IWCF Surf. Equip.Supv. 02.doc

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IWCF SURFACE SUPERVISOR EQUIPMENT PAPER NO. 2 Name:

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Date:

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Start time:

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Finish time:

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Mark:

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Percentage Mark:

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Training Centre Name:

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Invigilator Name:

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Invigilator Signature:

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Duration:

One hour (1 hour)

Total paper value:

226 marks

All questions require only ONE answer unless otherwise stated.

IWCF Surf. Supv.Equip 02. Sept. 05

1

. 1.

A BOP stack is made up from the wellhead as follows: Three ram BOP’s, Cameron type U, 135/8 “ 10,000 psi rated working pressure. One annular BOP, Hydril type GK, 135/8 “, 5,000 psi rated working pressure. After taking a kick the well is closed in on 3½” pipe using the annular BOP, the stabilised closed in pressures on the casing gauge reads 900 psi. To what hydraulic pressure should the annular closing pressure be adjusted to meet the Manufacturer’s recommendations.

Answer

psi. 4 marks

2.

Figure Alert 086 below shows an API example of a Diverter with an Insert-Type Packer. Match the numbers to the items listed below.


2

.

Alert 086

3.

Diverter Lockdown Dogs.

Closing Port.

Insert Packer.

Insert Packer Lockdown Dogs.

Support Housing.

Standard Packer.

1 mark for each correct Identify the parts of the Cameron Blind/Shear ram in Figure Alert 040 shown below.


3

.

Alert 040 Lower Ram Assembly

Blade Packer

Top Seal

Upper Ram Assembly

Side Packers

Upper Ram Body

4.

1 mark for each correct The Lower Kelly Cock, Upper Kelly Cock, Full Opening Safety Valve and IBOP are tools used to prevent flow from inside the drill string. To what pressure should these tools be tested to? a.

Twice the rated working pressure of the tool used (up to 5,000 psi).


4

. b.

150% of the rated working pressure of the BOP.

c.

One and a half times the rated working pressure of the tool used.

d.

Always use a pressure value equal to 10,000 psi.

e.

At least equal to 70% of the rated internal pressure at minimum yield strength for new drill pipe of the size and grade used in the upper part of the drillstring, but limited to the maximum rated working pressure of the Blow Out Preventer up to a maximum of (10,000 psi for a 10K stack). 2 marks

5.

What position are the 4 way valves in on the BOP master control panel while drilling? a.

Open.

b.

Close.

c.

Block.

d.

Open or Close. 3 marks

6.

According to API RP 53 what type of ring gasket is required for a 135/8” inch bore, 10,000psi flange? a.

RX 54 Ring Gasket.

b.

BX 159 Ring Gasket.

c.

R 53 Ring Gasket.

d.

RX 65 Ring Gasket. 2 marks

7.

According to the recommendations set out in API RP 53, accumulator unit closing pumps must be available at all times. These pumps should start automatically when the closing unit manifold pressure has decreased to what pressure? a:

2700 psi.

b:

2750 psi.

c:

2800 psi.


5

. d:

90% of the accumulator operating pressure. 3 marks

8.

According to the recommendations set out in API RP 53, accumulator units may have multi-banks of accumulator bottles. This should include: a:

An isolation valve for each bottle bank, open at all times.

b:

A pressure gauge for each bottle.

c:

Valves and fittings rated to 10,000 psi.

d:

12% excess capacity for a safety margin. 2 marks

9.

According to API RP 53, what is the meaning of the term “closing ratio for a ram type BOP”? a:

The ratio between closing and opening volume.

b:

The ratio of wellhead pressure to the pressure to close the BOP.

c:

The ratio between the closing time and opening time. 4 marks

10.

What is the meaning of the term “6 BX” for a flange? a:

Type.

b:

Dimension.

c:

Trademark.

d:

Serial number.

e:

Size and pressure rating. 2 marks


6

. 11.

Which of the following functions is operated by manifold pressure? a:

Shear rams only.

b:

Pipe rams only.

c:

Annular only.

d:

All BOP functions.

e:

Rams and HCR valves. 4 marks

12.

According to API-RP16E, the Diverter system is designed to open one or more vent lines prior to closing the Diverter. True

False 3 marks

13.

What is the purpose of the choke manifold “blow-down” line? a:

To send returns to the M.G.S.

b:

To send returns to the mud pits.

c:

To send returns to the flare/waste pit.

d:

To maintain a constant backpressure while circulating out a kick. 2 marks

14.

What is the purpose of a “Vacuum Degasser”? a:

To use when circulating out a kick.

b:

Mainly used to remove gas from the mud while drilling.

c:

To separate the liquids while testing.

d:

To de-gas the kill mud before it’s pumped during the Wait & Weight method. 2 marks


7

.

3 marks 15.

What is API closing time for surface annulars smaller than 183/4”? a:

45 seconds.

b:

30 seconds.

c:

60 seconds.

d:

75 seconds. 2 marks

16.

From what direction should a valve in the choke and kill manifold be tested? a:

Upstream side only.

b:

Downstream side only.

c:

From the direction wellbore fluid is expected to come from.

d:

From either direction. 2 marks

17.

Which of the following allow a Driller to recognize he may be entering an Abnormal Pressure zone? THREE answers required. a:

ROP recorder.

b:

Pump Stroke Counter.


8

. c:

Gas detector.

d:

Casing pressure gauge.

e:

Mud temperature recorder.

f:

Standpipe pressure gauge. 5 marks

18.

A ram type BOP is designed to hold the same amount of pressure from either the top or the bottom. a

From top only.

b:

From both the top and from below.

c:

From below only.

d:

It is designed to take pressure from both sides but mainly from the bottom. 5 marks

19.

Match the items listed to the number on the following diagram, Alert 099.


9

.

CTC 099 Opening Hydraulic Ports.

Closing Side of Piston.

Donut.

Pusher Plate.

Packer.

Operating Piston.

Vent.

Quick Release Top. 1 mark for each correct

20.

Identify the items from the drawing of the Cameron “U” type ram, Alert 098 below


10

.

Alert 098 Ram Body. Operating Cylinder. Bonnet. Operating Piston. Locking Screw. Ram Assembly. Locking Screw Housing. Bonnet Seal. Ram Change Cylinder. 1 mark for each correct answer

21.

Based on the following diagram, Alert 007 with a mud weight of 11.3 ppg flowing through the MGS and liquid seal, how much hydrostatic head (back pressure) would have to be overcome to allow gas to vent to the shale shakers if the height of the liquid seal is 21ft?


11

.

Alert 007 21a.

psi 4 marks

21b.

If the liquid seal applied within the MGS exerted a backpressure of 13.6 psi, calculate the height of H3 if the current mud weight is 9.9 ppg. ft 4 marks

22.

Match the items listed to the number in the drawing, Alert 119 below.


12

.

Alert 119 Electric motor driven triplex pump assembly

Accumulator pressure relief valve

Pneumatic Pressure Switch

Manifold regulator

Accumulator shut off valve

Annular pressure gauge

Accumulator’s

Annular regulator

4 way valves

Air pump

Accumulator pressure gauge

Manifold pressure gauge 1 mark for each correct answer

23.

What is the purpose of Blind/Shear Rams? a:

To shear the pipe while simultaneously sealing of the hole.

b:

To shear the pipe while partially sealing of the hole.


13

. c:

To seal the hole and shear lightweight pipe with 1500 psi. 3 marks

24.

While drilling ahead, the rams and annular opening lines between the BOP stack and the accumulator unit are under pressure? True

False 3 marks

25.

According to API RP 53, which of the following is a recommendation for BOP pressure testing? TWO answers required. a:

After setting casing.

b:

After BOP repairs.

c:

Before circulating out a gas kick.

d:

No less than once every two months. 4 marks

26.

27.

A 95/8” cup tester is used to test a 10,000-psi BOP to maximum pressure using 5” drillpipe. The area of the cup tester under pressure is 42.5 sq. ins. What is the minimum grade of drillpipe that can be used for the BOP test? a:

Grade E drill pipe.

Tensile strength of 311,200 lbs.

b:

Grade X 95 drill pipe.


c:

Grade G 105 drill pipe.


d:

Grade S 135 drill pipe.


e:

Any of the above grades of drill pipe.

4 marks Where are the proximity-switches (sensors) positioned for activating the open/close lights on the Driller's pneumatic remote panel? a:

In the back of the remote panel.

b:

Inside the BOP ram cavities.

c:

On the accumulator unit.

d:

On the remote panel operating handles.


14

. 2 marks 28.

According to API RP 53, with the accumulators isolated from service, the triplex pump should be capable of closing an annular preventer on the size of drill pipe in use at the time of operation, open an HCR valve and obtain a minimum of 200 psi above the pre-charge pressure of the accumulator system within: a:

1 minute or less.

b:

2 minutes or less.

c:

3 minutes or less.

d:

5 minutes or less. 3 marks

29.

The use of “Hydraulic Ram Locking Devices” is for what purpose? a:

To lock the ram in the closed position during well control or hang-off operations.

b:

Hold the ram open under pressure.

c:

Stop the ram from closing during normal drilling operations.

d:

Stop “Ram Creep” during stripping operations. 3 marks

30.

Figure Alert 051 below shows a Cameron Wedgelock assembly. Match the numbers to the items listed below.


15

.

Alert 051 Opening port.

31.

b.

Closing port

Tail rod extension.

Wedge piston.

Tail rod slot.

Locking piston.

1 mark for each correct answer What is the purpose of Glycol or Methanol injection on a choke manifold system? a:

To reduce the effect of hot dry desert environments.

b:

To help prevent Hydrate formation during a kick.


16

. c:

To assist well fluids to flow during testing operations.

d:

This is only an addition to Swaco Super Chokes. 3 marks

32.

For a BOP system, API RP 53 requirements for charge pumps are that they should be capable of charging the accumulator bank from pre-charge to maximum rated working pressure within: a.

Less than 12 minutes.

b.


c.


d.

Less than 18 minutes. 3 marks

33.

Are all pipe rams designed to be closed against their full rated working pressure? YES

NO 4 marks

34.

Are all pipe rams designed to be opened against their full rated working pressure? YES

NO 4 marks

35.

Why are variable bore rams not used exclusively in place of positive bore rams on BOP stacks? a.

Depending on the pipe size hang-off is not possible with variable rams.

b.

It is not recommended to strip through variable rams.

c.

Variable rams must be replaced after each well.

d.

Variable rams have serious temperature limitations.


17

. 3 marks 36.

What is meant by the terms, Primary and Secondary seals, when used in connection with ram BOP’s. a.

The Primary seal is closing in the well using the annular. The Secondary seal is closing in the well using the rams after the annular has been closed.

b.

The Primary seal is a seal established by a ring gasket between connections on the side outlets or on end outlets. The Secondary seal is a seal established by a ring gasket covered with Teflon tape.

c.

The Primary seal is a well control method utilising mud hydrostatic pressure. The Secondary seal is a well control method utilising both mud hydrostatic pressure and the BOP to balance the formation pressure.

d.

The Primary seal is the mechanical ram shaft packing. The Secondary seal is plastic packing injected to activate an additional seal on the ram shaft in an emergency should the Primary seal be leaking. 5 marks

37.

When annular BOP’s are pressure tested, it often happens that the test pressure cannot be held constant but has to be re-pressurised several times before a constant value is obtained. Select the correct answer from the list below. a.

Annular BOP’s always leak until the packing unit finds its new shape. This can take several minutes.

b.

The compressibility of the hydraulic fluid from the accumulator unit below the closing piston affects the test pressure to drop.

c.

38.

The packing unit rubber is forming a new shape. As well as being effected by hydraulic pressure. Test pressure also effects the deformation of the packing unit and results in a decrease in pressure. 4 marks Select from the “Ram Locking Systems” listed below the type of system that locks in position regardless of the amount of wear on the ram packer rubbers. a.

Cameron Wedgelock.

b.

Shaffer LWS Poslock.

c.

Shaffer LWS Manual-lock.

d.

Koomey Autolock.

d 2 marks


18

. 39.

On a Drillers electric BOP panel, for a surface BOP stack, a ram close function was activated and the following was observed: Green light went out. Red light came on. Annular pressure did not change. Manifold pressure did not change. Accumulator pressure did not change. Identify the problem. a.

The electric triplex pump is malfunctioning.

b.

The electric pressure switch is malfunctioning.

c.

There is a blockage in the hydraulic line between the BOP and the accumulator unit.

d.

The selector valve (3-position/4-way valve) is stuck in open position.

e.

There is leak in the hydraulic line between the BOP and the accumulator unit. 3 marks

40.

Given the data for a surface ram BOP. Nominal size: Maximum rated working pressure: Closing Ratio: The hydraulic fluid required for this ram BOP:

135/8” 15,000 psi 10.6: 1 165 gallons.

The data for an accumulator bottle is: Bottle capacity (Nitrogen & Fluid): Pre-charge pressure: Maximum operating pressure for the BOP control unit: Minimum operating pressure for the BOP control unit:

10 gallons. 1,000 psi. 3,000 psi. 200 psi above pre-charge pressure.

Calculate the minimum number of accumulator bottles required on the accumulator bank to enable the closing of the ram on rated working pressure. IWCF Surf. Supv.Equip 02. Sept. 05

19

. Answer

Bottles 5 marks

41.

The designation 135/8” on an item of BOP equipment designated as 15M - 135/8 “ refers to which of the following statements. a.

The bore, (nominal size/inside diameter) of the preventer.

b.

The external diameter of the flange of hub.

c.

The cylinder diameter of the hydraulic actuator for a ram BOP.

d.

The external diameter of the BOP.

e.

The external diameter of the side outlets. 3 marks

42.

From the list below select the statements that are correct regarding fixed bore ram BOP’s. TWO answers required. a.

Ram BOP’s are designed to contain and seal Rated Working Pressure from above the closed rams as well as from below.

b.

Ram BOP’s must be equipped with a mechanical locking system.

c.

Fixed bore ram BOP’s can close and seal on various pipe sizes.

d.

Fixed bore ram BOP’s can be used to hang off the drill string.

e.

Ram BOP’s require a minimum operating pressure of 3000 psi. 5 marks

43.

When a ram BOP on a surface stack is closed, what happens to the operating fluid displaced from the opening chamber? a.

The fluid drains into the well bore.


20

. b.

The fluid is used to assist closing pressure.

c.

The fluid vents overboard.

d.

The fluid is returned to the reservoir. 2 marks

44.

e

From the list below select the main components of a 291/2” Diverter System? TWO answers required. a.

A low-pressure annular preventer with a large internal diameter.

b.

A vent line of sufficient diameter to permit safe venting using the mud/gas separator.

c.

A high-pressure ram type preventer with a large internal diameter.

d.

A vent line with a manually operated full opening valve.

e.

A vent line of sufficient diameter to permit safe venting and proper disposal of flow from the well. 5 marks

45.

Most front packer elements fitted on BOP rams are enclosed between steel plates. What are the reasons for this. TWO answers required. a.

To protect the ram rubber.

b.

To support the weight of the drill string during hang-off.

c.

To prevent damage to the rubber between the pipe and ram blocks when wellbore pressure is applied.

d.

To extrude elastomer into sealing contact with the pipe when the sealing face becomes worn.

e.

To prevent any swelling when in use during high temperature operations. 5 marks

46.

According to API RP 53 what is the minimum diameter of surface Diverter vent line? a.

6 inches or larger.

b.

4 inches or larger.


21

. c.

8 inches or larger.

d.

10 inches or larger. 2 marks

47.

On a BOP accumulator control unit manifold for a BOP a number of Manipulator valves are installed. From the list below, which is the correct description of a Manipulator, valve? a.

A manipulator valve is a 3 position - 4 way directional control valve that has the pressure inlet port blocked and the operator ports vented when in the centre (or block) position.

b.

A manipulator valve is a 3 position - 4-way directional control valve that has all ports blocked when in the centre (or block) position.

c.

A manipulator valve has two or more supply pressure ports and only one outlet port. When fluid is flowing through one of the supply ports the internal shuttle seals off the other inlet port and allows flow to the outlet port only.

d.

A manipulator valve is an electrically operated valve that controls a hydraulic or pneumatic pilot signal or function. 4 marks

48.

Identify from Figure Alert 038a below, which is the low-pressure flange.


22

. A

B

3 marks

49.

In the Figures Alert 037 & CTC 038 illustrated below are the profiles of two API flanges.

Alert 037: API Type 6B


23

. Alert 038: API Type 6BX Which one of the above flanges requires that the torque on the bolts, studs and nuts be checked at regular intervals. API Type 6BX 50

API Type 6B

3 marks The gauges on the Driller’s Remote BOP Control Panel for a surface BOP system are used to observe the status of the BOP accumulator unit. The Figure Alert 042e below shows the pressure readings on the gauges at the accumulator unit while drilling ahead, the BOP has not been operated.

Alert 042e TWO answers required. a.

Accumulator pre-charge pressure too low.

b.

Accumulator pre-charge pressure too high.


24

.

51.

c.

Hydroelectric pressure switch on triplex defective.

d.

Leak in accumulator system.

4 marks The gauges on the Driller’s Remote BOP Control Panel for a surface BOP system are used to observe the status of the BOP accumulator unit. The Figure Alert 042f below shows the pressure readings on the gauges at the accumulator unit while drilling ahead, the BOP has not been operated.

Alert 042f TWO answers required. a.

Leaking manifold regulator.

b.

Defective annular regulator.

c.

Hydroelectric pressure switch on triplex defective.

d.

Leak in accumulator system. 4 marks


25

. 52.

The gauges on the Driller’s Remote BOP Control Panel for a surface BOP system are used to observe the status of the BOP accumulator unit. The Figure Alert 042h below shows the pressure readings on the gauges at the accumulator unit while drilling ahead, the BOP has not been operated.

Alert 042h

53.

a.


b.

Defective annular regulator.

c.

Hi/Lo bypass open.

d.


4 marks The gauges on the Driller’s Remote BOP Control Panel for a surface BOP system are used to observe the status of the BOP accumulator unit. The Figure Alert 042i below shows the pressure readings on the gauges at the accumulator unit while drilling ahead, the BOP has not been operated.


26

.

Alert 042i

54.

a.


b.

Defective hydroelectric switch.

c.

Hi/Lo bypass open.

d.


4 marks Given the BOP configuration in Figure Alert 004 below, answer Yes or No if it is possible to perform the stated operations.


27

.

a.

Alert 004 With the well shut in with the Blind/Shear rams, can repairs be carried out to the drilling spool? Yes

b.

No

With the well shut in with the Blind/Shear rams, can the kill line and/or choke line is used? Yes

c.

No

55.

2 marks

With the well shut in with the pipe rams, and drill pipe in the hole, can the Blind/Shear rams be changed to pipe rams? Yes

d.

2 marks

No

2 marks

With the well shut in on the pipe rams, can repairs be carried out to the drilling spool?

Yes No 2 marks The main purpose of having stored fluid under pressure in the accumulator bottles is: a.

To reduce the closing time of BOP functions.

b.

To enable the BOP to be closed in the event of a power failure.

c.

To store hydraulic fluid.


28

. d.

To operate the remote choke.

e.

To operate the 3 position valves. 3 marks

56.

The "unit/remote" switch on the accumulator allows the Driller to perform which of the following when "unit" is selected: TWO answers required. a.

Adjust the annular regulator from the remote panel.

b.

Adjust the manifold regulator from the accumulator.

c.

Adjust the manifold regulators from the remote panel.

d.

Adjust the annular regulator from the accumulator.

e.

Operate no functions from the remote panel.

f.

Operate all functions from the remote panel. 3 marks

57.

Two types of valves may be used in the drill string: Non-return valve (Gray Valve IBOP). Full opening safety valve (TIW Valve). A kick was taken on a trip out of the hole for a bit change. The well was secured and it was decided to use the Volumetric Stripping Technique to return the bit to bottom. From the list below select the correct answer for the position in the drill string of each of the above valves. a.

Non-return valve on top closed, full opening safety valve below closed.


29

. b.

Full opening safety valve on top open, non-return valve below closed.

c.

Non-return valve on top open, full opening safety valve below open.

d.

Non-return valve on top closed, full opening safety valve below open. 4 marks


30

IWCF Surf. Equip.Supv. 02.doc

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