WC

WELL CONTROL
EQUIPMENT &
PROCEDURES

IADC Drilling Manual 12th Edition

IADC Drilling Manual • Copyright © 2015

Proven Leadership
Then. Now. Always.
Covering well control events of all magnitudes for the past 40
years, our experience and dedication to quality, timely execution
of operations has positioned us as industry leaders.

When the largest of the world’s oilfield disasters calls for a

company that can take on the impossible, Wild Well is there.
There then, here now, and always ready with innovative solutions.

wildwell.com
 WELL CONTROL EQUIPMENT & PROCEDURES WC-i

CHAPTER

WC
WELL CONTROL
EQUIPMENT &
PROCEDURES

he IADC Drilling Manual is a series of reference guides assembled by volunteer drilling-industry professionals with
T expertise spanning a broad range of topics. These volunteers contributed their time, energy and knowledge in developing
the IADC Drilling Manual, 12th edition, to help facilitate safe and efficient drilling operations, training, and equipment mainte-
nance and repair.

The contents of this manual should not replace or take precedence over manufacturer, operator or individual drilling company
recommendations, policies or procedures. In jurisdictions where the contents of the IADC Drilling Manual may conflict with
regional, state or national statute or regulation, IADC strongly advises adhering to local rules.

While IADC believes the information presented is accurate as of the date of publication, each reader is responsible for his own
reliance, reasonable or otherwise, on the information presented. Readers should be aware that technology and practices ad-
vance quickly, and the subject matter discussed herein may quickly become surpassed. If professional engineering expertise is
required, the services of a competent individual or firm should be sought. Neither IADC nor the contributors to this chapter war-
rant or guarantee that application of any theory, concept, method or action described in this book will lead to the result desired
by the reader.

CONTRIBUTORS
Fred Mueller, Chevron
Lachelle Ahmed, GE Oil & Gas
Richard Grayson, Nabors Offshore Drilling
David Cormack, Auriga Training Limited
Arash Haghshenas, Boots & Coots A Halliburton Service
Bhavesh Ranka, Cudd Well Control
Mel Whitby, Cameron Drilling Systems
Darren Mourre, National Oilwell Varco

REVIEWERS
Jason Sasarak, BP
WC–ii WELL CONTROL EQUIPMENT & PROCEDURES

This is a chapter of the IADC Drilling Manual, 12th edition.

Copyright © 2015 International Association of Drilling Contractors (IADC), Houston, Texas.

All rights reserved. No part of this publication may be reproduced or transmitted in any form
without the prior written permission of the publisher.

International Association of Drilling Contractors

10370 Richmond Avenue, Suite 760
Houston, Texas 77042
USA

ISBN: 978-0-9909049-4-6

Printed in the United States of America.

IADC Drilling Manual Copyright © 2015

 WELL CONTROL EQUIPMENT & PROCEDURES Contents WC-iii

CHAPTER WC

WELL CONTROL EQUIPMENT &

PROCEDURES Contents
Introduction................................................................... WC-1 Typical diverter system for onshore and/or
Blowout preventer stack equipment...................... WC-1 bottom-supported offshore installations............WC-26
Typical stack arrangement........................................WC-5 Typical diverter system
BOP design considerations.......................................WC-5 for floating installations............................................WC-27
BOP arrangement considerations...........................WC-6 Diverter system maintenance................................WC-27
BOP arrangements: surface stacks........................ WC-7 BOP performance characteristics.........................WC-28
Testing surface stacks with one pipe size..........WC-11 Blowout preventer control systems......................WC-29
BOP arrangements: subsea stacks.......................WC-15 Diverter types............................................................ WC-41
Inside blowout preventers.......................................WC-17 Well control procedures......................................... WC-47
Choke manifold..........................................................WC-19 Appendix 1: Glossary..............................................WC-A1
Diverter systems........................................................WC-22 Appendix 2: IADC Kill sheets...............................WC-A3

IADC Drilling Manual Copyright © 2015

 IADC
Safety Toolbox
Essential safety alerts
and other tools for the
crew on the rig floor

IADC SAFETY TOOLBOX

DESIGNED TO SHARPEN SAFET Y SKILL S
Sharpen your safety skills with the new IADC Safety Toolbox. Available at no charge
at www.IADC.org/safety-toolbox, the searchable IADC Safety Toolbox provides easy
access to key IADC safety information, including safety alerts, safety meeting topics,
near miss/hit forms, safety posters and more.

The IADC Safety Toolbox is easy to use. Users can narrow their search by type of
operation (rigging up, lifting, etc), incident classification (LTI, equipment damage,
etc.), body part, location (rig type, etc.), incident type (slip, etc.) and equipment.

The Online Safety Toolbox provides a practical, user-friendly resource that will
seamlessly integrate into daily drilling operations. Contents include:

• 700 IADC Safety Alerts;

• 125 Safety Meeting Topics for JSAs or other meetings;
• Near Miss/Hit Report forms for both drilling and well servicing/workover;
• 60 IADC Safety Posters.

The Online Safety Toolbox puts critical safety related tools and resources directly in
the hands of the rig crew, and is one of several IADC initiatives aimed at enhancing
safety in the industry. Access it today!

www.iadc.org/safety-toolbox
 WELL CONTROL EQUIPMENT & PROCEDURES WC-1

Introduction
Preventing and, when prevention is not sufficient, respond-
ing to potential uncontrolled releases of oil or gas ("blow-
out") is critical to safe drilling operations. A kick is an influx
of formation fluids into the wellbore. A blowout is an uncon-
trolled kick exiting the well at surface.

Well control is a process that begins with spudding the well

and is not complete until the well is put on production and all
drilling operations cease.

This chapter will examine equipment commonly used in well

control and processes used to control kicks of oil or gas.

Blowout preventer stack equipment

Annular blowout preventer
The annular blowout preventer is installed at the top of the
BOP stack (Figure WC-1) and has the capability of closing
(sealing off) on anything in the bore or completely shutting
off (CSO) the open hole by applying closing pressure.

The sealing device of an annular blowout preventer is re-

ferred to as the “packing element”. It is basically a do-
nut-shaped element made out of elastomeric material. To
reinforce the elastomeric material, different shapes of me-
tallic material are molded into the element. This keeps the
elastomeric material from extruding when operating system
pressure or wellbore pressure is applied to the bottom of the
packing element. Since the packing element is exposed to
different drilling environments (i.e., drilling fluid/mud, cor-
rosive H2S gas and/or temperature of the drilling fluid), it is
Figure WC-1: Schematic (top) and photo of annular blowout
important to make sure that the proper packing element is preventers. Photo courtesy GE Oil & Gas. Top image, IADC drawing.
installed in the annular preventer for the anticipated envi-
ronment of the drilling operation. anything in the bore or on the open hole. Compression of
the elastomer throughout the sealing area assures a strong,
During normal wellbore operations, the preventer is kept ful- durable seal off against almost any shape, even with a previ-
ly open by applying hydraulic pressure to position the piston ously used or damaged packer.
in the open (down) position. This position permits passage
of drilling tools, casing, and other items which are equal to The piston is moved to the closed position by applying hy-
the full bore size of the BOP. The blowout preventer is main- draulic pressure to the closing chamber. Guidelines for clos-
tained in the open position by relaxing all hydraulic control ing pressures are contained in the operational section for
pressures to the closing chamber and applying hydraulic each manufacturer’s type of annular blowout preventer and
pressure to the opening chamber. Application of hydraulic in the Operator’s Manual. The correct closing pressure will
pressure to the opening chamber ensures positive control ensure long life, whereas excessive or deficient closing pres-
of the piston. sures will reduce packer life. The pressure regulator valve of
the hydraulic control unit should be adjusted to the manu-
Close preventer operation facturer’s recommended closing pressure.
In order for the annular BOP to close on anything in the bore
or to perform a complete shut-off, CSO or open-hole clo- As the packing element rubber deteriorates, higher closing
sure, closing pressure must be applied. A CSO is typically pressures may be required to effect a seal. Subsea applica-
limited to 50% of the annular rated working pressure, RWP. tions may require an adjustment of closing pressure due to
As the piston is moved to the closed position, the elastomer effects of the hydrostatic head of the control fluid and of the
packer is squeezed inward to a sealing engagement with drilling fluid column in the marine riser. Some manufactur-

IADC Drilling Manual Copyright © 2015

WC-2 WELL CONTROL EQUIPMENT & PROCEDURES

Figure WC-2: Schematic of ram-type BOP. IADC drawing.

Video WC-1: Animation shows internal BOP

action. Courtesy National Oilwell Varco.

ers may also require limiting the closing pressure depending

upon the diameter and wall thickness of casing or large di-
ameter tubulars. The applicable operator’s manual will ex-
plain these requirements.

Stripping with an annular BOP

Drillpipe can be rotated and tool joints stripped through a
closed packer while maintaining a full seal on the drillpipe.
Longest packer life is obtained by adjusting the closing
chamber pressure just low enough to maintain a seal on the
drillpipe with a slight amount of drilling fluid leakage as the
tool joint passes through the packer. The leakage indicates
the lowest usable closing pressure for minimum packer wear
and provides lubrication for the drillpipe motion through the
packer. Figure WC-3: Schematic (top) and photo of typical subsea BOP
stack. Photo courtesy GE Oil & Gas. IADC drawing at top.
A pressure regulator valve should be set to maintain the
proper closing pressure. For stripping purposes, the reg- ping. Check manufacturer’s recommendations for proper
ulator valve is usually too small and cannot respond fast nitrogen precharge pressure for your particular operating
enough for effective control, so a surge bottle is connected requirements. In subsea operations, it is advisable to add an
as closely as possible to the BOP closing port (particular- accumulator to the opening chamber line to prevent unde-
ly for subsea installations). The surge bottle is pre-charged sirable pressure variations.
with nitrogen, and is installed in the BOP closing line in order
to reduce the pressure surge which occurs each time a tool
joint enters the closed packer during stripping. A properly
installed surge bottle helps reduce packer wear when strip-

IADC Drilling Manual Copyright © 2015

 WELL CONTROL EQUIPMENT & PROCEDURES WC-3

Figure WC-4: Blind rams. IADC drawing. Figure WC-6: Variable bore rams. IADC drawing.

Figure WC-5: Pipe rams. IADC drawing.

Ram-type blowout preventer

A ram-type blowout preventer is basically a large bore valve
(Figure WC-2). The ram blowout preventer is designed to
seal off the wellbore when pipe or tubing is in the well. In a Figure WC-7: Schematic (top) and photo of Upper
BOP stack, ram preventers are located between the annular and lower shearing blind rams. Photo courtesy
BOP and the wellhead. (See schematic of a typical subsea GE Oil & Gas. IADC drawing at top.
BOP stack in Figure WC-3.) The number of ram preventers
include production tubing, drill pipe, drill collars, and
in a BOP stack ranges from one to eight depending on appli-
casing that will seal off the wellbore around it (Figure
cation and water depth. Flanged or hubbed side outlets are
WC-5);
located on one or both sides of the ram BOPs. These outlets ŸŸ Variable bore rams: Sealing element is much more
are sometimes used to attach the valved choke and kill lines complex and allows for sealing around a particular
too. The outlets enter the wellbore of the ram preventer im- range of pipe sizes (Figure WC-6);
mediately under the ram cavity. ŸŸ Shearing blind rams: Blade portion of the rams shears or
cuts the drillpipe, and then a seal is obtained much like
Other than sealing off the wellbore, rams can be used to the blind ram (Figure WC-7);
hang-off the drillstring. A pipe ram, closed around the drill- ŸŸ Casing shear rams: Casing shear rams are typically
pipe with the tool joint resting on the top of the ram, can hold shearing rams only and will not seal. They are
up to 600,000 lb of drillstring. specifically designed to cut large diameter tubulars that
are incapable of being sheared by blind shear rams.
Several different types of rams are installed in the ram type
BOP body. The five main types of rams are blind rams, pipe Note: Shear rams are also available that are capable of
rams, variable bore rams, shearing blind rams, and casing shearing multiple tubing strings and large diameter tubulars
shear rams. Following is a brief description of each type: while maintaining a reliable wellbore pressure seal.
ŸŸ Blind rams: Rubber sealing element is flat and can seal
the wellbore when there is nothing in it, i.e., “open hole” Operation and use of pipe rams
(Figure WC-4); As described earlier, pipe rams are designed to fit around
ŸŸ Pipe rams: Sealing element is shaped to fit around a certain diameter tubulars to seal off the wellbore (annulus)
variety of tubulars with a particular diameter, which
in a blowout situation. Most pipe rams are designed with re-

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WC-4 WELL CONTROL EQUIPMENT & PROCEDURES

placeable elastomer packers and top seals. Besides sealing Ram locking device
off the wellbore in an emergency situation, the pipe rams A ram locking device must be fitted to all ram blowout pre-
can be used for stripping. Use of two ram-type preventers venters. This device is used whenever it is necessary to re-
would only be resorted to if the annular preventer was bad- move hydraulic operating pressure from the “close” side of
ly worn. However, stripping drillpipe through rams can be the ram operating system, but maintain the ram preventer in
done with less string weight than if the annular preventer is the close position. Ram locking devices are used when rams
used, since there is no closure around the larger diameter of will be closed in for a long period of time as a contingency
the tool joints. One additional ram-type BOP must always plan for a loss of hydraulic pressure scenario.
remain available below any used for stripping, to allow the
well to be closed in safely. On BOP stacks that are used in a surface application, the
ram locking device is a threaded rod, referred to as a “lock
Stripping with ram-type BOPs screw”. This lock screw reacts between the operating pis-
Stripping through ram-type BOPs requires at least three ton in the ram operating system, and the housing of the lock
preventer ram cavities fitted with the proper size rams for screw. The locking device on a ram preventer that is used in
the pipe to be stripped. If the pipe string is a tapered string, a subsea application must be designed to be remotely actu-
i.e., having more than one size pipe in the string, two pre- ated by either the BOP hydraulic control unit, or by the ac-
venter ram cavities will be required for each size of pipe in tual movement of the operating piston in the ram operating
the string. A tapered pipe string can be stripped using only system.
two preventer ram cavities provided variable (multiple) bore
rams are used. Variable bore rams have a specified pipe size Operation and use of shearing blind rams
range and will seal off on any size pipe within the size range. Under normal operating conditions, shearing blind rams are
The two preventer ram cavities used for stripping should used as blind rams. The large front packer in the upper shear
be spaced sufficiently far apart so that closed rams in each ram seals against the front face of the lower shear ram, re-
preventer cavity will clear the length of a pipe connecting sulting in prolonged packer life similar to that of standard
joint. This also includes any upset (increased pipe diameter) blind packers.
portions adjacent to the connection. The distance between
the two preventer ram cavities should provide enough addi- If emergency conditions make it necessary to shear the
tional space so that positioning the pipe joint between the drillpipe, the closing shearing blind rams will shear the pipe
cavities does not require an excessive amount of precise and seal the wellbore whether the fish (the lower section
positioning. of sheared pipe) is suspended on the lower pipe rams or
dropped. If the fish is not dropped, the lower shear ram will
When operations indicate that a considerable amount of bend the sheared pipe over a shoulder and away from the
stripping may be required, it is advisable to include a third front face of the lower shear ram which then seals against
preventer ram cavity fitted with pipe rams for added safety the packer in the upper shear ram.
and to permit replacement of the ram packers in the strip-
ping preventers. The pipe rams in the upper two preventer If different grades, weights, or large diameter pipe has to be
cavities would be considered the “stripping” rams while the sheared, each oil tool manufacturer has a variety of shear
pipe rams in the third preventer cavity would be “safety” rams available to perform the shearing operation.
rams. Stripping pipe through ram packers causes wear on »» Recommended shearing procedures
the packers and packer replacement is sometimes required. 1. Raise the bit off the bottom and position the pipe in the
The safety rams in the third preventer cavity will permit well preventer so that the tool joint is positively NOT in the shear
pressure to be shut in below the stripping preventers when ram cavity.
required. The preventer with safety rams is only closed on a
stationary pipe string and therefore the rams do not receive 2. To ensure proper alignment for shearing, a set of pipe
much wear, thus always providing a reliable backup closure. rams may be closed before the shearing blind rams are
closed. Also, if the fish is not to fall downhole after being
Stripping requires no special equipment beyond what is nor- sheared, a tool joint may be landed on closed and locked
mally available on a drilling rig; however, as the pipe string pipe rams at least 30 in below the shear rams. The tool joint
becomes insufficient to overcome the upward force of the and upset portion of the drillpipe must be below the low-
er edge of the shear ram cavity to ensure that the pipe is
well pressure acting on the pipe, provisions must be made
sheared successfully.
for restraining the pipe string against upward movement. At
this point, the stripping operation becomes a “snubbing” op- 3. Close the shearing blind rams with 3,000 psi on the BOP
eration. Capability for pipe snubbing is also required when operating system. The accumulator system should be sized
starting a pipe down into the wellbore against well pressure. such that the pressure does not fall below 2,700 psi during

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-5

the shearing operation. The hoses for

the open and close functions of the Figure WC-8: Typical blowout preventer arrangement
BOP are recommended to be at least for 10,000-psi and 15,000-psi working pressure
one inch in diameter. service surface installations. IADC drawing.

4. Lock the shearing blind rams in the

closed position by actuating the man-
ual lock or applying locking (closing)
pressure to the appropriate locking
mechanism as required.

5. If the lower fish is suspended in

pipe rams below the shearing blind
rams, killing mud may be circulated
through a BOP outlet between the
shearing blind rams and the pipe rams
and into the lower fish in order to cir-
culate a kick out of the hole in the con-
ventional manner.

Care and maintenance of

all blowout preventer stack
equipment
Each manufacturer has individual care
and maintenance manuals for each
product of the blowout preventer
stack. They should be contacted for
detailed information regarding their
specific recommendation on each
piece of equipment. Proper care and
maintenance is essential to keep the
equipment working. * Annular preventer A and rotating head G can have lower pressure ratings.

Typical stack arrangement Example API BOP stack

and testing procedures for a surface stack "5M - 13 5/8 in. SRRA" describes a 5,000-psi W.P., 13 5/8-in.,
5M bore stack with components from bottom up, consisting
of a drilling spool, two single rams and an annular BOP.
The American Petroleum Institute has established standard
nomenclature for describing BOP components and ratings, For control of any well, blowout preventer stacks and as-
including the following information: sociated kill/choke lines and valving must be arranged to
provide a high degree of backup and flexibility. Figure WC-8
BOP component codes illustrates typical arrangements for BOP and choke/kill
manifolds. However, this API standard deals with the sub-
Code Component
ject only in a general way. The majority of this section will
A Annular
be devoted to analyzing several specific BOP stack arrange-
G Rotating Head
ments. Before doing this, first consider certain general facts
R Single Ram
concerning BOP design and arrangements.
Rd Double Ram
Rt Triple Ram
S Drilling Spool BOP design considerations
The principal BOP design considerations are to:
Pressure code ŸŸ Confine wellbore pressure;
M = 1,000-psi rating ŸŸ Provide for passage of tools.
working pressure
Controlling bottomhole pressure while killing a well is the
primary purpose of a BOP. In most cases, the BOP working

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WC-6 WELL CONTROL EQUIPMENT & PROCEDURES

pressure exceeds the limit of all other well control system Flexibility and safety
elements. A BOP stack should be able to contain the max- The rest of this section will analyze two BOP stack arrange-
imum anticipated surface pressure, which is essentially the ments used for maintaining control below surface casing on
full bottomhole formation bore pressure. non-floating type rigs.
Obviously, the BOP bore must be large enough for passage Both arrangements consist of a singular annular and three
of anticipated tool sizes. On occasion, underreamers must rams. The advantages and disadvantages of these arrange-
be used to open the hole because of BOP bore restrictions. ments in terms of flexibility and safety will be discussed.
Pilot holes are sometimes drilled to investigate formation
pressure and the BOP is removed to open the hole and run Also, included are recommendations for developing a safe,
casing. This practice could be disastrous. The BOP bore efficient BOP test procedure and the description of a specific
should be sufficient to provide protection during any drilling test sequence for one of the subject stack arrangements.
process.
There can be no “best” standard stack arrangements, since
each drilling environment and rig influences, to some de-
BOP arrangement considerations gree, BOP equipment configuration. But a closer look at sev-
Specific BOP arrangements are based on the following con-
eral good hookups highlights principles that will be helpful to
siderations:
anyone responsible for arranging or inspecting BOP stacks.
ŸŸ Governmental regulations;
ŸŸ Company policy;
ŸŸ Physical size and cost; BOP arrangements: surface stacks
ŸŸ Flexibility and safety. The drilling business is often a series of compromises, both
in equipment and practices. This is certainly true with BOP
Governmental regulations stack arrangements.
Rules and regulations governing the operation of a BOP in
the USA outer continental shelf areas are contained in the Location of the shear/blind ram
Bureau of Safety and Environmental Enforcement (BSEE) 30 Consider placement of blind rams in a 3-ram surface BOP
code of Federal Regulations Part 250. These rules and reg- stack. If blind (or shear) rams are placed at the bottom of the
ulations must be complied with. Likewise, in other areas of stack, with no flowlines below, then the BOP stack has the
the world, governments will usually have local regulations advantage of a “master valve” for open hole situations or a
governing the use and testing of BOP stacks. last resort valve if all else fails during a kick. But this place-
ment also imposes limitations on stack use.
Company policy
Both the Operator and the Contractor will usually have their For example, drillpipe cannot be hung off on pipe rams be-
own policies concerning BOP stack configuration and test- low the blind ram and the well killed by circulating through
ing. The operator should be made aware of the contractor’s the drill stem. This arrangement may also force placement
policies prior to the occurrence of any kick. of pipe rams so close together that adequate space is not
available for ram-to-ram stripping.
Physical size and cost On the other hand, if blind rams are placed at the top of the
If physical size and cost is no consideration, the ideal sit-
ram BOP stack, they can be replaced with pipe rams for ram-
uation would be to have only one BOP stack of sufficient
to-ram stripping operations to either protect the lower pipe
bore, working pressure and backup components to drill
ram or in the event of a tapered string, to furnish the pipe
the complete well. Such stacks are actually being built for
ram size that will fit the size of drillpipe being stripped. But
deepwater subsea operations where such designs can be
this arrangement also presents a problem because it pre-
justified. Most non-floating rig BOPs are surface mounted.
vents the utilization of the blind ram as a master valve in
Two independent stack arrangements are normally used.
open hole situations, for repair of items above it or changing
A large-bore, relatively low-pressure stack consisting of an
to casing rams. It also may force spacing of pipe rams so
annular only, or an annular plus one or two rams, is used
close that the ram-to-ram stripping is impossible.
for well control until surface casing is set. This large bore
stack sometimes is used as part of a diverter system. After The question arises as to how to best maximize advantages
setting surface casing, a small bore stack of higher working of both of these placements and minimize disadvantages.
pressure is normally used to TD. The two compromise arrangements illustrated in this sec-
tion (Figures WC-9 and WC-10) place blind rams on top
for tapered string drilling and in the middle when one size
drillpipe is being used. This allows hanging off pipe in the

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-7

pipe rams and circulation through the drill stem when kill
and choke lines are placed properly, adequate clearance for
To Test Manifold
ram-to-ram stripping and partial utilization of the blind ram Vent
P P
as a master valve for equipment out of hole repairs (top ram
change to casing size obviously being safer with the blind
ram in the middle).
To
Shaker

Arrangement of a double and a single ram unit

A standard size 13 5/8-in., 5,000-psi flanged double ram From From 5 P
Cement Mud
should be mounted on top of a single ram unit. This provides Unit Pumps Annular
Top Pipe
sufficient space for shearing above a standard 5–in. API Ram

NC50 connection hung in the bottom pipe ram as illustrated Shear/

2a
Blind
in Figure WC-11. This is the best arrangement for use with a Ram Alternate
location
1
single drillpipe size.
Bottom 2
Pipe Ram 4
Figure WC-11 depicts a standard length API NC50 pin and
box joint. An extra-long joint would probably not clear the 3
shear ram in a standard 5,000-psi BOP. Each arrangement
must be reviewed on a case-by-case basis. Figure WC-9: BOP arrangement for one pipe size. IADC drawing.

Some contractors prefer to assemble the single on top so

that the annular and the single can be separated from the To Test Manifold
Vent
double for purposes of easier handling. Trade-offs may be
P P
necessary in this matter. The primary aim here is not to de-
bate each point, but to emphasize the importance of critical-
ly reviewing BOP arrangements.
To
Shaker
Activities possible: One pipe size
From From
Refer to Figure WC-9: Cement Mud 5 P
Unit Pumps
Annular
Blind Ram
1. Normal kill down drillpipe using either pipe ram; 1
Small
a. Choke flowlines 2 and 4 below each pipe ram. Pipe
Ram
2. Kill with blind or shear ram closed;
a. Double ram unit must be on top of single ram to pro-
vide sufficient space for hang off and shear; Large
4 2
Pipe Ram
b. Kill flowline 1 and choke flowline 4 must be arranged
as shown. 3
3. Ram-to-ram stripping;
a. Blind ram must be in middle to provide sufficient Figure WC-10: BOP arrangement for two pipe sizes. IADC drawing.
space;
b. Kill flowline 1 to equalize pressure before opening
bottom ram; Annular
Must Shear
Above Upset
c. Choke flowlines 2 and 4 to bleed fluid and monitor Pipe
pressures below each ram during stripping; Top Pipe Ram Upset

Pin
d. Kill flowline 3 to lubricate in fluid (volumetric method
when bleeding gas) or kill below bottom ram; Shear Ram
14.56” 25”

e. Could also strip between annular and either ram and

do items 2, 3, or 4 above. Bottom 25.56” Box
Pipe
4. Location of blind ram in the middle. Ram
Set on
a. More room for ram-to-ram stripping as previously Ram
Pipe
mentioned; Ram

b. Safe “out of hole” top ram change, annular element CIW 13 5/8” 5000 psi Type-U Double and Single
5” XH Tool Joint (standard)

change or repairs to the single ram unit or annular.

Figure WC-11: Clearance for shearing. One pipe size. IADC drawing.

K1-4C
Clearance for Shearing

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WC-8 WELL CONTROL EQUIPMENT & PROCEDURES

NOTE: Location of primary choke flowline 2 at alternate lo-

cation 2a will allow all previously mentioned activities but is
somewhat more exposed to mechanical damage.

Double ram units can be special ordered with enough room

between rams to hang-off and shear. This special “long
neck” double ram unit could be put on bottom, best satisfy-
ing both single and tapered string application. This discus-
sion considers standard height double and single BOP units
only, with no spool or special stacks, so the most practical
compromise is to place the double ram unit on top.

Activities possible: Two pipe sizes

Refer to Figure WC-10:

1. Normal kill down drill pipe using either pipe ram;

Figure WC-12: Normal kill down drill pipe using a. Choke flowlines 2 and 4 below each pipe ram.
ram. One pipe size. IADC drawing. 2. Kill with blind or shear ram closed;
b. Can hang off in large pipe (bottom) rams, shear, and
kill;
c. Can hang off in small pipe (top) rams but cannot
shear due to small space so must back off before
closing blind rams;
d. Kill flowline 1 and choke flowlines 2 and 4 must be
arranged as shown.
3. Ram-to-ram stripping;
a. Could change blind ram to large pipe size and strip
ram-to-ram but the arrangement shown provides in-
sufficient space to strip small pipe ram-to-ram;
b. Kill flowline 1 to equalize pressure before opening
bottom rams;
c. Choke flowlines 2 and 4 to bleed fluid and monitor
pressures below each ram during stripping;
d. Kill flowline 3 to lubricate in fluid (volumetric method
when bleeding gas) or kill below bottom ram;
Figure WC-13: Kill with blind or shear ram
e. Could also strip between annular and either small or
closed. One pipe size. IADC drawing.
large ram and do items 2, 3 and 4 above.

NOTE: Relocation of kill flowline 1 required to accomplish kill

procedures mentioned in items 2c and 3b;

4. Location of blind rams on top:

a. Can accomplish kill with either size pipe hung off;
b. Can change to large pipe size for ram-to-ram strip-
ping;
c. Can change to either pipe size thereby minimizing
wear on lower pipe rams, which inevitably occurs
when pipe is worked with rams closed;
d. A disadvantage is open-hole exposure while install-
ing casing rams while out of hole.

NOTE: If the single ram unit were arranged on top of the

double unit or there was enough space between the top and
Figure WC-14: Ram-to-ram stripping. One pipe size. IADC drawing. the middle ram provided some other way, then small pipe
ram-to-ram stripping might be possible.

IADC Drilling Manual Copyright © 2015

 WELL CONTROL EQUIPMENT & PROCEDURES WC-9

NOTE: Refer to items 2b and 3a for Figure WC-10: Arrange-

ment for tapered strings indicates that space between the
blind rams and small pipe rams limits certain activities.
For tapered string application, this space problem could be Annular
eased by stacking the single ram unit on top of the double
ram unit. Figure WC-3 shows the double on top, another Blind Ram

compromise. In field use it is not practical to rearrange the

BOP stack just before picking up a smaller drillpipe string.
1 2

Double ram units can be special ordered with enough room Small Pipe Ram
Flow with annular or
between rams to hang-off and shear. This special “long Large Pipe Ram
small ram closed
4
neck” double ram unit could be put on bottom, best satisfy-
ing both single and tapered string applications. This discus-
Flow with large ram closed
sion considers standard height double and single BOP units 3

only, with no spool or special stacks, so the most practical

compromise is to place the double ram unit on top.
Figure
FIGUREWC-15: Kill
K1-8C Kill down
down drill drill pipeeither
pipe using usingram.
either
ram. Two pipe sizes. IADC drawing.
Choke and kill flowlines
Arranging rams is important, but choke and kill flowline
(wing valves) placement is equally important to fully utilize
the BOP. Again, compromises are made between the most
conservative position of having no flowlines below the bot-
Annular
tom ram and a middle road position of arranging the flowline
for maximum BOP usage. Blind Ram

Figures WC-9 and WC-10 illustrate two BOP and wing valve
arrangements. Activities possible with each of these two 1 2

arrangements are summarized near the figures and further Small Pipe Ram

illustrated in Figures WC-12 through WC-17. Large Pipe Ram

Check (non-return) valves, are located in each “kill” wing

valve assembly for the following reasons: 3

ŸŸ To stop backflow in case the kill flowline ruptures while

pumping into the well at high pressure;
FIGURE K1-9C Kill blink or shear ram closed.
ŸŸ Other kill flowline gate valves between the check valve Figure WC-16: Kill blind or shear ram closed.
and BOP can be left open during kicks for pumping into Two pipe sizes. IADC drawing.
the well whenever desired without personnel having to
open them. Kill lines should not be used as fill-up lines.
Constant use could result in erosion of lines and valves
which would result in an unsuitable kill flowline. A
separate line from the mud standpipe (independent of
all choke and kill flowlines) is desirable for filling the Annular

hole during trips. Large Pipe

Ram

Inboard valves adjacent the BOP stack on all flowlines are

manual operated “master” valves to be used only for emer- 1
2
gency. Outboard valves should be used for normal killing
Small Pipe Ram
operations. Hydraulic operators are generally installed on
Large Pipe Ram
the primary (flowlines 1 and 2 in Figures WC-9 and WC-10) 4
choke and kill flowline outboard valves. This allows remote
control during killing operations. Choke/kill flowlines are
3
generally not connected to the casing wellhead outlets but
valves and unions are provided there as:
Figure WC-17: Ram-to-ram stripping. Two pipe sizes. IADC drawing.
FIGURE K1-10C Ram to ram stripping K1-10C

IADC Drilling Manual Copyright © 2015

WC-10 WELL CONTROL EQUIPMENT & PROCEDURES

Alternate

P P
P P Lift
Drill
Pipe

From
Cement
Unit

From
Test Cement
Pressue From From P
P Unit Mud
From Mud Annular
Cement Pumps Annular Pumps
Pump Top Ram
Top Ram Pipe
Pipe

Blind Blind
Ram Ram

Bottom Bottom
Pipe Ram Pipe Ram

Casing Head

Figure WC-18: Testing entire casing string and Figure WC-19: Testing upper casing joints
casing head valves. IADC drawing. after drilling shoe. IADC drawing.
FIGURE K1-12C Testing Upper Casing Joints after Drilling Shoe

ŸŸ Reserve outlets for emergency use only; 4. All connections in choke, kill and relief lines, and the
ŸŸ Relief openings to prevent pressurizing of casing and choke manifold should have a pressure rating at least
open hole should a casing head plug tester leak during equal to the rating of the BOP stack;
BOP testing.

Flowing through a casing head outlet should be avoided. 5. Choke and kill wing valves are subjected to severe me-
Should this connection be ruptured or cut out, there is no chanical and vibrational stresses during drilling opera-
control. Therefore, primary and secondary choke and kill tions and when handling or controlling a “kick”. Where
flowlines should all be connected to heavy duty BOP out- practical, all overhanging valves, piping and connections
lets (or spool outlets) with wellhead outlets used only in an should be supported.
emergency.
NOTE: When operating wing valves that have pressure on
them, proper manufacturer procedures should be observed
Suggestions for rigging up surface stacks to prevent explosive decompression of the elastomer.
The following practices and principles should be considered:

1. All ring grooves should be cleaned of heavy grease. A ring 6. Swivel joint pipe sections in flowlines are necessary for
will not seal properly if the ring groove is full of grease or ease of rig-up, but where practical, “choke” flowlines
“puddled” oil. A “light” film of oil only should be applied from BOPs to manifold should be straight or curved
to ring grooves before nippling up. Avoid using a wire (hoses). Sharp turns should be minimized, and where
brush which would damage seal surfaces; practical, targeted tees with lead-filled bull plugs should
be used to minimize flow stream erosion. Using swivel
2. To achieve proper make-up torque on flange, clamp or joint pipe in kill flowlines is not as bad, because of less
BOP bonnets, a power torque wrench is useful. Bonnet severe vibrations and fluid conditions.
bolt makeup torque is high and, if not properly tightened,
could vibrate loose during drilling. Makeup torque tables 7. Choke flowlines conduct well fluid under pressure from
are available from BOP manufacturers. Most tables give the well to the choke manifold. Flow velocities are some-
required torque using either API 5A thread lube or Mo- times greater than through the kill line by virtue of the
ly-lube. Torque requirements using Moly-lube are much expansion of gas in the annulus, so small lines may cre-
less so always be aware of the relationship between the ate high pressure drops and erosion. By sizing the prima-
lubricant and the torque requirement; ry choke line to a larger size (minimum 3–in. I.D. instead
of 2–in.), the line will have greater strength, less friction-
3. Plug all BOP control lines not in use to prevent acciden- al pressure loss and be subjected to less wear. All lines
tal loss of accumulator fluid. Do not couple unused open should be properly secured.
and close control lines together. Plug them!
8. Where applicable, all connections, piping and valves in
flowlines should be protected from freezing by draining,
heating or keeping the line filled with non-freezing fluid.

IADC Drilling Manual Copyright © 2015

 WELL CONTROL EQUIPMENT & PROCEDURES WC-11

P P P P Test
Pressure
Through
Drill Pipe

From
Cement
Test Unit
Pressure From
from From Cement
P
Unit From P
Cement Mud Mud Annular
Pumps Annular
Pump Pumps
Top Ram Top
Pipe Ram
Pipe

Blind Blind
Ram Ram

Bottom Remove Checks When

Testing Kill Wing Valves Bottom
Pipe Ram Pipe Ram

Open Casing Head Open Casing Head Keep Open Keep Open

Casing Head Plug Tester

Stand of Drill Collars Casing Head Test Plug with Port

FIGURE K1-13C Testing Blind Ram FIGURE K1-14C Testing pipe rams, annular, all choke and kill manifolds,
Figure WC-20: Testing blind ram. IADC drawing. K1-13C
Figure WC-21: Testing pipe rams, annular and all choke and kill
flow lines, and BOP wing valves.

manifolds, flow lines, and BOP wing valves. IADC drawing.

Rams and choke manifold should be tested to full working

9. The gas/mud separator (gas box), vessel diameter, gas
pressure upon:
vent exhaust and mud seal at the discharge should be
ŸŸ Initial installation of BOP on wellhead;
designed to separate the maximum expected influx and
ŸŸ Maintenance or repair. Only test the affected
not allow gas to exit the mud discharge or mud to exit component(s).
the gas vent.
Routine ram and choke manifold maximum test pressure
Testing surface stacks with one pipe size should be limited to the lesser of:
This section contains a typical BOP test procedure using the ŸŸ 70% of rated working pressure;
Figure WC-9 (one pipe size) arrangement. Figures WC-18 ŸŸ Wellhead rated working pressure;
ŸŸ 70% of casing minimum internal yield strength.
through WC-21 illustrate each test step. The objective of this
test example is to focus on principles that could apply for However, in no case should these or subsequent test pres-
testing any BOP systems. sures be less than the maximum anticipated surface pres-
sure.
Test frequency, pressures and fluids
BOP test pressure and frequency requirements vary among The annular BOP maximum test pressure should not exceed
governmental regulators, operators and contractors. 70% of rated working pressure or 70% of casing minimum
burst strength, whichever is less. If governmental regula-
The following are general recommendations. tions or the operator does not stipulate annular BOP test
pressures, do not exceed 50% of working pressure.
Frequency
ŸŸ After initial installation; All well control system components should be tested in the
ŸŸ After each casing setting operation; direction normally felt by wellbore pressure during a kick.
ŸŸ Before drilling into any known or suspected high-
pressure zones;
Test fluids
ŸŸ Routine test no less than once each seven days of
ŸŸ For water-based muds, use water.
operation;
ŸŸ For oil-based muds, use diesel or acceptable alternative.
ŸŸ After a ram change, maintenance or BOP repair, test the
component that was affected;
ŸŸ Prior to a production test. General testing procedures
ŸŸ All choke manifold and choke and kill flowlines should
Test pressures be flushed out before each test and clean water be
inside all systems being tested when pressure is
The rams and annulars should betested in two stage, at a
applied. Drilling mud is a good sealant, which makes it
low pressure test of 200-300 psi and then at maximum test
an unsuitable test fluid.
pressure. Both pressure holding periods should not be less ŸŸ Pipe-rams should be closed only when there is pipe in
than three minutes. A 5 or 10 min holding period is common. the hole. Closing rams on the wrong size pipe or ON

IADC Drilling Manual Copyright © 2015

WC-12 WELL CONTROL EQUIPMENT & PROCEDURES

a swab and must have the proper OD to fit upper size

and weight casing joints. This test should be per-
formed regularly. However, actual test interval de-
pends upon regulations and company policy.

The appropriate cup tester is made up on drill pipe

and lowered approximately 90 ft (two casing joints)
below the casing head. Some operators require that
the cup tester be run into the casing to a point below
cement on the outside. After filling the stack with
clean water, the top pipe rams or annular is closed.
Pressure is built up by either pumping down the flow-
lines or by hoisting the drill string slowly (as shown
in Figure WC-19) to provide desired pressure. Hoist-
ing the drillstring is preferred over pumping, because
there is less chance of accidentally exceeding casing
yield or drillpipe strength.

Pressure applied to the cup tester directly imposes

a load on the drillpipe test string which could cause
drillpipe failure, particularly with Grade E. The usual
problem is collapsed pipe due to a combination of
outside crushing forces and pull.

A safe approach is to use Grade S135 or heavy wall

Figure WC-22: Cup-type Figure WC-23: Test plug. IADC drawing. drillpipe for all casing tests. Another technique is to
tester. IADC drawing. run a casing head plug tester in combination with a
cup tester. The casing head plug would be spaced
OPEN HOLE could result in ram front packer damage. out 90 ft above the cup with heavy wall pipe. After
This fact is often overlooked.
landing the casing head plug, test pressure would be applied
ŸŸ To prevent collapsed pipe, vent the annulus when
through the casing head outlets. This allows the cup-in-
closing a pipe ram. If a ram is forced into a closed BOP
bore, the trapped fluid pressure will rise rapidly as the duced forces to be supported by the casing head.
operating cylinder rod enters the BOP cavity.
Regardless of the approach, remember that all cup testers
are swabbing devices. To prevent swabbing, pull the cup
A BOP test sequence slowly and never run a test string that is not fully open to
Figures WC-18 through WC-21 provide schematics for test- atmosphere. In other words, the underside of the cup must
ing BOP stacks and casings. Explanations and reasoning be- always be open through the test string bore.
hind the different schematics and procedures are discussed
briefly in this section. 1. Before drilling out any casing shoe, test entire casing to
operator’s specifications, but never exceed 70% of rated
Entire casing string and casing head valves casing burst pressure;

Figure WC-18 shows the schematic for testing the BOP and 2. Flush all lines and fill BOP with test fluid. (Test fluid might
casing. There is no cup tester in the BOP stack. To avoid be water or diesel, depending on the type of fluid, as dis-
exerting external pressure to the formation, this test is per- cussed on page WC-11 ["Test fluid"].) Close blind ram.
formed after cementing the casing and when the bumped Pressure up using cementing pump through kill manifold
cement plugs are sealing. Some operators prefer to apply or a special test pump through (alt.) point. This tests en-
casing test pressure when the cement plug bumps. The rea- tire casing string plus casing head valves.
soning is that micro-cracks in the cement may occur if test
pressure is applied after cement has set up. NOTE: Casing tests are the only tests where casing head
valves are closed. These valves should always be open for
Upper casing joints after drilling the shoe other tests to prevent casing or formation rupture should
See Figure WC-19. After drilling the casing shoe, all future casing head plug tester leak.
tests of casing and casing head requires use of a casing cup
tester (Figure WC-22). The cup tester is nothing more than

IADC Drilling Manual Copyright © 2015

 WELL CONTROL EQUIPMENT & PROCEDURES WC-13

3. Run appropriate size and weight casing cup tester on Wellbore test pressure, psi
5,000
drillpipe to approximately 90 ft below casing head. Fill
annulus with water and close top ram;

GK

during actual kic k

Limit to min. 50 psi
1
3-
4,000

5/

0 psi
8”
4. Build up test pressure to operator’s specifications by lift-

,1

psi
18-3/4” 5,00
6-
3/
ing drilling pipe, being careful not to exceed 70% of rat-

GL 13-5/8”, 5,000
4”
3,000

5,0
ed casing burst pressure or tensile strength of drill pipe

00
ps
being used.

GL 16-3/4”,
MS
2,000

P2
Testing BOP stack

,00
02
Most kill and choke manifold valves, flowlines, and BOP 1/2
”
1,000 29-

1-1
wing valves could be pressured during the Figure WC-20 500

/4”
P
MS
test. However, the test string arrangement in Figure WC-21
(pressuring down the drillpipe which simulates a well kick) is 0
1,500 1000 500 0 500 1,000 1,500
best suited for this purpose because all valves can be tested
Opening pressure Closing pressure
in the direction that the pressure is applied during a kick.
Therefore, Figure WC-20 test is designed primarily to test Opening pressure, psi
the blind ram only by pressuring down a kill flowline. * Operating pressure may vary with individual packing elements (bags).
Adjust operating pressures accordingly, but do not exceed maximum
closing pressure of 1,500 psi except on CIW Type-D annulars.
See Figure WC-21. Some casing head plug testers are man-
ufactured with an integral port which allows the BOP bore ** During actual kick situations, for safety’s sake, operating pressure
should not be applied to the OPENING chamber of wellbore pressure.
cavity to be pressured by pumping down the drillpipe test
string. If the plug tester is not equipped with an integral port, Figure WC-24: Annular operating characteristics with 5-in.
a perforated sub could be used with the test plug. Be sure drillpipe.* (Actual values may vary.) IADC drawing.
the casing head outlet is open to prevent pressuring casing
and open hole. Failure to select the proper size and style test plug can cause
problems. Casing head hanger contours vary. For example, a
Because the BOP bore is being pressured through the drill- CIW Type “F” 5,000-psi tubing head has tapered contours,
pipe, all valves can be tested in the normal well kick direc- while the Type DCB head is straight contoured.
tion. By sequencing valves, open and closed in proper order,
a minimum of repressuring will be necessary. Always leave Insert a Type “F” plug tester in a Type DCB head, pressure
K1-18C
downstream valves open and remove the spring loaded up,Figure K1-18C:
and 5-inch
the two Annular operating
will become characteristics
almost with Always
inseparable.
drill pipe (Actual values may vary).
check in the check valve (when applicable) to ensure a valid consult with the casing head manufacturer to ensure that
test on each kill valve. It is important that all manifolds and the appropriate plug tester is being used.
flowlines be flushed out before this test so that all are clear
and full of water. The rams, annular, and hydraulic operated valves should be
tested in two stages. API Standard 53 (4th edition, section
Several precautionary notes are necessary for test steps il- 6.5.3.2) recommends a low pressure test of 250-350 psi
lustrated in Figures WC-20 and WC-21. held for at least 5 minutes before pressuring up to full test
pressure.
1. Ensure that casing head valves are always open when a
casing head plug tester is in use. This allows detection There are several reasons for this. Many preventers are de-
of a plug tester seal leak and prevents over pressuring of signed such that the wellbore pressure (test pressure) caus-
casing or open hole; es a closing force, so the BOP may be more likely to leak at
low pressure than at full test pressure. Because actual well
2. Casing head plug testers come in many shapes and sizes. kicks are normally closer to 300 psi than full working pres-
Figure WC-23 illustrates a test plug. Some have special sure, the low pressure test is significant. Also, mud solids
features such as integral ports. Some have open bore sometimes plug a potential leak hole. A low pressure test
with bull plugs provided for testing the blind rams while will come closer to uncovering this hole than the full test
others are solid bore. Some function as combination plug pressure.
testers and wear bushing retrievers.
Some annular preventers will hold maximum test pressure
with no more than 700-1,000 psi operating pressure. Be-
cause of special design features, operating pressure (from
accumulator) should be reduced on Hydril GK and 21 1/4–in.

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WC-14 WELL CONTROL EQUIPMENT & PROCEDURES

Table WC-1: Schedule of operating vs. test pressure »» High-pressure test

Psi-regulated Operating pressure Opening 1. All equipment in this test should be tested to rated work-
Psi pressure closing test side side ing pressure of the weakest member;
0 700* N/A
2. From previous test, open blind rams, install appropriate
1,000 300 N/A test string and screw into plug tester. Fill BOP with water
1,500 50 N/A and close top pipe ram.
2,000 N/A 50**
3. Apply test pressure down drill pipe and through perfo-
2,500 N/A 300 rated sub or plug tester if it has an integral port.
3,000 N/A 500
4. Bottom ram can be tested in similar manner. Test string
3,500 N/A 700 must fit ram size.

MSP annulars as the test (wellbore) pressure increases. This 5. Annular preventer can also be tested similarly, but do
greatly reduces element stress. For example, on a GK 16 3/4– not test to more than 70% of rated working pressure in
in. 5,000-psi annular, if operating pressure is held at 700 the U.S. Gulf or 50% of rated working pressure where
psi (closing chamber), the compression force on the element regulations do not specify.
increases from approximately 380,000 lb at zero test pres-
sure to about 780,000 lb at 3,500-psi test pressure. NOTE: Most annular preventers will hold maximum test
pressure with no more than about 700-psi regulated accu-
On the other hand, if operating pressure is reduced accord- mulator operating pressure. Reducing accumulator operat-
ing to Figure WC-24, compression force on the element will ing pressure as the test pressure increases is recommended
actually reduce to about 180,000 lb. If an annular BOP of for some annular preventers. This can greatly reduce ele-
this type is tested, use an operating pressure versus test ment stress. Where applicable, use an operating pressure
pressure chart to minimize element stress. Alway consult versus test pressure chart during testing.
the operating manual and/or the manufacturer for testing
procedure and operating recommendations.
1. All equipment in this test should be tested to rated work-
From Figure WC-24, the schedule for test pressure vs op- ing pressure of the weakest member.
erating pressure shown in Table WC-1 was developed for a
13 5/8–in. or 16 3/4–in. GK 5,000-psi annular on 5–in. drillpipe. 2. Pick up kelly, install full open safety valve on bottom of
Notice that at test pressures higher than about 2,000 psi, lower kelly valve. Using an adapter, connect to an inde-
regulated operating pressure is applied to the OPENING pendent test pump or cement pump.
chamber instead of the closing chamber.
3. Open appropriate standpipe valves and all kelly valves.
»» Low-pressure test Fill system with water and close standpipe and kelly. By
alternatively closing upstream and opening downstream
1. All equipment in this test should be tested to 200-300 valves, all kelly valves could be tested without pressuring
psi; up again, although it may not be possible to operate the
upper kelly valve under pressure.
2. Install one stand drill collars below appropriate casing
head plug tester. Land plug tester and back off running 4. Although not shown, the inside BOP (float-type) can be
joint. NOTE: Open bore-type plug testers can be provid- tested similarly by installing below the safety valve and
ed with a plug to test blind rams with drillstring removed. opening all valves through the standpipe.
Fill BOP with water and close blind rams;
Remember that each make, size and model annular pre-
3. Open casing head valves to prevent casing rupture or venter may have unique characteristics. For example, most
formation break-down should the plug tester leak; annulars require increasing, not decreasing, closing pressure
to prevent leaks as test pressure increases. Using incorrect
4. Apply test pressure as illustrated. Although test pres- procedures could cause damage or be unsafe. Always con-
sure is applied to a number of flowlines and valves, the sult the manufacturer for testing recommendations.
primary purpose of this test is to evaluate blind rams and
certain BOP connections as indicated by the arrows. Casing sizes larger than 7 in. might be collapsed by annular
element forces if the operating pressure is too high. Recom-

IADC Drilling Manual Copyright © 2015

 WELL CONTROL EQUIPMENT & PROCEDURES WC-15

Kill / Choke Line

Riser
Adaptor
Rotary Hose

Kill / Choke Line

Flex
Joint
Alternate Mud
Standpipe
Swivel Upper
Annular
P P Lower Kelly Preventer
Kelly Valve
Valve
Full Open Hydraulic
Safety Connector
Valve

Pressure Annular
From Preventer
Test Pump
P
From
Cement
Unit From Ram-type Preventer
Mud Pipe Rams
Pumps
Annular
Ram-type Preventer
Top Ram Pipe
Blind/Shear Rams

Blind Ram Ram-type Preventer

Pipe Rams

Ram-type Preventer
Pipe Rams

Bottom
Pipe Ram
Hydraulic
Connector

Figure WC-26: Typical subsea BOP arrangement. IADC drawing.

Figure WC-25: Testing inside BOPs, kelly valves,

swivel and rotary hoses. IADC drawing.
FIGURE K1-17C Testing inside BOPs, kelly Valves, Swivel and Rotary Hose.
Figure K1-21C: Typical Subsea BOP Arrangement

mended maximum operating pressures for closing on var-

ious manufactures size casing can be obtained from most
annular preventer manufacturers.

Testing inside BOPs, kelly valves, swivel sand rotary

hoses
Refer to Figure WC-25. Although only one mud standpipe
and rotary hose test is shown, the other side should be test-
ed before being put into service.

Instead of using an adaptor sub as illustrated, an alternative Figure WC-27: Deepwater BOP stacks are built in two,
method for testing this equipment would be to move directly sometimes three, sections to facilitate transport. Here,
from the test illustrated to Figure WC-21. Pick up the kelly, if the top half of a 20,000- psi BOP stack is loaded onto
it was not already connected, and apply test pressure down a trailer for transit to port. Courtesy GE Oil & Gas.
a kill flowline with the cement pump or special test pump (at
ŸŸ Blind shear rams are generally set high in the stack to
an alternate inlet location). The perforated test sub or plug
provide more pipe hang-off options below. With the
tester ingetral port will allow the test string to be pressured blind shear rams closed over hung-off pipe, the well can
in the direction normally felt during an actual kick. be monitored or circulated in pipe or annulus;
ŸŸ Choke and kill lines are dual purpose, i.e., either can be
BOP arrangements: subsea stacks used to kill (pump in) or choke (direct to choke
Figure WC-26 illustrates a typical subsea BOP arrangement. manifold);
Figure WC-27 shows only a portion of a 20,000-psi subsea ŸŸ Two fail-safe valves for each choke and kill BOP outlet
that are fail-safe in the closed position;
BOP. Note how it towers over the attendants.Some of the
ŸŸ Two hydraulic or electro hydraulic control PODs each
differences when compared to surface stacks are:
with 100% redundancy;
ŸŸ More backup units needed because of the difficulty of ŸŸ All rams equipped with remote operated ram locks.
retrieving and deploying a subsea BOP;
ŸŸ Upper annular(s) can be recovered with the riser for Testing subsea BOP stack
repairs without removing the “big” stack; Test pressures and test frequency are similar to surface
ŸŸ Do not normally pull BOP for casing ram change so two stacks with the following notable exception.
annulars are needed for back-up;
ŸŸ Variable bore rams usually installed in one of the ram All subsea BOP stack rams and valves are generally tested
cavities to provide redundancy when tapered strings at surface (on a test stump) to their rated working pressure.
are used or when running production casing;

IADC Drilling Manual Copyright © 2015

WC-16 WELL CONTROL EQUIPMENT & PROCEDURES

The choke manifold, valves, kill and choke lines and fail-safe
Table WC-2: 'Inside' BOPs—Rigs with Kelly drive
valves should be pressure tested with water to the rated
Inside BOP Normal
Common type
Figure working pressure of the ram type preventers, or the rated
name location Illustration
working pressure of the manifold, whichever is the lower.
Upper kelly
Between swivel Flapper or full
valve or upper Figure WC-28
kelly cock
and kelly open ball The kelly or top drive and kelly stopcocks should be pressure
tested to their rated working pressure with a test sub.
Lower kelly Between kelly
valve or upper and kelly saver Full open ball Figure WC-29
kelly cock sub Tests during lowering and after connecting the BOP stack,
kill and choke lines, marine riser and operating hoses.
In front of
Safety valve Full open ball Figure WC-29
drawworks
When running the BOP stack on riser joints, the kill and
choke lines should be pressure tested at least when the
Table WC-3: 'Inside' BOPs—Rigs with top drive
stack is below the splash zone and both before and after
Inside BOP Normal
Common type
Figure landing. More frequent testing may be stipulated, i.e., each
name location Illustration
5 or 10 riser joints.
Between main
Upper remote Figures
shaft and lower Full open ball
safety valve
valve
WC-30 & -31 After the BOP stack is connected to the wellhead, a full
Lower safety Below upper Figures
function test on both pods and a low pressure test should
Full open ball be conducted.
valve safety valve WC-30 & -31

Table WC-4: 'Inside' BOPs—Kelly drive or top drive rigs The pressure test upon initial and any subsequent mating of
the BOP and wellhead should be performed with sea water
Inside BOP Normal Figure
Common type to the maximum anticipated pressure at TD of the well to
name location Illustration
In front of confirm connector/wellhead integrity. This pressure is only
Inside BOP Poppet check Figure WC-32
drawworks required against one pipe ram if the stack has been com-
Drop-in check pletely stump-tested prior to running. For routine tests, the
Top of BHA Ball check Figure WC-33
valve BOP will be tested with the fluid in the hole at the time of
Installed in bit Flapper or the test.
Bit float Figure WC-34
sub poppet check
In deep water, a serious well control problem could develop
The annular is generally tested to 70% of rated working due to loss of hydrostatic head, with the choke and kill line
pressure. The subsea stack, once deployed and connected full of water. Therefore, after initial and subsequent mating
to the conductor casing wellhead is not disconnected until of the BOP on the wellhead, the choke and kill lines will be
the well is complete. Therefore, a higher stump test pressure kept full of in-hole drilling fluid. All lines should be flushed
is required than is normal for surface stacks. daily to ensure they are not blocked.

In shallow water (less than 1,500 ft), operators may prefer

Testing procedure for subsea BOPs to keep the choke/kill lines filled with sea water to prevent
solids from settling out. Blind shear rams are normally test-
Tests before lowering the BOP stack ed against casing prior to drilling out, first at low pressure
All subsea BOP stack components should be installed,
and again at a higher pressure, as indicated on the actual
checked, and pressure tested to their rated working pressure
drilling prognosis. The blind shear rams are generally not re-
and to a low pressure of 250 psi while the stack is mounted
tested during the normal test intervals as is done with the
on the test stump. After the surface tests, all clamp connec-
other BOP components unless the seal integrity is in ques-
tions and all studded connections should be checked for
tion, but will be retested prior to drilling out of subsequent
tightness. The complete BOP operating unit should be test-
casing strings.
ed in accordance with manufacturer’s recommendations
and pressure tested to its rated working pressure. The test
Routine tests
should include at least the following:
The opening/closing times and the volumes of hydraulic
ŸŸ Test every BOP control; operating fluid required for the operation of the various un-
ŸŸ Check that each function is properly connected; derwater stack components (i.e., rams, kill and choke line
ŸŸ Activate the functions which are indicated from both valves, annular preventers, hydraulic connectors, etc.) shall
control pods; be recorded during testing of the stack underwater. These
ŸŸ Check and record test volumes and response times for results shall be compared with the normal opening/closing
each function. times and volumes required of the hydraulic system. Any

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-17

major differences are an in-

dication that the system is
not operating “normally” and
shall require further inves-
tigation and possible repair.
Pressures of the wellhead or
preventers should be to the
anticipated wellhead pres-
sure with a maximum limit
for the annular preventer of
70% of its working pressure.
It should also be pressure
tested at low pressure, as
described earlier.

"Inside" blowout
preventers
There are several pieces of
equipment in addition to the
primary blowout prevention
equipment that are some-
times necessary to control

a kick. The equipment which

furnishes closure inside the
drill string is called an “in-
side” blowout preventer.

A number of devices serve

this purpose. The “names” of
these devices are often con-
fusing. Tables WC-2 through
WC-4 classify inside BOPs to
eliminate this confusion.

Upper Kelly valve

The upper kelly valve, or kelly
cock (Figure WC-28), is in-
stalled between the kelly and
the swivel and normally has
left hand threads. Because it
is installed above the kelly, it
is always available. The basic
purpose of this valve is to iso-
late the fluid in the drillstring
from the swivel, rotary hose
or standpipe and to prevent
The most common design has a flapper as shown in Figure
leaks or rupture under well conditions. If the drillpipe pres-
WC-28. The other design is a full open ball similar to the
sure exceeds the rating of the rotary hose, closing the valve
lower kelly valve.
allows a safe change to higher pressure connections. It also
permits removal of the swivel so that wire lines or tools may The upper kelly valve should have a WP rating equal to or
be run into a pressurized drillstring. greater than that of the blowout preventer assembly being
used, and should have an inside opening equal to that of the

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WC-18 WELL CONTROL EQUIPMENT & PROCEDURES

kelly. To operate this valve, a special wrench is required, and

should be kept in an accessible place on the rig floor.

Lower Kelly valve

A lower kelly valve (Figure WC-29), sometimes called a low-
er kelly cock. It is installed on the lower end of the kelly, and
is used when the upper kelly valve is damaged or not easily
accessible. If the kill pressures approach the rotary hose rat-
ings, this valve is closed, the kelly broken out and set back
and the cement standpipe hose is connected via a circulat-
ing head to the lower kelly valve.

Safety valve
During trips on rigs with kelly drive, the kelly and both up-
per and lower kelly valves are stored in the rat hole. For this
reason, another valve, identical to the lower kelly valve, is
stored close by so it can be quickly installed on the drillpipe
during a trip should a kick occur. When used in this manner,
it is called a safety valve.

If a tapered drillstring is being used, then a safety valve for

each size pipe and crossovers to drill collar connections
must be available on the rig floor.

All of these kelly and safety valves should be operated at the

Figure WC-30: Safety valves installed in
beginning of each tour. They should be tested when the BOP
top drive system. IADC drawing. is tested and the pressure should be applied in the direction
pressure would be felt should the well be closed.

Upper remote safety valve and lower safety valve

The upper and lower safety valves on top drive systems are
connected together. They are a ball type design. Both are very
likely to be inaccessible should a kick occur during drilling op-
erations, so the upper valve is remote operated as shown in
Figure WC-30. The body on this particular design is splined to
accommodate the pipe handler system. Some top drive units
use a different kind of torquing mechanism which does not
require a special OD profile on the upper safety valve. In these
cases, the upper and lower safety valves may be identical ex-
cept that the upper is fitted with a remote actuator crank and
the lower is plain manual operated. Figure WC-30 illustrates
the two valves installed in the top drive assembly. Figure WC-
31 show these two valves separated.

During trips with the top drive system, the swivel and safety
valves are not set back but rather are hoisted with the drill-
string. Should a kick occur during the trip, the safety valves
are immediately connected to the drillstring, and the upper
valve remotely closed. There is no need to have another safe-
ty valve on standby as with kelly drive operations.

Figure WC-31: Splined and plain top- Should a top drive require repairs, it's recommended to stab
drive safety valve. IADC drawing. a safety valve atop the drillpipe, should there be a need to
close the drillpipe.

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-19

Figure WC-32: Inside BOP. IADC drawing. Figure WC-33: Wireline retrieval and drop-
in check valve. IADC drawing.

sembly of the drillstring. These inside BOPs are often used

Inside BOP in stripping operations and particularly stripping “out” oper-
Although all valves that secure the drillstring bore are “in-
ations. Some are wireline retrievable. Figure WC-33 shows
side” BOPs, the check valves discussed in the following
one type of drop-in check valve.
paragraphs are — confusingly — the only ones commonly
called “inside BOPs” (Figure WC-32). They are normally
Bit float
used for stripping in the hole under pressure when a kick oc-
A bit float (Figure WC-34) may be considered an “inside”
curs off bottom during a trip.
preventer. It is basically a flapper or poppet-type check valve
By utilizing a special tool, the inside BOP or check valve may that is installed in the bit sub to prevent backflow during
be kept open to permit stabbing into the drillstring when the connections; however, it is subjected to severe wear by the
well is kicking. Once made up in the drillstring, the tool is drilling mud and may not function when needed. A common
released and the check valve closes. The inside BOP on the practice is to use a slotted flapper. This reduces backflow to
rig floor should be kept in open position, as a guard against a a minimum, yet allows stabilized closed-in pipe pressure to
kick or flow through the drillpipe. be easily read should the well kick.

However, check valves are more difficult to stab against drill Most operators discontinue the use of bit floats after setting
pipe flow than are full open ball valves. Therefore, the full surface casing. Kicks are more likely to occur below surface
open safety valve should be installed first and then the “in- casing and the bit float might interfere with a good stabilized
side” BOP (check valve) installed if it is necessary to strip closed-in drillpipe pressure reading. Bit floats are most use-
back in the hole. ful in top-hole drilling where backflow during connections is
more likely due to imbalanced annular fluid density.
Drop-in check valve
Another type inside BOP is the pump down or drop-in type
which requires a special sub near or in the bottomhole as-

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WC-20 WELL CONTROL EQUIPMENT & PROCEDURES

Choke manifold
If the hydrostatic head of the drilling fluid is insufficient to
control subsurface pressure, formation fluids will flow into
the well. To maintain well control, back pressure is applied
by routing the returns through adjustable chokes until the
well flow condition is corrected. The chokes are connect-
ed to the blowout preventer stack through an arrangement
of valves, fittings and lines which provide alternative flow
routes or permit the flow to be halted entirely. This equip-
ment assemblage is designated the “choke manifold.”

Design Considerations
Choke manifold design should consider such factors as an-
ticipated formation and surface pressures, method of well
control to be employed, surrounding environment, corrosiv-
ity, volume, toxicity, and abrasiveness of fluids.

Installation guidelines
Recommended practices for planning and installation of
choke manifolds for surface installations include:
ŸŸ Manifold equipment subject to well and/or pump
pressure (normally upstream of and including the
chokes) should have a working pressure equal to the
rated working pressure of the blowout preventers in
use. This equipment should be tested when installed to
pressures equal to the rated working pressure of the
blowout preventer stack in use.
ŸŸ Components should comply with applicable
specifications to accommodate anticipated pressure,
temperature and corrosivity of the formation fluids and
drilling fluids.
ŸŸ For working pressures of 3,000 psi and above, flanged,
welded or clamped connections should be employed on
components subjected to well pressure.
ŸŸ The choke manifold should be placed in a readily
accessible location, preferably outside of the rig
Figure WC-34: Clockwise from top left: Bit float, poppet- substructure.
type, flapper-type and plunger type. IADC drawing.

Figure WC-35:
Typical 2,000-psi
(13.8 MP) manifold.
IADC drawing.

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-21

Figure WC-36: Typical

5,000-psi (34.5 MPs)
manifold. IADC drawing.

Figure WC-37: Typical

10,000-20,000-psi
(69.0-138.0 MP) manifold.
IADC drawing.

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WC-22 WELL CONTROL EQUIPMENT & PROCEDURES

Packing unit/
Packing element/
Sealing element

Piston

Vent
outlet

Lower piston
seal seat

Figure WC-38: Diverter with annular Figure WC-39: Diverter with insert-type
packing element. IADC drawing. packing element. IADC drawing.

ŸŸ The choke line (which connects the blowout preventer ŸŸ All choke manifold valves subject to erosion from well
stack to the choke manifold) and lines downstream of flow should be full-opening and designed to operate in
the choke should: high pressure gas and drilling fluid service. Double,
ŸŸ Be as straight as practicable; turns, if required, full-opening valves between the blowout preventer
should be targeted; stack and the choke line are recommended for
ŸŸ Be firmly anchored to prevent excessive whip or installations with rated working pressures of 3M and
vibration; above.
ŸŸ Have a bore of sufficient size to prevent excessive ŸŸ For installations with rated working pressures of 5,000
erosion or fluid friction. psi and above the following are recommended:
ŸŸ Minimum recommended size for choke lines is 3-in. ŸŸ One of the valves should be remotely actuated.
nominal diameter (2-in. nominal diameter is acceptable ŸŸ Double valves should be installed immediately
for Class 2M installations). upstream of each choke.
ŸŸ Minimum recommended size for vent lines downstream ŸŸ At least one remotely operated choke should be
of the chokes is 3-in. nominal diameter. installed. If prolonged use of this choke is
ŸŸ For high volumes and air or gas drilling operations, 4-in anticipated, a second remotely operated choke
nominal diameter lines are recommended. should be used.
ŸŸ Alternate flow and flare routes downstream of the ŸŸ A valve should be installed downstream of the choke
choke line should be provided so that eroded, plugged to provide isolation from the buffer tank when
or malfunctioning parts can be isolated for repair changing wear items while circulating through the
without interrupting flow control. second choke.
ŸŸ Consideration should be given to the low temperature ŸŸ Downstream of the choke, a decrease of one
properties of the materials used in installations to be pressure rating, i.e., 5,000 psi down to 3,000 psi,
exposed to unusually low temperatures. 10,000 psi down to 5,000 psi, etc., may be
ŸŸ The bleed line (the vent line which bypasses the considered for the valves and buffer tank.
chokes) should be at least equal in diameter to the ŸŸ Spare parts for equipment subject to wear or damage
choke line. This line allows circulation of the well with should be readily available.
the preventers closed while maintaining a minimum of ŸŸ Testing, inspection, and general maintenance of choke
back pressure. It also permits high-volume bleed-off of manifold components should be performed on the
well fluids to relieve casing pressure with the preventers same schedule as employed for the blowout preventer
closed. stack in use.
ŸŸ Although not shown in the typical equipment ŸŸ All components of the choke manifold system should be
illustrations, buffer tanks are sometimes installed protected from freezing by heating, draining or filling
downstream of the choke assemblies for the purpose of with proper fluid.
manifolding the bleed lines together. It also provides a ŸŸ Figures WC-38 through WC-40 illustrate typical choke
large chamber for gas expansion and reduction in gas manifolds for various working pressure service.
velocity. When buffer tanks are employed, provisions Refinements or modifications such as additional
should be made to isolate a failure or malfunction hydraulic valves and choke runs, wear nipples
without interrupting flow control. downstream of chokes, redundant pressure gauges
ŸŸ Pressure gauges suitable for drilling fluid service should be and/or manifolding of vent lines will be dictated by the
installed so that drillpipe and annulus pressures may be conditions anticipated for a particular well and the
accurately monitored and readily observed at the station degree of protection desired. The guidelines discussed
where well control operations are to be conducted. and illustrated represent typical industry practice.

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-23

Side Flow Line

View Fill-Up Line

Bell Nipple

30” - 1,000 psi W.P.

A-A Annular Preventer

Hydraulic-Operated
Ball Valve Hydraulic Operated
Ball Valve

Diverter Vent Line Diverter Vent Line

30” - 1,000 psi W.P.

30” Conductor Pipe Drilling Spool/Mud Cross
with 30” - 1,000 psi W.P.
Welded on Top
View A-A

Figure WC-41: Typical diverter system with control- K1-4F

sequenced flow system. IADC drawing.
FIGURE K1-4F: Typical Diverter System with Control
Overboard Overboard Sequenced Flow System
Vent Vent
Packing unit/
Packing element/
Sealing element

Piston
Two-Position
Target Plug Diverter Exhaust
K1-3F
Figure WC-40: Switchable 3-way target valve. IADC drawing.
Figure K1-3F: Switchable 3-Way Target Valve
Vent
outlet
For economic reasons, it may be desirable at the beginning
of a drilling operation to install a manifold with a pressure
rating equivalent to that of the highest pressure rated sys- Lower piston
seal seat
tem which will be used on that well. This will preclude the
necessity of always matching manifolds with BOP stack
Figure WC-42: Example of purpose-designed diverter
ratings, minimizing time lost changing choke manifolds and with built-in vent valving. IADC drawing.
reduce the number of manifolds held in inventory.

Screwed connections are optional for only the 2,000-psi Annular sealing device
manifold; all others shall be welded or flanged. Suggested The annular sealing device is available in three different de-
configurations are shown in Figures WC-38, WC-39 and signs.
WC-40 as 2,000-psi and 3,000-psi, 5,000-psi, 10,000-
psi, and 15,000-psi manifolds. Annular packing element
Figure WC-41 is an example of an annular sealing device
Diverter systems that utilizes an annular packing element as the sealing
The function of a diverter system is to provide a low mechanism. The annular packing element can effect a seal
pressure well flow control system to direct controlled or on any pipe or kelly size in the wellbore, or can effect a seal
uncontrolled wellbore fluids or gas away from the im- on open hole where no pipe is present. This is often times
mediate drilling area for the safety of personnel and referred to as “complete shut-off” (CSO).
equipment involved in the drilling operation. The divert-
er system is not designed to shut in or halt well flow. Insert-type packing element
Figure WC-42 is an example of an annular sealing device
that utilizes an insert-type packing element as the sealing
Diverter system equipment that can be exposed to a hydro-
mechanism.
gen sulfide environment should comply with NACE MR-01-
75: Material Requirements Sulfide Stress Cracking Resistant An insert-type packing diverter element uses a group of in-
Metallic Materials for Oil Field Equipment, latest edition. serts. The inserts are placed one inside the other. Each in-
sert in the group is designed to close and seal on different
A diverter system comprises the following components: ranges of pipe diameters. A hydraulic or mechanical func-

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WC-24 WELL CONTROL EQUIPMENT & PROCEDURES

tion serves to latch each insert in place. The correct size in- full-opening, have at least the same through-bore opening
sert should be in place for the pipe size in use. In order to as the vent outlet that it is attached to, and should be capa-
pass large bottomhole assemblies, it is necessary to remove ble of opening with maximum anticipated pressure across
some or all of the inserts. An insert-type packing element the valve sealing mechanism. Several types of full-opening
cannot CSO. valves which can be used in this application are gate valves
(various types), ball valves, knife valves, switchable 3-way
Rotating head targeted valves (Figure WC-40), and valves that are integral
A rotating head can be used as a diverter to complement a to the annular sealing device. Any valve used in a diverter
blowout preventer system. The stripper rubber is energized system application should be fitted with remote actuators
by the wellbore pressure to seal the rotating head element capable of operation from the rig floor. The actuators can
against the drillpipe, kelly or other pipe to facilitate divert- be operated either with hydraulics or pneumatics. The ac-
ing return wellbore media and can be used to permit pipe tuator should be sized to open the valve with the maximum
movement. system rated working pressure across the closed valve seal-
ing mechanism, with hydraulic or pneumatic pressure that is
Vent outlet(s) available from the diverter system remote control unit. The
Vent outlet(s) for the diverter system are located below the trim of the internal components of the valve actuator should
annular sealing element. One or more vent outlets can be be suitable for the media that is going to be used to operate
used in a system. Vent outlet(s) may either be incorporated the actuator. If a water-based fluid is the media, the actuator
in the housing of the annular sealing device, or may be an trim should be suitable for water service, corrosive. Exces-
integral part of a separate drilling spool/mud cross that is sive resistance due to drilled solids in the valve should be
assembled using a flange or clamp type connection just be- kept in mind, especially if using a pneumatic system where
low the annular sealing device. variations in rig air pressure are common.

Design considerations for the connection between the vent Vent line piping
outlet(s) and the vent line(s) should include ease of instal- There are various considerations that need to be investigat-
lation, leak-free construction and freedom from solids accu- ed for the vent line piping in a diverter system. These consid-
mulation. Regarding the size of the vent outlet(s), different erations are as follows:
regulator bodies have different requirements, depending
on the area of operation. For example, the requirements for
drilling operations that utilize a surface wellhead configura- Sizing
tion in areas regulated by the U.S. Minerals Management The vent line piping in a diverter system should be sized
Service (reference CFR 30, Chapter II, 7-1-88 Edition, para- to minimize back pressure on the wellbore while diverting
graph 250.59) require that no spool outlet or diverter line wellbore media. The vent line should be run as straight as
shall have an internal diameter less than 10 in.; except in the possible, keeping in mind that bends, tees and elbows not
case where dual outlets are provided, in which case the min- only create higher back pressure than straight pipe, but are
imum internal diameter of each vent outlet is 8 in. For drill- more susceptible to erosion during a diverting operation
ing operations where a floating or semi-submersible type than straight piping. Just as with the vent outlet(s) discussed
drilling vessel is used, the vent outlet internal diameter shall in the above paragraph, government regulatory bodies have
not be less than 12 in. For drilling activity outside the United minimum requirements for the internal diameter of the vent
States, the drilling contractor is advised to become familiar line piping. The drilling contractor should be familiar with
with the regulations for that particular area of operation. the requirements for the area where the drilling operation is
going to take place.
Drilling spool/mud cross
If a drilling spool/mud cross is utilized under the annular Flexible lines
scaling device, the through-bore diameter of the drilling Flexible lines with integral end couplings can be employed in
spool/mud cross should be equal to the through-bore diam- a diverter vent line piping system. If used, the flexible lines
eter of the annular sealing device. The design working pres- should have the same or larger internal diameter as the vent
sure rating of the drilling spool/mud cross should be equal outlet and valve, they should be resistant to fire and erosion,
to the design working pressure rating of the annular sealing have end couplings that are compatible with those utilized in
device. the hard piped section(s) of the vent line piping system, and
supported adequately.
Valves
Valves used in a diverter vent line(s), or in the flow line to
the shale shaker in a floating drilling operation, should be

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-25

Routing Volumetric capacity

The vent line(s) used in a diverter system should be rout- As a minimum, the volumetric capacity of the diverter con-
ed so that at all times, one line can vent wellbore media to trols system accumulators should be sufficient to provide
the downwind side of the rig. Routing changes should be as the usable fluid volume (with pumps inoperative) required
gradual as possible. Long radius bends are preferred over to close and open all functions in the diverter system and
short radius bends. In the case of a 90° bend, it is preferred still retain a 50% reserve. Usable fluid volume is defined
to use a targeted tunning tee equipped with a blind flange or as the fluid recoverable from an accumulator between
plug to minimize effects of erosion. If the vent line is required maximum operating pressure of the system (the pressure
to change direction two times in one location, it is preferred at which the pumps automatically shut off) and 200 psi
to use a “y-type” branch over a tee. The vent line (s) should above the gas pre-charge pressure. The API RP-16E, Recom-
be sloped along their entire run in order to eliminate low mended Practices for Design of Control Systems for Drill-
spots which may accumulate drilling media and debris. ing Well Control Equipment, latest edition, should be used
to assist in determining the accumulator volume required.
Support For a control system that incorporates an integral divert-
The vent lines should be firmly secured. The dynamic ef- er system with the blowout preventer control system, the
fects of high-volume fluid/gas flow and the impact of drilling accumulators required for the diverter system should have
solids are to be considered in the vent line(s) support. Sup- their supply isolated from the accumulators required for the
ports located at points where piping direction changes must blowout preventer system by a check valve. On systems uti-
be capable of restaining pipe deflection. Special attention lizing pneumatically-operated valves, an independent power
should be given to the supports located at the end sections source should be provided to supply the necessary air/gas
of the vent line(s). This area will tend to whip and vibrate required in the event of reduction or loss of rig air pressure.
during a diverting operation.
Response time
Cleanouts The diverter control system should be capable of operating
Provisions for cleaning and flushing any accumulated debris the vent line valve(s) and the flow line valve (if so equipped),
from the vent line(s) should be made. Cleanouts should be and closing the annular sealing device packing element on
placed upstream of all valves and sharp direction changes, pipe in use within 30 seconds if the packing element of the
with flushing jets located to aid removal of sharp debris and annular sealing device has a nominal open bore of 20 inches
drilling solids. Cleanouts and flushing ports should be ade- or less. For annular sealing devices that have a packing ele-
quately sealed to prevent the escape of any wellbore media ment nominal open bore greater than 20 inches, the diverter
when the diverter is in use. The cleanout should have the control system should be capable of operating the vent line
same rated working pressure as the piping into which they valve(s) and flow line valve (if so equipped), and closing the
are installed. Well-monitoring devices (flow indicators, etc.), annular sealing device packing element on pipe in use within
gumbo busters, etc., which are exposed to diverting media 45 seconds.
should be able to withstand the anticipated back pressure
without leaking or failing. Pump requirements
The pump(s) used in a diverter control system should be
Fill-up lines capable of recharging the diverter control system accu-
If a fill-up line is positioned below the annular sealing device, mulator system to full system operating pressure within 5
it should be valved. The valve can be either a remote-operat- minutes after one complete divert mode operation of the
ed gate, ball or knife-type valve, or a check valve. The pres- diverter control system. The discharge pressure rating of
sure rating of the valve should be equivalent to the pressure the pump(s) should be equal to the rated working pressure
rating of the rest of the diverter system valve components. of the diverter control system. Power supply to the pumps
should be available to the diverter control system at all
Control system times, such that the pump(s) will automatically start when
The diverter control system is usually hydraulic or pneumat- the system supply pressure in tile accumulator(s) decreas-
ic, or a combination of both. The system should be capable es to less than 90% of the accumulator operating pressure.
of being controlled from two or more remote units. All units The pump(s) should automatically stop when the full design
should be available for ready access by operating personnel. operating pressure is reached. An over-pressure protection
The diverter control system may be a completely self-contained device (i.e., relief valve) should be set to function at no more
system, or it may be an integral part of the blowout preventer than 110% of the design operating pressure. The overpres-
control system. In some cases, the blowout preventer control sure protection device should be designed to automatically
system can double as the diverter control system. This is de- shut off and reset within 25% decrease of the design oper-
pendent on the type/configuration of diverter system used. ating pressure.

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WC-26 WELL CONTROL EQUIPMENT & PROCEDURES

Back-up system not practical. The complexity of the control sequencing sys-
An alternate means, or back-up system, should be employed tem is dependent on the design of the diverter system and
to permit operation of the diverter system should the pri- the components selected to be used in the diverter system.
mary control system become inoperative. This can be ac-
complished by use of an alternative pump source, separate Control system location
isolated accumulator capacity, bottled nitrogen, or other The main pump/accumulator/control manifold unit should
means. The back-up system need not be automatic, but be located in a safe place which is easily accessible to rig
should be available if the need arises. personnel in an emergency. It should also be located such
that maintenance to the components on the system can be
Valves, fittings, lines, and manifolds done in an easy manner. The distance of the main unit from
All valves, fittings, lines and manifolds should have the same the diverter system components will determine the sizing of
rated working pressure as the pump(s). Sizing of valves, fit- the control lines between the two, keeping in mind the re-
tings, lines and manifolds should be adequate enough to sponse time requirement for operating the annular sealing
supply the diverter system components volume enough device and vent line valve(s). In addition to the main pump/
to satisfy the response time required. Pressure-regulating accumulator/control manifold unit, remote control units
valves should be provided for the annular sealing device, and should also be incorporated. These too should be located
for all other components in the diverter system. Accurate in a position that is readily accessible by the rig person-
pressure gauges should be incorporated to indicate critical nel in an emergency. At least one of these remote control
system pressures. Pressure regulating valves utilized in the units should be located a safe distance from the rig floor.
system should have the capability to be manually operated The design of all components utilized in the diverter control
within their rated operating pressure range should the re- system should comply with the area classifications found
mote control capability fail. in API RP 500B, Recommended Practice for Classification
of Locations for Electrical Installations on Drilling Rigs and
Fluid reservoir capacity Production Facilities on Land and Marine Fixed and Mobile
The reservoir capacity of the diverter control system should Platforms, latest edition.
be equal to at least 2 times the usable fluid capacity of the
diverter control system accumulator system. Mounting of diverter
An important consideration for diverters is to structural-
Fluid recommendation ly secure the mounting, since the device receives the full
A suitable hydraulic fluid (nonflammable petroleum or wa- force of diverted wellbore media. If the diverter is mounted
ter-based) should be used as the operating fluid. In cold utilizing API or MSS/ANSI type flanges, refer to the appro-
ambient environments, sufficient volume of glycol should be priate standards for these flanges to determine the proper
added to the operating fluid in order to keep the fluid from bolting material and method of making up the flange. If the
freezing. Use of diesel oil, motor oil, chain oil or any other diverter is attached to the rig floor structure (e.g., rotary ta-
similar fluid is not recommended due to the possibility of ex- ble beams), the connection should be designed so that the
plosion or resilient seal damage. upward force is directed back into the structure.

Control sequencing Typical diverter system for onshore and/or

The diverter control system should have the capability to be
operated such that the well can never be shut in with the
bottom-supported offshore installations
When diverter systems are deemed necessary, they should
diverter system. For installations where the annular sealing
be installed on the drive or conductor pipe.
device is located below the flow line, the control sequencing
should be that the vent line valve(s) always open before the
annular sealing device is closed. If more than one vent valve
System arrangement
There are various arrangements of diverter systems for on-
is installed, both valves should remain open during the ini-
shore and/or bottom-supported offshore installations. The
tial closing of the annular sealing device, and then allow for
most common of these consists of an annular sealing de-
closure (either automatic or manual) of the upwind vent line
vice attached to a drilling spool/mud cross (Figure WC-41).
valve, if so desired. On installations where the flow line is
The drilling spool/mud cross generally has one or two vent
below the annular sealing device, the desired vent valve(s)
outlets. The annular sealing device often times used is an
should be opened (if not already open) while simultaneously
annular type blowout preventer. The typical sizes of annular
closing the shale shaker/flow line valve and annular sealing
preventers used are:
device. If possible, the design of the control system and/or
the vent line piping system should allow that the vent(s) fail ŸŸ 29 1/2-in. - 500-psi W.P.
to the open position. Although desired, this is sometimes ŸŸ 30-in. - 1,000-psi W.P.

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 WELL CONTROL EQUIPMENT & PROCEDURES WC-27

ŸŸ 20 3/4-in. - 3,000-psi W.P.

ŸŸ 21 1/4-in. - 2,000-psi W.P.

There are insert-type preventers that are available for this

application. The typical size for this type of diverter is a 30-
in., - 2,000-psi W.P.

Also available for onshore and bottom-supported off- shore

installations are annular preventers purpose designed for a
diverter application, in that the vent valving has been de-
signed into annular preventer (Figure WC-42).

Additionally, substructure mounted diverter systems are

also available for onshore and/or bottom-supported off-
shore installations (Figure WC-43). These are similar in
design to the diverters that are designed for floating drilling
rigs. One of the major advantages of this design system is
that it allows the diverter, overshot spool and overshot pack-
er assembly to be pulled or run without having to connect
or disconnect flow line, fill-up line and diverter vent lines.
Hydraulic-actuated seals are used to isolate the flow line,
diverter vent lines and fill-up lines by providing a reliable, Figure WC-43: Substructure-mounted diverter system for onshore
positive seal between the diverter and the support hous- or bottom-supported offshore installations. IADC drawing.
ing. The diverter assembly is mechanically locked into the
support housing with a right-hand “J” which also positively
aligns the outlets of the diverter with the outlets in the sup-
port housing. The overshot packer, which is used to connect
the diverter to the conductor pipe, is a stab-over and seal
mechanism, thereby eliminating the need for welding and/
or making up flanges each time different size casing is run.
The overshot packers and spools are connected utilizing a
stab-type casing connector. Tools are available that allow
testing the diverter assembly seals, insert packer(s), and all
flow line and diverter vent valving. These types of diverter
systems are available for use with 37 1/2-in. and 49 1/2-in. ro-
tary tables. This diameter is not the internal diameter of the
diverter, but the minimum internal diameter of the support
Figure WC-44: Substructure mounted diverter with
housing. These types of diverters are available with either an annular packing element. IADC drawing.
annular packing element (Figure WC-38 and WC-44) or in-
sert-type packing elements (Figure WC-39). Compare Fig- Installation
ures WC-42 and WC-44 to see diverter vent connections Diverter systems on floating drilling rigs are typically mount-
for two different systems. ed to the drill floor substructure (rotary support beams). The
diverter system is the upper end of the marine drilling riser
Typical diverter system for floating rigs system. A floating drilling operation requires equipment
Floating drilling operations include operations from drill- that allows for relative motion between the subsea blowout
ships and semi-submersibles that drill in the floating mode. preventer stand and the drilling vessel. A flex/ball joint is
These vessels are distinguished from other types of drilling usually located above the blowout preventer stack (at the
units by the use of subsea blowout preventer stacks. The bottom of the marine drilling riser system) to allow for this
subsea blowout preventer stack and associated equipment motion. An additional flex/ball joint may be located at the
are connected to the drilling vessel via the marine drilling top of the marine drilling riser package as well in order to re-
riser system. duce bending stresses caused by vessel offset, vessel surge
and sway motions, and environmental forces. This flex/ball
joint is usually located between the bottom of the diverter
and the top of the telescopic joint.

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WC-28 WELL CONTROL EQUIPMENT & PROCEDURES

Flow Line
Diverter system maintenance
Packing
Unit A schedule for routine check-out and maintenance of
diverter systems equipment should be implemented and
Ported Valve kept by the rig operating personnel. Specific guidelines for
Sleeve
each diverter component or subsystem should be based on
maintenance manuals and recommendations provided by
Vent Line the equipment manufacturer.

Side Seal Visually inspect the rubber components of the system after
Piston
each test to verify that they are in good working condition.
Packer components should be replaced when their proper
functioning is questionable due to damage, wear, and/or
age. The diverter system should be function tested on a pe-
riodic basis. During diverter function tests, observe all com-
ponents of the diverter system including the diverter, valves,
valve actuators, valve actuator piping, and control panel to
verify that there are no leaks in the system. In the event a
Figure WC-45: Diverter for floater installations with built-
FIGURE K1-8F: DIVERTER FOR FLOATER INSTALLATIONS
in flow line and vent line valving. IADC drawing. leak is discovered, it should be repaired immediately.
WITH BUILT-IN FLOW LINE AND VENT LINE VALVING
K1-8F If the diverter system utilizes a separate control system from
System arrangement the blowout preventer control system, the unit requires peri-
Diverter systems used on floaters are similar in design to the odic maintenance including such items as checking various
substructure mounted systems used on bottom-supported fluid levels, cleaning air strainers, cleaning pump strainers
offshore installations. In fact, the idea for the substructure and cleaning filter elements.
mounted diverter systems used on bottom-supported off-
shore installations came from the floating installation de- Tightening of packing and lubrication of power actuating
sign. Because of the large diameter of the marine drilling cylinders should be performed. The nitrogen precharge in
riser that is used today, the most common size of diverter the system accumulator bottles should be checked as well.
system is one that is designed to work with a 49 1/2-in. ro-
Control hoses, tubing, vent line piping support brackets,
tary table. This diameter is not the internal diameter of the
targeted fittings, valves, fittings, etc., should be visually in-
diverter, but the minimum internal diameter of the sup-
spected on a routine basis. Due to the difficulty in hydro-
port housing. This large diameter allows conductor casing
statically pressure testing of the vent line(s) of a diverter
and marine drilling riser to be pulled or run without having
system, it is recommended that the wall thickness of these
to connect or disconnect flow line, fill-up line and diverter
lines and their associated fittings be checked using ultrason-
vent lines. Hydraulic actuated seals are used to isolate the
ic inspection devices. These lines are not only highly suscep-
flow line, diverter vent lines, and fill-up lines by providing a
tible to erosion due to high velocity flows, but they are highly
reliable, positive seal between the diverter and the support
susceptible to material loss due to corrosion.
housing. The diverter assembly is hydraulically locked into
the support housing with hydraulic operated dogs. When Control system pressure gauges should be calibrated and
properly installed and locked in place, the diverter outlets tagged at intervals not to exceed 12 months.
are positively aligned with the outlets in the support hous-
ing. Tools are available that allow testing the diverter as-
sembly seals, insert packer(s) and all flow line and diverter
BOP performance characteristics
Blowout preventers are valves which can close off the annu-
vent valving. Diverters for floating installations are available
lus space between the BOP bore and drillpipe, or as in the
with either an annular packing element (Figure WC-44) or
case of blind rams and annular blowout preventers, close off
insert-type packing elements (Figure WC-39). Additionally
the well when the hole is open. As with any valve, a pressure
available for floaters are diverters that incorporate automat-
differential can exist across the valve that opposes its open-
ic valving for the flow line and diverter vent line. A single hy-
ing or closing. This differential was not formerly considered
draulic function is used to close the diverter and at the same
a factor to reckon with when BOPs were only rated at 5,000-
time close off the flow line to the shale shakers and open the
psi MWP (maximum working pressure). The design of the
diverter vent line. Figure WC-45 shows an example of this
BOP, depending on manufacture, generally ranged from a
component. The figure does not show the support housing
4.5:1 to a 6.8:1 closing ratio. With the high closing ratio and
that the diverter fits into. This housing is similar in design to
low MWP rating of the BOP, and the advent of the 3,000-psi
the substructure mounted insert-type diverter.

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 Next Page

WELL CONTROL EQUIPMENT & PROCEDURES WC-29

closing units in 1953, there was always sufficient pressure to Prior to consideration of 10,000 psi and higher maximum
close the BOP against its full rated working pressure. working pressure BOPs, the accumulators on the BOP clos-
ing unit were precharged and the minimum working pressure
The closing ratio is a product of the area on the ram side of the accumulator calculated to optimize the fluid capacity
which is exposed to wellbore pressure versus the area of the of the accumulator system, and simplify the calculations us-
operator piston exposed to operating pressure. BOP manu- ing Boyles Law. The minimum pressure was established at
facturers calculate and publish the opening and closing ra- 1,200 psi (200 psi above precharge). The precharge pres-
tios. Since pressure in psi times area in inches equals force sure was established at 1,000 psi. When the accumulator
in pounds, it is easy to recognize that wellbore pressure was charged with hydraulic pressure to 3,000 psi, 50% of
versus operator pressure oppose each other. For example, the accumulator fluid volume could be discharged down to
if the difference in area exposed to operator pressure pro- the pressure at which the poppet valve in the accumulator
duces seven times greater force than the area exposed to closed and shut off flow. This would be between 1,200 psi
wellbore pressure, the ratio is said to be 7:1. This means op- and 1,000 psi. The minimum working pressure (1,200 psi)
erator pressure produces seven times the force to close as was used in calculations to ensure a margin of safety.
the wellbore side produces to resist closing. Another factor
that affects closing force is inherent friction; however, this The recommended practice for design of control systems for
is considered minimal and is not normally figured into the drilling well control equipment API RP16E, 1st edition, Octo-
closing characteristics of the BOP. ber 1, 1990, recognized the operating characteristics of the
BOP. The applicable reference today is API Spec 16D, 2013.
Simple calculations divide the BOP maximum working pres-
sure by the opening or closing ratios to determine the min- Opening or closing the ram BOPs at maximum rated well-
imum operator pressure required to open or close the BOP bore pressure is not recommended. However, operators
against full wellbore pressure. should be aware of the operating characteristics and lim-
itations of the well control equipment so that surprises can
With the advent of 10,000-psi and higher maximum work- be avoided when encountering well control problems. Users
ing pressure BOPs, the closing ratio does become a factor to should contact the manufacturers for any information not
reckon with if the BOP must be closed against high wellbore contained in the equipment users manual.
pressure. The following examples show the effect of closing
against full rated wellbore pressure assuming closing ratios To prepare for emergency operations, should the accumula-
of 4.5:1 and 6.8:1 tor pumps be out of service and wellbore pressure increases,
operators should isolate the pumps and, using the accumu-
4.5:1 Closing ratio lators only, create a table to show actual performance of the
MWP (psi) Operator Pressure Req’d (psi) system. This can be accomplished during initial installation
5,000 1,111 by checking the accumulator precharge then charging them
10,000 2,222 to full design pressure. Then isolate the pumps and chart the
15,000 3,333 finishing pressure each time a ram BOP is closed (exclude
shear rams).
6.8:1 Closing ratio
MWP (psi) Operator Pressure Req’d (psi) The resulting table will show what the final pressure will be
5,000 735 after certain numbers of ram closures based on the result-
10,000 1,470 ing decrease in accumulator pressure as volume is expelled.
15,000 2,205 With the known closing ratio of the BOP, the operator can
divide specific wellbore pressures by the BOP closing ratio
It must be noted that the BOP also has an opening ratio. The and know before attempting to do so if there will be suffi-
opening ratio is less than the closing ratio since the ram face cient accumulator pressure to effect closing and seal off
is sealed off against the drill pipe or the other blind ram block, against whatever elevated wellbore pressure is in the hole.
and is not exposed to wellbore pressure until this seal is bro- Most BOP closing units are equipped with a manifold pres-
ken. Prior to opening then, the ram block area is not exposed sure reducing and regulating valve that supplies the hydrau-
to wellbore pressure, thus the pressure in the ram cavity lic pressure to operate the ram BOPs, kill and choke valves.
actually assists in maintaining the ram in the closed posi- This device normally limits pressure to a maximum of 1,500
tion. This means the operator pressure must be increased psi and may often be regulated lower than that. There is also
to open against wellbore pressure. In some cases, this is a a manifold regulator bypass valve. When this valve is in the
moot point since the components for ram block retraction “high” pressure position, the ram control valves receive full
are not designed to pull the block open under pressure and accumulator pressure for operation. The bypass valve can
damage to the BOP would result if it were attempted. be placed in the “high” position anytime wellbore pressure

IADC Drilling Manual Copyright © 2015