Pressure and function testing programs are crucial for verifying the operational integrity and performance of equipment used in the oil and gas industry, particularly with regard to well control systems.
These tests are designed to ensure the equipment functions properly, maintains pressure integrity, and is compatible with the other equipment. In this discussion paper, we will explore the purpose, types, and importance of field pressure and function testing, as well as the procedures, documentation, and safety considerations involved in these processes.
Purpose of Field Pressure and Function Testing:
Field pressure and function testing serve several key purposes in verifying the readiness and functionality of installed equipment. The primary objectives of these test programs include:
– Verifying that all equipment functions are operational and ready for use.
– Ensuring the pressure integrity of the installed equipment.
– Confirming that the equipment is compatible with other system components.
These tests provide assurance that the equipment will operate as intended under the highest pressures and most severe conditions expected to be encountered during field operations, reducing the risk of malfunctions, leaks, and operational failures.
Types of Tests Involved
Visual Inspections:
Visual inspections are the first step in ensuring that equipment is properly installed and maintained. These inspections should be performed in accordance with the manufacturer’s recommendations and the owner’s policies. Any visible wear, damage, or potential issues with seals, bolts, and components should be documented for remediation. Visual inspections are essential for spotting problems early and preventing more serious issues arising during testing and operational phases.
Function Tests:
Function tests are performed to verify that each piece of equipment operates as intended. These tests should be conducted regularly, typically weekly, and involve alternating the driller’s panel and remote control stations to ensure all control systems are functioning properly. Additionally, pressure tests may be considered as function tests, since they assess the operational readiness of equipment under pressure. Function tests ensure that the equipment is capable of performing its intended task without malfunction.
Pressure Tests:
Pressure testing is an essential part of verifying the integrity of the equipment and ensuring its ability to contain the maximum pressures encountered during operations. Pressure tests should be performed periodically, with a maximum interval of 21 days, as specified by industry standards such as API RP 53. These tests are performed in the direction of flow, ensuring that the equipment can withstand the pressures encountered from the well. Pressure testing includes testing the pressure capacity of components such as Blowout Preventers (BOPs), pressure seals, and valves.
Hydraulic Chamber Tests:
Hydraulic chamber tests are used to assess the pressure integrity of BOP hydraulic operating chambers and valve actuators. These tests must be performed at least once a year to verify that hydraulic systems can safely handle operational pressures without leakage or failure.
Practice Drills:
Practice drills are conducted to simulate emergency scenarios, ensuring that personnel are trained in operating the equipment under high-pressure situations. These drills help reinforce safety protocols and ensure that the crew can react appropriately in case of an emergency.
Test Documentation
Documenting the results of inspections, drills, function tests, and pressure tests is essential for tracking the performance of the equipment and ensuring compliance with regulatory and safety standards. Test results should be recorded and include:
– The pressure test parameters and outcomes.
– The names and signatures of the personnel involved in the test, including the pump operator, contractor’s representative, and operating company’s representative.
– Any test failures and the corrective actions taken.
Pressure tests should be performed using a pressure chart recorder, which provides accurate data for analysis and future reference. Proper documentation ensures that the tests have been conducted thoroughly and provides a record of any remedial actions taken to address test failures.
Specialized Testing Equipment
Cup-Type Testers:
Cup-type testers are typically set in the casing, below the wellhead, to test everything above it, including the wellhead. These testers will swab the casing as they are pulled, making it is critical that it is pulled slowly. The underside of the cup must always be open through the test string bore to allow for safe operation.
BOP Test Plug:
The BOP test plug is used in the drill string to test the casing head body by applying hydraulic test pressure from below the rams. Both pipe and blind rams can be tested using this method, ensuring that the well control system can effectively isolate the well.
Hanger Test Plugs:
Note: When applying pressure against a casing head plug tester, always open the casing head outlets below the tester seals to recognize a leaking seal and/or prevent formation or casing damage should the seals leak
Test Frequency
Pressure and function tests should be performed at regular intervals, based on operational needs and industry standards. Test frequency should include the following:
– Before spudding or after the initial equipment installation.
– After each casing setting operation.
– Before drilling into a known or suspected high-pressure zone.
– At regular intervals, not exceeding 21 days, as outlined in API RP 53.
– After any maintenance, repair, or ram changes affecting pressure-containment seals.
– Before performing a production test.
Routine testing ensures that the equipment remains operationally ready and maintains its pressure integrity, helping to prevent accidents or equipment failure.
Test Procedures
The following steps should be followed during pressure and function tests to ensure safety and compliance:
– All personnel should be alerted when a pressure test is about to be conducted, during the test, and once it is concluded.
– Only designated personnel should enter the area during the test to inspect for leaks.
– Tightening or repair work should only commence once the pressure has been safely bled down, and there is no trapped pressure.
For BOP stack testing, the pressure on the casing should be monitored, and casing bowel valves must be left open to allow for safe monitoring during the test.
The pressure tests should be conducted in two stages: a low-pressure test (200–300 psi) followed by a high-pressure test. Both tests should be held for at least five minutes to ensure the integrity of the equipment.
Safety Considerations
Safety is paramount when conducting pressure and function tests. Several safety precautions must be followed:
– The non-pressured side of a barrier should be monitored for leaks or pressure buildup.
– During testing, always open the casing head outlets below the tester seals to prevent formation damage.
– Personnel should be properly trained and equipped to handle emergency situations.
– Pressure should be safely bled off through pressure release lines and bleed valves, and pressure returns should be monitored to confirm that all pressure has been dissipated.
Conclusion
Pressure and function testing are vital to ensuring the safety and operational readiness of equipment used in well control and other oil and gas operations. By conducting these tests regularly, documenting their outcomes, and adhering to safety procedures, operators can ensure that their equipment performs as expected and that any potential failures are identified and addressed promptly. These practices are essential for maintaining the integrity of well control systems, minimizing risks, and ensuring safe operations in challenging environments.
For more information on these and other Well Control subjects, read my Well Control Manual, which may be purchased in the Catalogue section of this website at: Well Control Manual V2.6 by Edwin Ritchie
Discussion Paper: Pressure and Function Testing
Introduction:
Pressure and function testing programs are crucial for verifying the operational integrity and performance of equipment used in the oil and gas industry, particularly with regard to well control systems.
These tests are designed to ensure the equipment functions properly, maintains pressure integrity, and is compatible with the other equipment. In this discussion paper, we will explore the purpose, types, and importance of field pressure and function testing, as well as the procedures, documentation, and safety considerations involved in these processes.
Purpose of Field Pressure and Function Testing:
Field pressure and function testing serve several key purposes in verifying the readiness and functionality of installed equipment. The primary objectives of these test programs include:
– Verifying that all equipment functions are operational and ready for use.
– Ensuring the pressure integrity of the installed equipment.
– Confirming that the equipment is compatible with other system components.
These tests provide assurance that the equipment will operate as intended under the highest pressures and most severe conditions expected to be encountered during field operations, reducing the risk of malfunctions, leaks, and operational failures.
Types of Tests Involved
Visual Inspections:
Visual inspections are the first step in ensuring that equipment is properly installed and maintained. These inspections should be performed in accordance with the manufacturer’s recommendations and the owner’s policies. Any visible wear, damage, or potential issues with seals, bolts, and components should be documented for remediation. Visual inspections are essential for spotting problems early and preventing more serious issues arising during testing and operational phases.
Function Tests:
Function tests are performed to verify that each piece of equipment operates as intended. These tests should be conducted regularly, typically weekly, and involve alternating the driller’s panel and remote control stations to ensure all control systems are functioning properly. Additionally, pressure tests may be considered as function tests, since they assess the operational readiness of equipment under pressure. Function tests ensure that the equipment is capable of performing its intended task without malfunction.
Pressure Tests:
Pressure testing is an essential part of verifying the integrity of the equipment and ensuring its ability to contain the maximum pressures encountered during operations. Pressure tests should be performed periodically, with a maximum interval of 21 days, as specified by industry standards such as API RP 53. These tests are performed in the direction of flow, ensuring that the equipment can withstand the pressures encountered from the well. Pressure testing includes testing the pressure capacity of components such as Blowout Preventers (BOPs), pressure seals, and valves.
Hydraulic Chamber Tests:
Hydraulic chamber tests are used to assess the pressure integrity of BOP hydraulic operating chambers and valve actuators. These tests must be performed at least once a year to verify that hydraulic systems can safely handle operational pressures without leakage or failure.
Practice Drills:
Practice drills are conducted to simulate emergency scenarios, ensuring that personnel are trained in operating the equipment under high-pressure situations. These drills help reinforce safety protocols and ensure that the crew can react appropriately in case of an emergency.
Test Documentation
Documenting the results of inspections, drills, function tests, and pressure tests is essential for tracking the performance of the equipment and ensuring compliance with regulatory and safety standards. Test results should be recorded and include:
– The pressure test parameters and outcomes.
– The names and signatures of the personnel involved in the test, including the pump operator, contractor’s representative, and operating company’s representative.
– Any test failures and the corrective actions taken.
Pressure tests should be performed using a pressure chart recorder, which provides accurate data for analysis and future reference. Proper documentation ensures that the tests have been conducted thoroughly and provides a record of any remedial actions taken to address test failures.
Specialized Testing Equipment
Cup-Type Testers:
Cup-type testers are typically set in the casing, below the wellhead, to test everything above it, including the wellhead. These testers will swab the casing as they are pulled, making it is critical that it is pulled slowly. The underside of the cup must always be open through the test string bore to allow for safe operation.
BOP Test Plug:
The BOP test plug is used in the drill string to test the casing head body by applying hydraulic test pressure from below the rams. Both pipe and blind rams can be tested using this method, ensuring that the well control system can effectively isolate the well.
Hanger Test Plugs:
Note: When applying pressure against a casing head plug tester, always open the casing head outlets below the tester seals to recognize a leaking seal and/or prevent formation or casing damage should the seals leak
Test Frequency
Pressure and function tests should be performed at regular intervals, based on operational needs and industry standards. Test frequency should include the following:
– Before spudding or after the initial equipment installation.
– After each casing setting operation.
– Before drilling into a known or suspected high-pressure zone.
– At regular intervals, not exceeding 21 days, as outlined in API RP 53.
– After any maintenance, repair, or ram changes affecting pressure-containment seals.
– Before performing a production test.
Routine testing ensures that the equipment remains operationally ready and maintains its pressure integrity, helping to prevent accidents or equipment failure.
Test Procedures
The following steps should be followed during pressure and function tests to ensure safety and compliance:
– All personnel should be alerted when a pressure test is about to be conducted, during the test, and once it is concluded.
– Only designated personnel should enter the area during the test to inspect for leaks.
– Tightening or repair work should only commence once the pressure has been safely bled down, and there is no trapped pressure.
For BOP stack testing, the pressure on the casing should be monitored, and casing bowel valves must be left open to allow for safe monitoring during the test.
The pressure tests should be conducted in two stages: a low-pressure test (200–300 psi) followed by a high-pressure test. Both tests should be held for at least five minutes to ensure the integrity of the equipment.
Safety Considerations
Safety is paramount when conducting pressure and function tests. Several safety precautions must be followed:
– The non-pressured side of a barrier should be monitored for leaks or pressure buildup.
– During testing, always open the casing head outlets below the tester seals to prevent formation damage.
– Personnel should be properly trained and equipped to handle emergency situations.
– Pressure should be safely bled off through pressure release lines and bleed valves, and pressure returns should be monitored to confirm that all pressure has been dissipated.
Conclusion
Pressure and function testing are vital to ensuring the safety and operational readiness of equipment used in well control and other oil and gas operations. By conducting these tests regularly, documenting their outcomes, and adhering to safety procedures, operators can ensure that their equipment performs as expected and that any potential failures are identified and addressed promptly. These practices are essential for maintaining the integrity of well control systems, minimizing risks, and ensuring safe operations in challenging environments.
For more information on these and other Well Control subjects, read my Well Control Manual, which may be purchased in the Catalogue section of this website at: Well Control Manual V2.6 by Edwin Ritchie