3/15/2019 Pressure testing of well cantroled equipment

LIB145857

Pressure testing of well cantroled equipment

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Well Heads and BOP Equipment

Pressure tests on the ram type preventers, other BOP equipment, wellhead components and their
connections in general shall be made in line with API RP 53, but see Drilling Programme for the
minimum required test pressures.
Where wellhead or BOP outlets are opened for testing or any other purposes theyshall not be left
unattended under any circumstances.
Manufacturer's approved handles shall be securely fitted to all wellhead and BOP valves
During subsequent drilling operations, the equipment shall be pressure-tested at regular intervals
using a plug type or cup type tester. Test to at least the anticipated pressures or to the original
casing test pressure (in case a cup type tester is used), whichever is lower.
Plug and cup type testers suitable for pressure-testing the wellhead and BOP equipment on all
casing strings shall be available on the rig site.
Use proper cup size for various casing weights. Retrievable packers with large slip areas may also
be used if available.
The pressure test shall consist of:

Low pressure test - 500 psi

High pressure test to the full rated working pressure of the equipment
All equipment shall hold the low pressure test for 10 minutes and the high pressure test for 10 minutes.

Pressure Test Wellhead Equipment

After each complete installation, the wellhead and ram type BOP equipment shall be pressure-
tested, using a plug type tester, to the rated working pressure of the wellhead, the ram type
preventers or the pressure detailed in the Drilling Programme, whichever is lower. The wellhead
side outlets below the tester shall be open, to prevent pressuring the casing.
Seals and bushings around casing stubs shall be tested through the test port to only 50% of the
collapse rating of the casing provided that this does not exceed the manufacturers rating for the
casing hanger when piston forces and string weight are taken into account. These seals can later
be tested to 65% of the casing burst rating (or flange rating whichever is the lower) using a cup-
type tester (test port open). Ensure that the cup-type tester does not leak and the drill pipe is open
so that the cemented casing is not tested as well.
During the drilling and completion phase, the outer side outlets of the wellhead exposed to the
live annulus shall have Manually operated side outlet valves.

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3/15/2019 Pressure testing of well cantroled equipment

Pressure Test BOP equipment

The annular preventer shall be pressure-tested to maximum 70% of its rated working pressure
unless specified differently in the Drilling Programme, and then only when closed around the pipe.
The complete BOP operating unit shall be tested in accordance with Manufacturer's
recommendations and pressure-tested to its rated working pressure / well rated pressure,
whichever is lower.
The choke manifold, valves, kill and choke lines and valves on side outlets shall be pressure-tested
with water to the test pressure of the ram type preventers.
All lines shall be flushed to ensure they are not blocked. No tests shall be performed against
closed chokes.
The kelly and kelly stop-cocks shall be pressure-tested to their rated working pressure with a test
sub. Pumps, discharge lines standpipe manifold shall be pressure tested.
If the BOP has been pressure and function tested on the stump, or if a new spool has been
installed, only the new connections need testing.
If the BOP is moved between wells, the BOP shall be fully pressure/function tested prior to any
operations on that well.

Pressure Test Frequencies

The pressure tests of all blowout preventers, wellhead components and their connections, BOP
operating unit, choke manifold, kill and choke lines, kelly and kelly-cocks shall be made:

After installation of wellhead and BOP assembly and prior to drilling.

Every 14 days. This period between tests may be extended, depending on the type of operation being
carried out and yet to be carried out during that period, but only after consultation with the Head of
Operations.
Prior to drilling into a suspected high pressure zone.
After setting casing and re-nippling BOP.
When rough drilling conditions are experienced e.g. stack shaking.
After changing out rams.
Any time requested by the Drilling Supervisor.

The results of all pressure tests shall be recorded on the Test Sheet for Blowout Preventers and
Related Equipment.

Pressure Test Casing Strings

After Installation
Newly installed casing strings shall be pressure tested to pressures as given in the Drilling
Programme. The test pressures will depend on the reservoir and the well location
(onshore/offshore). Ideally, this should be performed immediately once the cement slurry is in
place (i.e. immediately after bumping the top plug) to prevent the formation of a micro-annuli.
The test pressure shall be limited by the internal yield (burst) pressure of the casing (or coupling, if
lower) and/or the maximum collapse pressure of the cementing plugs. The effects of differential
pressure resulting from a difference in the fluid level and/or a difference in mud density in the
casing and annulus shall be considered when establishing the internal test pressure.

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3/15/2019 Pressure testing of well cantroled equipment

In the case of liners, the test pressure immediately after bump should not exceed 1500 psi unless
specifically authorised in the drilling programme.
Note: The acceptance criteria for the test shall be a stable pressure (i.e. straight line on the
pressure recorder) for a minimum of 10 minutes.
Casing test pressures are predetermined due to drilling in known reservoirs.
In general the following equations may be used for casing pressure tests.
For Production Casing the maximum expected surface pressure shall consider closed in pressure
arising from complete evacuation of the string to hydrocarbon gas from the deepest TD:

Surface Pressuremax = Po - HHgas

Where:

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