as for A1a) above.

BLIND SPOOL

b) Position PR/VBR in lower cavity, BR in upper cavity, Drilling spool or side outlets below both. Advantages and disadvantages same as for A1b) above.
BLIND PIPE/VBR SPOOL

ANNULAR

CASING

2. When Shearing blind rams are available and they can shear the drill string. a) Position SBR in lower cavity, PR/VBR in upper cavity. Drilling spool or side outlets below both. Advantages and disadvantages same as for A1a) above. b) Position PR/VBR in lower cavity, SBR in upper cavity. Drilling spool or side outlet below both. Advantages: May allow stripping tool joints from annular to PR. Disadvantages: Does not allows pipe hang-off and shear. CR installation only with PR blanking plug or drill pipe in the hole. CR installation removes SBR from stack. Cannot install shooting nipple above SBR
PIPE/VBR SHEAR SPOOL

ANNULAR

CASING

ANNULAR

SHEAR PIPE/VBR SPOOL

CASING

Some Considerations for Two-Cavity-Stacks Include:

A pipe ram (PR/VBR) above the blind ram (BR) is recommended to facilitate changing the PR to casing rams (CR). On surface BOPs without shearing capability the blind ram should rarely be in the uppermost ram cavity unless the possibility of high pressure stripping is anticipated. On two-cavity-stacks the SBR may be in the upper cavity provided that a PR blanking plug (or alternative method) is available to facilitate changing the SBR to

EP 2002-1500

- 101 -

Restricted to Shell Personnel Only

CR, and, the stack-up dimensions will permit drill pipe hang off and shear. This will normally only be possible with single rams separated by a spool.

There should be a minimum of one complete drill pipe tool joint length (including tapers) space between the top of the lowermost pipe ram and the bottom of the shearing blind ram. This is normally achieved with the drilling spool but may require a spacer spool if side outlets are used. With this configuration a blowout up the drill string may be shut off (sheared) without dropping the drill string. There should be a drilling spool or kill and choke side outlets below the lowermost ram. When more than one set of kill and choke lines are installed, the uppermost are always to be used first to maximise redundancy. Stack-up Options for Three-Cavity-BOP

4.2.4.

A One Double and One Single Ram Preventers 1. When blind ram cannot shear the drill string. Typical stack-up for three-cavity BOP made up with either a single and a double or three singles when there is no shearing capability.
ANNULAR

PIPE/VBR BLIND

CASING

SPOOL PIPE OUTLET

2. When Shearing blind rams are fitted and they can shear the drill pipe Typical stack-up for three-cavity BOP made up with either a single and a double or three singles when there is shearing capability.

ANNULAR

PIPE/VBR SHEAR

CASING

SPOOL PIPE OUTLET

EP 2002-1500

- 102 -

Restricted to Shell Personnel Only

4.2.5.

Use of Casing Rams

Casing rams (or appropriately sized VBRs) should be installed in the BOP when running casing whenever there may be hydrocarbon bearing or abnormally pressured water zones open in the well. It is recognised that in certain situations, the safety of the well may be jeopardised while changing rams preparatory to running casing. In those cases where it is decided casing rams should not be installed, the following shall be on the rig floor made up, ready for use:

a crossover from drill pipe to the casing; drill pipe matching the diameter of the pipe rams, of sufficient strength to support the casing weight; Full Opening Safety Valve; Inside BOP.

The possibility of dropping or shearing the casing, as a last resort, should also be assessed. See Section 4.8 for guidelines on pressure testing Casing rams. 4.3. Classification of Well Control Equipment

Well control equipment falls into five basic rated working pressure (WP) classifications. 1. 2. 3. 4. 5. 4.3.1. 13,800kPa (2000psi) WP 20,700kPa (3000psi) WP 34,500kPa (5000psi) WP 69,000kPa (10,000psi) WP 103,500kPa (15,000psi) WP Surface BOP Equipment (Definition)

Surface blowout prevention equipment is that equipment used in land operations and in offshore operations where the wellhead is above the water level. Given below are the MINIMUM requirements for each rated working pressure classification. 4.3.2. Either; 1. A double hydraulic operated ram type preventer (one equipped with correct size pipe or variable bore rams, the other with blind rams) and one full opening drilling spool with two 77.8mm (3-1/16") bore side outlets. 13,800kPa (2000psi) WP classification

Where equipment of this classification will suffice, the minimum BOP stack will consist of:

EP 2002-1500
2K ALTERNATIVE 1.

- 103 -

Restricted to Shell Personnel Only

PR/VBR

SBR

DRILLING SPOOL CASING HEAD HOUSING

1 2

76.2mm (3") GATE VALVE 76.2mm (3") HYDRAULICALLY OPERATED CHOKE LINE VALVE

50.8mm (2") GATE VALVE

NON RETURN VALVE

Or 2. One annular preventer capable of full closure and one full opening drilling spool with two 77.8mm (3-1/16") bore side outlets.

2 DRILLING SPOOL CASING HEAD HOUSING

ANNULAR

3 1 2 3 76.2mm (3") GATE VALVE 76.2mm (3") HYDRAULICALLY OPERATED CHOKE LINE VALVE 50.8mm (2") GATE VALVE 4 NON RETURN VALVE

EP 2002-1500

- 104 -

Restricted to Shell Personnel Only

Or 3. When no Drilling spool is available, a combination of a single hydraulic operated ram type preventer (with 3-1/16" bore side outlets and fitted with blind rams) and one annular preventer.
2K ALTERNATIVE 3.

ANNULAR 2 1 1 4

SBR

CASING HEAD HOUSING

The BOP stack shall have a dedicated kill line and a choke line. Each line should have two full-bore valves of which one valve on the choke line is remote hydraulically operated. A Non Return Valve (NRV) should be installed in the dedicated kill line. When the BOP stack consists of a double ram type preventer with side outlets that meet the above specified dimensional requirements, the kill and choke lines may be connected to the outlets of the lower preventer. In this case the drilling spool may be omitted. 4.3.3. 20,700kPa (3000psi) WP classification

Where equipment of this classification will suffice, the minimum BOP stack shall consist of: 1. 2. One annular preventer. One double, or two single hydraulic operated ram type preventers; one of which must be equipped with correct size pipe rams (either fixed or variable), the other with blind rams. One full opening drilling spool with two 77.8mm (3-1/16") bore side outlets.

3.

EP 2002-1500
3K WP MINIMUM REQUIREMENTS

- 105 -

Restricted to Shell Personnel Only

ANNULAR

PR/VBR

SBR

DRILLING SPOOL CASING HEAD HOUSING

1 2 3

76.2mm (3") GATE VALVE

NON-RETURN VALVE

76.2mm (3") HYDRAULICALLY OPERATED CHOKE LINE VALVE 50.8mm (2") GATE VALVE

The BOP stack shall have one dedicated kill line and a choke line. Each line should have two full-bore valves of which one valve on the choke line is remote hydraulically operated. A Non Return Valve (NRV) should be installed in the dedicated kill line. When the lowermost ram type preventer has side outlets that meet the above-specified dimensional requirements, the kill and choke lines may be connected to the outlets of the lower preventer. In this case the drilling spool may be omitted. 4.3.4. 34,500kPa (5000psi) WP classification

Where equipment of this classification will suffice, the minimum BOP stack shall consist of: 1. 2. One annular preventer. One double, or two single hydraulic operated ram type preventers; one of which must be equipped with correct size pipe rams (either fixed or variable), the other with shearing blind rams. One full opening drilling spool with two 77.8mm (3 1/16") bore side outlets.

3.

EP 2002-1500
5K WP MINIMUM REQUIREMENT

- 106 -

Restricted to Shell Personnel Only

ANNULAR

PR/VBR

SBR

DRILLINGSPOOL CASING SPOOL

CASING HEAD HOUSING 3

1 2 3

76.2mm (3") GATE VALVE 76.2mm (3") HYDRAULICALLY OPERATED CHOKE/KILL LINE VALVE 50.8mm (2") GATE VALVE

The BOP stack should have two dual-purpose kill and choke lines. Each line should have two full-bore valves of which one valve of each line is remote hydraulically operated. Both lines should be connected to the kill and choke line manifold (see Section 4.6.2). When dual purpose kill and choke lines are not employed, the BOP stack shall have one kill line and one choke line. Each line should have two full-bore valves of which one valve of each line is remote hydraulically operated. A Non Return Valve (NRV) should be installed in the dedicated kill line. When the lowermost ram type preventer has side outlets that meet the above-specified dimensional requirements, the kill and choke lines may be connected to the outlets of the lower preventer. In this case the drilling spool may be omitted.

EP 2002-1500

- 107 -

Restricted to Shell Personnel Only

ANNULAR

PR/VBR

SBR

DRILLINGSPOOL

PR/VBR

CASING SPOOL

CASING HEAD HOUSING 3

1 2 3

76.2mm (3") GATE VALVE 76.2mm (3") HYDRAULICALLY OPERATED CHOKE/KILL LINE VALVE 50.8mm (2") GATE VALVE

4.3.5.

69,000kPa (10,000psi) WP classification

Where equipment of this classification is required, the minimum BOP stack shall consist of: 1. One annular preventer with a working pressure of 69,000kPa (10,000psi). (A 34,500kPa (5000psi) WP annular preventer on a 69,000kPa (10,000psi) WP BOP stack is acceptable on existing stacks.) Three single, or one double and one single, hydraulic operated ram type preventers; one of which must be equipped with shearing blind rams and the other two with correct size pipe rams. Variable Bore Rams (VBRs) may be used instead of one of the fixed pipe rams. One full opening drilling spool with two 77.8mm (3 1/16") bore side outlets.

2.

3.

EP 2002-1500

- 108 -

Restricted to Shell Personnel Only

10K WP MINIMUM REQUIREMENTS

ANNULAR

PR/VBR

SBR

DRILLINGSPOOL

PR/VBR

CASING SPOOL

CASING HEAD HOUSING 3

1 2 3

76.2mm (3") GATE VALVE 76.2mm (3") HYDRAULICALLY OPERATED CHOKE/KILL LINE VALVE 50.8mm (2") GATE VALVE

Provided that the middle and lower ram type preventers are equipped with side outlets that meet the above-specified dimensional requirements, the kill and choke lines may be connected to these outlets and the drilling spool omitted. The BOP stack should have two dual-purpose kill and choke lines. Each line should have two full-bore valves of which one valve of each line is remote hydraulically operated. Both lines should be connected to the kill and choke line manifold. When dual purpose kill and choke lines are not employed, the BOP stack must have two kill line and two choke line entries which may be manifolded. Each entry should have two full-bore valves of which one valve of each choke line shall be remote hydraulically operated. The lowermost kill and choke lines shall be connected to the BOP stack below the bottom preventer and act only as spare kill and choke lines. The lines may be connected to the side outlets of the bottom preventer, provided that the preventer is equipped with side outlets that meet the above-specified dimensional requirements. When the lowermost kill and choke lines cannot be connected to the side outlets of the bottom preventer, they should be connected to the outlets of a drilling spool installed below the bottom preventer as shown.

EP 2002-1500

- 109 -

Restricted to Shell Personnel Only

4.3.6.

103,500kPa (15,000psi) WP classification

Where equipment of this classification is required, the minimum BOP stack shall consist of: 1. One annular preventer with a working pressure of 103,500kPa (15,000psi) or a 69,000kPa (10,000psi) WP unit, preferably with a body rated to 103,500kPa (15,000 psi). A four-ram stack is preferable. However, minimum requirements are three single, or one double and one single, hydraulic operated ram type preventers, one of which must be equipped with shearing blind rams and the other two with the correct size pipe rams. Variable Bore Rams (VBRs) may be used instead of fixed pipe rams, but at least one ram type preventer shall be equipped with fixed pipe rams. One full opening drilling spool with two 77.8mm (3-1/16") bore side outlets.

2.

3.

Provided that the middle ram type preventer is equipped with side outlets that meet the above-specified dimensional requirements, the kill and choke lines may be connected to these outlets and the drilling spool omitted. The 15K BOP stack configuration of the three-ram-cavity stack is the same as the 10K stack. The configuration of the four-ramcavity BOP stack is shown below.
15K WP FOUR-RAM-CAVITY BOP

ANNULAR

PR/VBR

SBR 2 1 PR/VBR

2 DRILLINGSPOOL

PR

CASING SPOOL

CASING HEAD HOUSING

1 2 3

76.2mm (3") GATE VALVE 76.2mm (3") HYDRAULICALLY OPERATED CHOKE/KILL LINE VALVE 50.8mm (2") GATE VALVE

EP 2002-1500

- 110 -

Restricted to Shell Personnel Only

The BOP stack should have two dual-purpose kill and choke lines. Each line should have two full-bore valves of which one valve of each line is remote hydraulically operated. Both lines should be connected to the kill and choke line manifold. When dual purpose kill and choke lines are not employed, the BOP stack must have two kill line and two choke line entries which may be manifolded. Each entry should have two full-bore valves of which one valve of each choke line shall be remote hydraulically operated. The lowermost kill and choke lines shall be connected to the BOP stack below the bottom ram preventer and act only as spare kill and choke lines. The lines may be connected to the side outlets of the bottom preventer, provided that the preventer is equipped with side outlets that meet the above-specified dimensional requirements. When the lower kill and choke lines cannot be connected to the side outlets of the bottom preventer, they must be connected to the outlets of a drilling spool installed below the bottom preventer as shown. 4.4. Blow Out Preventer Equipment Installation

A BOP will only act as a functional pressure containment device if properly installed and hooked up. This section comprises a list of critical issues to be addressed or guidelines to be applied during rig-up. The BOP equipment installation shall conform to the following: 1. 2. 3. Wellhead equipment should be designed to withstand anticipated pressures and allow for future remedial operations. Ram type preventers must always be installed the correct way up, as in most cases the seal is pressure assist and will only hold pressure in one direction. All connections, valves, fittings, piping, etc., subject to well pressure, must be flanged, clamped or welded and have a minimum working pressure equal to the rated working pressure of the preventers. Screwed valves and fittings are only acceptable on installations up to 13,800kPa (2000psi) WP. Valves must be of the flush through-bore type when in the open position. When installed, all ring gaskets should be new, checked for cleanliness and coated with light oil. Dry and/or previously used ring gaskets should never be installed. All correct size bolts/nuts and fittings shall be in place and tight. All connections shall be pressure tested before drilling is resumed. The use of a torque device for making up bolted connections is recommended. The ID of the bell nipple should be large enough for hanger and seal assemblies to pass through. Slip and seal assemblies should preferably be landed through the BOPs before lifting the BOP stack. Emergency slip and seal assemblies for mandrel type wellheads can rarely be installed without lifting the BOP stack. When lifting the stack is necessary is shall only be done after the cement seal has adequate integrity and the well cannot flow. When non-fluted boll-weevil hangers are used to land the casing string before cementing, wellhead side outlets shall have a bore, large enough to avoid excessive annular backpressure whilst cementing. A hydraulically operated valve should be installed in both side outlets to allow closing in the well in an emergency.

4. 5. 6.

7.

8.

EP 2002-1500

- 111 -

Restricted to Shell Personnel Only

9. 10. 11.

Fluted hangers are recommended so as to avoid bypassing the wellhead/BOP stack during cementing operations. All manually operated valves should be equipped with hand wheels, and be ready for immediate use, including the valves on the wellhead. Ram preventer hand wheels are not a general requirement. The locking screws should be operated each time the preventers are tested to ensure that they turn freely. Rams should be locked whenever used for secondary control. BOP equipment shall be function tested and pressure tested, when installed, and at the appropriate times during operations to determine that the system will function properly. (See Section 4.8) The Company drilling representative shall inspect and approve every BOP installation after flanging up and testing. He/she or an authorised delegate shall witness every BOP pressure test. Circulating access to the well bore (or annulus) should always be possible, hence provision must be made for connection of one kill/choke line below the lower-most preventer. Wellhead side outlets shall not be used for killing purposes, except in case of emergency. In an emergency situation, the kill line may be connected to the side outlet of the casing spool when circulating access to the well bore is required. The casing spool outlet should have the proper connection to allow changing over the permanent kill line. Kill lines shall not be used for routine fill-up operations. When critical operations are being carried out on high-pressure wells, a second kill line should be employed and tied into the kill line near the BOP stack. A highpressure pump should be lined up to this kill line. All pipelines shall be securely anchored and fitted with snub lines across the connections. Choke lines shall be as straight as practicable and firmly anchored to prevent excessive whip or vibration. Turns, if required, should be targeted. Flexible kill and choke hoses, longer than 4m (12ft), shall be supported and anchored in accordance with manufacturer's recommendations. The distance between anchoring points shall be 4m (12ft) or less. Ensure that the manufacturer's BOP operating manual is followed and no alterations are made to the BOP equipment without written consent from the manufacturer. Recertification may be required after making equipment alterations. The primary kill and choke lines of a three-ram-cavity BOP stack should be connected between the lower pipe and the shearing blind rams. i.e. between the lower two cavities. The primary kill and choke lines of a two-ram-cavity BOP stack should be connected below the lowermost ram preventer. Multiple choke lines should be connected to a kill and choke line manifold. There should be only one line from the kill and choke line manifold to the choke manifold.

12.

13.

14.

15.

16. 17.

18. 19.

20.

21.

22. 23.

EP 2002-1500

- 112 -

Restricted to Shell Personnel Only

4.5.

Control System Requirements for Surface Bop Stacks

The specifications and hook-up of the control system are critical to the safe and effective operation of the stack. This section defines the minimum equipment requirements and specification. Control systems for surface BOP stacks shall consist of the following as a minimum: 1. One independent automatic accumulator unit rated for 20,700kPa (3000psi) WP with a control manifold, clearly showing 'open' and 'closed' positions for preventer(s) and the remote hydraulic operated kill and choke line valves.

It is essential that all air and hydraulic BOP operating units be equipped with 0-20,700kPa (0-3000 psi) regulator valves similar to the Koomey type TR-5 which will not 'fail open', causing complete loss of operating pressure. Without recharging, the accumulator capacity shall be adequate for closing and opening all preventers and closing again the annular preventer and one ram type preventer, and holding them closed against wellbore pressure equal to the rated working pressure of the preventers. Accumulator units must be provided with electrically and air-driven high pressure pumps which automatically charge the accumulator bottles to the preset pressure. The electric pump should be fitted with an electric pressure switch, which automatically stops the electric pump when the accumulator pressure reaches 20,700kPa (3,000psi) and starts the pump again when the pressure drops to 18,970kPa (2,700psi) or below. The air-driven pump should be fitted with an air pressure switch, which automatically stops the air-driven pump when the manifold pressure reaches 20,700kPa (3,000psi) and starts the pump again when the pressure drops to 18,620kPa (2,700psi) or below A backup power supply should be available to maintain accumulator pressure in case of failure of the primary power source. In addition to the energy stored in the accumulator for emergency closing of preventers, a backup storage system independent of rig power could also be made available equal in capacity to accumulator needs (when a hydraulic system is mandatory).

Note: High pressure bottled nitrogen provides a practical and inexpensive backup system. A standard nitrogen bottle contains 1.53 cu. ft. or 11.5 gallons of nitrogen at 2,200 psi. If this is allowed to expand to 1,200 psi, there is a volume increase of 9.5 gallons. Thus, the same volume requirements set for the accumulator can be set for the bottled nitrogen backup system, and a relatively small number of bottles manifolded together will provide the needed capacity. The piping should be arranged so that the nitrogen can be routed through a pressure regulator directly to the BOP stack, bypassing the accumulator, and, optionally, also be piped to operate the closing unit pumps if desired. (See Figure 5.A.4 in API RP 53.)

The unit shall be located in a safe area away from the drill floor. Control lines shall be protected from damage. It shall include a low pressure warning alarm and hydraulic fluid level indicator or low fluid level warning alarm.

EP 2002-1500

- 113 -

Restricted to Shell Personnel Only

2.

All BOP stack installations should have two graphic remote control panels, each one clearly showing 'open' and 'closed' positions for each preventer and the hydraulic operated choke line valves.

3.

Each of these panels should include a master shut-off valve and ideally, though mandatory, controls for regulator valves and for a bypass valve. One panel must be located near the Driller's position, the other panel to be located near the exit of the location or near the Toolpushers office.

Control hoses that are high-pressure and fire-resistant with a working pressure of 20,700kPa (3000psi) are preferred, although steel swivel joints are acceptable. The hoses should be steel wrapped (co-flex type) to provide greater resistance to fire and improved durability. All master and remote operating panel handles are to be free to move into either position at all times, i.e. the shear ram operating handles should not be locked (but should be protected from inadvertent operation). All spare operating lines and connections, which are not used in the system, are to be properly blocked off. Mud-Gas Separator

4.

5. 4.6.

Mud-Gas Separators are a vital component of the well kill system. Their specification and installation is crucial to their safe use during well control operations. This section comprises guidelines to their selection and evaluation. 4.6.1. Overview

Mud-Gas Separators (MGS) (or atmospheric degasser or poor-boy degasser) have been in use for many years with little change in fundamental design. They can be described as a passive type cascade/baffle gas knock-out unit. They operate at atmospheric pressure or slightly above (atmospheric plus vent line backpressure). Their function is to remove free gas from the contaminated mud leaving the choke manifold but equally important to remove mud/liquid droplets from liberated gas prior to entering the vent line. (Entrained gas is extracted at the vacuum degasser). The capacity of the MGS is dependent on the design. If the capacity is exceeded, liquid mud or oil droplets may be carried up through the vent line. More importantly, gas may blow straight through the U-tube (Seal leg) and into the shale-shaker house, where there may be potential for explosion and fire. It is critical therefore that the mud-gas separator specifications must be fully evaluated. In short:

For new rig contracts, the minimum required mud gas separator specifications must be calculated and stated in detail on tender documents. For existing rig contracts, the mud gas separator specification must be evaluated as part of the well design process. Instrumentation and alarm mechanisms must be in place, such that if the capacity of the MGS is approached, actions can be taken to reduce the gas rate, or the flow from the well diverted to by-pass the MGS. On a land rig, this would be to a flare and on an offshore rig to an overboard line.

EP 2002-1500

- 114 -

Restricted to Shell Personnel Only

High gas rates will typically be associated with high kick volumes. These high gas rates may also result from gas dissolved in OBM arriving at a wide-open choke. Evaluation Process

4.6.2.

A methodology for evaluating the capacity of mud gas separators was developed by J.M. Prieur of Shell Expro in 1990 and can still be used today. It is very complex to calculate gas rates it is only really feasible to do this using one of the realistic kick simulators. As stated previously, it is essential that the appropriate pressure gauges and alarms are installed on the MGS to warn personnel when the gas rate is approaching the capacity of the MGS. This section introduces the main steps in the evaluation sequence. Separation Capacity This is based on the minimum droplet size that will settle out of a moving gas stream. The maximum allowable gas velocity is calculated using the density of the liquid and gas phases. Blow Down Capacity A U-tube between the bottom of the separator vessel and the header tank forms a liquid seal preventing gas escape to the shaker house. Blow down is where the pressure in the separator vessel caused by back-pressure from gas in the vent line exceeds the hydrostatic head of the liquid seal. Gas Handling Capacity Separation is a function of the separator vessel dimensions, while blow down capacity is a function of the vent line. The gas handling capacity is the lower of the two. Flow Rate and Kill Rate The gas handling capacity is used to ensure that the flow rate during a kill operation is maintained within the safe operating range of the separator. This information is presented as a graph showing the safe operating envelope.

EP 2002-1500

- 115 -

Restricted to Shell Personnel Only

4.6.3.

System Schematic
Secondary Ventline Ventline Up Derrick

From Mud Pumps

From Cement Pumps

P Drilling Choke Manifold Atmospheri c Mud/Gas Separator T

Over Board Choke Line Kill Line To Burner Booms

Fill-Up and Flushing Line To Shale Shakers

Key P P T Pressure Gauge Differential Pressure Meter Pressure Sensor

Liquid Seal Tank

Liquid Seal Depth

P Temperature Sensor Valve Drain

4.6.4.

Detailed Evaluation

A computer program (created by Expro Group Integrated Services Aberdeen) for the evaluation of existing separators and the calculation of parameters required for tendering is available on the Wells Global Network, Forum 24 - Well Control, well control information No.9. Mud Gas seperator evaluation program This program will:

Calculate the gas throughput capacity of an existing system in mmscf/d Calculate the required gas throughput capacity in mmscf/d for a future well

EP 2002-1500

- 116 -

Restricted to Shell Personnel Only

4.6.5.

Other Considerations

Design Temperature Very low temperatures can be achieved down stream of the choke due to gas expansion. It is very difficult to calculate what temperatures will be reached under these dynamic conditions, however it is generally accepted within Shell that minus 45 Celsius is acceptable Pressure Rating During normal operations the vessel should not be submitted to any pressure in excess of the liquid seal hydrostatic head. However, if the seal line plugs the vessel could fill up to the top of the vent line with mud. The pressure vessel should therefore be able to withstand the pressure imposed by this mud column. As most vent lines are 40-55m (130 180 ft) in height, a pressure rating of 1000 kPa (150psi) will be fit for purpose 4.6.6. Instrumentation A low pressure 100kPa (15psi) gauge shall be fitted to the base of the line from the choke manifold. The gauge reading should be easily visible. Rig-Up and Operation

(Minimum equipment standards, maintenance, combined gauges, testing)

4.6.7.

The following shall be met when configuring (or specifying the configuration of) the pipe work for the mud-gas separator: There must be an injection point down stream of the choke to allow the use of glycol to inhibit hydrate formation

There are to be no valves, pipe expansion or constrictions within 3m (10ft) of the inlet nozzle; If a bend is required in the feed pipe it shall be long sweep and in a vertical plane through the axis of the feed nozzle; The pipe reducer of the gas outlet line should be no nearer to the top of the vessel than 0.6m (2ft). The gas outlet line shall be a minimum of 200mm (8") diameter. If the vent exists more than 40m (130ft) from the vessel this vent line diameter should be increased to ensure that the back pressure in the vent line does not exceed 15kPa (2psi), at a gas flow rate of 0.2 x 106m3(st)/d (7MMscf/d). No reduction in any vessel dimension is permitted. Internal mist mats are not permitted due to their unsuitability for the rugged service. The mud-gas separator shall have one or more vent lines leading a safe distance downwind from the well, and/or to the top of the derrick. Low places in the vent lines should be avoided to prevent accumulation of liquids. Never connect the choke manifold and/or mud-gas separator discharge lines directly to the degasser (always have an open pipe).

EP 2002-1500

- 117 -

Restricted to Shell Personnel Only

The mud-gas separator shall not be operated above its manufacturers design limitations as calculated. Operating outside of this envelope will give poor mud/gas separation and the possibility of gas blow through. An additional unit with dedicated vent line shall be installed when the mud-gas separator capacity is insufficient for the well to be drilled.

There must always be provision to divert flow from the choke manifold direct to the flare pit. 4.6.8. Common Industry Designs.

There are a number of mud-gas separators in current use, all working on the same principals. The mud-gas separator can be installed as:

A skid mounted horizontal unit outside a mud tank; Vertical unit outside a mud tank; Unitized with the trip tank;

The Shell philosophy on mud gas separator design has been captured in WEST and includes a review of all makes and models in common use. This information is available in the Shell intranet. More recently, Smedvig Technology AS in association with Shell Expro have produced an updated design which incorporates the latest legislation and regulatory guidelines. Full specification is available on the Shell intranet. 4.7. Other Well Control Equipment

In addition to the Blow Out Preventer, there are other items of equipment which are required to either contain or control flow from the well. 4.7.1. Diverter Equipment

The diverter is installed on top of the wellhead to enable flow from shallow formations to be diverted away from the work area in case of a shallow gas kick. However, current diverter equipment is not yet designed to withstand an erosive shallow gas kick for a prolonged period. The diverter system is still seen as a means of "buying time" to evacuate the drilling site. In principle, a diverter system must be installed on each well when both of the following conditions apply: 1. 2. There is a possibility of losing primary well control, which may result in a kick situation. The well cannot be closed-in with a BOP stack, because the formation below the stove pipe/marine conductor, conductor string, or surface string is too weak. Fracturing of the formation will occur if the well is closed-in.

See also "Shallow Gas Procedures Guidance Manual", report EP 88-1000. Plus Section 5.3 of this manual

EP 2002-1500

- 118 -

Restricted to Shell Personnel Only

Diverter Equipment Specifications Flow restrictions in diverter systems should be avoided where possible, because they may lead to formation breakdown and cratering of the well in case of a shallow gas blowout. The minimum required nominal ID of diverter outlets/lines is considered to be 304.8mm (12"). In principle two outlets are required on the diverter spool. They should face opposite directions to be able to vent flow downwind of the rig. However, one outlet only may be considered in the case where there is a prevailing wind direction, and the vent line extends a sufficient distance from the rig to permit safe venting. Diverter lines should be as short as possible, but long enough to conduct flow past the extremity of the offshore drilling structure, or away from any obstacle in land operations. Rig structure and/or cellar design may have to be modified to accommodate straight diverter lines. The minimum rated working pressure of diverter equipment is based on the anticipated backpressure during a shallow gas blowout and therefore largely depends on the size of the diverter lines. The minimum rated working pressure of the recommended large bore diverter line system should be 3450kPa (500psi) WP. Dynamic forces are much higher in the initial stage of diverting a well, when the expanding gas is forcing the mud out of the diverter system. The following considerations should be made when selecting diverter equipment: 1. 2. 3. 4. 5. 6. The equipment shall be selected to withstand the maximum anticipated surface pressures. Welded flange or hub connections are mandatory on diverter systems; quick connections in diverter lines are not allowed. Diverter lines should be straight and properly anchored. (especially at the end of the lines). Diverter lines should be sloping down towards the outlet so as to be self-draining, and to avoid blockage of the lines with cuttings, etc. Installation requirements for wellhead and BOP equipment also apply to diverter equipment. (See Section 4.4) A diverter system can be a BOP stack system with a diverter spool, or a specifically designed and developed diverter system. The faster closing diverter unit is preferred to a large and slowly closing annular preventer. In any case, the diverter lines and mud return lines should be separate, not partially integrated lines. This is necessary to avoid gas entering the rig system in case the separating valve between both lines fails to seal. Diverter valves shall be full opening valves with an actuator (pneumatic or hydraulic). The bore of the diverter valves shall be equal to the bore of the diverter lines. Each diverter system should incorporate a kill line facility (including a check valve) to be able to pressure and function test the system and to be able to pump water through the diverter system. The diverter control system should preferably be self-contained or may be an integral part of the BOP accumulator unit and control system. It shall be located in a safe area away from the drilling floor and have the control functions clearly identified.

7. 8.

9.

EP 2002-1500

- 119 -

Restricted to Shell Personnel Only

10.

The diverter control system should be capable of operating the diverter system from two or more locations, one to be located near the Driller's position. It should contain the minimum of functions. Preferably, a one-button or lever-activated function should operate the entire diverter system. A 1-1/2" hydraulic operating line should be used for diverter systems with a 1-1/2" NPT closing chamber port size. The hydraulic line for the opening chamber port may be 1". All spare operating lines of the control system, and connections which are not used should be properly plugged off. Control systems of diverters/annular preventers and BOPs should be capable of closing the diverter and annular preventers smaller than 508mm (20") within 30 seconds, and annular preventers of 508mm (20") or larger within 45 seconds. Diverter valves should be opened before the diverter element is completely closed. It should be possible to control pumping operations at the pumps as well as on the drilling floor. SURFACE DIVERTER INSTALLED ON STOVE PIPE OR MARINE CONDUCTOR

11.

12. 13.

14. 15.

29 Bag Type Preventer

Actuator

Actuator

Diverter Line

P Valve

Diverter Spool

P Valve Diverter Line

P NRV Kill Line

26 or 30 Stove Pipe / Marine Conductor

P Valve: Pressure Operated, R Controlled t Failsafe O

Figure 4.7.1: Surface Diverter on Stove Pipe Kill line on diverter spool

EP 2002-1500

- 120 -

Restricted to Shell Personnel Only

SURFACE DIVERTER INSTALLED ON STOVE PIPE OR MARINE CONDUCTOR

20 Bag Type Preventer

Option A
Actuator P Valve Diverter Spool Actuator P Valve

Diverter Line

Diverter Line

Kill Line NRV P 26 or 30 Stove Pipe / Marine Conductor

P Value: Pressure Operated, Remote Controlled Failsafe Open

20 Bag Type Preventer

Option B
P NRV Kill Line Actuator P Valve Diverter Spool Actuator P Valve Blind / Shear Rams P Choke Line

Diverter Line

Diverter Line

26 or 30 Stove Pipe / Marine Conductor

Figure 4.7.2: Surface Diverter on Stove Pipe Kill line on wellhead or single ram.

EP 2002-1500

- 121 -

Restricted to Shell Personnel Only

SURFACE DIVERTER INSTALLED ON STOVE PIPE OR MARINE CONDUCTOR

Option C

Pipe Rams

NRV Kill Line

Blind / Shear Rams

Choke Line

Diverter Line

Diverter Spool

Diverter Line

Conductor String Casing Housing 26 or 30 Stove Pipe / Marine Conductor

Figure 4.7.3: Surface Diverter on Stove Pipe Kill line below dual ram. 4.7.2. 1. Choke Manifold and Kill & Choke Line Manifold The manifolds shall be constructed in accordance with Figure 4.7.1 and Figure 4.7.2 which is the minimum requirement for all working pressure ratings over 13,800kPa (2000psi). Alternatively, a choke manifold as already installed by the owner of the drilling unit may be acceptable, but only if approved in writing by the Company Rig Superintendent. Whilst drilling, the block valves upstream of both chokes and valves downstream of the remote choke to the mud-gas separator shall be in an open position. The remotely adjustable choke, the manually operated adjustable choke and all valves at the choke manifold shall be left in a position (closed or open) to facilitate closing in by the hard or soft shut-in method, as agreed to be appropriate. The remote choke is to be operated from a control panel installed near the Driller's position. The minimum recommended size for all choke lines and valves is 76.2mm (3") through bore. Valve size and line bore size of BOP stack side outlets and valves, choke lines and choke manifold should be identical throughout the system.

2. 3.

4. 5.

EP 2002-1500

- 122 -

Restricted to Shell Personnel Only

6.

Choke manifolds rated to 103,500kPa (15,000psi) shall have hydraulically operated valves upstream of any choke to assist in opening/closing valves under pressure quickly, thus minimising gate and seat wear. Chokes should incorporate a suitable bleeder valve facility to ensure that the pressure can be released prior to removal of the bonnet nut. Hammer type threaded bonnet nuts are not recommended. Flanged or bonnet clamp connections are preferred. Temperatures downstream of the choke are to be limited to the design temperature rating of the choke manifold.

7.

8.

EP 2002-1500

- 123 -

Restricted to Shell Personnel Only

Figure 4.7.4: Typical Back Pressure Manifold arrangement

EP 2002-1500

- 124 -

Restricted to Shell Personnel Only

For Use With BOP-stack, Having A Rated Working Pressure Of:Item No. Qty. Description 103,500kPa (15,000 psi) kPa 1 2 3 3 3a 4 5 6 1 1 11 5 6 1 1 2 Studded cross 76.2 x 76.2 x 76.2 x 76.2 x 50.8mm (3 x 3 x 3 x 3 x 2) 50.8mm (2) nominal size gate valve with steel seat 76.2mm (3) nominal size gate valve with steel seat 76.2mm (3) nominal size gate valve with steel seat 76.2mm (3) nominal size gate valve with steel seat (hydraulic remote operated valve) 76.2mm (3) nominal size manual adjustable choke Hydraulic Remote operated choke 120.7mm OD x 76.2mm ID (41 OD x 3 ID) wear nipple 103,500 103,500 103,500 103,500 103,500 103,500 76.2mm flanges 103,500 103,500 103,500 103,500 103,500 103,500 103,500 77.79mm 103,500 103,500 psi 15,000 15,000 15,000 15,000 15,000 15,000 3 flanges 15,000 15,000 15,000 15,000 15,000 15,000 15,000 3 1/6 15,000 15,000 69,000 kPa (10,000 psi) kPa 69,000 69,000 69,000 69,000 (optional) 69,000 69,000 76.2mm flanges 69,000 69,000 69,000 69,000 69,000 69,000 69,000 77-79mm 69,000 69,000 psi 10,000 10,000 10,000 10,000 (optional) 10,000 10,000 3 flanges 10,000 10,000 10,000 10,000 10,000 10,000 10,000 3 1/6 10,000 10,000 34,500 kPa (5,000 psi) 20,700 kPa (3,000 psi) 13,800 kPa (2,000 psi) kPa 34,500 34,500 34,500 34,500 34,500 76.2mm flanges 34,500 34,500 34,500 41,500 41,500 34,500 34,500 79.38mm 34,500 34,500 psi 5,000 5,000 5,000 5,000 5,000 3 flanges 5,000 5,000 5,000 6,000 6,000 5,000 5,000 3 1/8 5,000 5,000

7 8 9 10 11 12 13 14

3 2 2 1 1 4 1 4

Studded cross 76.2 x 76.2 x 76.2 x 76.2mm (3 x 3 x 3 x 3) Flange companion lead filled 76.2mm (3) Martin-Decker Series GM6A pressure gauge or equivalent Martin-Decker Sensor Series GM6A or equivalent Y-piece: 76.2 x 76.2 x 76.2mm (3 x 3 x 3) 76.2mm (3) Nominal size gate valve with steel seat Check valve 50.8mm (2) Nominal size gate valve with steel seat

Figure 4.7.5: Back Pressure manifold component rating

EP 2002-1500

- 125 -

Restricted to Shell Personnel Only

4.8.

Tests for Surface Wellheads and Bop Equipment

Testing requirements are given for the following equipment: 1. Blowout preventers, wellhead components and their connections. 2. The BOP operating unit. 3. The choke manifold, valves, kill and choke lines and valves on the side outlets of the casing spool. 4. The kelly or top drive and kelly cocks stab in valves etc.. 4.8.1. Blowout Preventers, Wellhead Components And Their Connections

Function Tests Should be carried out on BOP hydraulic operated components when they are installed and weekly thereafter. Function tests should be performed with reduced operating pressure to avoid unnecessary wear and tear, particularly when there is no drill string in the hole. Pressure Tests Testson the blowout preventers, wellhead components and their connections should, on initial installation, be made with fresh water. Subsequent tests should also be with water. However, in circumstances where this is not practical, dispensation may be allowed for testing with the drilling fluid in the hole. Any such dispensation must be clearly indicated in the Drilling Programme. The following test tools may be used: 1. 2. 3. Plug Type Tester and test sub (PTT). Combination Cup Type Tester/hang-off tool (CCTT). Cup Type Tester (CTT).

The PTT or CCTT is run on drill pipe and landed in the wellhead whilst the CTT is suspended on drill pipe. Test tool design, application, and testing procedures depend on the type and the design of the wellhead. After any flanging up operation, the wellhead and each item of the BOP equipment should be high pressure tested to the rated working pressure of the wellhead or the blowout preventers, whichever is the lower, and to a low pressure of 3450 kPa (500 psi). When a CTT is used and it is seated in the casing, test pressure must not exceed 85% of casing burst rating. Wellhead side outlets below the PTT must be open during a test to avoid the risk of pressure increase below the test tool if there is a leak. During subsequent drilling operations, the equipment should be pressure tested at regular intervals. The frequency of tests will, as a minimum, comply with Company and/or government regulations and generally should be done:

After installation of any new wellhead component and BOP assembly and prior to drilling. Every fortnight, or other interval (maximum 3 weeks), depending on type of operation. Prior to a production test.

EP 2002-1500

- 126 -

Restricted to Shell Personnel Only

At any time requested by the Company drilling representative.

Subsequent tests of the wellhead and preventers should be to the anticipated maximum wellhead pressure with a maximum limit for the annular preventer of 70% of its rated working pressure. The CTT must be run with open-ended drill pipe to prevent pressurisation of the casing/hole below the cup in the event that it leaks. The drill pipe shall also be strong enough to withstand the tensile load caused by the hydraulic pressure on the cup area. The assembly should be suspended in the elevators, not set in the slips. Hook load must be monitored and care must be taken not to overload the derrick or hoisting equipment. Blind/shear rams shall be tested with the PTT converted into a blind plug. During this test the wellhead side outlets below the tester shall be open to prevent pressurising the casing. The wellhead side outlets must be monitored at all times, and closed immediately on completion of the testing. Casing rams should be visually inspected prior to installation. Casing rams and BOP bonnets should be pressure tested after installation with a Casing Ram Tester/CTT combination tool, to the usual test pressure. Plug and cup type testers, suitable for pressure testing the wellhead and BOP equipment installed on all casing strings, shall be available. Retrievable packers with large slip areas may also be used. NOTE: It should always be possible to close in the well or any annulus immediately, if flow is observed from the well or annulus while testing is in progress. Annular valves opened during pressure testing or any other type of operation shall not be left open unattended. All equipment should hold the applied test pressure for at least 10 minutes. A constant pressure during the full 10 minutes of test is the ideal result, but a certain drop in pressure is also often acceptable, depending on the way in which this drop occurs

P.Test

P.Test

10 mins

Time A. Even a slight pressure drop in way is unacceptable

Time B. Initial drop of less than 10% and then stable for remaining time is acceptable

Figure 4.8.1: Test pressure drop versus time 4.8.2. The BOP Hydraulic Control Unit

The complete BOP operating unit shall be tested in accordance with the manufacturer's recommendations. It shall be pressure tested to its rated working pressure and should hold the test pressure applied for at least 10 minutes.

EP 2002-1500

- 127 -

Restricted to Shell Personnel Only

The tests shall also confirm that all BOP controls:

are properly connected; activate the functions indicated on them; perform as per specification.

Accumulator Pre-Charge Pressure Test This test should be conducted on each well prior to spudding and approximately every 30 days thereafter, at convenient times. On closing units with two or more banks of accumulator bottles, the hydraulic fluid line to each bank must have a full opening valve to isolate individual banks. The valves must be in the open position except when accumulators are isolated for testing, servicing or transporting. The pre-charge test should be conducted as follows:

Shut off all accumulator pumps. Drain the hydraulic fluid from the accumulator system into the closing unit fluid reservoir. Remove the guard from the valve stem assembly on top of each accumulator bottle. Attach the charging and gauging assembly to each bottle and check the nitrogen precharge. If the nitrogen pre-charge pressure on any bottle or bank of bottles is less than the minimum acceptable pre-charge pressure listed below, recharge that bottle or bank of bottles (with nitrogen gas only) to achieve the specified desired pre-charge pressure. If the nitrogen pre-charge on any bottle or bank of bottles is greater than the maximum acceptable pre-charge pressure listed below, a sufficient volume of nitrogen gas must be bled from the accumulator bottle or bank of bottles to provide the specified desired pre-charge pressure.
Desired Pre-Charge Pressure Psig/kPa 750 1000 1000 5175 6900 6900 Minimum Acceptable Pre-Charge Pressure Psig/kPa 750 950 950 5175 6555 6555 Maximum Acceptable Pre-Charge Pressure Psig/kPa 850 1100 1100 5865 7590 7590

Accumulator Working Pressure Rating Psig /kPa 1500 2000 3000 10350 13800 20700

Accumulator Closing Test This test should be conducted routinely as part of BOP stack tests. The test should be conducted as follows: a) b) Position a joint of drill pipe in the blowout preventer stack. Close off the power supply to the accumulator pumps.

EP 2002-1500

- 128 -

Restricted to Shell Personnel Only

c)

Record the initial accumulator pressure. The pressure should be the design operating pressure of the accumulators. Adjust the regulator to provide 1500psi operating pressure to the annular preventer. Operate the sequence of functions as relevant to the rig type. For a Land Rig

d)

Close the annular preventer and one pipe ram (sized for the pipe in the stack). Open the HCR valve on the choke-line. Close and open all the well control functions (apart from blind/shear rams). Simulate the operation of the blind/shear rams by operating another pipe ram twice. After each function, record the volume used, the time taken and the residual accumulator pressure. The residual accumulator pressure after completing all the tests must be at least 200psi greater than the precharge pressure. Having completed the tests, recharge the accumulator system to its designed operating pressure. Record the time taken to recharge the system.

For the Floating Rig

e)

Turn on the accumulator pumps.

Closing Unit Test Prior to conducting any tests, the closing unit reservoir should be inspected to be sure it does not contain any foreign fluid or debris. The closing unit pump capability test should be conducted routinely as part of BOP stack tests. This test can be conveniently scheduled either immediately before or after the accumulator closing time test. The test should be conducted according to the following procedure: a) b) c) Position a joint of drill-pipe in the blow-out preventer stack. Isolate the accumulators from the closing unit manifold by closing the required valves. If the accumulator pumps are powered by air, isolate the rig air system from the pumps.

A separate closing unit air storage tank should be used to power the pumps during this test. When a dual power (air and electric) source system is used, both power supplies should be tested separately. Record the time (in seconds) required for the closing unit pumps to close the annular preventer. Record remaining pressure in the accumulator manifold. Pressure should not be less than 200 psi over the pre-charge perssure. Open the accumulator system to the closing unit and charge the accumulator system to its designed operating pressure using the pumps.

d)

Close the annular preventer and open one choke-line failsafe valve (or HCR valve).

e)

Close the choke-line failsafe (or HCR valve) and open the annular preventer.

EP 2002-1500

- 129 -

Restricted to Shell Personnel Only

4.8.3.

The Choke Manifold, Valves, Kill-&-Choke Lines And Valves On The Side Outlets

The choke manifold, valves, kill, choke lines and valves on the side outlets shall be pressure tested with water whenever feasible. The initial test should be to the rated working pressure of the ram type preventers or the rated working pressure of the manifold, whichever is the lower. Subsequent tests may be limited to the BOP test pressure. The equipment should hold the test pressure applied for at least 10 minutes. All lines should be flushed prior to testing to ensure they are not blocked and all air is removed from the lines. A pressure test schedule should be drawn up to ensure that all components are tested correctly and in the most efficient manner. No tests shall be performed against closed chokes. 4.8.4. The Kelly Or Top Drive Kelly Stop-cocks And Stab-in Valves

The kelly or top drive and kelly cocks shall be pressure tested to their rated working pressure with a test sub. The equipment shall hold the applied test pressure for at least 10 minutes. 4.9. Maintenance and Inspection of Surface Well Control Equipment

The general recommendations on maintenance, inspection and testing of BOP and associated equipment are presented in this section. 4.9.1. The Blow Out Preventer A BOP body pressure test shall be carried out once a year on the test stump at surface, in accordance with the manufacturer's specification for such a test. BOP's shall undergo a regular major overhaul and inspection, depending on the type of work and period in use. Periods between checks shall not exceed 5 years. During maintenance of BOP stacks (also transportation & rigging up), operating practices should be used which avoid cold work and hence, hardening of equipment components. BOP hydraulic operating lines shall be tested to the maximum accumulator manifold pressure when newly installed and during every regular BOP stack test, by opening the KR bypass valve. The control lines to the annular preventer shall be tested once per well to the maximum operating pressure. The control lines are to be disconnected from the annular preventer in order to avoid damaging the annular preventer rubber. Inspect the tightness of flange bolts and clamps frequently, particularly after pressure testing. Ensure the manufacturer's BOP operating manual is followed and no alterations are made to the BOP equipment without written consent from the manufacturer. Recertification may be required after making equipment alterations. Only manufacturer genuine or approved spares/replacement parts shall be used on BOP and associated equipment.

EP 2002-1500

- 130 -

Restricted to Shell Personnel Only

A maintenance schedule and checking procedures for BOP's shall be available on the drilling location and workshop. During pressure tests, all pressure gauges will be cross checked. Records of maintenance shall be kept, both scheduled and unscheduled, in a BOP history file.

Note: For full details on BOP Inspection, refer to API RP 53, Section 7-A 4.9.2. Choke Manifold Any replacement parts: flanges, valves, fittings, and discharge lines (flare lines) used in the maintenance of the choke manifold assembly should contain metals and seals in accordance with API RP 53. Pump through kill-and choke lines at regular intervals and displace weighted mud from choke manifold and kill lines. In freezing conditions replace mud in lines with inhibited fluid. Gas Detection Equipment H2S and Combustible gas detectors should be calibrated at a frequency determined by the manufacturers instructions. Detector heads should be checked regularly to ensure that mud build-up does not prevent activation. The mud-logging contractors gas and H2S system must be calibrated weekly. In addition, the system must be checked for sensitivity to changing levels. A calibration and sense check record must be maintained and available for inspection. Inside Pipe Shut-off Tools The Full Opening Safety Valve (stab-in valve) and the IBOP must be available on the rig floor at all times. In addition to routine inspection, it must be confirmed prior to any operation that: They are in the open position; The FOSV is full bore and does not present a restriction to well flow; They can be crossed-over to any pipe in the string; They can be easily man-handled.

4.9.3.

4.9.4.

The hydraulically operated IBOP (kelly cock) of a top drive should be function tested every day.

EP 2002-1500

- 131 -

Restricted to Shell Personnel Only

Note: This page has been left blank intentionally