Conduct the high-pressure test next at the pressure specified in previous requirements

7) By alternating closing upstream and opening downstream valves, all the kelly valves could be tested without pressuring up again, although it may not possible to operate the upper kelly valve under pressure.

8) The inside BOP (float type) can be tested similarly by installing below the full- opening safety valve and opening all valves through the standpipe.

4.16 Wellhead Valves

Test all valves on the wellhead individually to their rated working pressure on installation (using a VR plug) and to 80% of casing burst on subsequent pressure tests, with a cup tester located at + 90’.

5.0 ACCUMULATOR TESTS

These tests are for the purpose of determining the operating condition of the accumulator and BOP system. They shall be performed every 14 days, at the same time the BOP equipment is pressure tested, and at any other time deemed necessary by the Saudi Aramco Foreman. The results shall be noted on the Saudi Aramco BOP Pressure Test Report (see Figure C.13, or Form

# 2.0 in Section S of this manual). To analyse the performance of the accumulator, the results of each test should be compared with results of several previous tests. Any increase in closure or recharge time indicates an immediate need for a thorough examination of the accumulator system. The accumulator test shall include the following,

• Record the accumulator capacity and useable volume

• Record the accumulator pressure

• Record the pre-charge pressure and last date checked

• Record the closing and opening times for each component

Note: Alternate accumulator bi-weekly tests between the main nitrogen unit (with charging system isolated) and air/electric back-up system (with bottle banks isolated).

Preventer functions should also be operated remotely to insure proper operation of all functions from the remote stations.

The accumulator test shall also comply Saudi Aramco’s general requirements as follows:

• Closing time for ram preventers should not exceed 30 seconds.

• Closing time for annular preventers (less than 18-3/4”) should not exceed 30 seconds.

• Closing time for annular preventers (18-3/4” and larger) should not exceed 45 seconds.

• The accumulator must have enough stored fluid under pressure to close all preventers, open the choke hydraulic control gate valve (HCR), and retain 50% of the calculated closing volume with a minimum of 200 psi above pre-charge pressure, without assistance of the accumulator pumps.

• The accumulator-backup system shall be automatic, supplied by a power source independent from the power source to the primary accumulator-charging system, and possess sufficient capability to close all blowout components and hold them closed.

INTENTIONALLY LEFT BLANK

Figure C.13

Saudi Aramco BOP Pressure Test Form

6.0 HANG-OFF LIMITATIONS WHILE TESTING

Many times, a portion of the bottom-hole assembly will be hung-off below the test plug while conducting a BOP test. This is done for a variety of reasons including:

• Leaves pipe in the hole to circulate through in case the well kicks.

• Shortens the trip time by not having to pull completely out of the hole.

IT MUST BE REMEMBERED however, that hanging-off weight below the test plug reduces the maximum allowable BOP test pressure. The table below lists the maximum allowable hang-load for a given BOP test pressure for the wellhead manufacturers used by Saudi Aramco. This chart should be reviewed before hanging-off and testing BOP equipment.

Bowl

7.0 TEST PRESSURE REQUIREMENTS FOR CASING/TUBING RAMS

Casing rams (and annular preventer) shall be pressure tested with a test plug and casing/tubing joint.

The test pressure shall be 80% of collapse of the pipe of the pipe or the working pressure of the flanges, whichever is less.

8.0 RE-CERTIFICATION REQUIREMENTS

8.1 A full OEM certification or recertification of the BOP, choke manifold (including chokes) and all related equipment must be performed at the start of the contract and least once every three years thereafter. The documentation package shall be kept with the equipment and must be available for inspection at the rig site by Saudi Aramco personnel. This includes, but is not limited to [See Chapter A of Saudi Aramco Well Control Manual (WCM)]:

 Ram preventers.

 Annular preventers.

 Gate, HCR and Check Valves on the kill, emergency kill, choke line and choke manifold.

 Drilling chokes.

 Kill, emergency kill and choke lines (and line components) including both hard line and flexible hoses.

 Drilling spools.

NOTE: Recertification can only be performed by the OEM or their licensee and the facility must be Certified and Registered to API Q1 and/or Q2 in addition to API Specification’s 6A, 16A, and 16C. If recertified by a licensee, the document package shall include a copy of the license issued by the OEM and Registration Certificates

for the applicable API Specifications. The Repair Level (RL) for API Specification 6A equipment (Valves, Drilling Spools, Flanged Hard Lines, etc.) must correspond to the relevant Product Specification Level (PSL) as specified when manufactured.

NOTE: Choke and Kill flanged hard-lines mounted in semi-permanent locations may have in-situ recertification using NDT methods to accurately determine Wall Thickness (erosion or corrosion), Material Defects and Material Hardness.

NOTE: Re-Certified Gate, HCR and Check Valves must correspond and comply to Repair Level RL-2 for 3000 and 5000 PSI and 10,000 and 15,000 must correspond and comply to Repair Level RL-3 with Gas Test (Ref. API 6A, Annex J and Section A of Saudi Aramco WCM, Line Item 2.4)

NOTE: New/Repaired equipment shall be accompanied by the manufacturer's/Repair Facility certificate of compliance and a full documentation package including inspection and test reports.

8.2 There is no re-certification requirement for Accumulator Control Systems. However, the Accumulator Control Unit must undergo maintenance and testing every five years with individual hydrostatic testing of the accumulator bottles. All documentation including individual Accumulator Bottle test charts must be resident at the rig.

CHAPTER D: WELL CONTROL POLICIES