Publication No.

M07

BLOWOUT
PREVENTION
In California
Equipment Selection and Testing

California Department of Conservation

Division of Oil, Gas, and Geothermal Resources

STATE OF CALIFORNIA RESOURCES AGENCY DEPARTMENT OF CONSERVATION

ARNOLD SCHWARZENEGGER, Governor MIKE CHRISMAN, Secretary BRIDGETT LUTHER, Director
 This manual is for guidance in establishing
blowout prevention requirements. Nothing
herein is to be regarded as an approval or
disapproval of any specific product.

DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

HAL BOPP, State Oil and Gas Supervisor
BLOWOUT PREVENTION
in California
Equipment Selection and Testing

by
Peter R. Wygle

California Department of Conservation

Division of Oil, Gas, and Geothermal Resources

Sacramento

Tenth Edition, 2006

Ninth Edition, 2001
Eighth Edition, 1998
Seventh Edition, 1997
Sixth Edition, 1995
Fifth Edition, 1985
Fourth Edition, 1981
Third Edition, 1980
Second Edition, 1978
First Edition, 1977
 OIL AND GAS DISTRICT OFFICES
Headquarters 801 K St., MS 20-20, Sacramento, CA 95814-3530
Phone: 916-445-9686, TDD: 916-324-2555
Fax: 916-323-0424

District No. 1 5816 Corporate Ave., Suite 200, Cypress, CA 90630-4731

Phone: 714-816-6847
Fax: 714-816-6853

District No. 2 1000 S. Hill Rd., Suite 116, Ventura, CA 93003-4458

Phone: 805-654-4761
Fax: 805-654-4765

District No. 3 5075 S. Bradley Rd., Suite 221, Santa Maria, CA 93455
Phone: 805-937-7246
Fax: 805-937-0673

District No. 4 4800 Stockdale Hwy., Suite 417, Bakersfield, CA 93309

Phone: 661-322-4031
Fax: 661-861-0279

District No. 5 466 N. Fifth St., Coalinga, CA 93210

Phone: 559-935-2941
Fax: 559-935-5154

District No. 6 801 K St., MS 20-22, Sacramento, CA 95814-3530

Phone: 916-322-1110
Fax: 916-322-1201

LEGEND
Oil & Gas Districts
Geothermal Districts

GEOTHERMAL DISTRICT OFFICES

Headquarters & 801 K St., MS 20-21, Sacramento, CA 95814-3530

District No. G1 Phone: 916-323-1788
Fax: 916-323-0424

District No. G2 1699 W. Main St., Suite E, El Centro, CA 92243-2235

Phone: 760-353-9900
Fax: 760-353-9594

District No. G3 50 D St., Room 300, Santa Rosa, CA 95404

Phone: 707-576-2385
Fax: 707-576-2611
 CONTENTS
SECTION PARAGRAPH PAGE

1. SCOPE ............................................................................................................................ 1
2. CLASSIFICATION AND SELECTION OF EQUIPMENT .......................................... 2 2
GENERAL ............................................................................................................... 2-1 2
Classification and Selection System .................................................................... 2-1a 2
Complete BOPE Classification ............................................................................ 2-1b 2
Proposed Well Operation ................................................................................... 2-1c 2
Minimum Equipment ........................................................................................ 2-1d 2
Stack Arrangements ........................................................................................... 2-1e 2
BOP Stack Component Codes ............................................................................ 2-1f 2
Diverter System .................................................................................................. 2-1g 2
CLASSIFICATION OF BLOWOUT PREVENTION EQUIPMENT ........................... 2-2 4
Diverter System .................................................................................................. 2-2a 4
Class I BOPE ....................................................................................................... 2-2b 4
Class II BOPE ..................................................................................................... 2-2c 4
Class III BOPE ................................................................................................... 2-2d 6
Class IV BOPE .................................................................................................... 2-2e 9
Class V BOPE ..................................................................................................... 2-2f 11
CLASSIFICATION OF HOLE-FLUID MONITORING EQUIPMENT ...................... 2-3 11
Class A ............................................................................................................... 2-3a 11
Class B ................................................................................................................ 2-3b 11
Class C ............................................................................................................... 2-3c 11
SELECTION OF BOPE AND HOLE-FLUID MONITORING EQUIPMENT ............ 2-4 13
SELECTION OF PRESSURE RATING ..................................................................... 2-5 13
Maximum Predicted Casing Pressure (MPCP) ................................................... 2-5a 13
Maximum Allowable Casing Pressure (MACP) ................................................. 2-5b 13
ADDITIONAL REQUIREMENTS ............................................................................ 2-6 17
BOPE Inspection ................................................................................................. 2-6a 17
BOPE Practice Drills and Training Sessions ........................................................ 2-6b 17
Records ............................................................................................................... 2-6c 17
3. EQUIPMENT DESCRIPTIONS, OPERATING
CHARACTERISTICS, AND REQUIREMENTS .......................................................... 3 18
GENERAL ............................................................................................................... 3-1 18
PREVENTERS .......................................................................................................... 3-2 18
Annular or “Bag” Preventers .............................................................................. 3-2a 18
Ram Preventers .................................................................................................. 3-2b 19
Closed Preventers ............................................................................................... 3-2c 21
THE ACTUATING SYSTEM .................................................................................... 3-3 21
Accumulator Unit (Closing Unit) ....................................................................... 3-3a 21
Emergency Backup System ................................................................................ 3-3b 26
Control Manifold ................................................................................................ 3-3c 29
Remote Station(s) .............................................................................................. 3-3d 31
Hydraulic Control Lines ..................................................................................... 3-3e 31
Hydraulic Fluid .................................................................................................. 3-3f 33
THE CHOKE AND KILL SYSTEM .......................................................................... 3-4 33
Choke Line and Manifold ................................................................................... 3-4a 33
Kill Line .............................................................................................................. 3-4b 35
AUXILIARY EQUIPMENT ...................................................................................... 3-5 36
Fill-up Line ......................................................................................................... 3-5a 36
Standpipe ........................................................................................................... 3-5b 36
Kelly Cock(s) ...................................................................................................... 3-5c 36
Pipe Safety Valve ............................................................................................... 3-5d 37
Internal Preventer ............................................................................................... 3-5e 37
HOLE-FLUID MONITORING EQUIPMENT .......................................................... 3-6 37
Class A ............................................................................................................... 3-6a 39

iii
SECTION PARAGRAPH PAGE
Class B ..................................................................................................................... 3-6b 39
Class C ..................................................................................................................... 3-6c 39
3A. SUBSEA BOPE INSTALLATION ................................................................................... 3A 40
GENERAL .................................................................................................................. 3A-1 40
THE DIVERTER SYSTEM .......................................................................................... 3A-2 40
Purpose ................................................................................................................ 3A-2a 40
Installation and Equipment Requirements ........................................................... 3A-2b 40
THE BLOWOUT PREVENTER STACK ..................................................................... 3A-3 42
Variance from Surface Installations ...................................................................... 3A-3a 42
API Stack Component Codes ................................................................................ 3A-3b 42
Stack Arrangements ............................................................................................. 3A-3c 42
Pressure Rating Requirements .............................................................................. 3A-3d 42
Pipe Stripping Arrangements ............................................................................... 3A-3e 45
SUBSEA ACTUATING SYSTEM ............................................................................... 3A-4 45
Variance from Surface Installations ...................................................................... 3A-4a 45
Accumulator Units ............................................................................................... 3A-4b 45
Hydraulic Fluid Mixing System ............................................................................ 3A-4c 46
Accumulator Charging Pumps ............................................................................. 3A-4d 46
The Hydraulic Control System ............................................................................. 3A-4e 46
The Electrohydraulic Control System .................................................................... 3A-4f 46
The Control Stations ............................................................................................. 3A-4g 46
Hose Bundles and Hose Reels .............................................................................. 3A-4h 47
Subsea Control Pods .............................................................................................. 3A-4i 47
CHOKE/KILL LINE VALVE AND PIPING ASSEMBLIES ........................................ 3A-5 47
Riser Line Types ................................................................................................... 3A-5a 47
Wellhead Piping and Valves ................................................................................. 3A-5b 47
Installation Guidelines .......................................................................................... 3A-5c 53
CHOKE MANIFOLD ................................................................................................. 3A-6 53
Variance from Surface Installations ...................................................................... 3A-6a 53
Installation Guidelines .......................................................................................... 3A-6b 53
AUXILIARY EQUIPMENT ........................................................................................ 3A-7 55
General ................................................................................................................. 3A-7a 55
Safety Valves ........................................................................................................ 3A-7b 55
Wellhead Connector ............................................................................................. 3A-7c 56
Marine Riser System ............................................................................................. 3A-7d 56
Guide Structure .................................................................................................... 3A-7e 58
Guideline System ................................................................................................... 3A-7f 58
INSPECTION AND MAINTENANCE OF SUBSEA
BLOWOUT PREVENTION EQUIPMENT ................................................................. 3A-8 58
4. GEOTHERMAL EQUIPMENT DESCRIPTIONS, OPERATING
CHARACTERISTICS, AND REQUIREMENTS ................................................................. 4 60
GENERAL ..................................................................................................................... 4-1 60
GEOTHERMAL ENVIRONMENTS .............................................................................. 4-2 60
Hot Dry Rock ........................................................................................................... 4-2a 60
Hydrothermal .......................................................................................................... 4-2b 60
BOPE DESCRIPTIONS AND REQUIREMENTS ........................................................... 4-3 61
High-temperature Reservoirs .................................................................................. 4-3a 61
Low-temperature Reservoirs ................................................................................... 4-3b 64
RELATED WELL CONTROL EQUIPMENT ................................................................. 4-4 64
Full-opening Safety Valve ........................................................................................ 4-4a 64
Upper Kelly Cock .................................................................................................... 4-4b 64
Internal Preventer .................................................................................................... 4-4c 64
BOPE TESTING, INSPECTION, TRAINING, AND MAINTENANCE ......................... 4-5 66
Testing ..................................................................................................................... 4-5a 66

iv
SECTION PARAGRAPH PAGE
Inspection and Actuation ............................................................................................ 4-5b 66
Crew Training ............................................................................................................. 4-5c 67
Records ...................................................................................................................... 4-5d 67
Maintenance ................................................................................................................ 4-5e 67
5. INSPECTION AND TESTING PROCEDURES ................................................................... 5 68
GENERAL ......................................................................................................................... 5-1 68
BOPE Inspection and/or Testing Required ................................................................. 5-1a 68
Pressure Testing .......................................................................................................... 5-1b 68
Suitable Pressure ......................................................................................................... 5-1c 68
Test Results ................................................................................................................ 5-1d 68
TESTING THE ACTUATING SYSTEM ............................................................................. 5-2 69
Accumulator Unit ....................................................................................................... 5-2a 69
Emergency Backup System ......................................................................................... 5-2b 70
Control Manifold ........................................................................................................ 5-2c 71
Remote Station ........................................................................................................... 5-2d 71
TESTING THE BOPE STACK, CHOKE AND KILL SYSTEM,
AND AUXILIARY EQUIPMENT ...................................................................................... 5-3 71
General ........................................................................................................................ 5-3a 71
Testing All Connections (except the connection of the annular preventer to the
upper ram preventer), the CSO Rams, the Drilling Spool (mud cross), the
Choke-manifold Blowdown-line Control Valve, the Choke Bodies, the
Choke Downstream Isolation Valves, the Kill-line High-pressure Access
Valve, the Casinghead, and the BOPE Test Plug ....................................................... 5-3b 75
Testing the Kill-line Check Valve ................................................................................ 5-3c 75
Testing the Lowermost Ram Preventer, the Swivel, the Rotary Hose and
Connections, and the Standpipe Connections .......................................................... 5-3d 78
Testing the Upper Pipe-ram Preventer and the Standpipe Valve ................................ 5-3e 78
Testing the Upper Kelly Cock ..................................................................................... 5-3f 78
Testing the Lower Kelly Cock ..................................................................................... 5-3g 78
Testing the Kill-line Control Valve .............................................................................. 5-3h 85
Testing the Choke-manifold Outboard Wing Valve(s) and the
Kill-line Master Valve ................................................................................................ 5-3i 85
Testing the Choke-manifold Inboard Wing Valve(s) .................................................... 5-3j 85
Testing the Choke-manifold Blowdown-line Master Valve ......................................... 5-3k 85
Testing the Choke-line Control Valve .......................................................................... 5-3l 85
Testing the Choke-line Master Valve ......................................................................... 5-3m 85
Testing the Annular Preventer and the Connection of the Annular Preventer to
the Upper Ram Preventer .......................................................................................... 5-3n 85
Testing the Internal Preventer and the Drill Pipe Full-opening Safety Valve .............. 5-3o 94
SUBSEA BOPE INSPECTION AND TESTING .................................................................. 5-4 94
Surface Inspection and Testing .................................................................................... 5-4a 94
Subsea Pressure Testing .............................................................................................. 5-4b 95
Subsea Preventer Actuation Testing ............................................................................ 5-4c 95
Testing the Subsea Actuating System ......................................................................... 5-4d 95
Testing the Auxiliary Equipment ................................................................................ 5-4e 96

APPENDICES

APPENDIX A - General Operating Specifications for Ram-type Preventers ................................ 97

APPENDIX B - Table B.1. - General Operating Specifications for Annular Preventers .............. 99
Table B.2. - Approximate Volume of Fluid (US Gallons) Required to
Close Annular Preventers on Various-sized Tubular Goods .......... 100
APPENDIX C - General Operating Specifications for Hydraulic Control Valves ......................... 101
APPENDIX D - Calculated Internal Yield Pressure of Casing, Drill Pipe, and Tubing ................. 102

v
SECTION PAGE

APPENDIX E - Formation Fracturing ............................................................................................. 103

APPENDIX F - Fluid Moved vs. Accumulator Pressure for Systems of Various Capacities ........... 104
Figure F.1. - Accumulator Systems with 1,500 psi Working Pressure, 750 psi Nominal Precharge ............... 104
Figure F.2. - Accumulator Systems with 2,000 psi Working Pressure, 1,000 psi Nominal Precharge ............ 105
Figure F.3. - Accumulator Systems with 3,000 psi Working Pressure, 1,000 psi Nominal Precharge ............ 106
APPENDIX G - API Flange Data ..................................................................................................... 107

SELECTED REFERENCES ................................................................................................................. 108

GLOSSARY OF BOPE AND ASSOCIATED TERMS ....................................................................... 110

SELECTED INDEX ............................................................................................................................ 117

vi
 1. SCOPE
Section 3219, Division 3, of the Public Resources Code rized to initiate a blowout drill without the knowledge of
(PRC) of the State of California states, in part, that either the operator’s representative or the contractor’s
operators must equip wells...”with casings of sufficient foreman.)
strength, and with such other safety devices as may be
necessary, in accordance with methods approved by the The operator must post at the well site of each well a copy
supervisor, and shall use every effort and endeavor of the division’s Permit to Conduct Well Operations
effectually to prevent blowouts, explosions, and fires”. (Form OG 111). This report contains, among other
Additional requirements for casing and blowout pre- provisions, the class of BOPE required and lists any tests
vention equipment (BOPE) are provided by several sec- and procedures, including BOPE tests, that must be
tions of Title 14 of the California Code of Regulations, witnessed by a division representative.
particularly Section 1722.5, which establishes this manual
as the guide for engineers of the Department of Conser- Section 2 of the manual outlines the division’s require-
vation, Division of Oil, Gas, and Geothermal ments for BOPE, emphasizing the fact that the require-
Resources...”in establishing the blowout prevention ments are tailored to the individual well.
equipment requirements specified in the division’s ap-
proval of proposed operations”. Section 3 explains the function and operating character-
istics of BOPE components. For the purposes of the
Besides serving as a guide for Division of Oil, Gas, and manual, BOPE components are grouped into five major
Geothermal Resources (division) engineers, the manual functional areas: preventers, actuating system, choke
is designed to help operator personnel in planning their and kill system, auxiliary equipment, and hole-fluid
well operations. By serving as a single-source guide to monitoring equipment. In most cases, a list of division
blowout prevention equipment (BOPE) used in oil, gas, requirements for a component follows the operational
and geothermal operations in California, the manual explanations.
will help operators conform to the BOPE requirements of
the Public Resources Code and the California Code of Section 3-A describes the additional equipment and
Regulations. modification of BOPE components necessary for install-
ing and operating blowout prevention equipment on the
The manual is oriented primarily toward the equipment ocean floor.
involved in blowout prevention. Therefore, several
important aspects of kick control and blowout preven- Section 4 describes the equipment and modification of
tion practices, such as casing programs, kick-control BOPE components necessary for drilling geothermal
procedures, and crew training are discussed only briefly, wells.
if at all. This does not mean that the division places
reduced emphasis on these aspects of blowout preven- Section 5 outlines inspection and testing procedures for
tion. In fact, Section 1722(c), Title 14, California Code of all components of the BOPE array, except the hole-fluid
Regulations requires that “For certain critical or high- monitoring system. These procedures may be modified
pressure wells designated by the supervisor, a blowout in the field by a division inspector to conform to current
prevention and control plan, including provisions for policy, but complete testing may be ordered if the appar-
the duties, training, supervision, and schedules for test- ent condition of the BOPE is such that a question exists as
ing equipment and performing personnel drills, shall be to the ability of the components to function satisfactorily.
submitted by the operator to the appropriate division
district deputy for approval”. Once approved, a copy of During the preparation of this manual, personnel were
the plan must be available at each well site for use by the consulted from oil, gas, and geothermal operating com-
operator and contractor personnel for training rig crews. panies, equipment manufacturing firms, service compa-
The plan is also used by division inspectors when evalu- nies, petroleum consulting firms, and industry organiza-
ating blowout prevention (BOP) preparedness. For criti- tions, and many of their suggestions are included. Much
cal or high-pressure wells, the division may elect to material is based on industry and trade publications,
witness one or more of the required weekly blowout particularly the specifications and recommended prac-
drills in the company of the operator’s representative or tices of the American Petroleum Institute (API).
contractor’s foreman. (Division engineers are not autho-

BLOWOUT PREVENTION IN CALIFORNIA 1

 2. CLASSIFICATION AND SELECTION OF
EQUIPMENT
2-1 GENERAL modify the BOPE to handle any anticipated de-
mands or to bring it into conformance with current
a. The classification and selection system described API specifications and arrangements.
in this section is used by the Division of Oil, Gas,
and Geothermal Resources to arrive at uniform e. The stack arrangements, depicted in Figures 1
requirements for blowout prevention equipment through 6 of this section, are for illustrative purposes
in California. Each proposed program of well only. The operator may use any desired arrange-
operations is reviewed by a division engineer ment of preventers and drilling spools, provided the
and, if warranted by the operation, one or more total system meets the BOPE classification assigned
BOPE classifications are assigned. These classifi- by the division and provisions have been made to
cations are based on accepted engineering prac- control the well under any predictable conditions.
tices based on the proposed operations, surface
environment, geological conditions, and known f. The following BOP stack component codes, as used
or anticipated subsurface pressures. in paragraphs 2-2c and 2-2d and in Figs. 1 through 6
of this manual, are taken from API RP 53: Blowout
b. A complete BOPE classification (e.g., Class III B Prevention Equipment for Drilling Wells. The codes
3M) is composed of three elements that identify, are:
respectively, the division’s requirements for blow-
out prevention equipment, hole-fluid monitoring A = annular-type blowout preventer.
equipment, and rated working pressure of the weak-
est component of the wellhead stack and choke G = rotating head.
system. In this example, the well is to be equipped
with Class III BOPE, as outlined in paragraph 2-2d R = single ram-type preventer with one set of
and a Class B hole-fluid monitoring system, as out- rams.
lined in paragraph 2-3b. The equipment must have
a rated working pressure minimum of 3,000 psi Rd = double ram-type preventer with two sets of
(3M). The three elements may be assigned in any rams.
combination that will provide adequate blowout
protection. Rt = triple ram-type preventer with three sets of
rams.
Table 1, is provided as a quick guide to BOPE classi-
fication (shown in box d) that will probably be S = drilling spool with side outlet connections for
required by the division for any well, given the choke and kill lines.
proposed operation (box a), the well environment
(box b), and the anticipated surface pressure (box c). M = 1,000 psi rated working pressure.

c. Each proposed well operation will be considered in Components are listed from the bottom component
its entirety by a division engineer before BOPE clas- to the top component, that is from the uppermost
sifications are assigned. More than one BOPE clas- piece of permanent wellhead equipment or the bot-
sification will be assigned if warranted by different tom of the preventer stack.
stages of the proposed casing program. The
classification(s) will be specified on the division’s g. If conditions warrant, the division may approve the
Permit to Conduct Well Operations (Form OG 111). installation of a diverter system when a well is to be
drilled to a shallow total depth. However, in areas
d. Paragraph 2-2 describes the minimum equipment where steam injection or other sources of shallow
for each class of BOPE. Additional requirements overpressure might present a threat of blowout, the
may be specified, on an individual well basis, to division may require an operator to install a diverter

2 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 Table 1. Guidelines for selection of BOPE and hole fluid monitoring equipment.

BLOWOUT PREVENTION IN CALIFORNIA

3
 system on shallow casing strings before it becomes As an alternative to this valve, the system may
practicable to install one of the regular classes of be designed as an open flow system as depicted
BOPE, as described in paragraph 2-2. If a diverter in Figure 13A of this manual and in the illustra-
system is required by the division, it must be de- tions accompanying Section 2-A, API RP 53 (see
signed to direct the flow of well fluids away from the Selected References).
working area of the rig, and away from public roads,
buildings, or sensitive environments in the immedi- For a rework operation in which side openings
ate area. The crew must be trained in the use of the on the existing wellhead are smaller than 6
system. inches ID, a mud cross with 6-inch outlets must
be installed between the wellhead and the
diverter. If the operator intends to install a vent
Proper installation and use of a diverter system will
line(s) smaller than 6 inches to the side opening(s)
minimize the possibility of the crew shutting in the
of the wellhead, permission to do so must be
well completely when this might damage forma-
obtained from the division engineer who evalu-
tions that would be exposed to annulus pressures. ates the proposal, and the 6-inch requirement
This will protect against formation fracture that must be waived on the Permit to Conduct Well
could cause an underground blowout (the escape of Operations, form OG111.
hole fluid through the walls of the hole), which could
cause injury or loss of life, property loss, and/or loss 3. A diverter vent system of the same minimum ID
of natural resources. as the diverter outlets that fulfills the following
requirements:
2-2 CLASSIFICATION OF BLOWOUT
PREVENTION EQUIPMENT a) For onshore wells, a single vent line may be
installed. This line must terminate in a
a. A diverter system, when required, must be installed sump or other suitable receptacle at a loca-
on the conductor casing, drive pipe, or first surface tion from which it is unlikely that effluent
casing before drilling out the shoe of that string of from the vent line will be blown or carried
casing, and must be maintained in good working toward the rig or toward any building, pub-
order until an adequate BOPE anchor string has lic road, or sensitive environment in the
been cemented in the hole and the required BOPE immediate area.
system has been installed.
b) For offshore wells, multiple vent lines must
The well crew must be trained in the use of the be installed, with a selector valve system
diverter system and a weekly diverter drill held for that will permit the crew to select the down-
each crew. Records of the drills must be entered in wind line or the gas stack.
the daily log book.
c) Vent lines must be as straight as practicable,
The diverter system will contain, as a minimum, the with any necessary turns targeted as de-
following components: scribed in paragraphs 3-4a7. The line(s)
must be anchored securely to prevent whip-
1. Either a special purpose annular preventer, de- ping or vibration damage, and no sleeve-
signed specifically as a diverter, with an outlet type couplings may be used.
below the packing element that opens automati-
cally as the diverter is closed, or a regular annu- b. A Class I BOPE system consists of, as a minimum,
lar preventer with special attention to the valving any device installed at the surface that is capable of
and venting requirements listed in paragraphs complete closure of the well bore with the pipe out
2-2a2 and 2-2a3, which follow. of the hole. The device must be closed whenever the
well is unattended. See paragraph 3-2a1 for addi-
2. A six-inch (onshore drilling wells) or eight-inch tional requirements if an annular preventer is used
(offshore drilling wells) minimum ID outlet be- as the closing device.
low the diverter, equipped with a full-opening
gate, ball, plug, or butterfly valve or an easily c. A Class II BOPE system (API arrangements A, Rd,
broken (frangible) diaphragm that will prevent RR, or RA) consists of, as a minimum, the following
the flow of wellbore fluids through the line components:
during normal operations, but which opens au-
tomatically or may be quickly and easily opened 1. Annular and/or ram-type preventers capable of
manually before-or-as the diverter is closed. providing complete closure of the well bore, and

4 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 fig. 1

closure around the pipe in use. See paragraph 3- 5. Kelly cock or standpipe valve.*
2a1 for additional requirements if an annular
preventer is used alone (API arrangement A). 6. Full-opening safety valve readily available on
the rig floor, in the open position, with fittings
2. Manual closing devices, unless a remote actuat- adaptable to all pipe to be used in the proposed
ing system is specified. operations. If this valve is of the type that is
made up into the working string, it must fit
3. Access line of 2-inch minimum outside diam- through the wellhead equipment in use.
eter into the well bore below the preventer(s),
with suitable valves and fittings for pressure 7. Internal preventer inside the pipe in use, or
relief or well killing operations. readily available at the rig in the open position,
with fittings adaptable to the safety valve re-
4. Fill-up line into the bell nipple above the quired by 2-2c6. This valve must fit through the
preventer stack, but not in direct line with the wellhead equipment in use and must be stored
flow line.* in such a position or identified in such a manner
that it will not be the first valve installed by the
crew in response to a kick taken while tripping
* For workover operations not requiring a drilling-type pipe.*
circulating system, requirements 4, 5, and 7 do not apply.

BLOWOUT PREVENTION IN CALIFORNIA 5

 pipe, which are to be used in the proposed
operations. All ram-type preventers must have
independent, positive-locking devices.

2. An actuating system with the primary source of

energy (usually the accumulator unit) located at
least 50 feet from the well bore. The actuating
system must be capable of accomplishing ALL
of the following actions within two minutes
with the source of power to any charging pump(s)
disconnected:

a) Close and open one ram-type preventer;

b) Close the annular preventer on the smallest-

diameter pipe for which pipe rams have
been installed;

c) Perform all immediate kick-control re-

sponses involving any installed auxiliary
equipment for which this actuating system
fig 2 serves as the source of energy.

For preventers with very large operating vol-

umes, the two-minute time limit may be ex-
tended to cover the time during which fluid is
moving continuously in the system to perform
this sequence of actions.

If the actuating system is of the hydropneumatic

type, it must contain enough USABLE FLUID to
accomplish actions a), b), and c) just discussed
with the source of power to the accumulator
pump disconnected.

NOTE: USABLE FLUID is defined as the vol-

ume of fluid that may be withdrawn from the
accumulator(s) without lowering the pressure
in the actuating system below 1,000 psi, or 200
psi above the manufacturer’s recommended
accumulator precharge pressure, whichever is
greater. The value of 1,000 psi is selected as the
minimum acceptable pressure because it ap-
proximates the pressure required to hold an
annular preventer closed on open hole.

In addition, an emergency backup system must

d. A Class III BOPE system (API arrangements SRdA, be installed at the source of energy for the actu-
SRRA, or RSRA) consists of, as a minimum, the ating system. The backup system must contain
following components: enough usable fluid, or enough usable fluid
equivalent, to close the annular preventer on
1. Annular preventer, blind (CSO) ram-type open hole and open any installed remote-con-
preventer, and pipe ram-type preventer(s) ca- trolled valves on the choke line. The backup
pable of closure around all pipe, exclusive of system must utilize an independent, explosion-
drill collars and short “stinger” strings of smaller safe source of actuating energy.

6 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 fig 3

BLOWOUT PREVENTION IN CALIFORNIA 7

 fig 4

8 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 3. Dual control stations: one within 10 feet of the through the wellhead equipment in use and
driller’s station if the configuration of the drill- must be stored in such a position, or identified in
ing floor permits (preferably on the nearest exit such a manner, that it will not be the first valve
route from the rig floor), and the other at the installed by the crew in response to a kick taken
actuating system. while tripping pipe.*

4. Kill line of 2-inch minimum outside diameter, e. A Class IV system consists of, as a minimum, the
containing at least one control valve, one check following components:
valve, and fittings for an auxiliary pump con-
nection. See paragraph 3-4b for specific require- 1. Annular preventer, blind (CSO) ram-type
ments. The kill line should enter the well bore preventer, and two or more pipe ram-type
beneath one set of pipe rams, with an optional preventer(s) capable of closure around all pipe,
auxiliary connection below the lowermost rams. exclusive of drill collars and short “stinger”
strings of smaller pipe, to be used in the pro-
5. Choke system containing at least one control posed operations. The blind rams must be above
valve, one adjustable choke, a bleed line, and an at least one set of pipe rams. All ram-type
accurate pressure gauge. See paragraph 3-4a for preventers must have independent, positive-
specific requirements. Normally, the choke line locking devices.
outlet from the well bore will be located beneath
one set of pipe rams. However, if the operator’s 2. An actuating system with the primary source of
BOPE guidance recommends that the pipe rams energy (usually the accumulator unit) located at
be placed in a “master gate” position at the base least 50 feet from the well bore. The actuating
of the BOPE stack (API arrangement RSRA), the system must be capable of accomplishing ALL
division will approve the placement of the choke of the following actions within two minutes
line outlet between the pipe rams and the CSO with the source of power to any charging pump(s)
rams with the provision that the operator main- disconnected:
tains an extra set of pipe rams at the well site to
exchange for the CSO rams if a kick is taken with a) Close and open one ram-type preventer;
pipe in the hole. The division will not approve
placement of the choke line outlet above all of b) Close the annular preventer on the smallest-
the ram preventers. In offshore and critical diameter pipe for which pipe rams have
onshore areas, the choke line must discharge been installed;
into existing production facilities or a suitable
container. c) Perform all immediate kick-control re-
sponses involving any installed auxiliary
6. Kelly cock, standpipe valve, and standpipe pres- equipment for which this actuating system
sure gauge.* serves as the source of energy.

7. Fill-up line into the bell nipple above the For preventers with very large operating vol-
preventer stack, but not in direct line with the umes, the two-minute time limit may be ex-
flow line.* tended to cover the period of time during which
fluid is moving continuously in the system to
8. Full-opening safety valve, readily available on perform this sequence of actions.
the rig floor in the open position, with fittings
adaptable to all pipe to be used in the proposed If the actuating system is of the hydropneumatic
operations. If this valve is of the type that is type, it must contain enough USABLE FLUID to
made up into the working string, it must fit accomplish a), b), and c) just discussed with the
through the wellhead equipment in use. source of power to the accumulator pump dis-
connected.
9. Internal preventer inside the pipe in use, or
readily available on the rig floor in the open NOTE: USABLE FLUID is defined as the vol-
position, with fittings adaptable to the safety ume of fluid that may be withdrawn from the
valve required by 2-2d8. This valve must fit accumulator(s) without lowering the pressure
in the actuating system below 1,000 psi, or 200
* For workover operations not requiring a drilling-type psi above the manufacturer’s recommended
circulating system, requirements 6, 7, and 9 do not apply.

BLOWOUT PREVENTION IN CALIFORNIA 9

 fig 5

10 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 accumulator precharge pressure, whichever is the rig floor in the open position, with fittings
greater. The value of 1,000 psi is selected as the adaptable to all pipe to be used in the proposed
minimum acceptable pressure because it ap- operations. If this valve is of the type that is
proximates the pressure required to hold an made up into the working string, it must fit
annular preventer closed on open hole. through the wellhead equipment in use.

In addition, an emergency backup system must 10. Internal preventer inside the pipe in use, or
be installed at the source of energy for the actu- readily available on the rig floor in the open
ating system. The backup system must contain position, with fittings adaptable to the safety
enough usable fluid, or enough usable fluid valve required by 2-2e9. This valve must fit
equivalent, to close the annular preventer on through the wellhead equipment in use and
open hole and open any installed remote-con- must be stored in such a position, or identified in
trolled valves on the choke line. The backup such a manner, that it will not be the first valve
system must utilize an independent, explosion- installed by the crew in response to a kick taken
safe source of actuating energy. while tripping pipe.*

3. Dual control stations: one within 10 feet of the f. A Class V BOPE system applies only in the case of
driller’s station if the configuration of the drill- a subsea BOPE stack (see paragraph 3A-3 for re-
ing floor permits, (preferably on the nearest exit quirements and Figure 6 for BOP stack configura-
route from the rig floor), and the other at the tion).
actuating system.

4. Kill line of 2-inch minimum outside diameter, 2-3 CLASSIFICATION OF HOLE-FLUID

containing at least one control valve, one check MONITORING EQUIPMENT
valve, and fittings for an auxiliary pump con-
nection. See paragraph 3-4b for specific require- a. Class A - Any device capable of a reasonably accu-
ments. The kill line should enter the well bore rate determination of mud system gains and losses.
beneath one set of pipe rams, with an optional
auxiliary connection below the lowermost b. Class B
preventer.
1. Mud pit level indicator with audible alarm.
5. Choke system containing at least one control
valve, two adjustable chokes, a bleed line, and 2. Any device, such as a pump stroke counter, trip
an accurate pressure gauge. See paragraph 3-4a tank, etc., capable of a reasonably accurate de-
for specific requirements. The choke line outlet termination of the volume of fluid required to
from the well bore should be located above one keep the hole full when pulling pipe.
set of pipe rams, with an optional auxiliary
connection below the lowermost preventer. In c. Class C
offshore and critical onshore areas, the choke
line must discharge into existing production 1. A recording mud pit level indicator or pit vol-
facilities or a suitable container. ume totalizer system to determine mud pit vol-
ume gains and losses. This indicator must in-
6. Upper and lower kelly cocks installed in the clude both visual and audible warning devices.
kelly at all times. See paragraph 3-5c for kelly
cock requirements when using a downhole mud 2. A mud volume measuring device capable of
motor or a top drive system.* accurately determining the mud volume neces-
sary to keep the hole full when pulling pipe from
the hole.
7. Standpipe valve, and standpipe pressure gauge.*
3. A mud return or full-hole indicator to show
8. Fill-up line into the bell nipple above the when returns have been obtained, or when they
preventer stack, but not in direct line with the occur unintentionally, and that returns essen-
flow line.* tially equal the pump discharge rate.

9. Full-opening safety valve, readily available on If slim hole operations are anticipated, the mud
return indicator should be of an electromag-
* For workover operations not requiring a drilling-type
circulating system, requirements 6, 7, 8, and 10 do not apply.

BLOWOUT PREVENTION IN CALIFORNIA 11

 fig 6

12 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 netic or impulse design because of their in- where no zone pressure data are available, an ac-
creased sensitivity and accuracy, rather than the ceptable BHP may be estimated by multiplying the
customary paddle-type flow line indicator. proposed total vertical depth by a normal formation
pressure gradient of 0.465 psi/foot. The BHP may
4. Gas-detection equipment to monitor the drill- then be multiplied by the MPCP/BHP ratio for that
ing mud returns for hydrocarbons and hydro- depth (Fig. 7) to obtain a MPCP for the hole. This
gen sulfide (H2S) at critical locations along the pressure condition would occur if all liquids were
mud system. removed from the hole due to gas entry or lost
circulation and would place the greatest demand on
the BOPE.
2-4 SELECTION OF BOPE AND HOLE-
FLUID MONITORING EQUIPMENT b. The Maximum Allowable Casing Pressure (MACP)
is the basis for selection of an interim BOPE pressure
The classification system outlined in paragraphs 2-2 and rating.
2-3 is applied by the division to each proposed well so the
required equipment will provide an adequate margin of For a drilling well containing hole fluid of a given
safety. Table 1, Guidelines for Selection of BOPE and density, the MACP is the surface pressure that would
Hole-Fluid Monitoring Equipment, is intended to assist be likely to fracture the formation immediately be-
selection in areas where field rules do not apply. low the shoe of the BOPE anchor string or rupture
any casing string subjected to that pressure.
EXAMPLE:
For a workover, the MACP is usually determined by
the density of the workover fluid and the depth to
An operator proposes to sidetrack a bad liner in a well
open perforations or, occasionally, the minimum
located in a residential area. There are no flowing wells
internal yield pressure of the BOPE anchor string of
in the field. The zone pressure is 800 psi and the oil
casing. See Appendix E for an explanation of the
gravity is 19o API. The depth to the top of the zone is
relationship between the MACP applied against
3,600 feet. What class of equipment should be used?
open hole and the MACP applied through perfo-
rated casing.
SOLUTION:
In either case, the MACP must be recalculated when-
Well Conditions ever additional casing is cemented and when the
hole-fluid density is changed significantly. This
Proposed well operations: Redrill-development pressure will be the lesser of the following two
pressures:
Well environment: Onshore critical
1. Formation Fracture Pressure - the surface pres-
Anticipated surface pressure: Medium pressure sure that, when added to the hydrostatic pres-
sure exerted by the column of fluid in a hole,
could reasonably be expected to fracture the
From Table 1: Class III B equipment should be used. formation at the shoe of the anchor string or at
the perforations, whichever occurs higher in the
2-5 SELECTION OF PRESSURE RATING hole. A value for this pressure may be approxi-
mated from Figure 8. A more accurate fracture
Two separate pressures may have to be considered pressure may be obtained by performing a
before selecting the pressure rating portion of a BOPE leakoff test of the exposed formation.
classification, one for a final pressure determination and
another if an interim determination is requested. 2. Casing Yield Pressure - the surface pressure
that, when added to the hydrostatic pressure
a. The Maximum Predicted Casing Pressure (MPCP) exerted by the column of hole fluid at any depth,
is the basis for the selection of a final BOPE pressure would result in an overbalance (with respect to
rating. The MPCP is the maximum known or esti- the pressure behind the casing at that depth) that
mated bottom-hole pressure (BHP) at total depth, exceeds the minimum internal yield strength of
minus the back pressure exerted by a column of gas that casing as listed in Appendix D.
extending from total depth to the surface. In areas

BLOWOUT PREVENTION IN CALIFORNIA 13

SAMPLE PROBLEM FOR DETERMINING THE a. Obtain the Formation Fracture Pressure from Figure
BOPE PRESSURE RATING 8 as follows:

An operator proposes to reperforate the producing zone 1) Enter the chart from the left margin at the depth
in a well for which the BOPE requirement has been of the exposed formation (i.e., top perfs, at 4,400').
determined to be Class II. The operator provides the
following information concerning the well: 2) Move to an interpolated point (between 70 pcf
and 80 pcf fluid curves) that would represent the
8-5/8", 32#, J-55 casing cemented at 4,000'. proposed workover fluid weight (73.5 pcf).

5-1/2", 17#, J-55 liner cemented from 3,960' to 4,500'. 3) Move to the upper margin to obtain the pressure
applied through the perfs.
Water shut-off (WSO) on 5-1/2" x 8-5/8" lap.
4) Read the Formation Fracture Pressure (1,450
Liner perforated from 4,400' to 4,500'. psi).

Total depth: 4,500'. NOTE: If the liner in this example had been installed
with a hanger instead of being cemented in place, the
Producing clean, 38o API gravity oil (sp. gr. 0.835). formation would be exposed to well pressure at the
shoe of the 8-5/8" casing at 4,000'. In this case, the
Static fluid level at 1,500' below surface. lower margin of the graph (Fig. 8) would have
applied, and the Formation Fracture Pressure would
Shut-in casing pressure: 50 psig. have been 960 psi.

Proposed workover fluid weight: 73.5 pcf. b. Calculate the Casing Yield Pressure for the anchor
string of casing as follows:
Formation pressure gradient : 0.465 psi/ft.
1) Calculate the pressure gradient of the proposed
workover fluid using the factor 0.0069 (i.e., 0.433
SOLUTION:
/ 62.4) to convert fluid weight in pcf to pressure
gradient. 73.5 x 0.0069 = 0.510 psi/ft.
STEP 1. Determine the Maximum Predicted Casing
Pressure (MPCP) as follows: 2) Calculate the overbalance gradient with respect
to the formation pressure gradient by multiply-
a. Calculate the BHP by using fluid level, pressure ing the pressure gradient of the proposed
gradient, and shut-in casing pressure information workover fluid by the formation pressure gradi-
and the following formulas. (Pressure gradient of ent. 0.510 - 0.465 = 0.045 psi/ft.
the produced fluid x height of the fluid column) +
shut-in casing pressure. 3) Calculate the overpressure at the top of the liner
lap by multiplying the overbalance gradient by
The pressure gradient of the produced fluid is the the depth to the liner top. 3,960 x 0.045 = 178 psi.
product of the specific gravity of the produced fluid
and the pressure gradient of fresh water. 4) Subtract the overpressure from the minimum
internal yield pressure of the anchor string using
Therefore, BHP = [(0.835 x 0.433)(4,500 - 1,500)] + 50 Appendix D to obtain the casing yield pressure.
= 1,135 psi For 8-5/8" 32# J-55 casing, the minimum inter-
nal yield pressure is 3,930 psi.
b. From Figure 7, obtain the MPCP/BHP ratio for the
total depth and multiply by the BHP to obtain the Casing Yield Pressure= 3,930 - 178 = 3,752 psi
MPCP.
NOTE: For a well in which the anchor string is made
up of several grades of casing, or in areas where a
The MPCP/BHP for a TD of 4,500'= 0.91
uniform formation pressure gradient does not apply
MPCP = 0.91 x 1,135 = 1,033 psi.
from surface to total depth, the casing yield pressure
may have to be calculated for several points in the
STEP 2. Calculate the Maximum Allowable Casing hole to determine a minimum value for the well.
Pressure (MACP) for the existing hole conditions.

14 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

 fig 7

BLOWOUT PREVENTION IN CALIFORNIA 15

 fig 8

MAXIMUM ALLOWABLE SURFACE PRESSURE (MACP) vs. DEPTH AND ASSUMED

FRACTURE GRADIENT
FIGURE 8

PROCEDURE FOR USE OF FIGURE 815

ASSUMPTIONS: 1. Formation pressure is 0.465 psi/ INSTRUCTIONS: 1. Enter the graph from the left mar-
foot at all depths. gin at the depth to the shoe of the
2. Fracture gradient behaves according BOPE anchor string or the top of the
to Cristman.14 production perfs., as applicable.

In areas where these assumptions are known to be invalid, 2. Move horizontally to a point cor-
the MACP as determined from the graph must be multiplied responding to the density of the fluid
by one or both of the following factors, as applicable: to be used during the proposed opera-
tions. Interpolate if necessary.
1. Known fracture gradient
3. Move vertically from that point
Fracture gradient from right margin of graph to the lower margin if there is to be
open hole below the shoe of the BOPE
and/or anchor string. Move to the upper mar-
gin if the pressure is to be applied to
existing production perforations in a
2. Known formation pressure fully cased hole (see Appendix E).
0.465 x depth

15
Superior figures refer to the list of Selected References at the end of the report.

16 DIVISION OF OIL, GAS, AND GEOTHERMAL RESOURCES

c. The MACP for existing hole conditions is the lesser f) Adjustable chokes.
of the amounts in Step 2, a.4 and b.4 of this solution.
In this case, the MACP is the formation fracture g) Hydraulic valves, if any.
pressure of 1,450 psi.
3. Once each seven days, the following are to be
STEP 3. The minimum final working pressure rating for actuated:
the BOPE is 1,033 psi (the MPCP from Step 1 of this
solution). The lowest rated working pressure rating a) The annular preventer on drill pipe or tub-
commonly available in BOP equipment is 2,000 psi; ing.
therefore, the BOPE classification would be Class II 2M.
In this case, there is no requirement for hole-fluid moni- b) All gate valves in the choke and kill systems.
toring equipment. The MACP that should be brought to
the attention of the rig crew is 1,450 psi. It is unlikely that c) All manually operated BOP locking devices.
the surface pressure would reach that value, since the
MPCP is only 1,033 psi. b. BOPE practice drills and training sessions must be
conducted at least once each week for each crew.
2-6 ADDITIONAL REQUIREMENTS These drills may be performed in conjunction with
the operational readiness tests outlined in para-
The following requirements are mandatory for all opera- graph 2-6a, and must provide training for each mem-
tions conducted on offshore, onshore critical, or high- ber of the crew to ensure (as a minimum):
pressure areas.
1. A clear understanding of the purpose and the
a. All required BOPE must be inspected and, if appli- method of operation of each preventer and all
cable, actuated periodically to ensure operational associated equipment.
readiness. The minimum frequency of this inspec-
tion/actuation is as follows: 2. The ability to recognize the warning signs that
accompany a kick.
1. At least once during each eight-hour tour, the
following are to be performed: If the proposed work involves any slim hole
operations, the crew must be alerted to the fact
a) Check accumulator pressure. that the warning signs of a kick can develop very
rapidly during slim hole operations because of
b) Check emergency backup system pressure. the reduced volume of the annulus. The crew
must be continuously alert to any kick signs
c) Check hydraulic fluid level in accumulator such as changes in pit volume or hole-fluid flow
unit reservoir. rate, changes in the physical properties of the
hole fluid, and unexplained changes in the drill-
d) Actuate all audible and visual indicators ing rate and/or the pump pressure.
and alarms.
3. A clear understanding of each crew member’s
2. On each trip, but not more often than once each station and duties in the event of a kick while
24-hour period, the following are to be actuated: drilling, while tripping pipe, while drill collars
are in the preventers, and while out of the hole.
a) Pipe rams (before starting out of the hole).
4. A clear understanding of the maximum allow-
b) Blind (CSO) rams (after pulling the pipe able casing pressure (MACP) and the signifi-
from the hole). cance of the pressure for well conditions that
exist at the time of the drill or training session.
c) All installed kelly cocks.
c. A record of all inspections, tests, crew drills, and
d) Drill pipe safety valve. training sessions must be kept in the daily log book.

e) Internal preventer.

BLOWOUT PREVENTION IN CALIFORNIA 17