BOP系统试验大纲(中英文).doc

伊拉克鲁迈拉项目
750修井机BOP系统联动试验大纲

甲方：大庆油田公司井下作业分公司
乙方：河北华北石油荣盛机械制造有限公司

防喷器组试验
一、 试验目的
对大庆油田井下分公司所订购的防喷器组及配套设备进行功能试验。另外，按照需方的要求进行其它项目的试验。
二、 联动试验设备
防喷器组；钻井四通；防喷器控制装置；高压耐火软管；节流、压井管汇；
试验项目和要求
1、闸板防喷器液压开关动作操作，应无卡阻，到位准确；
2、闸板防喷器的四处密封试验；（闸板前部与管子的密封、闸板顶部与壳体的密封、侧门与壳体的密封、侧门腔与活塞杆间的密封）
3、FH28-35环形防喷器密封用3 1/2〞钻杆，进行35Mpa液压密封试验；
4、2FZ 28-35双闸板防喷器上腔装3 1/2〞闸板总成，进行35Mpa液压密封试验；
5、2FZ28-35双闸板防喷器下腔装全封闸板；进行35Mpa液压密封试验；
三、试验前准备工作
1、联接F 28-35 防喷器组，安装顺序从上向下依次为: FH35-35环形防喷器、2FZ 35-35 双闸板防喷器、FS 35-35钻井四通和试压底座；
2、把防喷器组用地矛固定；
3、地面控置装置通过高压耐火软管与F28-35防喷器组相连接；
4、FS28-35钻井四通与手动阀门、液动阀门、内控管线、节流、压井管汇连接；
5、节流管汇低压区的法兰口用手动闸板阀安装好；
6、把地面控置装置油箱的液压油加到额定容量；同时把液压泵电机的电源、气动泵的气源连接好；
8、试压泵加满清水并把高压管线与试压底法兰进液口进行连接；
9、防喷器及节流、压井管汇内加满清水，
10、把地面控置装置的储能器压力升至21Mpa。
四、试验程序
（一） FH28-35环形防喷器试验
1、下入3 1/2"钻杆；
2、用液控压力10.5Mpa，关闭FH28-35环形防喷器，记录该压力值；
3、井压从0升至35Mpa，稳压15min，记录各段压力值、稳压时间；
4、密封情况：目测油路、油缸无渗漏，密封部位无渗漏为合格。
5、泄井压为零；
6、打开FH28-35环形防喷器；
（二） 2FZ28-35双闸板防喷器上腔半封闸板试验
1、下入-3 1/2"钻杆；
2、用液控压力10.5Mpa，关闭2FZ28-35双闸板防喷器上腔的3 1/2"闸板，记录该压力值；
3、打井压至1.4~2.1Mpa，稳压10min，压力降允许试验压力值的5%，升井压至
35Mpa，稳压10min，压力降允许试验压力值的5%，记录各段压力值、稳压时间；
4、密封情况：目测各密封处无渗漏为合格；
5、泄井压为零；
6、打开2FZ2835双闸板防喷器上腔3 1/2"闸板；
7、取出3 1/2"钻杆。
（三）2FZ28-35双闸板防喷器下腔全封闸板试验
1、用液控压力10.5Mpa，关闭2FZ28-35双闸板防喷器下腔全封闸板，记录该压力值；
2、 打井压至1.4~2.1，稳压10min，压力降允许试验压力值的5%，升井压至35Mpa，稳压10min，压力降允许试验压力值的5%，记录各段压力值、稳压时间；
3、密封情况：目测各密封处无渗漏为合格；
4、泄井压为零；
5、打开2FZ28-35双闸板防喷器下腔全封闸板；
五、试验完毕后
1、泄掉各部压力，排空防喷器内清水及控制回路的液压油，放空储能器的压力。

2、将环形防喷器、双闸板防喷器、钻井四通上面的水用空气吹扫干净，注意保护密封槽。

FKQ640-6G防喷器地面控制装置调试
一、 试验目的
对大庆油田井下作业分公司所订购的防喷器地面控制装置及配套设备进行功能试验。另外，按照需方的要求进行其它项目的试验。
二、 联动试验设备
防喷器控制装置；防喷器组；钻井四通；高压耐火软管。
三、 试验项目和要求
1、远程台三位四通液转阀开、中、关动作操作，应无卡阻，到位准确；
2、储能器组充压时间试验；
3、电动泵、气动泵自动启停试验；
4、溢流阀超压保护试验：
5、司钻台与远程台开关动作一致性试验；
6关闭时间试验；
四、试验前准备工作
1、远程控制台储能器充气压力7±0.7MPa，气源压力0.65—0.8 MPa,电源电压380±19V。
2、将远程控制台、司钻台、防喷器组、液压管线安装好。
五、调试程序
1、储能器组充压时间试验：远程控制台泄压到7 MPa，各三位四通液转阀处于“中位”的情况下，启动泵组给储能器组充压，记录从充压开始至压力升高到21 MPa的时间，充压时间应小于15 min。
2、电动泵、气动泵自动启停试验：主令开关在“自动”位置，在油压降至接近19MPa时自动接通电路，油压升至21MPa时自动切断电路。关闭气泵旁通阀，接气源0.53 MPa～0.8 MPa使气泵在17.9MPa时自动启动，油压升至21MPa时自动停止，自动启停三次，启停可靠、运转正常。
3、溢流阀超压保护试验：在主令开关放在手动位置、切断液气开关的情况下，启动泵组逐渐升压，观察益流阀开始产生溢流的压力，并且观察随着系统压力降低，导致溢流阀关闭的压力。其调定压力不大于23.1MPa，其关闭压力不得低于18.9MPa。
4、司钻台与远程台开关动作一致性试验：操作司钻控制台上各操作阀，观察远程控制台上相应的三位四通转阀的开关动作是否一致。
5、关闭时间试验：在调压阀出口压力为10.5 MPa条件下，操作司钻控制台上的各操作阀，记录关闭闸板防喷器、环形防喷器、液动阀的时间。
地面防喷器控制装置应能在30s内关闭任一个闸板防喷器。
标称通径小于476mm的环形防喷器，关闭时间不应超过30s。标称通径等于或大于476mm的环形防喷器，关闭时间不应超过45s。
关闭或打开液动阀的时间，应小于防喷器组任一闸板防喷器的实际关闭时间。

节流管汇和压井管汇连调试验

一、试验目的
对YG35、JGY35压井、节流管汇进行联组，并进行功能试验。
二、试验项目和要求
YG35、JGY35压井、节流管汇试验液动节流阀动作操作，应无卡阻，到位准确；
1、节流管汇控制箱试验；
2、 压井管汇和节流管汇的密封试验。
三、试验前的准备工作
1、按YG35、JGY35压井、节流管汇示意图，分别将压井、节流管汇安装到防喷器钻井四通两侧，将节流管汇外出口端用平行闸板阀关闭（没有阀的可用盲板法兰封死）。
2、节流、压井管汇内加满水。
四、试验程序
1、节流管汇出口端3只阀门关闭，其余阀门全部开启；压井管汇阀门关闭，井压至1.4-2.1Mpa，稳压10min，升压至35Mpa，稳压10min，记录各段压力值、稳压时间及密封情况。
2、节流管汇出口四通后1只阀门和节流阀前2只阀门关闭，其余阀门全部开启；压井管汇阀门关闭，井压至1.4-2.1Mpa，稳压10min，升压至35Mpa，稳压10min，记录各段压力值、稳压时间及密封情况。
3、节流管汇节流阀后2只阀门和五通出口前1只阀门关闭，其余阀门全部开启；压井管汇阀门关闭，井压至1.4-2.1Mpa，稳压10min，升压至35Mpa，稳压10min，记录各段压力值、稳压时间及密封情况。
4、节流管汇五通出口前三只阀门关闭，其余阀门全部开启；压井管汇单流阀前阀门开启，其余阀门全部关闭，井压至1.4-2.1Mpa，稳压10min，升压至35Mpa，稳压10min，记录各段压力值、稳压时间及密封情况。
5、钻井四通旁的液动平板阀与防喷器控制系统联动试验：在液缸操作压力不超过10.5Mpa的情况下，保证阀门的正常开启与关闭。
全部试验结束。

Iraq鲁迈拉项目
BOP System Joint Test Program of 750 workover rig

Part A: Downhole Operation Branch of Daqing Oilfield
Part B: Rongsheng Machinery Manufacture Ltd. Of Huabei Oilfield, Hebei

BOP Stack Test
一、Test purpose
Do capacity test for BOP stack and matching equipment ordered by Downhole Operation Branch of Daqing Oilfiel. And, do other items test according to Part A’s requirements.
二、Equipments for test
BOP stack, drilling spool, BOP control unit, high-pressure fire hoses; choke and kill manifold
Test item and its requirements
1、The hydraulic open and close operation of ram BOP should be smooth and accurate.
2、Four position seal test of ram BOP(seal between the front of ram assembly and pipe, seal between the top of ram assembly and the body, seal between the bonnet and the body, seal between the bonnet cavity and piston rod)
3、Hydraulic seal test of 11”-5000psi Annular BOP uses 3 1/2” drill pipe with pressure of 5000psi.
4、3 1/2” ram assembly is installed into the top cavity of 11”-5000psi Double Ram BOP. Do hydraulic seal test with pressure of 5000psi.
5、Blind ram assembly is installed into the bottom cavity of 11”-5000psi Double Ram BOP. Do hydraulic seal test with pressure of 5000psi.
三、Preparation before test
1、Install 11”-5000psi BOP stack. The order (from top to bottom) is 11”-5000psi annular BOP, 11”-5000psi double ram BOP, 11”-5000 spool and test base.
2、Fix the BOP stack with spear.
3、Connect the BOP control unit with 11”-5000psi BOP stack by high-pressure fire hoses.
4、Connect 11”-5000psi spool with manual valve, hydraulic valve, inner control pipe, choke and kill manifold.
5、Flange of kill manifold should be installed by manual gate valve.
6、Add hydraulic oil in the oil box of BOP control unit to the rated volume. Connect the power of the hydraulic pump motor, gas source of the air pneumatic pump.
8、Fulfill water into the testing pump. Connect the high pressure pipe with inlet of testing bottom flange.
9、Fulfill water into BOP, choke and kill manifold.
10、Increase pressure of BOP control unit pressure accumulator to 3000psi.
四、Test procedure
Test of 11”-5000psi Annular BOP
1、Install 3 1/2" drill pipe.
2、Close 11”-5000psi annular BOP with 10.5MPa hydraulic pressure. And record the pressure data.
3、Increase the well pressure from 0 to 5000psi and maintain for 15min. Record the pressure and time of each period.
4、Seal condition: Observe no leakage from oil pipe and oil cylinder. There is no leakage on sealing parts.
5、Drain the well pressure to 0.
6、Open 11”-5000psi annular BOP.
Half seal pipe ram assembly test in top cavity of 11”-5000psi double ram BOP
1、Install 3 1/2" drill pipe.
2、Close 3 1/2” ram assembly in top cavity of 11”-5000psi double ram BOP with 10.5MPa hydraulic pressure. And record the pressure data.
3、Increase the well pressure to 200~ 300psi and maintain for 10min. Pressure drop is allows 5% of test pressure data. Increase the well pressure to 5000psi and maintain for 10min. Pressure drop is allows 5% of test pressure data. Record the pressure and time of each period.
4、Seal condition: Observe no leakage on seal positions.
5、Drain the well pressure to 0.
6、Open 3 1/2” ram assembly in the top cavity of 11”-5000psi double ram BOP.
7、Take off 3 1/2" drill pipe.
（三）Blind ram assembly test in top cavity of 11”-5000psi double ram BOP
1、Close blind ram assembly in bottom cavity of 11”-5000psi double ram BOP with 10.5MPa hydraulic pressure. And record the pressure data.
2、 Increase the well pressure to 200~ 300psi and maintain for 10min. Pressure drop is allows 5% of test pressure data. Increase the well pressure to 5000psi and maintain for 10min. Pressure drop is allows 5% of test pressure data. Record the pressure and time of each period.
3、Seal condition: Observe no leakage on seal positions.
4Drain the well pressure to 0.
5、Open blind ram assembly in the bottom cavity of 11”-5000psi double ram BOP.
五、After test
1、Drain each part pressure. Drain off water in the BOP and hydraulic oil in control circuit. Relieve all pressure of the accumulator.
2、Clean the water on the annular BOP, double ram BOP and spool by air. Pay attention to protect the sealing groove.

FKQ640-6G BOP control system test
四、 Test purpose
Function test for BOP control system and matching equipment which make for 大庆油田井下作业分公司. Also contain other test according the request of buyer.
五、 Test equipment
BOP Control system；BOP stacks；Drilling spool；High-pressure refractory hose
六、 Test item and Requirement
a) The switch of 3-position 4-way valve should be flexible and reliable;
b) Test of Time for oil pressure rising to 21MPa for Accumulator group；
c) Start and Stop Test of Oil Pump and Air Pump；
d) Overpressure protect test of Relief valve：
e) Test of control system’s on-off action same with Drilling’s panel’s operation；
f) Close time test；
七、 Prepare job for test
a) Accumulator charge pressure is 7±0.7MPa，Air pressure is 0.65—0.8 MPa, voltage is 380±19V。
b) Fix BOP control system，Drill’s panel，BOP stacks and hydraulic line
八、 Program of test
a) Test of Time for oil pressure rising to 21MPa for Accumulator group：Pressure relief of the system, make sure that nitrogen pressure is 7MPa±0.7MPa, close the relief valve, 3-position 4-way valve is at “middle” position, and make oil pressure rising from 7MPa to 21MPa. Start electric pump and air pump, time for pressure rising of the accumulators is less than 15 minutes.
b) Start and Stop Test of Oil Pump and Air Pump：When the command switch is at the ”automatic” position, adjust system pressure control, starts automatically when oil pressure is 190+0.5MPa and stops automatically when oil pressure is rising to 210-0.5MPa. Turn off the bypass-valve of air pump, connect air source (0.53-0.8)MPa. The air pump shall start automatically prior to the pressure decreasing below 17.90+0.5MPa and shall stop automatically when oil pressure is rising to 210-1MPa, Stops and starts automatically thrice.
c) Overpressure protect test of Relief valve：When the command switch is at the ”manual” position and shut off the air for Hydro-pneumatic pressure switch, start pump unit, when pressure raise, observe the pressure of Relief valve overflow, and when pressure decrease, observe the pressure of Relief valve shut. The overflow pressure no more than 23.1MPa, and the shut pressure no less than 18.9MPa。
d) Test of control system’s on-off action same with Drilling’s panel’s operation：Operate all valve of Drilling’s panel; observe the corresponding 3-position 4-way valve of BOP control system whether or not same with the operation.
e) Close time test：when the Air/manual operate regulating valve’s out port pressure at 10.5MPa, operate all valve of Drilling’s panel, note the time of shut ram preventer, annular blowout preventer, hydraulic valve separately.
The BOP control system should close every preventer in 30s.
When the Annular blowout preventer’ drift diameter less than 476mm, the time of closing should no more than 30s. When the Annular blowout preventer’ drift diameter less than 476mm the time of closing should no more than 45s.
The time of close or open hydraulic valve should less than the actual time of closing each ram preventer.

Connection test of Choke Manifold & Kill Manifold
1. Purpose of test
Connect the YG35, JGY35 Choke & Kill manifold, and conduct the function test.
2. Description and requirements of the test
Conduct the operation test of the hydraulic choke valve of YG35, JGY35 Choke & Kill manifold, there should be no encumbrance, and shall be in place;
2.1 Test of control panel of the Choke manifold;
2.2 Sealing test of Choke manifold & Kill manifold.
3. Preparation for the test
3.1 According to the schematic drawing of YG35, JGY35 Choke & Kill Manifold, respectively install the kill, choke manifolds on two sides of the drilling spool of BOP, and shut off the exit of the choke manifold using the slab gate valve (if there is no valve, blind it off with a blind flange).
3.2 Fill the Choke & kill manifold with water.
4. Test procedure
4.1 Close 3 pieces of valve on the exit of the choke manifold, open the rest valves; close the valves of the kill manifold, increase the pressure to 1.4-2.1Mpa, hold the pressure for 10min, increase the pressure to 35Mpa, hold the pressure for 10min, and record each pressure value, holding time and sealing condition.
4.2 Close 1 piece of valve behind the exit cross of the choke manifold and the 2 pieces of valve in front of the choke valve, open the rest valves; close the valve of kill manifold, increase the pressure to 1.4-2.1Mpa, hold the pressure for 10min, increase the pressure to 35Mpa, hold the pressure for 10min, and record each pressure value, holding time and sealing condition.
4.3 Close 2 pieces of valve behind the choke valve of the choke manifold and 1 piece of valve in front of the five-way coupling exit, open the rest valves; close the valve of the kill manifold, increase the pressure to 1.4-2.1Mpa, hold the pressure for 10min, increase the pressure to 35Mpa, hold the pressure for 10min, and record each pressure value, holding time and sealing condition.
4.4 Close 3 pieces of valve in front of five-way coupling exit of the choke manifold, open the rest valves; open the valve in front of check valve of the kill manifold, close the rest valves, increase the pressure to 1.4-2.1Mpa, hold the pressure for 10min, increase the pressure to 35Mpa, hold the pressure for 10min and record each pressure value, holding time, and sealing condition.
4.5 Perform the connection test of hydraulic slab gate valve beside the drilling spool and BOP control system, ensure the valve can be normally opened and closed, for the cylinder operation pressure of less than 10.5Mpa.
End of the test

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