30 CFR § 250.737 - What are the BOP system testing requirements?
Your BOP system (this includes the choke manifold, kelly-type valves, inside BOP, and drill string safety valve) must meet the following testing requirements:
(1) When installed;
(2) Before 14 days have elapsed since your last BOP pressure test, or 30 days since your last blind shear ram BOP pressure test. You must begin to test your BOP system before midnight on the 14th day (or 30th day for your blind shear rams) following the conclusion of the previous test;
(3) Before drilling out each string of casing or a liner. You may omit this pressure test requirement if you did not remove the BOP stack to run the casing string or liner, the required BOP test pressures for the next section of the hole are not greater than the test pressures for the previous BOP test, and the time elapsed between tests has not exceeded 14 days (or 30 days for blind shear rams). You must indicate in your APD which casing strings and liners meet these criteria;
(b)Pressure test procedures. When you pressure test the BOP system, you must conduct a low-pressure test and a high-pressure test for each BOP component. You must begin each test by conducting the low-pressure test then transition to the high-pressure test. Each individual pressure test must hold pressure long enough to demonstrate the tested component(s) holds the required pressure. The table in this paragraph (b) outlines your pressure test requirements.
|You must conduct a . . .||According to the following procedures . . .|
|(1) Low-pressure test||All low-pressure tests must be between 250 and 350 psi. Any initial pressure above 350 psi must be bled back to a pressure between 250 and 350 psi before starting the test. If the initial pressure exceeds 500 psi, you must bleed back to zero and reinitiate the test.|
|(2) High-pressure test for blind shear ram-type BOPs, ram-type BOPs, the choke manifold, outside of all choke and kill side outlet valves (and annular gas bleed valves for subsea BOP), inside of all choke and kill side outlet valves below uppermost ram, and other BOP components||The high-pressure test must equal the RWP of the equipment or be 500 psi greater than your calculated MASP, as defined for the operation for the applicable section of hole. Before you may test BOP equipment to the MASP plus 500 psi, the District Manager must have approved those test pressures in your APD.|
|(3) High-pressure test for annular-type BOPs, inside of choke or kill valves (and annular gas bleed valves for subsea BOP) above the uppermost ram BOP||The high pressure test must equal 70 percent of the RWP of the equipment or be 500 psi greater than your calculated MASP, as defined for the operation for the applicable section of hole. Before you may test BOP equipment to the MASP plus 500 psi, the District Manager must have approved those test pressures in your APD.|
(c)Duration of pressure test. Each test must hold the required pressure for 5 minutes, which must be recorded on a chart not exceeding 4 hours. However, for surface BOP systems and surface equipment of a subsea BOP system, a 3-minute test duration is acceptable if recorded on a chart not exceeding 4 hours, or on a digital recorder. The recorded test pressures must be within the middle half of the chart range, i.e., cannot be within the lower or upper one-fourth of the chart range. If the equipment does not hold the required pressure during a test, you must correct the problem and retest the affected component(s).
(d)Additional test requirements.You must meet the following additional BOP testing requirements:
|You must . . .||Additional requirements . . .|
|(1) Follow the testing requirements of API Standard 53 (as incorporated in § 250.198)||If there is a conflict between API Standard 53, testing requirements and this section, you must follow the requirements of this section.|
|(2) Use water to test a surface BOP system on the initial test. You may use drilling/completion/workover fluids to conduct subsequent tests of a surface BOP system||(i) You must submit test procedures with your APD or APM for District Manager approval.
(ii) Contact the District Manager at least 72 hours prior to beginning the initial test to allow BSEE representative(s) to witness testing. If BSEE representative(s) are unable to witness testing, you must provide the initial test results to the appropriate District Manager within 72 hours after completion of the tests.
|(3) Stump test a subsea BOP system before installation||(i) You must use water to conduct this test. You may use drilling/completion/workover fluids to conduct subsequent tests of a subsea BOP system.|
|(ii) You must submit test procedures with your APD or APM for District Manager approval|
|(iii) Contact the District Manager at least 72 hours prior to beginning the stump test to allow BSEE representative(s) to witness testing. If BSEE representative(s) are unable to witness testing, you must provide the test results to the appropriate District Manager within 72 hours after completion of the tests.|
|(iv) You must test and verify closure of all ROV intervention functions on your subsea BOP stack during the stump test.|
|(v) You must follow paragraphs (b) and (c) of this section.|
|(4) Perform an initial subsea BOP test||(i) You must perform the initial subsea BOP test on the seafloor within 30 days of the stump test.|
|(ii) You must submit test procedures with your APD or APM for District Manager approval.|
|(iii) You must pressure test well-control rams according to paragraphs (b) and (c) of this section.|
|(iv) You must notify the District Manager at least 72 hours prior to beginning the initial subsea test for the BOP system to allow BSEE representative(s) to witness testing.|
|(v) You must test and verify closure of at least one set of rams during the initial subsea test through a ROV hot stab.|
|(vi) You must pressure test the selected rams according to paragraphs (b) and (c) of this section.|
|(5) Alternate testing pods between control stations||(i) For two complete BOP control stations:|
|(A) Designate a primary and secondary station, and both stations must be function-tested weekly;|
|(B) The control station used for the pressure test must be alternated between pressure tests; and|
|(C) For a subsea BOP, the pods must be rotated between control stations during weekly function testing and 14 day pressure testing.|
|(ii) Remote panels where all BOP functions are not included (e.g., life boat panels) must be function-tested upon the initial BOP tests and monthly thereafter.|
|(6) Pressure test variable bore-pipe ram BOPs against pipe sizes according to API Standard 53, excluding the bottom hole assembly that includes heavy-weight pipe or collars and bottom-hole tools|
|(7) Pressure test annular type BOPs against pipe sizes according to API Standard 53|
|(8) Pressure test affected BOP components following the disconnection or repair of any well-pressure containment seal in the wellhead or BOP stack assembly|
|(9) Function test annular and pipe/variable bore ram BOPs every 7 days between pressure tests|
|(10) Function test shear ram(s) BOPs every 14 days|
|(11) Actuate safety valves assembled with proper casing connections before running casing|
|(12) Function test autoshear/deadman, and EDS systems separately on your subsea BOP stack during the stump test. The District Manager may require additional testing of the emergency systems. You must also test the deadman system and verify closure of the shearing rams during the initial test on the seafloor||(i) You must submit test procedures with your APD or APM for District Manager approval. The procedures for these function tests must include the schematics of the actual controls and circuitry of the system that will be used during an actual autoshear or deadman event.
(ii) The procedures must also include the actions and sequence of events that take place on the approved schematics of the BOP control system and describe specifically how the ROV will be utilized during this operation.
(iii) When you conduct the initial deadman system test on the seafloor, you must ensure the well is secure and, if hydrocarbons have been present, appropriate barriers are in place to isolate hydrocarbons from the wellhead. You must also have an ROV on bottom during the test.
(iv) The testing of the deadman system on the seafloor must indicate the discharge pressure of the subsea accumulator system throughout the test.
(v) For the function test of the deadman system during the initial test on the seafloor, you must have the ability to quickly disconnect the LMRP should the rig experience a loss of station-keeping event. You must include your quick-disconnect procedures with your deadman test procedures.
(vi) You must pressure test the blind shear ram(s) according to paragraphs (b) and (c) of this section.
(vii) If a casing shear ram is installed, you must describe how you will verify closure of the ram.
(viii) You must document all your test results and make them available to BSEE upon request.
(e) Prior to conducting any shear ram tests in which you will shear pipe, you must notify the District Manager at least 72 hours in advance, to ensure that a BSEE representative will have access to the location to witness any testing.