BOP Equipment Assessor Guide

BOP Equipment eOJT Assessor’s Guide

Training Procedures Section 1 Training Procedures

BOP Equipment OJT Module Training Procedures Sheet Objectives Upon completion of this module, the participant should be able to: 1. demonstrate a clear understanding of the role and responsibilities of Transocean BOP equipment operators, and 2. perform basic BOP maintenance tasks safely and competently. Training Procedure Completing the BOP module should take about sixteen working weeks, depending on the effort put in. The mandatory task list is the basic tool for recording progress, and each item on the list shall be completed before participants can receive a module certificate. The task list evaluation guide in this assessor’s guide is to help you assess the competence of the participants. Some flexibility is permitted, but you must be thoroughly satisfied that the level of skill and knowledge demonstrated by each participant is consistent with the objectives of this OJT module. Only when you believe that a participant has truly achieved the required skill level and knowledge required by each task, should you sign off on it. The suppporting self-study DVD-ROMs, CD-ROMs, books and workbook questions helps participants understand the tasks. The use of these tools is voluntary. Many training participants will find the tools very helpful in providing fundamental knowledge. You can customize the task list according to the requirements of your particular rig. A blank section is provided for you to add additional tasks you feel are important and want participants to perform. You cannot, however, delete tasks, except where they do not apply to your rig. When the participant completes the task list requirements to your satisfaction, and has successfully completed the computergenerated final test, complete and sign a completion notification form (CNF). Also, ensure that the participant fills in the employee comments section. Then, forward the completed and signed CNF to the regional training center. After receiving the CNF, the training center will complete the participant in the Training Management System. The RSTC will then be able to print a module certificate from the Training Management System. Keep the completed task list on file at each participant’s assigned location. The training file shall be transferred when the participant is transferred.

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Section 2 Task List Evaluation Guide

Task List Evaluation Guide

BOP Equipment Task List Evaluation Guide 1.

Show how to perform a task-risk assessment for a major BOP related job. Observe participants performing a task-risk assessment for a major BOP related job. This assessment should include identifying risks and initialing risk reduction measures. The risk assessment should involve everyone concerned with the job and should be documented. The assessment should also include: daily THINK drill, permit to work and task specific THINK procedures. ALARP on reduction measures.

2.

Show how to conduct a THINK drill prior to an operation involving the BOP equipment. Observe participants assembling the crew and conducting a THINK drill prior to an operation involving the BOP equipment. The task should follow rig-specific procedures and use START observations. Reference HS&E Manual 9.30000.

3.

Show how to use personal protective equipment when working on the BOP equipment. Observe participants using PPE while performing BOP tasks. Ensure that they use proper safety harness and fall arrestor equipment when working at heights and that they don work vests and antifall devices when working over water (standby boat in attendance if applicable). When working over water a permit to work must be issued. Reference HS&E Manual 9.30000.

4.

Explain and show the safety precautions to take when working in the cellar or spider deck area, if applicable. Observe participants using safety precautions, such as conducting a task-risk analysis, START process, zoning off the work area, ensuring the presence of a standby boat when working over water, and procuring work permits. No tripping and slipping hazards should be present, such as oily or muddy grating or out-of-place tools in the cellar or spider deck area.

5.

Explain and show the safety precautions to take when performing high-pressure testing on the BOP equipment. Observe participants using safety precautions, such as procuring a work permit, zoning off a work area, placing warning signs and barriers, snubbing high-pressure lines, making an announcement on the PA system, and establishing telephone or radio communication with a third-party operator when using a cement pump or a test pump. Inspect the condition of all high-pressure BOP hoses and safety lines. Follow safe working practices such as never tightening a leaking fitting under pressure or never standing directly in front of the bleed-off line when bleeding off pressure.

6.

Explain and show the safety precautions to take when working on the accumulator unit. Observe participants working on the accumulator unit while following fundamental safety precautions, such as procuring a work permit, using START process, using RSP, locking out and tagging out, ensuring pressure is bled from the hydraulic lines before disconnecting, and ensuring that persons assigned to the task are qualified for the job. Check the participant’s work area. It should be clean and orderly. No tripping and slipping hazards should exist, such as an oily or muddy deck area. Make sure that access to the accumulator unit is unhindered in case of an emergency. Report any damaged or bent grating, steps, or handrails around the accumulator unit and deck area. Reference CD-ROM 61.10010.

7.

Show how to determine H S certification of the BOPs and related well-control equipment. 2

Participants should confirm whether the BOPs and well-control related equipment is H2S certified. If it is, ensure that the BOPs and related equipment certificates state that all surfaces exposed to wellbore fluids are H2S rated and meet NACE-MR-0175 (National Association of Corrosion Engineers) requirements.

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BOP Equipment Task List Evaluation Guide 8.

Explain why BOP components should never be field welded unless performed under controlled conditions. Ask participants why BOP components should never be field welded unless performed under strictly controlled conditions. Any heating of the BOP material without the proper specifications for that material will alter the metal properties that could lead to catastrophic failure of the component. Ask participants to explain the controlled conditions for welding on BOP equipment. Certified welder, manufacturer’s approved welding procedure, availability of heat-treating and stress-relieving equipment. Never allow welding of pads on the annular to enable hydraulic jacking open of cap. Reference IADC Drilling Manual 10.10010 and CD-ROM 61.20070.

9.

Explain and show the safety precautions when using BOP lifting gear. Ask participants to explain the safety precautions when using BOP lifting gear. All lifting gear used for BOP maintenance, such as the removal of ram blocks or bonnets, should be properly maintained and the certification and color-coding kept up-to-date. This maintenance includes items such as pad eyes, eyebolts, slings, shackles, chain hoists, turnbuckles, and air winches. Visual inspection should be performed before use. Lifting gear should be used within its rated capacity. Beware of the change in loading when lifting equipment at an angle. Know the full load of all the components to be lifted. Company policies on lifting should be followed.

10. Explain and show the safety precautions to take when using BOP power tools that are designed specifically for the BOPs. Observe participants practicing safety precautions when using BOP-specific power tools such as the hydraulic torque wrench or pneumatic impact wrench. Ensure that these power tools are properly maintained and that they are functiontested before use. The tools should also be properly lubricated before use. Participants should be aware of pinch points when using the hydraulic torque wrench. Ask them to set the hydraulic pressure for a specific torque (the gauge should be certified). They should explain how the torque wrench works. Ensure that securing devices are used on impact wrench air connections. Tie off the tool(s) when working at heights or over water. Ensure that socket and extensions are secured to the tool, and use the correct size socket for the size of bolt. Ensure that the power tool components are working within their rated limits and the regulators are properly set. Observe participants cleaning, maintaining, and storing BOP-specific power tools. This should include running lubricant through the air wrench and emptying the water trap in the air line. Tools should be stored at designated locations. Damaged tools such as worn impact sockets should be replaced immediately. 11. Show how make up a flexible hose assembly. Participants should select compatible hoses and fittings and assemble using of the rig’s crimping machine. Hose and fitting must match (diameter & pressure rating) and crimping dies must be the correct type for the hose assembly. Participants should explain the difference between skive and no-skive hose. 12. Show how to clean, maintain, and store BOP hand tools that are used only on the BOPs. Observe participants cleaning, maintaining, and storing BOP-specific hand tools. Tools should be clean and stored at designated locations. Damaged tools such as worn pipe wrench jaws, splayed spanners, worn impact sockets, rounded hammer wrenches, and broken sledgehammer handles should be replaced immediately. Always use the correct tool for the job. Clean and function-test the wellhead grease packing tool. 13. Show how to clean, maintain, and store wellhead tools. Observe participants cleaning, maintaining, and storing wellhead tools. All wellhead tools should be cleaned and inspected after use. Any tool with minor damage shall be reported so that it can be properly repaired. Any tool with major damage must be reported and replaced. Tools such as wear bushing and running tools, casing, packer, seal assembly running tools, and plug- and cup-type testers must be lubricated, fitted with required protectors, and stored in their designated place. Use lubrication bath for storage where possible. Page: 2.2

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BOP Equipment Task List Evaluation Guide 14. Show how to clean, maintain, and store BOP rams and elastomers. Observe participants cleaning, maintaining, and storing BOP rams and elastomers. Go to the storeroom with participants and inspect rams and elastomers. Rams should be greased and stacked in sets according to their size. Elastomers must be stored in a temperature- and humidity-controlled environment, fully wrapped, and sealed. They should make sure that all new elastomers are marked with shelf life (use by date). Reference Hydril Blowout Preventers 9.00601 and DVD-ROM 20.0406. 15. Describe your rig’s current BOP stack including its pressure rating, connection type, and size. Participants should define the blowout preventer stack specifications. Ask them to verify its size, either by physically measuring it or reading installation specifications. Ask a question such as: “What is the size of BOP, its pressure ratings, and the connections in use?” Reference IADC Drilling Manual 10.10010, Drilling Data Handbook 10.12010, and CD-ROM 61.10160. 16. Describe your rig’s current BOP stack configuration and its operational advantages and disadvantages. Ask participants to describe the rig’s BOP stack configuration. They should explain operational advantages and disadvantages during functions such as bleed-off between rams, circulating procedures for specific well-control events, spaceout for hang off, and clearances for tool joints during shearing, stripping, and BOP ram replacement or repairs. Reference IADC Drilling Manual 10.10010 and Drilling Data Handbook 10.12010. 17. Explain how to run and retrieve the BOP stack on your rig. Ask participants to describe the BOP run & retrieve procedures on the rig. This explanation should include a full description of a stack, as well as the installation of wellheads. The description should also include rig-specific lifting equipment and hoists, tools, ring gaskets, lubricants, scaffoldings, all safety procedures required including job-risk analysis, and permits. 18. Explain and show how to install the diverter and flow line, if applicable. Ask participants to describe how to install the diverter and flow line. Observe them carrying out these operations. Ensure that all safety precautions are followed such as job risk analysis and permits, clear verbal and visual communications, slinging and hoisting procedures, and use of safety belts and inertia reels. 19. Explain and show how to install BOPs on the test stump. Ask participants to describe how to install a BOP on the test stump. They should describe the use of rig-specific lifting equipment and hoists, tools, ring gaskets, lubricants, scaffoldings. Ensure that all safety precautions are followed such as job risk analysis, and permits. Observe participants installing the BOP on the test stump. 20. Explain the operating sequence of a ram-type BOP hydraulic circuit. Ask participants to explain the sequence of events when a ram BOP function is activated from the remote panel. They should trace functions on a schematic and at the unit. Ask participants to describe the normal and maximum ram operating pressures and closing ratio. They should describe the closing ratio and what effect it has on maximum operating pressure relative to wellbore pressure. If the wellbore pressure exceeds a certain value, the operator may need to increase the closing pressure to close the rams. Reference Blowout Prevention book 2.30330, Cameron Type ‘U’ Blowout Preventer book 9.22001, DVD-ROM 20.0418, and CD-ROM 61.10130.

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BOP Equipment Task List Evaluation Guide 21. Identify and explain the use of different ram types. Ask participants to describe the different ram types and their application. This description should include variable bore rams, blind rams, shear blind rams, fixed pipe rams, and dual-string fixed pipe rams. Ask questions such as: “Which grades of pipe can be sheared using the shear rams at normal operating pressure and maximum operating pressure?” “How do you apply maximum operating pressure to the shear rams?” Using the bypass valve. “What bonnet types are used on your rig’s BOP shear rams?” They are either standard or large bore. “What is the difference between standard and large bore bonnets?” Standard bonnets have a cylinder liner. Large bore bonnets do not have a cylinder liner, which gives a larger operating area. “What is the effect of wellbore pressure on the sealing element once the rams are closed?” The rams are wellbore-pressure energized. Wellbore pressure assists in sealing and keeping the rams closed. Note that the rams seal pressure from the bottom only. Because pressure is sealed from the bottom only, it is vitally important that rams be installed correctly. Reference Blowout Prevention book 2.30330, DVD-ROM 20.0418, and CD-ROMs 61.10130 and 61.20130. 22. Explain the purpose of the weephole in the ram shaft packing area of the bonnet, where applicable. Ask participants to explain the purpose of the weephole in the ram shaft packing area of the bonnet. In the event of ram shaft seal failure, the weephole prevents wellbore fluid from entering the operating cylinder, opening the rams, and possibly causing major damage to the bonnet. On rigs with surface stacks so equipped, participants should explain and show how to energize the ram shaft emergency packing mechanism in the event of main ram shaft failure and resulting visible leakage from the weephole. Reference Cameron Type ‘U’ Blowout Preventer book 9.22001 and CD-ROMs 61.10130 and 61.20130. 23. Identify different types of ram elastomers available and describe their application. Ask participants to describe some different types of common ram elastomers available and their application. Natural rubber, neoprene, nitrile. Natural rubber is used with water-base drilling fluids, Neoprene rubber is for low temperature operating service and oil-base drilling fluids, Nitrile rubber is for use with oil-base or oil-additive drilling fluids. Participants should show data book/catalogue identifying all the different types of elastomers available for special applications. They should describe the shelf life for elastomers in use on the rig. Ask a question such as: “What type of elastomers are installed on the ram-type BOPs on your rig?” Reference Blowout Prevention book 2.30330, DVD-ROM 20.0418, and CD-ROMs 61.10130 and 61.20130. 24. Explain and show the operating sequence of a ram-type BOP locking system. Ask participants to describe and show the operating sequence of the ram-type BOP locking system on their rig. Reference Blowout Prevention book 2.30330, Cameron Type ‘U’ Blowout Preventer book 9.22001, DVD-ROM 20.0418, and CD-ROMs 61.10130 and 61.20130.

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BOP Equipment Task List Evaluation Guide 25. Explain and show how to perform PMS tasks on a ram-type BOP. Observe participants performing PMS tasks on the ram-type BOPs. These tasks should include opening bonnets, changing rams, inspecting bonnet seal grooves, replacing bonnet seals, replacing ram packers and top seals, inspecting bonnets, measuring ram cavities and ram blocks, and ensuring that measurements are within specifications. Lubricate the ram cavity and ram block. Close the bonnets. Apply correct lubricant to bonnet bolts and torque bolts to the correct value. Ask participants to explain how to strip down, inspect, and rebuild the bonnet. These procedures include removing the bonnet from the BOP body, inspecting all internal parts, replacing the seals, rebuilding the bonnet and testing it, and refitting the bonnet to the BOP body. Participant to explain all safety procedures to be followed when performing the PMS tasks. Participant to show the rig specific procedure (RSP) if applicable. Reference Blowout Prevention book 2.30330, Cameron Type ‘U’ Blowout Preventer book 9.22001, DVD-ROMs 20.0405 and 20.0418, and CD-ROMs 61.10130 and 61.20130. 26. Explain and show how to perform PMS tasks on the ram-type BOP locking system. Observe participants performing PMS tasks on the ram-type BOP locking system. In case of a screw-thread lock, they should clean the threads using a wire brush, inspect the thread condition, lubricate the threads, and function test the locking system. On internal systems such as Wedgelock, MPL, Ultralock, or Poslock, participants should give a full explanation of system operation and carry out related PMS tasks. The rams should be tested by closing on a test joint, venting the closing pressure to zero, and applying full wellbore pressure to confirm the correct operation of the locks. Participant should explain all safety procedures to be followed when performing the PMS tasks. Participant should show the rig specific procedure (RSP) if applicable. Reference Cameron Type ‘U’ Blowout Preventer book 9.22001, DVD-ROMs 20.0405 and 20.0418, and CD-ROMs 61.10130 and 61.20130. 27. Explain and show the operating sequence of an annular BOP hydraulic circuit. Ask participants to explain the sequence of events when an annular BOP function is activated from the remote panel. They should trace the function on a schematic and at the unit. Ask participants to describe normal and maximum annular operating pressures and closing and opening times. Ask them what precautions to take prior to running the casing. Ask questions such as: “What is the recommended closing pressure to avoid collapsing the casing in use?” “What is the recommended closing pressure during stripping operations to avoid excessive wear on the packer element?” “How does the annular packing element work?” The response should include whether it is wellbore energized, slightly wellbore energized, or not energized. They should also explain the use of surge bottles and the effects on the element when it is closed on open hole. Reference Blowout Prevention book 2.30330, Hydril Blowout Preventers book 9.00601, DVD-ROMs 20.0414 and 20.0416, and CD-ROM 61.10030.

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BOP Equipment Task List Evaluation Guide 28. Explain and show how to perform PMS tasks on an annular BOP. Observe participants performing PMS tasks on the annular BOP. These tasks may include opening the cap, inspecting the element and changing it if necessary, removing and inspecting the piston, replacing seals, and inspecting cylinder bores. Rebuild, function test, and pressure test the annular BOP after it is maintained. Participants should explain all safety procedures to be followed when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. Reference Hydril Blowout Preventers book 9.00601, DVD-ROMs 20.0414 and 20.0416, and CD-ROM 61.10030. 29. Describe different types of annular packing elements and their application. Ask participants to describe the different types of packing element material available and their application. Packing elements are designed for oil-base muds (OBMs), water-based muds (WBMs), and for low and high temperatures. Ask questions such as: “What type of packing element would be used in an oil-base mud system at low temperatures?” Nitrile rubber can be used in an OBM but at standard operating temperature. Nitrile becomes brittle at temperatures below -7 degrees Celsius or 20 degrees Fahrenheit. Neoprene becomes brittle below -35 degrees Celsius or -30 degrees Fahrenheit. “How would you identify the different types of packing elements?” Neoprene has a green colored band and serial number with the suffix N or CR. Nitrile rubber has a red colored band and the suffix S or NBR. Natural rubber is an all black unit with the suffix R or NR. Reference Hydril Blowout Preventers book 9.00601, DVD-ROMs 20.0414 and 20.0416, and CD-ROM 61.10030. 30. Explain and show how a manual BOP choke line gate valve operates. Ask participants to explain how a manual BOP choke line gate valve operates. It is a floating gate with a back-seating stem. Ask participants to explain the principle of the floating gate. As pressure is applied, pressure pushes the gate across the body (the gate floats) to seal against the seat and seal ring. Therefore, the stem must be backed off a quarter turn after fully closing. Ask participants to explain the principle of the back-seating stem. A device within the valve provides sealing of the stem packing area; this sealing allows the stem packing to be changed while the valve is under pressure. To energize the back-seating stem, the valve must be fully closed rather than backed off a quarter turn. On rigs with subsea stacks, explain failsafe valve operation. Reference DVD-ROM 20.0419 and CD-ROM 61.20080. 31. Explain and show how to perform PMS tasks on a manual BOP choke line gate valve. Observe participants stripping down the valve, inspecting gate and seats, checking the body’s internal sealing surfaces, replacing seals and worn parts, reassembling the valve, and testing it. Participants should demonstrate the rig specific procedure and all safety precautions when performing the PMS tasks. On rigs with subsea stacks, show how to perform PMS tasks on failsafe valves. Reference DVD-ROMs 20.0405 and 20.0419 and CD-ROMs 61.20080 and 61.20090.

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BOP Equipment Task List Evaluation Guide 32. Explain and show how a hydraulic (HCR) BOP choke line gate valve operates. Ask participants to explain the sequence of events when a BOP choke line gate valve operating function is activated from the remote panel. They should trace the function on a schematic and at the unit. Ask participants how to identify an internal hydraulic leak in the valve actuator. Remove the inspection plugs on the accumulator tank and check for fluid leaking from the return line through the 3-position 4-way valve. Reference Blowout Prevention book 2.30330 and DVD-ROM 20.0419. 33. Explain and show how to perform PMS tasks on a hydraulically operated BOP choke line gate valve. Observe participants stripping down the valve, inspecting the gate and seats, inspecting the body’s internal sealing surfaces, stripping down and inspecting the hydraulic actuator, replacing seals and worn parts, reassembling the valve, and testing it. Participant should explain all safety procedures when performing the PMS tasks. Reference DVD-ROM 20.0419 and CD-ROM 61.20040. 34. Explain and show how a choke & kill line non-return valve operates. Participants should explain and show how a choke & kill line non-return valve operates and why it is used. The valve is either a spring-actuated gate-and-seat valve or a ball-and-seat one-way check valve. The purpose of either type is to prevent over pressurizing such surface equipment as the standpipe, mud pumps, and surface lines. Ask participants to explain when a check valve should be removed from the line and why it should be removed. The valve is removed only during BOP testing and it is removed to maintain it and check that it is operating properly. It is vital to always have this valve in place and functioning properly; otherwise, well pressure could be applied to such surface equipment as the standpipe, pumps, and surface lines, which could be catastrophic. It is also important to note the flow direction of the valve to ensure that it is reinstalled properly after it is maintained or repaired. 35. Explain and show how to perform preventive maintenance on a choke & kill line non-return valve. Observe participants stripping down the valve, inspecting the gate and seats, inspecting the body’s internal sealing surfaces, replacing seals and worn parts, and reassembling and testing it. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. 36. Explain and show the connections of the high-pressure flexible lines from the BOP to the choke manifold and kill line. Observe participants tracing the high-pressure flexible lines from the BOP to the choke manifold and kill line. They should explain how the system works. Any leaks or possible wear points should be noted and corrected. Check to ensure that the hoses are supported adequately. Verify the pressure ratings of all components including each union and hose. Ask participants to show the certification of the hose. Reference CD-ROM 61.20040. 37. Explain and show the choke manifold valve alignment options. Observe participants aligning the choke manifold for specific operations such as: drilling, well-kill operations through one or two chokes, using a degasser, flaring gas through the flare line, and using a stripping tank. Ask participants why it may be necessary to circulate through two chokes simultaneously. If well pressure becomes high enough, it may be necessary to remove kick fluids through two chokes to maintain proper bottomhole pressure. Ask participants what modifications are required for high-temperature operation on the rig. Install a glycol injection system, install temperature recorders, change valve stem packing to high-temperature material. Note that it is important to control the temperature of the mud to keep the hydrates stable. Reference CD-ROM 61.20040.

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BOP Equipment Task List Evaluation Guide 38. Explain and show how to perform PMS tasks on choke manifold valves. Observe participants stripping a gate valve, inspecting the gate and seats, checking the body’s internal sealing surfaces, replacing seals and worn parts, and reassembling and testing the valve. They should take care to properly reinstall Teflon seals. Identify lead target flanges on the manifold and observe participants inspecting and removing the target flange. Ask participants why a hole should be drilled through the center of the lead target. A hole should be drilled through the center of the lead plug to allow venting off any pressure trapped behind the plug. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. Reference CD-ROM 61.20040. 39. Explain and show how to perform PMS tasks on choke manifold sensors and gauges. Participants should describe how each sensor works. They should disassemble the diaphragm. They should be able to identify whether the valve is trimmed for H S service and explain why it is important. They should show current calibration 2 certification of all gauges. Participants should also be aware of any variations in the readouts of the choke manifold system gauges. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable Reference CD-ROM 61.20040. 40. Explain and show the operating sequence of a remote choke hydraulic circuit. Ask participants to explain the sequence of events when a remote choke valve is activated from the remote panel. They should trace functions as follows: the hydraulic valve is actuated, which allows regulated hydraulic fluid to flow to the remote choke actuator. Note the time it takes to operate the valve from the fully open to fully closed positions. Observe participants adjusting the operating speed of the choke. Ask participants to explain how the choke-position indicator works. Participants should show and explain how to activate the choke in the event of a power failure. Participants should demonstrate how to use the hand-operated hydraulic pump to operate the choke. Reference Drilling Data Handbook 10.12010, DVD-ROM 20.0409, and CD-ROM 61.20040. 41. Identify the different types of BOP flange-and-hub connections and explain the use of each. Ask participants to identify the flange-and-hub connections on the rig’s BOPs. They should identify which connections are studded, bolted, clamped hub, face-to-face, nonface-to-face, ring-groove type, and ring-gasket type. Torque requirements for each connection and the lubricant used on the fastening mechanism should be described. Ask questions such as: “What is the correct torque for the through-bore connections on your BOP?” “What is actually happening when you torque up (tighten) a connection?” The bolts stretch, gaskets compress, and the hub faces are preloaded. “How often should a ring gasket be used?” Use it only once. “What effect does the wrong lubricant have on the preload applied to the connection?” It causes incorrect preload that could lead to separation of the components under pressure, which, in turn, could wash out the ring groove and ring gasket. “Why is it important to periodically check the torque on flange connections?” Vibration and/or improper line support may cause the connection to work loose, which causes a leak. “What lubricant should be used on the ring groove and gasket?” Never use any type of lubricant. Reference Drilling Data Handbook 10.12010, DVD-ROM 20.0409, and CD-ROM 61.20040.

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BOP Equipment Task List Evaluation Guide 42. Identify the different types of ring gaskets and explain their use. Ask participants to identify and show where the following gasket types are used on the rig: - R type gasket. Nonpressure-energized with nonface-to-face hubs, octagonal or oval. - RX type gasket. Pressure-energized face-to-face or nonface-to-face hubs. - BX type gasket. Pressure-energized, face-to-face hubs. Ask participants to identify the pressure rating for each gasket. Reference Drilling Data Handbook 10.12010. 43. Explain and show how to perform BOP stack and choke manifold pressure and function tests. Observe participants performing BOP and choke manifold pressure and function tests. Ask them to explain the use of each component in the test assembly. Plug-type tester, cup-type tester, and test pump and chart recorder. Observe participants completing the BOP and choke manifold test forms. Confirm that the test follows the rig-specific procedures. Participant to explain all safety procedures to be followed when performing the tests. Ask a question such as: “What is the purpose of the low-pressure test?” To identify equipment problems such as worn ram cavities that may seal under high-pressure situations only. A lowpressure test should always precede a high-pressure test. 44. Explain and show how to perform PMS tasks on BOP test equipment. Observe participants performing PMS tasks on equipment such as plug-type tester, cup-type tester, and test pump and chart recorder. They should show how to replace seals on plug and cup testers, ensure that the port is open on plug testers, and calibrate the chart recorder if required. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. 45. Show how to rig up Chiksans for high-pressure operations and perform PMS tasks on them. Observe participants rigging up Chiksans for high-pressure operations. They should be properly secured. All rig-specific safety procedures should be followed. Observe strip down, inspection, and rebuild of a Chiksan swivel joint. Highpressure Chiksan lines shall be snubbed at each joint. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. 46. Explain the operation and show how to perform PMS tasks on a plug-type (Lo-Torq) valve, if applicable. Ask participants to explain how the plug-type (Lo-Torq) valve works. Observe disassembly, inspection, seal change, reassembly, and function and pressure testing. Ensure that only correct high-pressure grease is used in the valve. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. 47. Explain the operation and show how to perform PMS tasks on a Gray-type non-return valve, if applicable. Ask participants to explain how the Gray-type nonreturn valve works. Observe disassembly, inspection, seal change, reassembly, and pressure testing. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure if applicable. Ask participants to give an example of when this valve should be used. Only used in conjunction with full-opening safety valve during stripping operation. Reference CD-ROM 61.10010.

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BOP Equipment Task List Evaluation Guide 48. Explain the operation and show how to perform PMS tasks on IBOPs. Ask participants to explain how the upper and lower IBOPs work. Observe disassembly, inspection, seal change, reassembly, function, and pressure testing. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure if applicable. Ask a question such as: “When should this valve be used?” It is used anytime a backflow is expected or encountered up the drill string. It is not designed to be used as a mud saver valve. Reference CD-ROM 61.10010. 49. Explain the operation and show how to perform PMS tasks on a drop-in valve (DIV) and landing sub. Ask participants to explain how the drop-in valve (DIV) works. A special landing sub is installed in the drill string near the bottom of the string. The valve is dropped into the drill string and pumped down to the sub. There, it seats in the sub and prevents flow up the drill string. Observe disassembly, inspection, seal change, reassembly, function, and pressure testing. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. Ask a question such as: “When should this valve be used?” It is used anytime a backflow is encountered up the drill string and there is a landing sub installed in the drill string. Ensure there are no ID restrictions in the drill string above the landing sub. Reference CD-ROM 61.10010. 50. Explain the operation and show how to perform PMS tasks on a drill string float valve. Ask participants to explain how the drill string float valve works. It is installed in the drill string, usually just above the bit. Normally, it is open so that drilling fluid can flow down the string, through the valve and bit and up the annulus. Should a kick occur, this back-pressure in the drill string causes the valve to close and thus prevent flow up the string. Observe disassembly, inspection, seal change, and reassembly. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. Ask questions such as: “When should this valve be used?” It is often used when drilling top hole prior to setting surface casing or anytime the posted well-control plan is to divert. It can also be used in deeper, small diameter sections of the hole. The float valve prevents sudden influx entry in the drill string and prevents back flow of cuttings plugging bit nozzles. “Explain the purpose of a ported float.” It allows reading SIDPP. Reference CD-ROM 61.10010. 51. Identify different types of hammer unions and show how to perform PMS tasks on them. Ask participants to identify the hammer unions used on the rig. They should describe the union type, its size, and its manufacturer. They should also describe the pressure rating and sealing mechanism. Observe participants inspecting the hammer union locks, threads, and sealing surfaces; also, observe them replacing seals. Ask the participants why it is imperative not to mis-match similar union halves.

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BOP Equipment Task List Evaluation Guide 52. Explain and show how to operate the surface control (accumulator) unit. Ask participants to explain operation of the entire unit. Using a schematic, they should trace all hydraulic and pneumatic circuits. Ask them to identify the system components such as the fluid reservoir, 3-position 4-way valves, reservoir inspection ports and sight glass, suction shutoff valves, pump suction strainers, the interface between different system pressures, and the remote panel, pumps, intake check valves, outlet check valves, manifold regulator, annular regulator, bypass valve, pressure transducers, pressure switches, accumulator shutoff and bleed-off valves, and pressure manifolds. Reference DVD-ROM 20.0409 and CD-ROM 61.10110. 53. Explain and show how to perform PMS tasks on the surface control (accumulator) unit. Ask participants to explain the procedure for isolating an accumulator bank to change a bladder. Observe participants checking nitrogen precharge and charging an accumulator bottle as required. Participants should show how to adjust gland packings on pumps, adjust triplex and air pump pressure switches, reset the regulators, calibrate the gauges, and adjust transducers. Participants should explain all safety precautions when performing the PMS tasks and show the rig specific procedure (RSP) if applicable. Reference DVD-ROMs 20.0408–20.0413 and 20.0417. 54. Explain the pressure ratings, connection types, and applications of BOP hydraulic hose assemblies. Ask participants to identify the BOP hydraulic hoses by pressure rating, construction, crimp fitting style (skived or nonskived), and crimping procedure. Participants should show crimping chart for use with the rig’s crimping machine. They should also describe hose inspection procedure and identify any faults that they may find. Reference Vickers Industrial Hydraulics Manual 10.05010. 55. Show how to read and interpret accumulator unit hydraulic and pneumatic schematic symbols. Ask participants to read and interpret accumulator unit hydraulic and pneumatic schematic symbols such as pumps, check valves, motor, 3-position 4-way manipulator valve, regulators, flowmeter, pneumatic and hydraulic lines, and pressure switches. Reference CD-ROM 61.20050. 56. Explain and show how to troubleshoot surface BOP control unit and remote panel problems. Ask participants to troubleshoot hypothetical surface BOP control unit and remote panel malfunctions involving items such as the transducers, pressure switches, and battery banks. Ask questions such as: “You press a function on the driller’s remote BOP control panel and nothing happens. What could be wrong?” “You press a function on the driller’s remote BOP control panel and the function light turns on but nothing happens to the pressure gauges. What could be wrong?” “You press a function on the driller’s remote BOP control panel and the function light doesn’t turn on but pressure gauges register a drop. What could be wrong?” Reference DVD-ROM 20.0410.

Rev. 02: January 2004

Page: 2.11

BOP Equipment Task List Evaluation Guide 57. Show how to calculate the volume of usable fluid in the accumulator bottles. Observe participants calculating the usable fluid in the accumulator bottles using Boyle’s law. Confirm sufficient capacity on your rig to meet Transocean well-control manual requirements. Reference the Transocean workbook titled Accumulator Unit Bladder Replacement and Precharge and/or the Well Control Manual. Reference Accumulator Unit Bladder Replacement and Precharge book 9.20001 and DVD-ROM 20.0404. 58. Explain the importance of maintaining the quality of BOP fluid correctly. Ask questions such as: “What maintenance should be carried out on the BOP control system fluid?” Keep it clean and free of contaminants and change strainers and filters on a regular basis. Follow fluid analysis procedures and replace when required. “Why is it important to maintain the BOP fluid correctly?” The fluid comes into contact with all internal surfaces of all components of the BOP system. A poorly maintained system can cause damage to seals and sealing surfaces leading to malfunction of equipment. 59. Explain how to set the accumulator unit pump pressure switches. Ask participants to explain the required settings of the triplex and air-operated pumps. For example, triplex pumps should kick in at 90 percent of maximum working pressure (2,700 psi) and kick out at 3,000 psi. Air pumps should kick in at 2,650 psi and kick out at 2,950 psi. Reference CD-ROM 61.20050. 60. Explain the diverter system operation on your rig. Ask participants to explain the sequencing of the diverter and associated valves. Ask questions such as: “What is the purpose of the diverter system?” To divert the flow of wellbore fluids away from the rig. “When should a diverter system be used?” When shallow gas is encountered. Reference Blowout Prevention book 2.30330, DVD-ROM 20.0407, and CD-ROM 61.10160. 61. Explain how to perform PMS tasks on the diverter assembly, piping, valves, and controls. Observe participants performing PMS tasks on the diverter assembly, piping, valves, and controls. Ask them to explain how to change the diverter packer and carry out wall thickness checks on piping. Also, they should service and function test the diverter valves. Participants should explain all safety precautions when performing the PMS tasks and show rig specific procedures. Reference DVD-ROM 20.0407. 62. Explain how a rotating head operates, if applicable. Ask participants to explain the basic principles of the rotating head and when it is used. A rotating head is an annular preventer which, through a bearing and seal arrangement, allows the head to rotate while drilling underbalanced. 63. Explain and identify the wellhead system and components on your rig. Ask participants to identify the components of the wellhead system in use on the rig and explain their function. They should identify the high-pressure wellhead, casing hangers, seal assemblies, and wear bushings. Reference CD-ROM 61.20060. Page: 2.12

Rev. 02: January 2005

BOP Equipment Task List Evaluation Guide 64. Explain how the BOP handling system and work platforms operate and show how to rig them up. Ask participants to explain how the BOP handling system works. Their explanation should include the load capacity, the type of system, and the operation of the system. Observe participants performing PMS tasks on the BOP handling system. Tasks should include servicing the load cell and lubricating the hoist mechanism and the track. Observe participants performing PMS tasks on the work platform. These tasks should include checking the grating for damage or corrosion, checking guard chains, and checking handrails. Participants should explain all safety precautions when performing the PMS tasks and show rig specific procedures. 65. Show how to verify BOP equipment certification. Ask participants to show you the file certification sheets for BOP components such as rams, choke and kill hoses, and the annular preventer. Certification documents are contained in the PMS central filing system. 66. Explain basic coiled tubing BOP operations. Ask participants to explain basic coiled tubing BOP operations. They should explain when and how to shut in the well in case of an emergency. Participants should explain all safety precautions when performing the PMS tasks and show rig specific procedures. 67. Explain basic wireline BOP operations. Ask participants to explain the basic wireline BOP operations. They should explain how to install the shooting nipple, the BOPs, and test the assembly. Ask when and how to shut in the well in case of an emergency. Participants should explain all safety precautions when performing the PMS tasks and show rig specific procedures. 68. Explain how to use the annular BOP for stripping operations. Ask participants to state the precautions to take to prevent the annular BOP from excessive wear during a stripping operation. Reduce closing pressure to the minimum required to maintain the seal. There should be a slight leakage of wellbore fluid to aid in lubrication. It may be worthwhile to manually lubricate the pipe as it passes through the rotary. File smooth any major burrs on the tool joints and pipe body that may damage the annular packing element as it passes through. Monitor displacement during stripping. Participants should explain all safety precautions when performing the PMS tasks and show rig specific procedures. 69. Explain how to use the BOP rams for stripping operations. Ask participants to state the precautions to take to prevent the BOP pipe ram packers from excessive wear during a stripping operation. Reduce closing pressure to the minimum required to maintain the seal. Manually lubricate the pipe as it passes through the rotary. File smooth any major tong die burrs on the pipe body that may damage the ram packers as it passes through. Monitor displacement during stripping. Ask participants to state the procedure for ram-to-ram stripping in the hole. Reduce ram operating pressure. Close upper rams. Strip tool joint to the top of upper rams. Close lower rams. Bleed off the pressure between the upper and lower rams. Open the upper rams. Strip the tool joint down to the top of the lower rams. Close the upper rams. Open the lower rams. Repeat the process. Monitor displacement during stripping. Participants should explain all safety precautions when performing the PMS tasks and show rig specific procedures.

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Page: 2.13

Section 3 Workbook Question & Answers

Workbook Questions and Answers

BOP Equipment OJT Module

Workbook Questions and Answers BOP Equipment OJT Module workbook questions are provided to enhance learning on subjects covered by the task list. Workbook questions should be completed as fully as practical, with local translation if necessary. Completing the workbooks does not exempt a participant from the mandatory task list. Participants should achieve a score of 70% or more on each workbook. Where scores fall below 70%, the participant should review the corresponding books, DVD-ROMS, and/or CD-ROMs. The supervisor should coach the participant on any weak points to ensure that material is understood. The following workbooks are provided in this section: Workbook 1. 2. 3. 4. 5. 6. 7.

Vickers Industrial Hydraulics Manual Rotary Drilling Blowout Prevention Cameron Ram-Type U Blowout Preventer Rucker Ram-Type Blowout Preventer Hydril Ram BOP Hydril GL Annular Preventer Accumulator Bottles–Bladder Replacement and Precharge

Rev. 02: January 2005

Page Numbers 02–05 06–07 08–09 10–11 12–13 14–15 16–17

Page: 3.1

BOP Equipment OJT Module Vickers Industrial Hydraulics Manual - Workbook Answers

1.

A fundamental law of physics states that energy can neither be created nor destroyed. A. True B. False

2.

What determines the speed of an actuator? A. Its size B. Rate of oil flow into it C. both A and B above D. none of the above

3.

Hydraulic fluid in a working system contains energy in two forms: kinetic and potential. A. True B. False

4.

Viscosity is the measure of a fluid’s ______ A. density. B. water content. C. weight. D. resistance to flow.

5.

Demulsibility is the ability of a fluid to be anticorrosive. A. True B. False

6.

Nitrile seals can be used in the temperature range of ______ A. -10 degrees F to 120 degrees F. B. -40 degrees F to 250 degrees F. C. -20 degrees F to 60 degrees F. D. -0 degrees F to 200 degrees F.

7.

A breather assembly on a reservoir should be ______ A. large enough to allow draining of the reservoir. B. threaded to allow plugging. C. large enough to handle air flow required. D. large enough to allow filling of the reservoir.

8.

Hydraulic systems are 100% efficient in controlling temperature. A. True B. False

9.

There are ______ types of particulate induced failures. A. one B. two C. three D. four

10.

A filter rated at ten (10) microns would trap particles ______ A. 10 microns in size or smaller. B. 10 micron size only. C. 10 microns in size or larger. D. none of the above

Page: 3.2

Rev. 02: January 2005

BOP Equipment OJT Module Vickers Industrial Hydraulics Manual - Workbook Answers

11.

Filter bypass valves ______ A. will eliminate the possibility of element collapse if the element becomes clogged. B. will eliminate the need to change a filter. C. are found in all filters. D. will allow continuous flow if the element collapses due to clogging.

12.

Double-acting cylinders are really found in industrial hydraulics. A. True B. False

13.

Compared to a straight check valve, the design of a right angle check valve allows ______ A. higher flows with less pressure drop. B. lower flows with less pressure drop. C. higher flow with large pressure drop. D. higher flow with no pressure drop.

14.

Rotary valves cannot be used to control a pilot flow in a pilot-operated system. A. True B. False

15.

A pressure compensated flow control valve _______ compensates for pressure changes. A. hydraulically B. pneumatically C. automatically D. electrically

16.

What electronic components are required in all equipment using proportional control valves? A. Operational amplifiers and floating gate transistors B. Electrical power supply and electronic controls C. Bidirectional and Zener diodes D. all of the above

17.

The voltage drop across a 7-ohm resistance is 70 volts. The power dissipated through the resistance is ______ A. 10 watts. B. 70 watts. C. 100 watts. D. 700 watts.

18.

AC solenoid failure due to heating may occur because of _______ A. blocked plunger or armature. B. excessive ambient temperature. C. low line voltage. D. all of the above

19.

The relief valve ______ A. is found in virtually every hydraulic system. B. is a normally-closed valve connected between the pressure line (pump outlet) and the reservoir. C. limits pressure in the system to a preset maximum. D. all of the above

20.

Pressure reducing valves are normally open-pressure controls used to maintain reduced pressures in certain portions of the hydraulic system. A. True B. False

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Page: 3.3

BOP Equipment OJT Module Vickers Industrial Hydraulics Manual - Workbook Answers

21.

An unloading relief valve is used in accumulator charging circuits to _______ A. limit maximum pressure. B. unload the pump when the desired accumulator pressure is reached. C. both of the above D. none of the above

22.

The four-way directional control valve ______ A. is a poppet valve. B. is a shuttle valve. C. provides four flow paths, two at a time. D. is a pilot-operated check valve.

23.

Cartridge valves must be sized for the highest flow at any one port. A. True B. False

24.

The device that forms the basic element of most amplifier circuits is a ______ A. capacitor. B. resistor. C. transistor. D. diode.

25.

The input impedance of the op-amp is ______ A. very high. B. very low. C. equal to the output impedance. D. none of the above

26.

A current input signal is preferred over a voltage input signal in many process control applications. A. True B. False

27.

Deadband compensation is primarily caused by ______ A. malfunction of the op-amp. B. spool overlapping the valve ports. C. overheating of the pressure transducers. D. none of the above

28.

In normal operation, a proportional valve has ______ A. one flow path. B. two flow paths. C. three flow paths. D. none of the above

29.

In a pilot-operated proportional directional valve, the pilot spool has ______ possible controlling positions. A. one B. two C. three D. four

30.

In a mechanical servo valve, the part that is connected with the load is the ______ A. valve body. B. control handle. C. valve spool. D. all of the above

Page: 3.4

Rev. 02: January 2005

BOP Equipment OJT Module Vickers Industrial Hydraulics Manual - Workbook Answers

31.

Linearity is the relationship between the valve’s control flow and its ______ A. output flow. B. input signal. C. output signal. D. none of the above

32.

PLCs are generally programmed in ______ A. serial logic. B. parallel logic. C. ladder logic. D. symbolic logic.

33.

When using an AND logic gate, to get 1 as an output ______ A. both inputs should be 0. B. one input should be 0 and another input 1. C. both inputs should be 1. D. any of the above

34.

The flow capacity of a pump can be expressed as ______ A. maximum operating pressure. B. displacement per revolution. C. hydraulic horsepower. D. none of the above

35.

The volumetric efficiency of a 10-gpm pump delivering 8.5 gpm at 850 psi is ______ A. 75% B. 80% C. 85% D. 90%

36.

In axial piston pumps, the pistons reciprocate perpendicular to the axis of rotation of the cylinder block. A. True B. False

37.

The type of accumulator that works at constant pressure is a ______ A. spring-loaded type. B. gas-charged type. C. weight-loaded type. D. all of the above

38.

The Bourdon tube gauge and Schradder gauge are examples of ______ A. flow meters. B. pressure gauges. C. temperature gauges. D. none of the above

39.

Conventional reciprocating circuits provide reversal through the use of a ______ A. unidirectional valve. B. two-way directional valve. C. three-way directional valve. D. none of the above

40.

An accumulator can be used to ______ A. maintain the pressure during a holding operation. B. augment pump delivery during short periods of large volume demand. C. absorb hydraulic shock. D. all of the above

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Page: 3.5

BOP Equipment OJT Module Rotary Drilling Blowout Prevention - Workbook Answers

1.

In the equation P = 0.052 x W x TVD, the units P, W, and TVD are expressed in ______ A. pascals, kilograms, and metres. B. psi, ppg, and metres. C. psi, ppg, and feet. D. lbs, gallons, and feet.

2.

The ______ the relative movement of mud past the pipe, the ______ the pressure required to overcome the friction. A. slower, greater B. faster, greater C. faster, smaller D. none of the above

3.

Measurement of actual number of barrels used to fill the hole is generally made by ______ A. trip tank. B. pump stroke counter. C. pit level change. D. all of the above

4.

A fracture pressure of 1,248 psi at 2,000 feet corresponds to an equivalent mud weight of ______ A. 12 ppg. B. 13 ppg. C. 14.1 ppg. D. 15 ppg.

5.

Abnormally pressured shales are found to have a lower porosity than would normally be found at the same depth. A. True B. False

6.

Gas may enter the mud as a result of ______ A. trip gas that follows round trips of the drill string. B. connection gas that is associated with each drill pipe connection. C. gas from drilled gas-bearing sands. D. all of the above

7.

High permeability formation underbalanced by mud pressure is the most dangerous type of kick. A. True B. False

8.

The first step when controlling a well kick if on bottom is to ______ A. check for well flow. B. shut down the pump. C. raise the kelly to clear the tool joint above the rotary, or pick the bit up off bottom. D. read and record the stabilized SIDPP.

9.

For stripping operations, the methods that can be used are ______ A. stripping through the annular. B. stripping from annular to ram. C. stripping from ram to ram. D. all of the above

10.

Large-size mechanical snubbers are capable of exerting 350,000 pounds of force. A. True B. False

Page: 3.6

Rev. 02: January 2005

BOP Equipment OJT Module Rotary Drilling Blowout Prevention - Workbook Answers

11.

One should always open or close the valve next to the well before flow commences or after flow has been stopped by the downstream valve. A. True B. False

12.

The working pressure of the BOP assembly should exceed the least of the following: 1. The burst rating of the casing to which it is attached. 2. The formation breakdown pressure at the last casing shoe. 3. The maximum bottomhole pressure. 4. The maximum anticipated surface pressure. A. 1 and 2 B. 1, 2, and 3 C. 1, 3, and 4 D. 1, 2, and 4

13.

The casinghead usually provides ______ opening(s) that can be used for bleeding off the pressure or for pumping into the well. A. one B. two C. three D. none of the above

14.

Pipe rams in the BOPs are designed to center the pipe in the hole when the rams are closed. A. True B. False

15.

Rotating heads have a body that rotates with the kelly while the packing element is stationary. A. True B. False

16.

The choke line and lines downstream of the choke should be ______ A. B. C. D.

as straight as practicable. firmly anchored to prevent vibrations. having a bore of sufficient size to prevent excessive erosion. all of the above

17.

Valves on a kill line ______ A. should be kept closed at all times when not in use. B. should be kept open at all times when not in use. C. should have a minimum internal diameter of 4 inches. D. none of the above

18.

One type of wireline preventer can close off the top of the drill string without a lubricator. A. True B. False

19.

All preventers and valves should be tested with pressure from ______ A. the downstream side. B. the upstream side. C. both of the above D. none of the above

20.

It is possible to test the blind rams when using a hanger plug for BOP testing. A. True B. False

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Page: 3.7

BOP Equipment OJT Module Cameron Ram-Type U Blowout Preventer - Workbook Answers

1.

What is the first step that should be taken before working on the type ‘U’ BOP? A. Connect the hydraulic line to the close port. B. Familiarize yourself with the BOP parts and their location and also with the inspection and maintenance procedures. C. Loosen the bonnet bolts. D. Open the ram locks.

2.

How are the rams removed? A. Using a nylon strap B. Using a lifting-eye and a steel bar or air hoist C. Using a standard pry-bar D. Using a sledge hammer

3.

Upon inspection of the ram core and all connecting surfaces of the preventer body and intermediate flange, which of the following would be a major problem? A. Small nicks and scratches B. Deep gouges and/or large nicks and scratches C. Water and dirt D. Fine abrasions and normal wear

4.

Can scratches and gouges be field-repaired? A. Yes, normally a file may be used to smooth down the problem area. B. Yes, only if the nick is very minor. C. No, never attempt to remove any nicks or scratches in the field. D. No, scratches can only be removed by Cameron repair shop service.

5.

A bad bonnet seal is ______ A. misshaped. B. unnaturally flattened on the sides. C. cracked and slightly cut. D. all of the above

6.

Wellbore pressure aids in closing and in holding rams closed. A. True B. False

7.

Two primary and one emergency seal with a vent hole in between prevent well pressure from bleeding into the operating cylinder. A. True B. False

8.

Rams may be locked in the closed position by using mechanical screw locks. There is no optional hydraulic ram lock function available. A. True B. False

9.

Each operating piston rod has a triple seal system which includes a Hycar lip seal, a plastic energized secondary seal, and large O-ring seals in the hydraulic operation system. Therefore, well pressure cannot reach the operating cylinders. A. True B. False

Page: 3.8

Rev. 02: January 2005

BOP Equipment OJT Module Cameron Ram-Type U Blowout Preventer - Workbook Answers

10.

How many foot-pounds should the bonnet bolts for a 5,000 psi rated 13 5/8-inch bore ram type BOP be torqued to? A. 3,000 ft/lbs B. 5,000 ft/lbs C. 7,000 ft/lbs D. 10,000 ft/lbs

11.

Ram preventers are designed to hold bidirectional pressure (from above and/or below). A. True B. False

12.

In an emergency, ordinary water can be used as an operating pressure fluid. A. True B. False

13.

On the surface BOP rams, the emergency plastic compression seal is used in the event of a leaking main seal. A. True B. False

14.

Never cut an old seal or O-ring in half. A. True B. False

15.

Bonnet bolts don’t require O-ring seals. A. True B. False

16.

Always coat O-ring seals with light oil when installing. A. True B. False

17.

Check for gaps between the intermediate flange and preventer body using a ______ feeler gauge along the surfaces of these two areas. A. .005-inch B. .010-inch C. .020-inch D. .030-inch

18.

In cold weather operations, the preventer should be kept as warm as possible as the rams are susceptible to freezing in place since water-base drilling fluids freeze quickly and solidly when they come to rest at such temperatures. A. True B. False

19.

In cold weather operations, water is a satisfactory operating fluid provided a soluble oil is used for corrosion protection and sufficient antifreeze is added to prevent freezing. A. True B. False

Rev. 02: January 2005

Page: 3.9

BOP Equipment OJT Module Rucker Ram-Type Blowout Preventer - Workbook Answers

1.

The first step in the 3-month test series is ______ A. the closing hydraulic pressure test. B. visual inspection. C. locking hydraulic pressure test. D. field wellbore pressure test.

2.

A leak past the piston is indicated in the opening hydraulic pressure test by the opening gauge ______ and the closing gauge rising. A. rising B. remaining stationary C. falling D. none of the above

3.

The closing hydraulic pressure test may be performed with the doors open or closed. A. True B. False

4.

The fluid used in the field wellbore pressure test is cold water. A. True B. False

5.

During the closing hydraulic pressure test, if the valve in the opening hydraulic line is closed and the pressure increases, hydraulic fluid is leaking past the piston. A. True B. False

6.

Excessive wear in the BOP bore is normally indicated by ______ A. 1/8 inch of wear. B. leaks at the hinge pin. C. 1/32 inch of wear. D. none of the above

7.

Only one door at a time should be opened unless the BOP is well supported because the weight from two open doors could cause it to tip over. A. True B. False

8.

The normal locking pressure for pipe and blind rams should be ______ to ______ psi. A. 5 to 10 B. 25 to 50 C. 100 to 200 D. 500 to 1,400

9.

A clearly visible mark on the torque tool and clamp will permit accurate counting of turns on the torque tool during adjustment. A. True B. False

10.

The 10-inch piston should be disassembled exactly the same way the 14-inch piston is disassembled. A. True B. False

11.

Before the piston can be removed, the ______ must be removed. A. ram rubbers B. opening hydraulic gauge C. locking plate D. all of the above

Page: 3.10

Rev. 02: January 2005

BOP Equipment OJT Module Rucker Ram-Type Blowout Preventer - Workbook Answers

12.

To prevent the ram shaft from turning during disassembly, ram blocks or ram holders are installed. A. True B. False

13.

To help push the cylinder head off, ______ is blown into the closing hydraulic line. A. water B. oil C. air D. none of the above

14.

The ramshaft is removed after the ramshaft packing is removed. A. True B. False

15.

During the adjustment sequence, the rams should be in the fully closed and locked position. A. True B. False

16.

The brass locking segments must be installed before the cylinder is installed over the piston. A. True B. False

Rev. 02: January 2005

Page: 3.11

BOP Equipment OJT Module Hydril Ram BOP - Workbook Answers

1.

The five main components of a Hydril ram BOP are the cylinder assemblage, fluid hinge assemblage, bonnet assemblage, upper latch assemblage, and the ram assemblage. A. True B. False

2.

The first step in the initial disassembly of the Hydril ram BOP is to ______ A. close the rams completely. B. disconnect the hoses. C. open the rams completely. D. remove the fluid hinges.

3.

If a deep scar is noticed on the upper seal seat during inspection, it is important to send the BOP back to an approved workshop for repair. A. True B. False

4.

When replacing the piston seals it is important to ______ A. ensure the seal on the piston rod side opens towards the shaft and the seal on the piston rod opens towards the mechanical lock. B. check that the mechanical lock is not in place as the seal is of a smaller diameter than the mechanical lock. C. ensure that the seals are completely dry and free of any silicon compound or oil. D. ensure the seal on the piston rod side opens towards the shaft and the seal on the mechanical lock side opens towards the mechanical lock.

5.

The removal of the cylinder-to-bonnet O-ring is the last seal on the cylinder, and ______ A. requires a special tool supplied by Hydril. B. can simply be pryed off. C. should never be removed as it is an integral part of the cylinder. D. none of the above

6.

The mechanical lock shaft must be screwed into the piston with a counterclockwise rotation. A. True B. False

7.

When aligning the bonnet of a Hydril ram BOP, the bonnet is raised by ______ A. building up the hinges with shims supplied by Hydril. B. loosening the upper hinge pin and then tightening the lower hinge pin. C. loosening the lower hinge pin and then tightening the upper hinge pin. D. all of the above

8.

The emergency or secondary seal is normally used only on surface BOPs and its function is to ______ A. retain hydraulic operating fluid within the BOP if the mud seal fails and can be energized manually on surface stacks. B. act as a backup to the mud seal and can be energized manually on surface stacks. C. act as a backup to the mud seal and can be energized by removing the pipe plug and attaching a hot line to its threaded port. D. none of the above

9.

It is important to never use screwdrivers during the removal of the upper seal from a ram block. A. True B. False

Page: 3.12

Rev. 02: January 2005

BOP Equipment OJT Module Hydril Ram BOP - Workbook Answers

10.

When tightening the bonnet bolts, it is important to ______ A. check the operator’s manual for the correct torque values. B. check that the bolts are dry and free of grease. C. take the weight of the bonnet with a chain hoist to help the alignment of the bonnet. D. all of the above

11.

A continual flow from the opening chamber port while pressure testing the closed chamber may mean a ______ leak, or a cylinder liner to bonnet seal leak. A. hinge pin B. upper seal seat C. piston seal D. none of the above

12.

A leak from the weephole means that there is a bad bonnet seal or piston rod seal. A. True B. False

Rev. 02: January 2005

Page: 3.13

BOP Equipment OJT Module Hydril GL Annular Preventer - Workbook Answers

1.

What is the purpose of the GL annular BOP? A. It is to allow returns during a kick situation. B. It is to seal off the wellbore during a kick situation. C. It is to allow kill mud to enter the wellbore during a kick situation. D. none of the above

2.

The main parts of the GL annular BOP are ______ A. the BOP head, packing unit, opening chamber head, piston, outer body sleeve, slotted body sleeve, BOP body, group of parts forming the head latch system. B. the BOP head, packing unit, opening chamber head, piston, outer body sleeve, group of parts forming the head latch system. C. the BOP head, opening head unit, closing chamber head, piston, outer body sleeve, slotted body sleeve, BOP body, group of parts forming the head latch system. D. the BOP head, packing unit, opening chamber lower body, piston, outer body sleeve, lower body sleeve, BOP body, group of parts forming the head latch system.

3.

The three different hydraulic hookups that can be used with a GL annular BOP are to connect the secondary chamber to the ______ A. opening chamber on a surface BOP, closing chamber to reduce the closing pressure by one third, and the marine riser to neutralize the effect of the drilling fluid. B. opening chamber on a surface BOP, closing chamber to reduce the closing pressure by one third, and the shear rams to allow faster closing time of the shear rams. C. closing chamber on a surface BOP, opening chamber to reduce the closing pressure by one third, and the marine riser to neutralize the effect of the drilling fluid. D. none of the above

4.

What methods can be used to limit wear on the packing unit of the GL annular BOP during stripping operations with the BOP in the closed position? A. Adjust the closing pressure so there is a slight leakage of drilling fluid. B. Keep to a slow stripping speed to reduce surge pressures. C. It is not possible to strip pipe through a GL annular BOP. D. both A and B above

5.

What are acceptable fluids for use in the GL annular BOP hydraulic system? A. Light petroleum hydraulic oil and diesel oil B. Water with water-soluble oil and diesel oil C. Light petroleum hydraulic oil only D. Light petroleum hydraulic oil and water with water-soluble oil

6.

What can be used in the hydraulic system to ease a particular disassembly procedure? A. Air, gas, and hydraulic fluid B. Air, gas, and water with water-soluble oil C. Any fluid can be used to ease a particular disassembly procedure. D. Light petroleum hydraulic oil and water with water-soluble oil

7.

How should you install a double “U” seal? A. The upper seal in each set of single “U” seals is installed with the groove opening UP. The lower seal in each set is installed with the groove opening DOWN. B. The upper seal in each set of single “U” seals is installed with the groove opening DOWN. The lower seal in each set is installed with the groove opening UP. C. The upper seal in each set of single “U” seals is installed with the groove opening UP. The lower seal in each set is installed with the groove opening UP. D. none of the above

Page: 3.14

Rev. 02: January 2005

BOP Equipment OJT Module Hydril GL Annular Preventer - Workbook Answers

8.

Explain the relationship between the length of the piston stroke needed for seal-off and the condition of the packing unit in the GL annular BOP. A. Measure the distance between the piston and the slotted body sleeve. After closing the annular with the new packing unit installed, remeasure the distance and record the difference. By taking subsequent measurements each time you test the BOP, you can determine the relative wear on the packing unit B. There is no relationship between the length of the piston stroke needed for seal-off and the condition of the packing unit. C. Measure the distance between the piston and the annular head. After closing the annular with the new packing unit installed, remeasure the distance and record the difference. By taking subsequent measurements each time you test the BOP, you can determine the relative wear on the packing unit. D. none of the above

9.

Why should you check the operator’s manual before pressure testing? A. For closing pressure B. For wellbore pressure C. For test pipe diameter D. for all of the above

10.

When you have closed the GL annular BOP around the test pipe, but have not yet pressurized the wellbore, how do you check for leaks? A. It is not possible to check for leaks until the wellbore is pressurized. B. Cover the top of the packing unit with water and watch for the water level rising. C. Use air to close the GL annular BOP, as it is possible to listen for the leak. D. none of the above

11.

We do not need to vent off any hydraulic chambers before disassembly of the GL annular BOP as they are all self-venting. A. True B. False

12.

To release the GL annular BOP head latching mechanism, we need to turn the jaw operating screws ______ turns counterclockwise. A. one B. two C. three D. four

13.

The GL 16 3/4" and the GL 18 3/4" use cap screws and head clamps to secure the BOP head to the body. A. True B. False

14.

If a major scar is found on the internal body of the GL annular BOP, ______ A. you can get the rig welder to build up over the scar and smooth down with emery cloth. B. you can fill the scar with a suitable hard-setting compound and file it smooth. C. you must send the body into an approved machine shop for repair. D. all of the above

15.

It is important to check the vertical bore of the head of a GL annular BOP for wear or damage as drill string tubulars and tools can cause damage here. A. True B. False

Rev. 02: January 2005

Page: 3.15

BOP Equipment OJT Module Accumulator Bottles - Bladder Replacement and Precharge - Workbook Answers

1.

Subsea accumulators with no temperature difference between surface and subsea ______ A. are charged to a set surface precharge pressure. B. are charged to hydrostatic pressure at seabed. C. are charged to surface precharge plus hydrostatic pressure. D. are charged to surface precharge plus hydrostatic pressure plus atmospheric pressure.

2.

Atmospheric pressure at sea level is ______ A. 0 psi. B. 14.7 pounds. C. 14.7 psi. D. 0.445 psi per foot.

3.

A lower temperature at seabed compared to the surface would cause ______ A. the nitrogen to contract. B. a decrease in pressure in the accumulator bottles. C. the last drop of fluid to come out of the bottle at a reduced pressure. D. all of the above

4.

Hydrostatic pressure exerted by a column of seawater is ______ A. .445 psi. B. .445 psi per foot. C. 14.7 psi per foot. D. none of the above

5.

Specific volume is ______ A. pounds of gas per cubic feet of gas. B. pounds of gas per 100 cubic feet of gas. C. cubic feet of gas per pound of gas. D. cubic feet of gas per gram of gas.

6.

Specific volume of nitrogen at 50 degrees Fahrenheit and 3,750 psia is ______ A. 0.06032 cubic ft/lb B. 0.05540 lb/cubic ft C. 0.05673 lb/cubic ft D. 0.05673 cubic ft/lb

7.

Specific volume of nitrogen at 55 degrees Fahrenheit and 3,750 psia is ______ A. 0.05673 cubic ft/lb B. 0.05804 cubic ft/lb C. 0.05737 cubic ft/lb D. 0.05739 cubic ft/lb

8.

Specific volume of nitrogen at 55 degrees Fahrenheit and 3,875 psia is ______ A. 0.05739 cubic ft/lb B. 0.05611 cubic ft/lb C. 0.05466 cubic ft/lb D. 0.05673 cubic ft/lb

9.

For a surface precharge of 1,500 psi, 300-feet water depth and no difference between surface and subsea temperatures, the subsea precharge would be ______ A. 1,649.2 psi. B. 1,633.5 psi. C. 1,633.2 psi. D. 1,648.2 psi.

Page: 3.16

Rev. 02: January 2005

BOP Equipment OJT Module Accumulator Bottles - Bladder Replacement and Precharge - Workbook Answers

10.

For question 9 above, if the surface temperature is 80 degrees Fahrenheit, and subsea temperature is 40 degrees Fahrenheit, the subsea precharge would be approximately ______ A. 1,650 psi. B. 1,830 psi. C. 1,740 psi. D. 1,870 psi.

11.

MMS states the minimum requirements for accumulator volumes to be ______ A. usable fluid volume should be 11/2 times the volume necessary to close all functions. B. after closing all functions, there should be a minimum pressure of 203 psi above precharge pressure. C. both A and B above D. none of the above

12.

Boyle’s gas law states that ______ A. pressure is directly proportional to the temperature. B. volume is directly proportional to pressure. C. pressure is inversely proportional to the volume. D. none of the above

13.

Following MMS guidelines, the total usable fluid in an 11-gallon accumulator bottle with 1,000 psi precharge and 3,000 psi final pressure is ______ A. 10 gallons. B. 4.97 gallons. C. 6.67 gallons. D. 3.33 gallons.

14.

Following MMS guidelines, the total usable fluid in an 11-gallon accumulator bottle with 1,203 psi precharge and 3,000 psi final pressure is ______ A. 6 gallons. B. 4 gallons. C. 8.5 gallons. D. 4.5 gallons.

15.

In an 11-gallon accumulator bottle, the available volume for nitrogen and fluid is ______ A. 1 gallon. B. 10 gallons. C. 5 gallons. D. 11 gallons.

Rev. 02: January 2005

Page: 3.17

© Transocean 2005 Issue Date: 01 January 2005