Drilling & Work Over Manual-2014

SAUDI ARAMCO
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DRILLING AND WORKOVER WELL CONTROL MANUAL

VOLUME I
5th EDITION, June, 2014
Saudi Aramco
Well Control Manual Volume I, 5th Edition
CHAPTER A
INTRODUCTION AND DOCUMENT CONTROL

EQUIPMENT REQUIREMENTS
CHAPTER B
BOP SYSTEMS
CHAPTER C
MAINTENANCE, TESTING AND RECERTIFICATION
CHAPTER D
WELL CONTROLLED POLICIES
CHAPTER E
WELL CONTROL DRILLS
CHAPTER F
SUPPLEMENTAL REFERENCES
WELL CONTROL MANUAL: 5TH EDITION
VOLUME I
Drilling & Workover
INTRODUCTION AND DOCUMENT CONTROL
1.0
INTRODUCTION
th
th
The 5 edition of the Well Control Manual has some significant changes from the 4 Edition. It is the
responsibility of the authorized users of this manual to familiarize themselves with the specifications
and instructions in its entirety.
2.0
REVISIONS
The Well Control Manual (WCM) will undergo a full review and revision every three (3) years. The WCM will
be reviewed by the Well Control Committee (WCC), endorsed by the General Manager of Drilling and
approved by the Vice President of Drilling and Workover.
Document Control:
The Well Control Manual (WCM) is subject to constant review, revision and updates by the Well Control
Committee (WCC). The timely implementation of the policies contained in this document is critical and steps
must be taken to ensure that the latest revision including published errata and amendments is available to
Drilling and Workover Rigs and Management.
Revisions and Updates will be controlled as follows:
1 The WCM will be fully reviewed and reissued after three (3) years.
2 Interim revisions and updates will be issued as errata or amendments as required.
3 A revision log will be maintained at the beginning of the WCM that will list and summarize any
changes
To ensure that the document is available to all concerned parties there will be two (2) versions of the manual
available, Electronic and Printed.
Electronic Version:
The Electronic version will reside on the Drilling Information Highway. This document is available for viewing
by all authorized DIH users. If a page or section is printed from DIH, it is considered uncontrolled as of the
print date.
Printed Version:
Printed copies will be issued as follows:
V.P. D&WO
General Manager, Drilling
All D&WO Managers
All Drilling and Workover Rig Superintendents
All Members of the Well Control Committee.
All rigs operating under Drilling and Workover will have one copy in the Foremans Office.
Each Drilling or Workover Rig Contractors local head office.
D&WO Contracts Administration Division
Updates and Revisions to printed copies will be controlled as follows:
1. When errata or an amendment is issued a notification will be sent to all D&WO personnel. The
master electronic copy on the DIH will have the errata and amendments placed at the beginning
of the file.
Current Revision: JUNE, 2014

Previous Revision: MAY, 2010
INT - 1

Drilling & Workover
VOLUME I
CHAPTER A - EQUIPMENT SPECIFICATIONS AND REQUIREMENTS
CHAPTER A: EQUIPMENT SPECIFICATIONS AND REQUIREMENTS

TABLE OF CONTENTS
1.0
2.0
3.0
PRIMARY WELL CONTROL EQUIPMENT REQUIREMENTS

1.1
General Requirements
A-3
1.2
Annular Units and Diverters
A-5
1.3
Fixed Ram Preventers and Elastomers
A-5
1.4
Variable Bore Ram Preventer Blocks and Elastomers
A-6
1.5
Shear Blind Ram (SBR) Blocks and Elastomers
A-6
1.6
Valve Removal Plugs and Blind Flanges on BOP Side Outlets
A-8
1.7
Drilling Spools
A-8
REQUIREMENTS FOR KILL, EMERGENCY KILL, CHOKE LINES AND CHOKES

2.1
Minimum Bore Size for Lines:
A-9
2.2
Material and Fabrication
A-9
2.3
Requirements for Drilling Chokes
A-11
2.4
Requirements for Valves
A-11
2.5
Requirements for Cup Testers
A-12
ACCESSORY BOP EQUIPMENT REQUIREMENTS

3.1
Pit Volume Totalizers
A-12
3.2
Mud Flow Indicators
A-12
3.3
Gas Busters
A-12
3.4
Full Opening Safety Valves
A-17
3.5
Inside BOP
A-17
3.6
Trip Tank
A-18
3.7
Bowl Protectors (Wear Bushings)
A-19
3.8
Valve Removal Plugs
A-19
3.9
Drillpipe Float Valves
A-19

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3.10 Weco Connections
A-19
3.11 Chiksans
A-19
3.12 Accumulator Closing Units
A-20
3.13 Stroke Counters
A-22
3.14 Gas Detectors
A-22
3.15 Drill Rate Recorders
A-22
3.16 Pump Lines for Existing Offshore Well Kill
A-23

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VOLUME I
1.0
WELL CONTROL EQUIPMENT SPECIFICATIONS AND

REQUIREMENTS
This Chapter of the Well Control Manual sets forth the specifications and requirements for Blow Out Prevention
Equipment (BOPE) and systems for use in Drilling and Workover Operations. Variations or deviations of BOPE,
specifications, arrangement, pressure rating or requirements from this standard requires endorsement of the
Well Control Committee, and approval by the Vice President of Drilling and Workover. The enforcement of these
equipment standards shall be the responsibility of the Drilling or Workover Rig Superintendent. The Rig
Foreman shall ensure that the proper equipment is available and correctly installed. If not specified in these
standards all BOP equipment shall comply with API Specifications and Recommended Practices.
1.1
General Requirements:
All Drilling and Workover Well Control Equipment shall meet the following requirements:
1.1.1
All BOPE (Annulars, Ram Type, Valves, Chokes, Crosses Flexible Lines, Hard Lines and etc.)
shall be of forged material, Monogrammed to API Specification 6A, 16A, 16C, 17D or other
applicable API Specification as appropriate.
1)
All equipment in service in Saudi Aramco D&WO Operations must be API Monogrammed.
This includes equipment transferred from other regions whether or not it is on a rig
already. Monogram and markings MUST be clearly visible through the painted coating of
the equipment. Care should be taken to preserve this monogram on the equipment
nameplate, flange or body to prevent it being obliterated or destroyed during handling
maintenance and use. Additionally, documentation must be available at the rig site
reflecting the equipment Serial Number and API Monogram Status.
2)
Any exceptions to this monogram policy (e.g.; 30" 1,000 psi annulars) are noted in the
section detailing that specific equipment.
1.1.2
All major BOPE components including, but not limited to, ram BOPs, annular BOPs, drilling
spools, ram blocks, valves, choke and kill lines, choke manifolds, gas busters etc. will have an
unique serial or asset identification number assigned at time of manufacture by the ORIGINAL
EQUIPMENT MANUFACTURER (OEM). The number must be permanently marked in the
metal of the component body and should be paint stenciled in a prominent and visible
location on the equipment. This number must be referenced on all accompanying
certification and recertification documents. Repair numbers are not acceptable for this
requirement.
1.1.3
Only OEM parts are acceptable when repairing or redressing the BOP, valves, chokes, and
closing units. Documentation (e.g.; PO, invoice, certificate of compliance etc.) must be
maintained for all parts verifying that they are OEM.
1.1.4
Maintenance and testing requirements may be found in Chapter C "Maintenance Testing and
Certification Requirements of this manual.
1.1.5
A drilling spool is preferred for primary choke and kill line installation. However in special cases,
such as space limitation, preventer side outlets may be used in lieu of a drilling spool. The
diameter of all preventer side outlets must be at least as large as the choke manifold lines.
NOTE: Side outlets are used for installation of the lower choke and kill lines on 10K/15K BOPs.

A-3
Copyright 2014, Saudi Aramco

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1.1.6
The through-bore size of the preventer stack, tubing head, and any adapters used in the BOP
hook-up shall be large enough for the maximum size bit, scraper, liner hanger, packer, plug, cup
tester, bowl protector or any other large diameter down-hole tools to be run in the well.
1.1.7
The pressure rating of all pressure control equipment (BOP, Valves, Lines etc.) must be greater
than the MASP (Maximum Anticipated Surface Pressure).
1.1.8
The inboard manual valves on the choke and kill lines are considered master valves and
normally would not, except for pressure testing, be closed unless the outside valve (HCR) has
failed.
1.1.9
Check valves must be installed on normal kill lines but shall not be used on emergency kill lines.
1.1.10 The kill line, emergency kill line and choke lines should be flushed and washed out frequently to
prevent mud solids settling.
1.1.11 BOP assemblies will be dismantled between wells to inspect for internal corrosion, erosion and
to check flange bolts. Refer to Chapter C for maintenance procedures and requirements.
1.1.12 All Rigs shall maintain a logbook of BOP schematics detailing the components installed. The
logbooks shall contain the part number, size, description, serial number (if applicable) and
installation date of ram blocks, top seals, ram and annular packers and bonnet or door seals.
This is be witnessed and co-signed by the Toolpusher and the Saudi Aramco Representative
(see form #1 in Chapter C) of this manual).
1.1.13 All ram preventers must be equipped with manual or automatic locking devices, which must be
locked whenever the rams are used to control the well. Hand crank, wrench or hand wheel
systems are acceptable manual locking devices.
1.1.14 All preventers and associated equipment must meet NACE MR-0175/ISO 15156, API
Specification 6A, 16A or 16C for sour service.
1.1.15 A full OEM certification or recertification of the BOP, choke manifold (including chokes) and all
related equipment must be performed at the start of the contract and least once every three
years thereafter. The recertification must be in accordance with the relevant API
Specification for repair/remanufacture. The documentation package shall be kept with the
equipment and must be available for inspection at the rig site by Saudi Aramco personnel. This
includes, but is not limited to:
Ram preventers.
Annular preventers.
Valves on the kill, emergency kill, choke line and choke manifold.
Drilling chokes.
Kill, emergency kill and choke lines (and line components) including both hard line and
flexible hoses.
Drilling spools.
NOTE: Recertification can only be performed by the OEM or their licensee facility. If recertified
by a licensee, the document package shall include a copy of the license issued by the
OEM. In-field recertification is not acceptable.

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NOTE: New equipment shall be accompanied by the manufacturer's certificate of compliance

and a full documentation package including inspection and test reports.
1.1.16 All BOPE including, but not limited to, annulars, ram type, valves, spools, crosses, tees and
other end and outlet connections with working pressures of 3,000 psi and above shall have
flanged, welded, integral, or hubbed connections only. Threaded connections and threaded
connections that have been seal welded are not permitted.
1.1.17 All Ram Type BOP cavities MUST CONTAIN a Ram. Vacant Ram cavities during operations
are not permitted.
1.2
Annular Units and Diverters:

1.2.1
All annular units must comply with the following in addition to the requirements in Section 1.1.
1.2.2
The minimum acceptable ratings for H2S and temperature are as follows,
2,000
3,000
5,000
10,000
psi and less

psi equipment
psi equipment
psi equipment
2.5% H2S and 0-170F

2.5% H2S and 0-180F
2.5% H2S and 0-180F
2.5% H2S and 0-180F
1.2.3
The acceptable annular manufacturers are Cameron, GE-Hydril and NOV-Shaffer.
1.2.4
GE Vetco KFDJ and Dril-Quip MD diverters are acceptable for offshore 500, 1,000 and 2,000
psi service. Dril-Quip, is currently the only approved design, for the 500 psi onshore
diverter.
NOTE: The Dril-Quip onshore diverter is not eligible for API Monogram and is not subject to the
3-year recertification requirement. Only repair after each nipple-up is required.
1.3
1.2.5
If a rotary diverter system is utilized on an offshore rig, the diverter lines must have the
capability of discharging below the bottom of the hull due to H2S concerns.
1.2.6
Bolted, latched and screwed top annulars are acceptable.
1.2.7
30 inch 1,000 psi annulars may not be monogrammed under API specification 16A. These
annulars are exempt from the monogram requirement.
Fixed Ram Preventer Blocks and Elastomers:

1.3.1
All fixed ram preventers must comply with the following in addition to the requirements in
Section 1.1 above.
1.3.2
Only fixed size rams are acceptable as the master pipe ram (bottom ram) on all BOP stacks.
1.3.3
The minimum acceptable ratings for H2S and temperature for ram assemblies are:
3,000
5,000

psi stack
psi stack
5.0% H2S and 0-250F

10.0% H2S and 0-250F
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10,000
15,000
1.3.4
psi stack
psi stack
20.0% H2S and 0-300F

20.0% H2S and 0-300F
Cameron, NOV-Shaffer and GE-Hydril are acceptable manufacturers for ram preventers. All
ram assemblies shall meet NACE Standard MR-01-75-2000 for sour service.
NOTE: Fixed size ram preventers CANNOT CLOSE on TOOL JOINTS

1.3.5
1.4
All ram preventers shall be equipped with manual or automatic locking devices which must be
locked whenever the rams are closed to control the well. A hand crank/wrench or handwheel
system are acceptable manual devices. Automatic devices (e.g.: Shaffer Posilocks) are also
acceptable.
Variable Bore Ram Preventer Blocks and Elastomers:

1.4.1
All variable bore ram preventers must comply with the following in addition to the requirements
in Section 1.1 above.
1.4.2
Variable bore rams (VBR) are optional for tapered drill string applications on Class A stacks.
In all cases the master pipe ram (bottom ram) must be a fixed ram.
1.4.3
The minimum acceptable ratings for H2S and temperature for VBR's are:
3,000
5,000
1.4.4
psi stack
psi stack
5.0% H2S and 0-250F

10.0% H2S and 0-250F
The Cameron Extended Range High Temperature VBR-II Packer (3-1/2 to 5-7/8 pipe sizes)
for the Cameron 13-5/8 U Type blowout prevented is acceptable for 3,000 and 5,000 psi
o
applications ONLY. This VBR was successfully tested to 250 F with a CAMLAST elastomer
rated for 20% H2S.
NOTE: The Cameron ER-HT VBR-II, described above, is approved for use in 3M and 5M Class
'A' BOPs. This is the ONLY APPROVED VBR.
1.5
Shear Blind Ram (SBR) Blocks and Elastomers:

1.5.1
SBR's are required on:
Close Proximity Wells (All Wells in Populated Areas)

Gas Cap Wells (Either 3,000 or 5,000 Class A Stacks)
Onshore Class A 5,000 psi stacks (Expl./Dev. Wells >10 % H2S)
Smart Well Completions and Downhole monitoring systems where more than one (1) line is
run on the OD of the tubing.
ESP Completions in areas where the well can flow naturally
Offshore Class A 5,000 psi stacks (Offshore Wells)
Class A 10,000 psi stacks (Deep Gas Exploration and Development Wells)
Class 'A' 15,000 psi stacks (Deep Gas Exploration and Development Wells)

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1.5.2
The minimum acceptable ratings for H2S and temperature for SBR's are:
3,000
psi stack
5.0% H2S and 0-250F
5,000
psi stack 10.0% H2S and 0-250F
10,000
15,000
1.5.3
Approved Shear Blind Rams are as follows:
Cameron Shearing Blind Rams

Shaffer V-Shear, T-72 and LFS (Low Force Shear) Rams
Hydril Blind/Shear Rams
1.5.4
All rigs utilizing SBR in 3,000 and 5,000 psi BOP equipment shall have a 3 emergency kill line.
This will provide additional kill line capacity in case the SBR does not make a proper seal after
cutting the pipe. If the wellhead spool outlet is 2, then the inboard manual valve shall be 2 with
DSA back to 3. Rigs with 10,000 psi and higher BOP equipment shall have dual choke and kill
lines as specified in Chapter B.
1.5.5
Shear Blind Rams are normally installed in Class A BOP stacks. When installed they will be in
the position immediately above the drilling cross as detailed in the individual stack
configurations shown in this manual. They may be used on Class B BOP stacks on close
proximity wells to allow the utilization of smaller rigs. When installed in Class B stacks, the
configuration must be a fixed pipe ram in the bottom position, a drilling cross above that, the
SBR and then the annular.
NOTE: Double rams may not be used in conjunction with SBRs on a Class B stack.
NOTE: SBRs are only to be used during testing and a well control incident. They shall not be
used to close the well when out of the hole. A steel hole cover (minimum thick with
locating pins) should be available on the rig floor to cover the rotary when pipe is out of
the hole.
1.5.6
The tables below indicate the shear capability of SBR for different BOP manufacturers, sizes
and pressure applications.
NOTE: Shear Blind Rams CANNOT BE CLOSED ON TOOL JOINTS.
SHEAR BLIND RAM CAPABILITY

10,000 - 15,000 PSI SERVICE
BOP
SERVICE
DEEP GAS
EXPL/ DEV.
BOPE
SIZE - WP
CLASS
13-5/8" 10M
CLASS 'A'
MFG.
CAMERON
(1)
SHAFFER (1)
11" 10M
CLASS 'A'
CAMERON
(1)
SHAFFER (1)

DRILL PIPE
SHEAR
CAPABILITY
ALL SIZES TO
5-1/2" 24.7# G-105
ALL SIZES TO
5-1/2" 24.7# G-105
ALL SIZES TO
5" 19.5# G-105
ALL SIZES TO
5" 25.6# G-105
A-7
REQUIRED
SHEAR
BLIND RAM
TYPE
OPERATOR
REQUIRED
SIZE
'SBR'
'V'
SIDE PACKER
YES/ LBT (2)
TEMP
(0F)
0-300
H2S,
(%)
20
14"/10" (3)
0-300
20
0-300
20
0-250
20
'SBR'
YES/ LBT
'T-72'
14"/10" (3)
(2)

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NOTE: (1)
(2)
(3)
CAMERON, HYDRIL AND SHAFFER ARE APPROVED MANUFACTURERS.

CAMERON - LBT REFERS TO LARGE BORE SHEAR BONNETS WITH TANDEM BOOSTERS.
NOV SHAFFER - 14" OPERATOR WITH 10" BOOSTER IS REQUIRED.
3,000 - 5,000 PSI SERVICE

BOP
SERVICE
BOPE
SIZE - WP
CLASS
OFFSHORE
ONSHORE
EXPL/DEV. w/ H2S >
10%
GAS CAP WELL
POPULATED
AREAS
13-5/8" 3-5M
CLASS 'A'
1.6
DRILL PIPE
SHEAR
CAPABILITY
ALL SIZES TO
5-1/2" 24.7# G-105
DUAL TUBING
STRINGS
ALL SIZES TO
5-1/2" 24.7# G-105
REQUIRED
SHEAR
BLIND
RAM TYPE
OPERATOR
REQUIRED
SIZE
'SBR'
YES/ LBT (2)
'V'
14"/10" (3)
ALL SIZES TO
'SBR'
YES/ LBT (2)
5" 19.5# G-105
SHAFFER (1)
ALL SIZES TO
'T-72'
14"/10" (3)
5" 25.6# G-105
CAMERON, HYDRIL AND SHAFFER ARE APPROVED MANUFACTURERS.
CAMERON - LBT REFERS TO LARGE BORE SHEAR BONNETS WITH TANDEM BOOSTERS.
SHAFFER - 14" OPERATOR WITH 10" BOOSTER IS REQUIRED.
CAMERON (1)
SIDE
PACKER
TEM
P
(0F)
0-250
TE
MP
(0F)
20
0-250
20
0-250
20
0-250
20
Side Outlets, Valve Removal Plugs and Blind Flanges

1.6.1
Two side outlets are required below each ram on a BOP. Therefore, a single ram body will
have two (2) outlets and a double ram body will have four (4).
1.6.2
Valve Removal (VR) plugs are not required on BOP side outlets, however they may be used.
The following conditions apply to the blind flanges installed on side outlets:
1.7
CAMERON (1)
SHAFFER (1)
11" 3-5M
CLASS 'A'
NOTE: (1)
(2)
(3)
MFG.
Flanges installed on the side outlets of ram preventers that do not have VR plugs installed shall
be blind with no penetrations.
Flanges installed on the side outlets of ram preventers that have VR plugs installed shall have a
inch NPT or an Autoclave tap (depending on the pressure rating) and have a plug installed.
Drilling Spools:
1.7.1
All Drilling Spools shall comply with the following requirements:
Monogrammed to API Specification 6A or 16A

PSL-2 (5,000 psi working pressure or lower)
PSL-2 with PSL-3 Gas Test (10,000 psi working pressure or higher)
PR-1 (or better)
MR-DD (or better)
TR-U (5,000 psi working pressure or lower)
o
TR-X Suitable for 350 F service (10,000 psi working pressure or higher)
Forged bodies

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2.0
REQUIREMENTS FOR KILL, EMERGENCY KILL, CHOKE LINES AND

CHOKES
All Kill, Emergency Kill and Choke lines shall comply with the following in addition to Section 1.1.
2.1
The Minimum Bore Size for Kill, Emergency Kill and Choke Lines Shall Be As Follows:
KILL LINE
Nominal Size/Bore (in)
2-1/16"
2-1/16"
3-1/16"
Working Pressure (psi)

3,000 and 5,000
10,000
15,000
EMERGENCY KILL LINE

2-1/16"
3-1/8" (with SBR)
3-1/8" (with SBR)
2-1/16"
3-1/16"

3,000 and 5,000
3,000
5,000
10,000
15,000
CHOKE LINE
3-1/8"
3-1/8"
4-1/16"

3,000
5,000
10,000 and 15,000
2.1.2
2.2
The complete piping system, valves, chokes and choke manifold will be the full working
pressure of the BOP through the block valves downstream of the chokes and the Choke
Manifold Buffer Chamber.
Material and Fabrication:

2.2.1
The lines from the BOP stack to the choke manifold shall have the same working pressure (or
greater) as the BOP stack. All lines shall meet Sour Service requirements for API
Specifications 6A and 16C.
2.2.2
Choke lines for 3M and 5M applications shall be either steel pipe, flexible hose or a combination
of these.
2.2.3
Choke lines for 10M and higher applications shall be either steel pipe or a combination of hard
line and flexible hose.
2.2.4
Flexible steel hose if used in combination flanged hard line may be used for the choke, kill and
emergency kill lines on 3M through 15M applications provided the following requirements are
satisfied:
Made by an approved manufacturer as listed in section 2.2.7 below.

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All components of the hose and end fittings in possible contact with wellbore fluids meet
Sour Service NACE MR-01-75/ISO 15156 (latest revision)
2.2.5
All lines and end connections shall be pressure tested and Monogrammed as per API
specification 6A, 16C or 17D as appropriate.
2.2.6
Steel line material shall meet the requirements of API specification 6A or 16C for H2S service.
2.2.7
Flexible choke and kill lines shall be monogrammed to API Specification 16C.
approved flexible choke and kill lines are:
The only
Technip/Coflexip (coflon lined)

Continental Contetich-Thermo plastic lined (only allowed in 5,000 psi and lower service)
Phoenix HNBR (only allowed in 5,000 psi and lower service)
NOTE: The Phoenix HNBR hose has the following limitations in chemical compatibility:
Product compatibility of HNBR lined Phoenix Rubber hoses
(choke and kill hoses acc. to API Spec. 16C 07 C draft &hoses c\w st. st. internal carcass acc. to API Spec. 17K)
Medium
Concentration
Hydrochloric acid HCl
15%
Hydrofluoric acid HF
0.6%
Xylene C6H4 (CH3)2
25%
Methanol CH3OH
100%
Zinc bromide ZnBr2
Saturated
Calcium bromide CaBr2
Saturated
Calcium chloride CaCl2
Saturated
Diesel
100%
Sea water
--Sodium hydroxide NaOH
50%
Hydrogen sulfide H2S
20%
(+) Suitable, (-) Not Suitable, (L) Limited Service
0oF
-18oC
+
+
+
+
+
+
+
+
+
L
+
75oF
24oC
+
+
+
+
+
+
+
+
+
L
+
150oF
66oC
+
L
L
L
L
+
+
+
200oF
93oC
L
L
L
L
L
+
+
250oF
121oC
L
L
L
L
L
+
2.2.8
Field welding is not permitted on choke and kill lines. These must be welded in an API licensed
shop to a qualified welding procedure and must, at a minimum, pass hardness tests (HRC 22 or
less) and radiography of the welds.
2.2.9
All choke and kill lines shall be as straight as possible with targeted, block tees at turns. The
tees will be lead targeted with renewable target flanges. Welded or threaded tees are not
acceptable.
NOTE: Threaded tees that are seal welded are NOT ALLOWED in any service.
NOTE: Chiksans are not acceptable for kill line, emergency kill line or choke line.
2.2.10 All kill, emergency kill, choke and choke manifold connections should be flanged, API licensed
factory welded, integral or hubbed and shall be monogrammed to API Specification 6A.

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2.3
Requirements for Drilling Chokes:

2.3.1
A remote controlled hydraulic choke(s) shall be installed on each manifold. All chokes used in
Saudi Aramco service must be from one of the approved models listed below. Acceptable
models are:
SWACO 'Super Choke'

Cameron Drilling Choke
NOV Shaffer Drilling Choke
NOTE: Choke makes and models not listed above will not be accepted.
2.3.2
All Chokes, regardless of make and model, shall comply with the following specifications:
2.4
Monogrammed to API Specification 6A or 16C

PSL-2 (or better) (With PSL-3 Gas Test)
PR-1 (or better)
MR-DD (or better)
o
TR-X Suitable for 0-350 F service (10,000 psi working pressure or higher)
Forged bodies and bonnets
Alloy 625 or better, inlaid ring grooves
Requirements for Manual Gate Valves, Hydraulic Gate Valves and Check Valves:
2.4.1
Manual Gate Valves shall be non-rising stem, single slab floating gate valves with one-piece
seat design (Body Bushings Not Allowed). Split gates or valves with floating or two-piece seats
that can pressure lock are not acceptable. Nitrile/Buna Elastomer Seals are not allowed.
PTFE/PEEK Based Seals are acceptable. Manufacturers are not specified for contractor owned
manual gate valves, however, it should be noted that each valve must be re-certified by the
OEM at contract start-up and every three (3) years thereafter. Hydraulic Controlled Remote
(HCR) Gate Valves will be required to meet the same specification with the exception of the
Stem. HCR Gate Valves are allowed to incorporate a rising stem and a balance stem on the
bottom of the valve body.
Approved Hydraulic Valve Manufacturers: Cameron (all sizes), Axon (7-1/16 only).
2.4.2
All Gate Valves shall comply with the following specifications (in addition to Section 1.1):
2.4.3
Monogrammed to API Specification 6A

PSL-2 (or better) with PSL-3 Gas Test (10,000 psi and higher)
PSL-2 (or better) (5,000 psi and lower)
PR-1 (or better)
MR-DD (or better)
o
TR-X suitable for 0-350 F service (10,000 psi working pressure or higher)
All Check Valves shall comply with the following specifications (in addition to Section 1.1):
Monogrammed to API Specification 6A

PSL-2 (or better) with PSL-3 Gas Test (10,000 psi and higher)

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2.5
PSL-2 (or better) (5,000 psi and lower)

PR-1 (or better)
MR-DD (or better)
o
TR-X suitable for 0-350 F service (10,000 psi working pressure or higher)
Top entry valves only, no bottom body penetrations.
Metal to metal seal valves only.
Requirements for Cup Testers:

2.5.1
Cameron Type F cup testers are the only approved model. All elastomers and other parts
must be OEM.
3.0
ACCESSORY BOP EQUIPMENT REQUIREMENTS
3.1
Pit Volume Totalizers:
3.2
3.3
3.1.1
All rigs shall have a pit volume totalizer installed. These should be kept on at all times, even
when out of the hole, changing bits or logging.
3.1.2
Charts and, or, warning devices (horn, lights etc.) should be installed at the Drill Floor, Mud
Logging unit and the Toolpushers or Drilling Representative's office.
Mud Flow Indicators:

3.2.1
All rigs shall have a mud flow indicator installed. These should be kept on at all times, even
when out of the hole, changing bits or logging.
3.2.2
Electrical Differential and the Flow Sensor types are approved.
Gas Busters:
3.3.1
Gas busters (poor boy degassers) shall be installed on every rig.
3.3.2
The vent lines must meet the following requirements:
Lines will be 8 minimum OD flanged or clamped steel line (minimum of 240 in length, from
the gas buster)
Same pressure rating (or greater) than that of the gas buster.
Shall terminate in a flare pit, positioned 50 beyond the edge of the reserve/waste pits to
prevent ignition of any waste hydrocarbons while circulating gas from the wellbore.
3.3.3
The gas buster design for deep gas rigs is shown in Figure A-3.1 The minimum internal
capacity for Gas Rig gas busters is 35 barrels.
3.3.4
The gas buster design for oil development rigs is shown in Figure A-3.2 The minimum internal
capacity for Oil Rig gas busters is 17.5 barrels.
3.3.5
Gas busters should be cleaned out periodically.

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3.3.6
Never circulate cement returns through a gas buster.
3.3.7
Gas busters have a tendency to shake and rattle when they are in use.
securely anchored.
3.3.8
All gas busters shall be built in compliance to ASME Boiler and Pressure Vessel Code, Section
VIII, Division I, with all materials meeting requirements of NACE Standard MR-01-75/ISO15156
(Latest Revision). All welding on the vessel shall meet ASME requirements. New gas busters
shall be hydrostatically tested to 190 psi to give a maximum working pressure of 150 psi, as per
ASME.
They should be
INTENTIONALLY LEFT BLANK

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FIGURE A-3.1: Mud Gas Separators for Gas Service

3.3.9
There should be a by-pass line upstream of the separator directly to the flare line and a valve on
the separator inlet line to protect the separator from high pressure.
3.3.10 The mud discharge line from the separator must have a vacuum breaker stacked vent line if the
discharge line outlet is lower than the bottom of the separator. This is to prevent siphoning gas
from the separator to the mud pits. The vacuum breaker stack must be as high as the separator.

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3.3.11 MGS/Gas Buster must be fully inspected and tested every five (5) years. Inspection will include
full visual, Pressure Testing, 100% Magnetic Particle or Dye Penetrant NDE and Ultra Sonic to
determine the integrity of the wall thickness. Additionally, Inspection Documentation with 3 year
validity must be submitted at new rig start-up as well as for rig contract renewal.

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FIGURE A-3.2: Mud Gas Separators for Oil Service

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3.4
Full Opening Safety Valves:

3.4.1
A full opening safety valve to fit each size of drill pipe and drill collar in use will be kept in the
open position on the rig floor (including a closing/opening wrench).
3.4.2
A safety valve and appropriate cross-over are also required when running casing and tubing.
3.4.3
Care should be taken to ensure that valves have the proper threads and that they will go
through the BOP stack and casing. This will allow the valves to be stripped into the hole below
an inside BOP.
NOTE: Full Open Safety and Kelly valves must be designed and manufactured in compliance with API
Spec 7-1.
The term 'full opening' does not mean that the ID of the valve is the same as the pipe, but rather
that the bore through the valve is not restricted.
3.5
Inside BOP:
3.5.1
An inside BOP to fit each size of drill pipe and drill collar in use will be kept in the open position
on the rig floor.
NOTE: Inside BOP must be designed and manufactured in compliance with API Spec 7-1.

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3.6
Trip Tank:
3.6.1
A circulating trip tank will be used on all rigs while tripping out of or back into the hole.
3.6.2
The trip tanks shall have two (2) 60 barrel compartments.
3.6.3
There shall be two (2) independent measuring devices, a mechanical float operated pit level
indicator graduated in inches and an electro-mechanical device.
FIGURE A-3.3: Typical Trip Tank

3.6.4 Calculated versus actual volumes shall be monitored and recorded in a log book recording the
following data:
Volume and weight of slug

Number of strokes the slug is pumped.
Time for slug to stabilize and flow to stop in the annulus.
Amount of mud to fill hole:
o 5 Stands for Drill Pipe
o 2 Stands for HWDP
o Every Stand for Dill Collars
NOTE: If the volume of mud used to fill the hole is not correct for any interval, stop pulling and
determine the reason the hole is not taking mud properly.
Total volume of mud per trip to fill hole (calculated and measured)
Leave drill pipe wiper rubbers off pipe for the first five (5) stands to observe hole.

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3.7
Bowl Protectors (Wear Bushings):

Bowl protectors, or wear bushings, protect the hanger bowl in the casing or tubing head during drilling
operations.
3.7.1
Bowl protectors shall be used in all operations when drilling through the wellhead.
NOTE: Bowl protectors, just like BOP test plugs have a Manufacturer specific profile.
protector used must match the Manufacturer and Model of the Wellhead.
3.8
The bowl
Valve Removal Plugs:

Valve Removal (VR) plugs are one-way check valves that can be installed through an outlet valve on a
casing head, casing spool or tubing spool into a female thread in the outlet for its repair or replacement.
Once the valve has been repaired or replaced the VR plug can be removed.
3.9
3.8.1
VR plugs shall be removed from the wellhead in order to have access to the annulus. This
should be confirmed prior to nippling up the wellhead.
3.8.2
VR plugs are to be installed under the blind flanges on all wellheads prior to the rig move/well
completion.
3.8.3
Under no circumstances should a VR plug be left in a side outlet that has a valve installed.
Drillpipe Float Valves:

Drill pipe float valves shall be run in all Saudi Aramco operations except when planned operations
preclude running a float; testing, treating or squeezing. The drillpipe float valve shall be positioned
directly above the bit.
3.10
Weco Connections:
3.10.1 Weco connections (other than the remote connections at the end of the catwalk) are not
acceptable for kill, emergency kill or choke line service.
3.10.2 Factory Manufactured Integral or butt welded Figure 1502 connections are acceptable
downstream of the choke manifold buffer tank for land and offshore operations. Field fabricated
connections are not acceptable.
3.10.3 Weco type connections are not acceptable on well test lines upstream of the Choke & Kill
Manifold.
3.10.4
3.11
2 inch Figure 602 connections are not allowed in any Saudi Aramco Drilling and Workover
Operation.
Chiksans / Swivel Joint:

3.11.1 Chiksans are sections of pipe with hammer unions and two swivels in each joint. The primary
use of chiksans is to run temporary lines for high pressure pumping and cementing operations.
3.11.2 Chiksans shall not be used in kill lines, emergency kill lines or choke lines.

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3.12
Accumulator Closing Units:

The brand of closing unit used by the Drilling or Workover Contractor is not specified by Saudi Aramco,
however, all closing units shall meet the following requirements.
Fluid Requirements:
3.12.1 The accumulator shall store enough fluid under pressure to close all preventers, open the choke
HCR valve and retain 50% of the calculated closing volume with a minimum of 200 psi above
pre-charge pressure without assistance from the accumulator pumps.
Design Requirements:
3.12.2 The accumulators and all fittings will be a minimum of 3,000 or 5,000 psi working pressure
depending on the BOP Ram Bonnet working pressure. The Accumulator and all Hydraulic lines
from the accumulator to the BOP stack shall be designed and manufactured in accordance with
API Specification 16D. All Accumulators and Lines must be manufactured by an API 16D
Licensed Facility. Onshore Hoses must be sleeved and shielded externally steel encased
(equivalent to Gates 16 EFBOP Blow-Out Preventer Hose). Offshore hoses are not required to
be externally steel encased. The hose end connection must be of a winged hammer or hex
union style. All piping and connections used from the Accumulator Unit to the BOP must be
ASME/ANSI SCH 160 or equivalent. Quick-Connect type connections are not allowed. Manifold
and BOP hydraulic lines should be tested to the system working pressure at installation.
NOTE: All air and hydraulic BOP operating units shall be equipped with regulator valves similar
to the Koomey type TR-5. These will not fail open causing loss of operating pressure.
Bottle Pre-Charge Requirements:
3.12.3 Accumulator bottles will be pre-charged with nitrogen as per manufacturers
specifications/recommendations. The minimum required pre-charge pressure for a 3,000 psi
(20.7 MPa) working pressure accumulator unit is 1,000 psi (6.9 MPa). The minimum required
pre-charge pressure for a 5,000 psi (34.5 MPa) working pressure accumulator unit is 1,500 psi
(10.3 MPa). The nitrogen pre-charge pressure shall be checked and adjusted prior to
connecting the closing unit to the BOP stack and any other time the accumulator must be
completely de-pressured.
3.12.4 The accumulator should be capable of closing each ram within 30 seconds. Closing time should
not exceed 30 seconds for annulars smaller than 18-3/4 nominal bore and 45 seconds for
annular preventers of 18-3/4 and larger.
Operating Controls:
3.12.5 All operating controls shall be clearly marked with function and ram sizes. Accumulator controls
must be in open or closed position, but not in neutral position. During normal drilling operations
the HCR valve next to the wellhead will be closed. Unused functions shall be marked Out of
Service, covered or have the handles removed on the main and remote units. Unused
functions shall have the open/close lines plugged at the main unit.

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Accumulator and Controls Locations:

3.12.6 Master Controls shall be at the accumulator. There must be at least two (2) sets of remote
controls for operating the accumulator to activate the BOPs and all HCR valves. HCR valves on
the choke line, kill line and the C&K manifold shall be powered by the main accumulator unit.
One remote control shall be on the rig floor, accessible by and visible to the driller and the other
shall be located near the Company Representatives office.
Onshore:
The accumulator shall be located at a remote location, at least 60 feet distance

from the wellbore for oil wells and 100 feet for gas wells, shielded from the wellhead
and protected from other operations around the rig.
Offshore:
The accumulator shall be shielded from the wellhead and the drill floor and
protected from other operations around the rig. It should be located as far as
practically possible from the wellhead.
Pump System:
3.12.7 Two pump systems are required. The preferred configuration is to have one electric/hydraulic
and the second pneumatic (air)/hydraulic. The primary electric/hydraulic pump system and the
secondary pneumatic/hydraulic pump system must be independent of each other and fully
operational when the accumulator is in use. The high-pressure set point for both the electric
pump and air pump should be 3,000 or 5,000 psi. The low-pressure set point should be above
2,800 psi for both systems. Do not bleed off pressure due to ambient temperature rise.
Pressure may vary from 3,000 to 3,400 or 5,000 to 5,400 psi in a 24-hour period.
It is permissible to have two independent electric/hydraulic systems. however, they must have
separate and totally independent prime movers.
Each of the two systems shall have the quantity and sizes of pumps such that, with the
accumulators isolated from service, the following steps are completed within two minutes:
The annular BOP closes on the minimum size drill pipe being used
All hydraulically operated valves opened
Provide the pressure recommended by the annular BOP manufacturer to effect a seal on
the annulus
Pressure Regulator Settings:

3.12.8 The pressure regulators for the annular preventer and ram preventers will be set as per
manufacturers specification/recommendation. All BOPs with Shear Blind Rams installed shall
have a bypass to route full system pressure to the SBR's.
NOTE 1 For non-emergency BOP operation, use of the lowest possible pressure will extend
elastomer life. Upon completion of the daily testing the pressure regulators shall be
returned to the normal operation pressure.
NOTE 2 DO NOT close annular preventers on open hole for complete shut-off except in an
emergency.

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NOTE 3 DO NOT close pipe rams without pipe in the hole. Pipe rams should only be closed
on the proper size pipe in order to avoid damage to the rubber packer or to the ram
carriers (DO NOT CLOSE on TOOL JOINTS).
Shear Ram Safety Covers and Alarms:
3.12.9 The Shear Blind Ram controls are to have the following safety and alarm features:
3.13
Safety covers (box style) shall be installed over all SBR controls. These covers will be
secured with a pin (that must be removed before opening the cover) and will be of a type
that must be lifted to operate the control. They should be clear plastic or have observation
holes in them so the position lights may be seen. Covers shall be installed on all SBR
controls at all remote stations and the accumulator.
The covers shall be fitted with switches that will activate horns and strobe lights when the
cover is lifted, before the control is operated. Horns will be installed on the rig floor and at
the accumulator. The alarms will be tested during each well control drill and BOP test. The
alarms should emit a significantly different sound than the H2S or any other alarms on the
rig.
Stroke Counters:
Stroke counters provide the Driller a method of measuring fluid volumes when displacing special fluids
or lost circulation pills. It is also used to determine pumped volumes when executing well control
procedures.
3.13.1 Stroke counters are required on all rigs at both the Driller's station and the choke control
console.
NOTE: The kill line should not be used in conjunction with the rig pumps and a stroke counter
for hole filling purposes. The kill line is an emergency piece of equipment and should
not be used for routine hole fill-up during trips.
3.14
Gas Detectors:
These devices, usually found in mud logging units, are useful in detecting abnormal pressure sections
as well as shows of hydrocarbons. Rig Supervisors should monitor the trip gas, connection gas, and
background gas for any significant change. The presence of gas in the mud can be one of the more
useful indicators of abnormal pressure. Gas Detector readings can sometimes be misleading, however,
and the important things to look for are the relative trends and magnitudes, rather than the individual
number of gas units reported.
3.15
Drill Rate Recorders:

These devices come in both analogue and digital styles. They are useful as correlation tools,
particularly if logs are available from other wells in the area. The records can be used to detect and
correlate formation tops and types, as well as in selecting bits and estimating their useful lives. A
sudden increase in penetration rate can be one of the first signs of a well kick.
3.15.1 All rigs should have a drill rate recorder.

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3.16
Pump Lines for Existing Offshore Well Kill:

Steel chicksan swivel joints, connections and piping may be used for the purpose of killing an existing
well with cased hole prior to or after rig arrival. However, only factory Manufactured Integral or butt
welded Figure 1502 connections are acceptable.

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CHAPTER B - BOPE SYSTEM CONFIGURATION
CHAPTER B: BOPE SYSTEM CONFIGURATION

TABLE OF CONTENTS
1.0
BOP EQUIPMENT SYSTEM CONFIGURATION

1.1
2.0
3.0
4.0
5.0
6.0
Pressure Rating of BOPE Systems
B-3
CLASS A 15,000 psi BOP STACK

2.1
Usage
B-3
2.2
Class A 15,000 psi BOP Stack Arrangement (Single Sized Drill Pipe)
B-4
2.3
Class A 15,000 psi BOP Stack Arrangement (Tapered Drill Pipe String)
B-7

3.1
Usage
B-8
3.2
B-8
3.3
B-11

4.1
Usage
B-12
4.2
B-12
4.3
B-15

5.1
Usage
B-16
5.2
Class A 3,000 psi BOP Stack Arrangement for Large Hole (Single Sized Drill Pipe)
B-16
5.3
Class A 3,000 psi BOP Stack Arrangement for Smaller Hole (Single Sized Drill Pipe)
B-18
5.4
B-18
CLASS B 3,000 psi BOP STACK

6.1
Usage
B-19
6.2
Class B 3,000 psi BOP Stack Arrangement
B-19
7.0
CLASS C 3,000 psi BOP STACK
B-21
8.0
CLASS D DIVERTER STACK
B-22
9.0
CLASS I 2,000 psi WORKOVER STACK

9.1
Usage
B-24
9.2
Class I 2,000 psi Stack Arrangement
B-24

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10.0
11.0
12.0
13.0
14.0
15.0
CLASS II 3,000 psi WORKOVER STACK

10.1 Usage
B-25
10.2 Class II 3,000 psi Stack Arrangement
B-25
CLASS III 5,000 psi WORKOVER STACK

11.1 Usage
B-25
11.2 Class III 5,000 psi Stack Arrangement
B-26
CLASS IV 10,000 psi WORKOVER STACK

12.1 Usage
B-26
12.2 Class IV 10,000 psi Stack Arrangement
B-26
CLASS V 15,000 psi WORKOVER STACK

13.1 Usage
B-26
13.2 Class IV 10,000 psi Stack Arrangement
B-26
SPECIAL WELL OPERATIONS BOP STACKS

14.1 BOP Equipment Requirements for Coil Tubing Operations
B-26
14.2 BOP Equipment Requirements for Snubbing
B-30
14.3 BOP Equipment Requirements for Electric Line Operations
B-33
CHOKE MANIFOLDS
15.1 15,000 PSI Working Pressure Choke Manifold
B-35
B-38
B-41
B-43
15.5 Location
B-44
15.6 Choke Manifold Pressure Ratings
B-44
15.7 Piping Specifications
B-44
15.8 Choke Manifold Discharge and Flare Lines
B-44
15.9 Gas Buster Lines
B-46

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1.0 BOP EQUIPMENT SYSTEM CONFIGURATION

This Chapter of the Well Control Manual sets forth the configurations for BOP equipment systems for use in
Drilling and Workover Operations. All equipment must comply with the other chapters in this manual.
Variations or deviations of BOP equipment, specifications, arrangement, pressure rating or requirements
from this standard requires endorsement of the Well Control Committee, and approval by the Vice President
of Drilling and Workover. The enforcement of these equipment standards shall be the responsibility of the
Drilling or Workover Rig Superintendent. The Rig Foreman shall ensure that the proper equipment is
available and correctly installed. If not specified in these standards all BOP equipment shall comply with API
Specifications and Recommended Practices. The BOP equipment must be arranged to allow:
1.1
A means of closing the top of the open hole, as well as around drill pipe or collars, and stripping the
drill string to bottom.
A means of pumping into a hole and circulating out a well kick.
A controlled release of the influx.
Redundancy in equipment in the event that any one function fails.
All preventers shall be installed so that rams can be changed without moving the stack.
The drilling program shall specify the Class BOP stack (not individual components) to be used.
Pressure Rating of BOPE Systems:
The pressure rating of the BOP system is based on the MASP (Maximum Anticipated Surface
Pressure). The minimum rated working pressure of the BOP system shall be selected based on
MASP for each hole section as detailed in the table below:
BOP Equipment
OIL WELL
GAS WELL
INJECTION WELL
Pressure Rating
MASP (in PSI)
MASP (in PSI)
MASP (in PSI)
3,000 PSI
2,550
2,700
< 3,000
5,000 PSI
4,250
4,500
< 5,000
10,000 PSI
8,500
9,000
< 10,000
15,000 PSI
12,750
13,500
< 15,000
NOTE-1: Does not include diverter requirements.
NOTE-2: BOPs with higher rated working pressure than shown above may be used at any time.
2.0
CLASS A 15,000 PSI BOP STACK
2.1
Usage:
A Class A 15,000 psi BOP stack shall be installed on all offshore and onshore wells with a MASP
up to the limits given in the table above. If MASP exceeds these limits a higher pressure rating will
be required.
The through bore of the BOP stack including drilling spools, risers, DSA's and any other equipment
will be at least as large as the wellhead section immediately below it. These BOP stacks are
available in 7-1/16", 11", 13-5/8" and 18-3/4" 15M.

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2.2
Class A 15,000 psi BOP Stack Arrangement (Single Size Drill Pipe):
When using a single size of drill pipe the stack arrangement (from bottom to top) shall be as
described below and as shown in Figure B-1:
2.2.1
A wellhead spool or tree with a 18-3/4", 13-5/8", 11 or 7" 15M flange with two (2) 3-1/16"
15M studded side outlets shall be installed. Each outlet shall have two (2) 3-1/16" (minimum)
15M flanged gate valves with a blind flange installed.
2.2.2
If the top flange of the wellhead is below ground level, a spacer spool spacer is required. If
the BOP Stack is larger than the wellhead a double studded adapter flange is required.
2.2.3
A flanged or studded double gate ram preventer shall be installed on the wellhead or spool.
The BOP shall be above ground level with master drill pipe rams in the bottom position (1)
and blind rams in the top position (2).
2.2.4
A flanged drilling cross shall be installed on the double ram preventer. The drilling cross shall
have two (2) 4-1/16" 15M flanged side outlets.
2.2.5
Kill Lines
There shall be two (2) kill lines, an upper and a lower. Both lines shall be 3-1/16" 15M and
configured as below:
From the drilling cross out on the kill line side, there shall be:
a double studded adapter flange 4-1/16" 15M to 3-1/16" 15M

a 3-1/16" 15M flanged manually operated gate valve
a 3-1/16" 15M flanged hydraulic control (HCR) gate valve
a 3-1/16" 15M flanged spacer spool
a 3-1/16" 15M studded tee
The bottom outlet of the tee will connect to the lower kill line. The other side of the tee will
have a flanged spacer spool followed by a second studded tee. On each side of the second
tee there shall be a 3-1/16" 15M flanged gate valve and a 3-1/16" 15M flanged check valve.
On the remote (emergency pump connection) side, the kill line shall be 15M and run at least
90 feet from the wellbore to the end of the catwalk, with a flange to Weco 3" welded union.
On the primary (mud pump) side, the kill line shall be connected directly to the mud pumps
or to the stand pipe manifold, with a 10M manual isolation valve between the kill line and the
7,500 psi stand pipe.
The lower kill line from the 4-1/16" 15M BOP master pipe ram side outlet out there shall be:
a 4-1/16" X 3-1/16" 15M DSA

two (2) 3-1/16" 15M flanged manually operated gate valves
3-1/16" 15M flanged spacer spools and studded (targeted) tees as required
a 3-1/16" 15M flanged manually operated gate valve attached directly to the studded
tee on the upper kill line.

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2.2.5
Choke Lines
There shall be two (2) choke lines, an upper and a lower. Both lines shall be 4-1/16" 15M
and configured as below:
From the drilling cross out on the choke line side there shall be:

The bottom outlet of the tee will connect to the lower choke line. The other side of the tee
will connect (through flanged line) to the manually operated gate valve at the choke
manifold.
The lower choke line from the 4-1/16" 15M BOP master pipe ram side outlet out there shall
be:

a 4-1/16" 15M flanged spacer spools and studded (targeted) tees as required
tee on the upper choke line.
NOTE: All steel piping shall be made with 15M flanges, targeted tees, block-tee elbows, and
factory-manufactured 15M working pressure line. All tees must be targeted with
renewable 15M blind flanges (welded tees are not acceptable).
Chiksans and Weco connections (other than the remote connections at end of the
catwalk) are not acceptable for kill line, or choke line. Coflex hose (refer to Chapter
A, Section 2.0) may be used in combination with steel line for the choke or kill line.
2.2.6
A 15M flanged or studded double gate ram preventer shall be installed on the 15M drilling
cross. There shall be shear blind rams in the bottom (3) and drill pipe rams in the top (4) of
the double ram preventer.
2.2.7
A 10M or 15M annular preventer will be installed on the top of the double ram preventer.
The annular shall be flanged bottom X studded top.
2.2.8
A flanged rotating head, with a flanged bottom connection to match the top connection of the
annular preventer and a 9" 3M flanged side outlet, may be installed on top of the annular
preventer. A spacer spool may be required if annular studded top is not compatible with the
rotating head flange.

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Figure B-1: Class 'A' 15,000 psi BOP Stack with Single Sized Drill Pipe

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2.3
Class A 15,000 psi BOP Stack Arrangement (Tapered Drill Pipe String):
When using a tapered string of drill pipe the stack arrangement shall be the same as that for the
single string EXCEPT the blind rams in the bottom double (2) shall be changed to pipe rams and
sized for the smaller sized pipe and the master pipe rams (1) and upper pipe rams (4) shall be sized
for the larger pipe as shown in Figure B-2:
Figure B-2: Class 'A' 15,000 psi BOP Stack with a Tapered String of Drill Pipe

B-7

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3.0
3.1
Usage:
A Class A 10,000 psi BOP stack shall be installed on all offshore and onshore wells with a MASP of
up to 8,000 psi.
available in 7-1/16", 11", 13-5/8" and 18-3/4" 10M
3.2
Class A 10,000 psi BOP Stack Arrangement (Single Size Drill Pipe):
3.2.1
A wellhead spool or tree with a 18-3/4", 13-5/8", 11 or 7" 10M flange with two (2) 3-1/16"
(minimum) 10M studded side outlets shall be installed. Each outlet shall have two (2) 3-1/16"
10M flanged gate valves with a 3-1/16 blind flange installed.
3.2.2
If the top flange of the wellhead is below ground level, a spacer spool spacer is required. If
the BOP Stack is larger than the wellhead a double studded adapter flange is required.
3.2.3
A flanged or studded double gate ram preventer shall be installed on the wellhead or spool.
The BOP shall be above ground level with master drill pipe rams in the bottom position (1)
and blind rams in the top position (2).
3.2.4
A flanged drilling cross shall be installed on the double ram preventer. The drilling cross shall
have two (2) 4-1/16" 10M flanged side outlets.
3.2.5
Kill Lines
There shall be two (2) kill lines, an upper and a lower. Both lines shall be 2-1/16" 10M and
configured as below:
a double studded adapter flange 4-1/16" 10M to 2-1/16" 10M

The bottom outlet of the tee will connect to the lower kill line. The other side of the tee will
have a flanged spacer spool and followed by another studded tee. On each side of this tee
there shall be a 2-1/16" 10M flanged gate valve and a 2-1/16" 10M flanged check valve. On
the remote (emergency pump connection) side, the kill line shall be 10M and run at least 90
feet from the wellbore to the end of the catwalk, with a flange to Weco 2" welded union. On
the primary (mud pump) side, the kill line shall be connected directly to the mud pumps or to
the stand pipe manifold, with a 5M manual isolation valve between the kill line and the 5,000
psi stand pipe.

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The lower kill line from the 4-1/16" 10M BOP master pipe ram side outlet out there shall be:
3.2.6
a 4-1/16" X 2-1/16" 10M DSA

two (2) 2-1/16" 10M flanged manually operated gate valves
tee on the upper kill line.
Choke Lines
There shall be two (2) choke lines, an upper and a lower. Both lines shall be 4-1/16", 10M
and configured as below:
From the drilling cross out on the choke line side there shall be:

The bottom outlet of the tee will connect to the lower choke line. The other side of the tee
will connect (through flanged line) to the manually operated gate valve at the choke
manifold.
The lower choke line from the 4-1/16", 10M BOP master pipe ram side outlet there shall be:

tee on the upper choke line.
factory manufactured 10M working pressure line. All tees must be targeted with
renewable 10M blind flanges (welded tees or field fabricated equipment is not
acceptable).
Chiksans and Weco connections (other than the remote connections at end of the
catwalk) are not acceptable for kill line, or choke line. Coflex hose (refer to Chapter
A Section 2.0) may be used in combination with steel line for the choke or kill line.
3.2.7
A 10M flanged or studded double gate ram preventer shall be installed on the 10M drilling
cross. There shall be shear blind rams in the bottom (3) and drill pipe rams in the top (4) of
the double ram preventer.
3.2.8
A 10M annular preventer will be installed on the top of the double ram preventer. The
annular shall be flanged bottom X studded top.
3.2.9
A flanged rotating head, with a flanged bottom connection to match the top connection of the
annular preventer and a 9" 3M flanged side outlet, may be installed on top of the annular

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preventer. A spacer spool may be required if annular studded top is not compatible with
rotating head flange.
Figure B-3: Class 'A' 10,000 psi BOP Stack with Single Sized Drill Pipe

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3.3
Class A 10,000 psi BOP Stack Arrangement (Tapered Drill Pipe String):
When using a tapered string of drill pipe the stack arrangement shall be the same as that for the
single string EXCEPT the blind rams in the bottom double (2) shall be sized for the smaller sized
pipe and the master pipe rams (1) and upper pipe rams (4) shall be sized for the larger pipe as
shown in Figure B-4.

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Figure B-4 Class A 10,000 psi BOP Stack with a Tapered String of Drill Pipe
4.0
CLASS A 5,000 PSI BOP STACKS
4.1
Usage:
A Class A 5,000 psi BOP stack shall be installed on wells where MASP may become more than
2,401 psi but not more than 4,000 psi. All of the elements of the BOP stack shall be 5,000 psi rated
working pressure. All preventers shall be installed so that rams can be changed without moving the
stack.
available in 7-1/16", 11", 13-5/8" and 18-3/4" 5M.
4.2
Class A 5,000 psi BOP Stack Arrangement:

The stack arrangement (from bottom to top) shall be as described below and as shown in Figure B-5:
4.2.1
A wellhead spool (or casing head) with a 18-3/4", 13-5/8", 11 or 7" 3M or 5M flange with two
(2) 2-1/16" or 3-1/16" 3M or 5M studded side outlets shall be installed. One outlet shall have
a flanged gate valve with a blind flange installed. The other outlet shall have a manually
operated flanged gate valve installed next to the wellhead and a hydraulically operated
(HCR) flanged gate valve connecting to the emergency kill line. The emergency kill line shall
be an individual line with flanged steel piping (no chiksan swings or hammer unions) and a
minimum 2 5M rated working pressure. Flexible hose (compliant with Chapter A section
2.0) may be used in combination with steel line.
The emergency kill line shall extend from the wellbore to end of the catwalk (approximately
90 feet), with a 2" 1502 Weco welded union (threaded connections are not acceptable) for
connection to an emergency pump. Offshore the emergency kill line will extend to the
emergency pump / cement unit.
NOTE: If shear blind rams are utilized, then the emergency kill line shall be 3 and 5M rated
working pressure. The manual gate valve shall remain as 2 with double studded
adapter to 3.
NOTE: If the wellhead spool has a 5M top flange, then the side outlet valves shall be 5M.
NOTE: All BOP equipment with working pressures of 3,000 psi and above shall have
flanged, welded, integral, or hubbed connections only.

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Figure B-5: Class 'A' 5,000 and 3,000 psi BOP Stack with VBRs

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4.2.2
If the top flange of the wellhead is below ground level, a spacer spool is required. If the BOP
Stack is larger than the wellhead a double studded adapter flange is required.
4.2.3
A 5M flanged single ram preventer shall be installed on the wellhead spool with master drill
pipe rams.
4.2.4
A 5M flanged drilling cross shall be installed on the single ram preventer. The drilling cross
shall have two (2) 3-1/8" (minimum) 5M side outlets.
4.2.5
There shall be a double studded adapter flange to adapt from one of the BOP side outlets to
the 2-1/16" 5M kill line and one from the other BOP side outlet to the 3-1/8 choke line.
4.2.6
Kill Lines:

a 2-1/16" 5M flanged hydraulic control gate valve
a 2-1/16" 5M flanged tee
On each side of the tee there shall be a 2-1/16" 5M flanged gate valve and a 2-1/16" 5M
flanged check valve.
On the remote side, the kill line shall be 5M and run at least 90 feet from the wellbore to the
end of the catwalk, with a flange to Weco 2" welded union.
On the primary side, the kill line shall be 5M and connected directly to the mud pumps or to
the stand pipe manifold.
4.2.7
Choke Lines:
On the choke line, from the drilling cross out, there shall be:

a 3-1/8" 5M flanged hydraulic control gate valve
a 3-1/8" 5M steel flanged line or flexible hose (Chapter A, Section 2.0) to a 3-1/8" 5M
flanged manually operated gate valve at the choke manifold
factory-made 5M working pressure line. All tees must be targeted with renewable
5M blind flanges (welded tees are not acceptable).
Chiksans and Weco connections (other than the remote connection at the end of the
catwalk on land operations) are not acceptable. Flexible hose (refer to Chapter A
Section 2.0) may be used in combination with steel line for kill, emergency kill line,
or choke line.
4.2.8
Either two (2) flanged/studded single ram preventers or a double ram preventer shall be
installed, with blind rams in the position immediately above the drilling spool and VBRs
installed immediately below the annular.

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Variable bore rams are required to be used on Class A 5M stacks. However, the master
pipe ram must be a fixed ram.
NOTE: Currently, Camerons Extended Range High Temperature VBR-II Packer is the only
variable bore ram that is approved for 5M applications (3-1/2" - 5-7/8" pipe sizes).
Additional information regarding the use of variable bore rams is provided in Chapter
A, Section 1.4.
4.2.9
A 5M flanged bottom and studded top annular preventer will be installed on the top ram
preventer.
4.2.10 A rotating head is optional.

4.3
Class A 5,000 psi BOP Stack Arrangement for Tapered Drill Pipe String:
The Class A 5,000 BOP Stack arrangement for tapered drill strings will be the same as it is for
single sized drillpipe EXCEPT the upper pipe rams (position 3) will be sized for the smaller sized drill
pipe as shown in Figure B-5. Alternatively, the upper pipe rams may be Variable Bore Rams as per
Chapter A Section 1.4. NOTE: Variable Bore Rams are not allowed in the Master Pipe Ram
position (lowermost rams).

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5.0
5.1
Usage:
Large Diameter Hole (as with Deep Gas Wells):
A Class A 3,000 psi BOP stack shall be installed on all wells where large diameter hole (as with
deep gas wells) is being drilled, as through 18-5/8" casing, and where hydrocarbon reservoirs with a
MASP of up to 2,400 psi may be drilled. All preventers shall be installed so that rams can be
changed without moving the stack.
Smaller Diameter Hole (as with Critical Oil Wells):
At the discretion of the Drilling Manager, some wells may require a Class A 3,000 psi stack instead
of a Class B 3,000 psi stack.
Shear blind rams on onshore stacks are required only on wells with high H2S, wells in gas cap areas
and wells in populated areas (close proximity). Further details on the use of shear blind rams is
provided in Chapter A section 1.5.
5.2
Class A 3,000 psi BOP Stack Arrangement for Large Diameter Hole (Single Size Drill Pipe):
All elements of Class A 3,000 psi stacks shall be at least 3,000 psi rated working pressure. The
through bore of the BOP stack including drilling spools, risers, DSA's and any other equipment will
be at least as large as the wellhead section immediately below it. These BOP stacks are available in
7-1/16", 11", 13-5/8" and 20-3/4 and 26-3/4" 3M. Each ram preventer shall have two (2) 4-1/16" 3M
side outlets. A double ram preventer will have four side outlets.
described below and as shown in Figure B5:
5.2.1
A wellhead spool (18-5/8" landing base or casing spool) with 20-3/4" 3,000 psi flange and
two (2) 3-1/16" 3M side outlets for emergency kill operations shall be installed. One outlet
shall have a 3-1/16" 3M gate valve with a 3-1/16" 3M blind flange. The other outlet shall
have a manually operated 3-1/16" 3M flanged gate valve next to the wellhead and a
hydraulic control 3-1/16" 3M flanged gate valve tied into the emergency kill line. The
emergency kill line shall be an individual line with flanged steel piping (no chiksan swings or
hammer unions) and a minimum 3 3M rated working pressure. Coflex hose (coflon lined)
may be used in combination with steel line. The emergency kill line shall extend from the
wellbore to end of the catwalk (approximately 90 feet), with a 3" 1502 Weco welded union
(threaded connections are not acceptable) for connection to an emergency pump.
5.2.2
If the wellhead top flange is below ground level a spacer spool is required. If the BOP Stack
is larger than the wellhead a DSA is required.
5.2.3
A 26-3/4 or 20-3/4 3M flanged single ram preventer shall be installed on the wellhead spool
above ground level with master drill pipe rams (1).
5.2.4
A 26-3/4 or 20-3/4 3M flanged drilling cross shall be installed on the single ram preventer.
A drilling cross shall have two (2) 4-1/16" 3M side outlets.

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5.2.5
Either a 26-3/4" or 20-3/4" 3M flanged double ram preventer or two (2) single ram preventers
shall be installed, with blind rams (2) and drill pipe rams (3).
5.2.6
A 26-3/4 or 20-3/4" 3M to 30 1M or 21-1/4" 2M double studded adapter flange (DSA) will

be required on top of this preventer. The DSA can be eliminated if a 26-3/4 or 20-3/4" 3M
psi flange is manufactured on the annular preventer.
5.2.7
A 30 1M or 21-1/4" 2M flanged bottom annular preventer shall complete this stack.
5.2.8
Kill Lines
a 2-1/16" 3M minimum flanged manually operated gate valve

a 2-1/16" 3M minimum flanged hydraulic control gate valve
a 2-1/16" 3M minimum flanged spacer spool
a 2-1/16" 3M minimum flanged tee
On each side of the tee there shall be a 2-1/16" 3M minimum flanged gate valve and a 21/16" 3M minimum flanged check valve.
On the remote side, the kill line shall be 3M minimum and run at least 90 feet from the
wellbore to the end of the catwalk, with a flange to Weco 2" welded union.
On the primary side, the kill line shall be 3M minimum and connected directly to the mud
pumps or to the stand pipe manifold.
5.2.9
Choke Lines

a 3-1/8" 3M minimum steel flanged line or flexible hose (Chapter A, Section 2.0) to a 31/8" 3M minimum flanged manually operated gate valve at the choke manifold
NOTE: All steel piping shall be made with 3M minimum flanges, targeted tees, block-tee
elbows, and factory-made 3M minimum working pressure line. All tees must be
targeted with renewable 3M minimum blind flanges (welded tees are not
acceptable).
Chiksans and Weco connections (other than the remote connection at the catwalk,
land operation) are not acceptable. Flexible hose (refer to Chapter A Section 2.0)
may be used in combination with steel line for kill, emergency kill line, or choke line.
5.2.10 A 3M minimum flanged bottom and studded top annular preventer will be installed on the top
ram preventer.
5.2.11 A rotating head is optional.

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5.3
Class A 3,000 psi BOP Stack Arrangement for Smaller Diameter Hole (Single Size Drill Pipe):
5.3.1
A wellhead spool (13-3/8" landing base) with 13-5/8" 3,000 psi flange and two (2) 2-1/16" 3M
side outlets for emergency kill operations shall be installed. One outlet shall have a 2-1/16"
3M gate valve with a 2-1/16" 3M blind flange. The other outlet shall have a manually
operated 2-1/16" 3M flanged gate valve next to the wellhead and a hydraulic control 2-1/16"
3M flanged gate valve tied into the emergency kill line. The emergency kill line shall be an
individual line with flanged steel piping (no chiksan swings or hammer unions) and a
minimum 3 3M rated working pressure (if SBR used) otherwise 2 3M. Coflex hose (coflon
lined) may be used in combination with steel line. The emergency kill line shall extend from
the wellbore to end of the catwalk (approximately 90 feet), with a 1502 WECO welded union
(threaded connections are not acceptable) for connection to an emergency pump.
Note:
5.4
If shear blind rams are utilized, then the emergency kill line shall be 3 and 3M rated
working pressure. The manual gate valve shall remain as 2 with double studded
adapter to 3.
5.3.2
If the wellhead top flange is below ground level, a 13-5/8 3M spacer spool may be required
to raise the bottom flange of the BOP to (or above) ground level.
5.3.3
A 13-5/8 3M flanged single ram preventer shall be installed on the wellhead spool above
ground level with master drill pipe rams.
5.3.4
A 13-5/8 3M flanged drilling cross shall be installed on the single ram preventer. A drilling
cross shall have two (2) 3-1/16" 3M side outlets. The same arrangement on the kill and
choke lines as for the Class A 5,000 psi BOP stack (land operation) shall be used, as
shown in Figure B-6.
5.3.5
Either two (2) 13-5/8" 3M flanged single ram preventers or a double ram preventer shall be
installed, with blind rams or shear blind rams, see required applications in Section 1.7.4,
(bottom) and drill pipe rams (top).
5.3.6
A 13-5/8" 3M flanged bottom with studded top annular preventer shall complete this stack.
5.3.7
Choke and kill lines shall be configured as per section 5.2 above.
Class A 3,000 psi BOP Stack Arrangement for Tapered Drill Pipe String:
The Class A 3,000 BOP Stack arrangement for tapered drill strings will be the same as it is for
single sized drillpipe EXCEPT the upper pipe rams (position 3) will be sized for the smaller sized drill
pipe as shown in Figure B-5. Alternatively, the upper pipe rams may be Variable Bore Rams as per
Chapter A Section 1.4. NOTE: Variable Bore Rams are not allowed in the Master Pipe Ram
position (lowermost rams).

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6.0
Class B 3,000 psi BOP Stack
6.1
Usage:
A Class B 3,000 psi BOP stack (Figure B-6) shall be installed, as a minimum, on all development oil
producers, water injectors, observation and water disposal wells. All BOP equipment shall be 13-5/8
3M (or 26-1/4 when used on deep gas wells), with kill and choke line requirements as previously
described in the Class A 3M. The kill line shall be 3M and connected directly to the mud pumps or
to the stand pipe manifold.
This stack will also be used for deep gas wells on 24 or 18-5/8 casing.
6.2
Class B 3,000 psi BOP Stack Arrangement:

All BOP equipment for these wells shall be arranged as described below.
6.2.1
A wellhead spool or casing head with a 3,000 psi flanged top and two (2) 2-1/16" 3M side
outlets for emergency kill operations shall be installed. One outlet shall have a 2-1/16" 3M
gate valve with a 2-1/16" 3M blind flange. The other outlet shall have a manually operated 21/16" 3M flanged gate valve next to the wellhead and a hydraulic control 2-1/16" 3M flanged
gate valve tied into the emergency kill line. The emergency kill line shall be an individual line
with flanged steel piping (no chiksan swings or hammer unions) and a minimum 3 3M rated
working pressure (if SBR used) otherwise 2 3M. Coflex hose (coflon lined) may be used in
combination with steel line. The emergency kill line shall extend from the wellbore to end of
the catwalk (approximately 90 feet), with a 1502 WECO welded union (threaded connections
are not acceptable) for connection to an emergency pump.
Note:
If used on deep gas wells with 24 or 18-5/8 casing the side outlets will be 4 and
kill lines will be 3 3M.
6.2.2
If the wellhead top flange is below ground level, a 3M spacer spool may be required.
6.2.3
A 3,000 psi single ram preventer shall be installed on the wellhead spool above ground level
with master drill pipe rams.
6.2.4
A 3,000 psi flanged drilling cross shall be installed on the single ram preventer. The drilling
cross shall have two (2) 3-1/16" 3M side outlets.
6.2.5
A 3,000 psi single ram preventer shall be installed on the top of the drilling cross with blind
rams.
6.2.6
A 3,000 psi flanged bottom with studded top annular preventer shall complete this stack.
6.2.7
Kill Lines

a 2-1/16" 3M minimum flanged spacer spool

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a 2-1/16" 3M minimum flanged tee
On each side of the tee there shall be a 2-1/16" 3M minimum flanged gate valve and a 21/16" 3M minimum flanged check valve.
On the remote side, the kill line shall be 3M minimum and run at least 90 feet from the
wellbore to the end of the catwalk, with a flange to Weco 2" welded union.
On the primary side, the kill line shall be 3M minimum and connected directly to the mud
pumps or to the stand pipe manifold.
6.2.8
Choke Lines

a 3-1/8" 3M minimum steel flanged line or flexible hose (Chapter A, Section 2.0) to a 31/8" 3M minimum flanged manually operated gate valve at the choke manifold
NOTE: All steel piping shall be made with 3M minimum flanges, targeted tees, block-tee
elbows, and factory-made 3M minimum working pressure line. All tees must be
targeted with renewable 3M minimum blind flanges (welded tees are not
acceptable).
Chiksans and Weco connections (other than the remote connection at the catwalk,
land operation) are not acceptable. Flexible hose (refer to Chapter A Section 2.0)
may be used in combination with steel line for kill line, emergency kill line, or choke
line.

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Figure B-6: Class 'B' 3,000 psi BOP Stack
7.0
CLASS C 3,000 PSI BOP STACK

A Class C 3,000 psi BOP stack (Figure B-7) shall be installed on all power water injector wells
during the drilling and acidizing operations in the Arab-D hole section. The minimum equipment
required will be an annular type preventer and a hydraulically operated dual ram preventer (or two
single ram preventers) with blind rams located on top and pipe rams on bottom. Two (2) 3-1/16 3M
side outlets below the pipe rams are required, one for the kill line hook-up and other for the choke
line. The kill line shall be adapted to 2-1/16 3M and connected directly to the mud pumps or to the
stand pipe manifold. A 10 3M Ball Valve (with 9 bore) is located below the ram preventers and
becomes part of the injection tree upon completion of the well.

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Figure B-7: Class 'C' 3,000 psi BOP Stack
8.0
CLASS D DIVERTER STACK

A Class D Diverter stack (Figure B-8) will be installed on the conductor and/or next casing of all
onshore exploration wells and development wells in the shallow gas area or areas where offset data
indicates possible shallow gas. In addition, this diverter stack will also be required on the conductor
of all offshore exploration wells and wells where offset data indicates possible shallow gas.
The diverter lines shall consist of Schedule 40 steel piping. This line shall be securely anchored and
terminate in the flare pit, 50 beyond the reserve pit or overboard. Saudi Aramco requires two (2) 6
minimum ID, full bore valves and 8 lines. All lines must be as straight as possible and all turns
targeted to minimize erosion. Offshore, the lines must allow diversion to port and/or starboard.
The emergency pump in connection shall be a 3-1/8 2M flanged connection, located 90 degrees
offset from the diverter lines (as noted in Figure B-8 below). The kill line shall be connected directly
to the mud pumps or to the stand pipe manifold.

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Figure B-8: Class D Diverter BOP Stack

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WORKOVER BOP STACKS

Maintaining control of a well during the completion and workover phases may be more complicated than well
control in drilling operations. Additional complications may exist as, a) various types of workover fluids
ranging from low-density diesel to high-density brine fluids may be used; b) interrelated activities may occur
simultaneously, such as workovers on a platform with producing wells.
Saudi Aramco has four (4) classes of BOP arrangements for workover operations. The workover program
shall specify the Class BOP stack (not individual components) to be used.
9.0
CLASS I 2,000 PSI WORKOVER STACK
9.1
Usage:
This class of BOP Stack is used on water supply wells and shallow, low-pressure aquifer observation
wells, where the operation to be performed on the well and/or space below the rig substructure
precludes use of ram-type preventers. NOTE: This class of BOP stack with a working pressure of
2,000 psi is not defined in Table 1.1; any given 21-1/4 Annular is typically rated to 2,000 psi and it
may be used on wells with a MASP of up to 1,600 psi.
9.2
Class I 2,000 psi Workover BOP Stack Arrangement:

9.2.1
The minimum equipment required will be a Hydril, Cameron, or NOV Shaffer annular type
preventer with a working pressure of 2,000 psi or greater. A 2 kill and/or fill-up line shall be
connected to the landing base side outlet as shown in Figure B-10.
9.2.2
When sufficient space below the rig substructure is available, a Power Water Injection Tree
(ball valve) shall be used below the annular, as shown in Figure B-9.
9.2.3
The annular preventer will be visually inspected and functionally tested prior to installation
and pressure tested after installation using a cup-type tester set at a depth of approximately
60. Test pressures, to be specified in the workover program, shall be greater than the
MASP, but shall not exceed 80% of the rated casing burst.

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Figure B-9: Class 'I' Workover BOP Stack
10.0 CLASS II 3000 PSI WORKOVER STACK

10.1
Usage:
This class BOP stack is used on most onshore workovers to be performed on producing, water
injection and reservoir observation wells. These wells are normally low-pressure and equipped with
up to 3,000 psi WP wellhead equipment.
10.2
Class II 3,000 psi Workover BOP Stack Arrangement:

This BOP stack is identical to the Class C Drilling stack as described in Section 7 above. Please
note that if SBRs are not being used, in special circumstances (such as low sub-structure height) it
is permissible to leave out the drilling spool and use the BOP side outlets for line connections.
11.0 CLASS III 5,000 PSI WORKOVER STACK

11.1
Usage:
This class BOP is used on all offshore workovers with wellhead equipment rated to 3,000 or 5,000
psi and onshore workovers with wellhead equipment rated to up to 5,000 psi.

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11.2
Class III 5,000 psi Workover BOP Stack Arrangement:

This BOP stack is identical to the Class A 5,000 psi Drilling stack as described in Section 4 and
Figure B-5 above.
12.0 CLASS IV 10,000 PSI WORKOVER STACK

12.1
Usage:
This class BOP is used on all workovers with up to 10,000 psi WP wellhead equipment.
12.2
Class IV 10,000 psi Workover BOP Stack Arrangement:

The Class IV 10,000 psi workover stack is arranged the same as the Class A 10,000 psi drilling
stack. All BOP equipment in this stack shall be 11 (or larger) 10M rated working pressure, including
the annular preventer. NOTE: The annular shall be 10,000 psi working pressure. All other
equipment requirements are as previously discussed in Section 3.0.
13.0 CLASS V 15,000 PSI WORKOVER STACK

13.1
Usage:
This class BOP is used on all workovers with up to 15,000 psi WP wellhead equipment.
13.2
Class V 15,000 psi Workover BOP Stack Arrangement:

The Class V 15,000 psi workover stack is arranged the same as the Class A 15,000 psi drilling
stack. All BOP equipment in this stack shall be 11 (or larger to provide full opening to the tubing
spool and production casing) 15M rated working pressure, except the annular preventer WHICH
shall be 10,000 psi working pressure. All other equipment requirements are as previously discussed
in Section 2.0.
14.0 SPECIAL WELL OPERATIONS BOP STACKS

The following represents Drilling and Workovers minimum BOP equipment requirements for coil
tubing, snubbing, and wireline operations. In some cases, the service companys internal policy may
exceed these BOP requirements.
14.1
BOP Equipment Requirements for Coil Tubing Operations:

BOP equipment requirements for low-pressure, high-pressure and critical well service coil tubing
(CT) operations are shown in Figures B-10, B-11 and B-12, respectively. Selecting the BOP
arrangement shall be based on the maximum anticipated operating or shut-in wellhead pressure.
These arrangements are for standard CT operations and should be modified as needed for special
or unusual applications.
14.1.1 Low-Pressure Coiled Tubing BOP Equipment Requirements
The low-pressure or standard arrangement (less than 5,000 psi WHP) includes 4 sets of
rams: tubing rams on the bottom in the #1 position, slip type rams in the #2 position, cutter

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rams in the #3 position and blind rams on top in the #4 position. In addition, there is a flow
cross with a valve installed below the cross. See Figure B-10.
SIDE DOOR
STRIPPER
SIDE
STRIP
SIDEDOOR
DOOR
DSA6
STRIPPER
GATE VALVE
BLIND
SHEAR
SLIP
QUAD
QUADBO
BOP
ES46
PIPE
Figure B-10: Low Pressure Coil Tubing BOP Stack

Low-pressure stacks shall comply with the following minimum requirements:
All equipment shall meet or exceed NACE MR-01-75 and API Standards for well control
Rated WP greater than the maximum anticipated well pressure
Side-door stripper
Minimum BOP configuration of blind, shear, slip, and pipe rams
Kill line with minimum 2-1/16 flanged connection
Flow cross with flanged outlets and double valves
Ability to monitor wellhead pressure below the pipe rams with isolator
Slip design that will minimize fatigue/deformation damage to the coil

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Slip rams capable of holding the pipe up to the yield point with maximum rated WP in a
hang-off mode
Accumulator shall be sized to operate all BOPE (close-open-close) at maximum rated
WP
14.1.2 High-Pressure (HP) and Critical Well Service (CWS) Coiled Tubing BOP Equipment
Requirements
The high-pressure arrangement (greater than 5,000 psi WHP) includes the same equipment
as in the low-pressure arrangement, plus a combination BOP containing a second set
shear/seal rams and a set of pipe/slip rams when flowing the well with coil tubing in the hole
(i.e. treating or production logging). A second stripper is also required when treating or
production logging. See Figure B-11.
SIDE DOOR
STRIPPER
OVER/ UNDER
SIDE
DOOR
DS
U6
STRIPPER
GATE VALVE
GATE
VALVE
BLIND
BLIND
GATE
VALVE
GATE VALVE
SHEAR
SHEAR
SLIP
SLIP
PIPE
PIPE
QUAD
QUAD
ES46
BOP
SHEAR/SEAL
DUAL
COMBI BOP
ES46
SHEAR/ SEAL
DUAL
COMBI
PIPE/ SLIP
BOP
Figure B-11: High Pressure Coil Tubing BOP Stack

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The critical well service arrangement (greater than 5,000 psi WHP) includes the same
equipment as in the high-pressure arrangement, plus a Coil Tubing Safety Head. The lower
master pipe rams on the Dual Combination BOP should be substituted for combination
shear/seal and pipe/slip rams when flowing the well with coil tubing in the hole (i.e. treating
or production logging). A second stripper is also required when treating or production
logging. See Figure B-12.
SIDE DOOR
STRIPPER
OVER/UNDER
SIDE
DOOR
STRIPPER
DSU6
GATE
VALVE
GATE VALVE
BLIND
BLIND
SHEAR
SHEAR
SLIP
SLIP
GATE
VALVE
GATE VALVE
PIPE
PIPE
QQUAD
UAD
BOP
ES46
SHEAR/SEAL
DUAL
COMBI BOP
ES46
SHEAR/SEAL
DUAL
PIPE/SLIP
COMBI
BOP
CT SAFETY
Figure B-12: Critical Well Service Coil Tubing BOP Stack

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High-pressure and CWS stacks shall comply with the following minimum requirements:
14.2
All equipment comply with or exceed NACE STANDARD MR-01-75 and API Standards
for well control
Rated WP greater than the maximum anticipated well pressure
Side-door stripper
Second side-door or radial stripper is required if flowing well w/CT in hole
Minimum BOP configuration of blind, shear, slip, pipe rams, and master pipe rams
below flow cross
Master pipe rams should be substituted for combination shear/seal and pipe/slip rams
when flowing the well with CT in the hole
Kill line with minimum 2-1/16 flanged connection
Flow cross with flanged outlets and double valves
Ability to monitor wellhead pressure below the pipe rams with isolator
Slip design that will minimize fatigue/deformation damage
Slip rams capable of holding the pipe up to the yield point with maximum rated WP in a
hang-off mode
Accumulator shall be sized to operate all BOPE (close-open-close) at maximum rated
WP
BOP Equipment Requirements for Snubbing Operations:

The stack arrangements in Figure B-13 and B-14 show basic set-ups for low-pressure and highpressure snubbing operations. Selecting the BOP arrangement shall be based on the maximum
anticipated operating or shut-in pressure.
14.2.1 Low-Pressure Snubbing BOP Equipment Requirements
The low-pressure (less than 5000 psi WHP) or standard arrangements basic features are the #1 and
#2 stripping rams, equalizing loop, safety, and blind rams. The primary rams are the #1 and #2
stripping rams. These rams are used in conjunction with the equalizing loop to strip the pipe into or
out of the hole. The equalizing loop and vent line are used to bleed off the pressure. Note that the
equalizing loop contains a fixed or positive choke to minimize the surge pressure when bleeding off
the pressure. Each set of valves contains one manual and one remotely operated valve. Below the
#2 rams is a set of safety or secondary rams to be used whenever either of the stripper rams begin
to leak or fail. Below the safety rams is a set of blind rams to be used to shut the well in when pipe is
out of the hole or landed in the hangar.

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Figure B-13, Low Pressure Snubbing Stack

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14.2.2 High-Pressure Snubbing BOP Equipment Requirements

The high-pressure arrangement (greater than 5000 psi WHP) includes everything the standard
arrangement has plus a second spool with dual outlets that contains a remotely operated choke, a
set of shear blind rams, and a second set of safety rams. The shear blind rams are considered a
third line of defence and are a last resort if primary control of the well is lost. In addition, a positive
choke is added to the vent line to allow a slower bleed-off of pressure from the well.
Figure B-14 High Pressure Snubbing Stack

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14.3
BOP Arrangements for Electric Line Operations:

The required BOP arrangement shall be determined by the electric line application (open-hole or
cased hole) and maximum anticipated surface pressure during the operation. All BOP equipment
shall comply with API 6A and NACE MR-01-75 (Latest Revision).
14.3.1 Open-Hole Electric Line BOP Requirements (Over-Balanced Condition)
When open-hole logging an oil well, an electric line BOP is not required, provided primary
well control (hydrostatic pressure > formation pressure) can be maintained and confirmed.
However, an electric line BOP is recommended on all gas wells.
14.3.2
Cased-Hole Electric Line BOP Requirements (Under-Balanced Condition)

When perforating or logging under-balanced, an electric line BOP and lubricator are required
with a wellhead adapter flange connected to the top of the test head or tree. Minimum
electric line BOP requirements for various cased-hole pressure applications are summarized
below.
Cased-Hole Electric Line

BOP Requirements:
(Under-Balanced Condition)
7/32 1/4 Line
Wells with Max.

Expected WHP
< 5,000 psi
Wells with Max.

Expected WHP
5,000 to 10,000
psi
5,000 psi
10,000 psi
Not Acceptable
Not Acceptable
Required
Required
Working Pressure
Manual BOP
Hydraulic BOP
Minimum Number of Rams
Minimum Temperature
Rating of Elastomer
250 F
300 F
Tool Trap
Required
Required
Tool Catcher
Optional
Optional
Ball Check Valve
Required
Required
Remote Grease Injection

Unit
Stuffing Box with Hydraulic
Operated Pack-Off
Required
Required
Required
Required
A stuffing box (w/ hydraulic operated pack-off) is required in unperforated cased hole when
running CBL, or similar logs, with + 1000 psi surface pressure while logging. An electric line
BOP is optional in this situation.
A typical electric line rig-up for cased-hole operations is shown in Figure B-15.

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Figure B-15 Electric Line BOP

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15.0 CHOKE MANIFOLDS

All choke manifolds and piping shall meet Sour Service NACE MR-01-75 (Latest Revision) and API
Specification 6A with the Hydraulic Chokes as per API 16C. Required specifications and applications
for the 15,000 psi, 10,000 psi, 5,000 psi, and 3,000 psi choke manifolds are shown below.
15.1
15,000 psi Working Pressure Choke Manifold:
FIGURE B-16: 4-1/16 15M Onshore Choke Manifold

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4-1/16 15M CHOKE MANIFOLD
All 15M psi choke manifolds shall comply with the following minimum requirements:
Valves and chokes shall be monogrammed to API Specification 6A or 16C and made to
the following,
PSL-2 or Better, (with PSL-3 Gas Test)

PR-1 or Better
MR-DD or Better
TR-X (Suitable for 350 F service)
Forged Bodies and Bonnets
All valves must be of a single gate (slab) design
Telescoping two-piece seats are not permitted
Nitrile/Buna Elastomer Seals are not permitted
All flanges and other components shall be monogrammed to API Spec-6A

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FIGURE B-17: 4-1/16 15M Offshore Choke Manifold

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15.2
FIGURE B-18: 4-1/16 10M Choke Manifold

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All 10M psi (& higher) choke manifolds shall comply with the following minimum requirements:
the following,
PSL-2 or Better, (with PSL-3 Gas Test)

PR-1 or Better
MR-DD or Better
TR-X (Suitable for 350 F service)
Telescoping two-piece seats are not permitted

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FIGURE B-19: 4-1/16 10M Offshore Choke Manifold

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15.3

Choke manifold configurations for 5,000 psi onshore and offshore applications are shown in Figure
B-20 and Figure B-21 respectively.
FIGURE B-20: Onshore 3-1/8 5M Choke Manifold

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FIGURE B-21: Offshore 3-1/8 5M Choke Manifold

the following,
PSL-2 or Better
PR-1 or Better
MR-DD or Better
TR-U (Suitable for 250F service)
Telescoping or floating seats are not permitted

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15.4

Valves and chokes shall be monogrammed to API Specification 6A or 16C made to the
following:
PSL-2 or Better
PR-1 or Better
MR-DD or Better
TR-U
Telescoping seats are not permitted
FIGURE B-22: 3-1/8 3M Choke Manifold

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15.5
Location:
The choke manifold shall be skid mounted on land rig (rig floor mounted on offshore rigs)
and located in an accessible area.
15.6
Choke Manifold Pressure Ratings:

The complete choke manifold, chokes, valves and piping will be full working pressure of the
BOP stack through the block valves down-stream of the chokes.
15.7
Piping Specifications:
The piping from the BOP stack to the choke manifold shall have the same working pressure
(or greater) as the BOP stack. All piping shall meet Sour Service NACE MR-01-75 (Latest
Revision) and API Specification 6A.
Choke lines for 3M and 5M applications shall either be steel pipe, Coflex hose (coflon lined
only), or combination of Coflex and steel pipe. All flexible hose shall be monogrammed to
API Specification 16C, and all end connections monogrammed to API Specification 6A.
Choke lines for 10,000 and higher psi applications shall be flanged pipe only.
All fabricated steel piping shall be as straight as possible, with targeted or block-tee elbows
at turns. All tees must be targeted with renewable blind flanges (welded tees are not
acceptable).
All choke line and manifold connections shall be flanged, welded, integral, or hubbed.
Chiksans and Weco connections are not acceptable.
15.8
Choke Manifold Discharge:

Provisions shall be made for the discharge from the choke manifold to be selectively diverted to:
15.8.1 Flare Lines
Two (2) 3-1/2, 9.3 #/ft., J-55, EUE flare lines, each approximately 400 feet in length,
shall be required for onshore oil wells.
Four (4) 4-1/2, 26#/ft., J-55, LTC gas flare lines and one (1) 3-1/2, 9.3#/ft., EUE
liquid flare line, each 1000 feet in length, shall be required for onshore gas wells.
Note:
Using drill pipe for flare line is not recommended because of the difficulty of
properly making up the connections on the ground.
15.8.1.1 One (1) each Flare Control Ignition Station located at choke manifold area,
complete with one (1) each igniter panel.
15.8.1.2 Two (2) each diesel drip system for back-up flare ignition at flare pit will be
required.

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15.8.1.3 On selected well sites a third party oil / gas separator with a vertical flare
stack will be required for well control.
An alternate flare pit and flare line will be rigged-up on deep gas wells (Figure B-23).
This emergency flare pit will be used in well kill operations if the main flare pit cannot
be utilized due to change in wind direction. Electronic flare ignition sources shall be
positioned in the main flare pit, alternate flare pit, and gas buster flare pit.
15.8.2 The following lines are to be positioned at an appropriate central aft point on the
drilling / workover unit and run to starboard and port sides with interconnecting
piping (Ref: Chapter A, 3.10 and 3.11) to the flare booms. Listed below are the
minimum piping requirements:
One (3) Oil line and one (4) Gas line, Schedule -160, ASTM-106 B black
pipe, H2S service manufactured and processed in accordance w / NACE
MR-01-75 and ANSI B.31.3. Including manifold to divert flow to starboard or
port side. Both lines must have a permanent / removable 3,000 psi WP Gate
Valve (Gate Valve Specification to be the same as choke manifold valves).
Note: a) flare lines should be as straight as possible and fitted with TARGETED
OR BLOCK TEE ELBOWS AT TURNS. Lines to be pressure tested
to 2000 psi during scheduled BOPE testing and prior to any flow
test.
b) All lines must be fully inspected and tested every five (5) years.
Inspection will include full visual, Pressure Testing, 100% Magnetic
Particle or Dye Penetrant NDE and Ultra Sonic to determine the integrity
of the wall thickness. Additionally, Inspection Documentation with 3 year
validity must be submitted at new rig start-up.

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FIGURE B-23: Deep Gas Flare Line Layout

15.9
Gas Buster Lines:

There should be a bypass line up-stream of the gas buster directly to the flare line and a valve on the
gas buster inlet line to protect the separator from high pressure. The mud discharge line from the gas
buster must have a vacuum breaker stacked vent line if the discharge line outlet is lower than the
bottom of the separator. This is to prevent siphoning gas from the separator to the mud pits. The
vacuum breaker stack must be as high as the gas buster.
One (1) 8 flanged/clamped steel vent line from the gas buster to at least 100 past the back of the
reserve pit shall be required for onshore oil wells.
Two (2) 8 flanged/clamped steel vent line, from the gas buster to at least 100 past the back of the
reserve pit shall be required for onshore gas wells.
The flare pit shall be positioned away from the reserve/waste pits to prevent ignition of any waste
hydrocarbons while circulating gas from the wellbore.

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CHAPTER C - MAINTENANCE, TESTING AND CERTIFICATION REQUIREMENTS
CHAPTER C: MAINTENANCE, TESTING AND CERTIFICATION REQUIREMENTS

TABLE OF CONTENTS
1.0
MAINTENANCE OF BLOWOUT PREVENTION EQUIPMENT
C3
2.0
GENERAL MAINTENANCE REQUIREMENTS
C3
3.0
TESTING OF BLOWOUT PREVENTION EQUIPMENT
4.0
3.1
General Pressure Testing Requirements (Test Frequency)
C5
3.2
Specific Requirements for Class A 15,000 psi BOP Stack
C7
3.3
C9
3.4
C 10
3.5
C 11
3.6
Specific Requirements for Class B 3,000 psi BOP Stack
C 12
3.7
Specific Requirements for Class C or II Workover Stack
C 13
3.8
Specific Requirements for Class D Diverter Stack
C 14
PRESSURE TESTING PROCEDURE

4.1
Function Testing and Flow Testing
C 15
4.2
Fill the Stack with Water
C 15
4.3
Casing Test (if required)
C 15
4.4
Blind Rams (if required)
C 16
4.5
Annular Preventer
C 17
4.6
Upper Pipe Rams
C 18
4.7
Positive Sealing Chokes
C 19
4.8
Choke Manifold (continued)
C 20
4.9
Choke Manifold (continued)
C 21
4.10 Choke Manifold (continued)
C 22

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4.11 Choke Line HCR Valve
C 23
4.12 Choke and Kill Line Manual Valves
C - 24
4.13 Master Pipe Rams
C 25
4.14 Small Pipe Rams
C 26
4.15 Kelly, Surface Circulating Equipment, and Safety Valves
C 27
4.16 Wellhead Valves
C 27
5.0
ACCUMULATOR TESTING
C 27
6.0
HANG-OFF LIMITATIONS WHILE TESTING
C 30
7.0
TEST PRESSURE REQUIREMENTS FOR CASING RAMS
C 30
8.0
CERTIFICATION AND RE-CERTIFICATION REQUIREMENTS
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1.0
MAINTENANCE, TESTING AND CERTIFICATION OF BLOWOUT

PREVENTION EQUIPMENT
This Chapter of the Well Control Manual sets forth the maintenance, testing and certification requirements
required for Saudi Aramco BOP equipment. These policies (as well as the equipment standards and
procedures throughout this well control manual) are considered mandatory. Variations or deviations from
these requirements require endorsement of the Well Control Committee, and approval by the Vice
President of Drilling and Workover. The enforcement of these requirements shall be the responsibility of
the Saudi Aramco Drilling Foreman (or Liaisonman) as directed by the Drilling Superintendent.
2.0
GENERAL MAINTENANCE REQUIREMENTS
Blowout prevention equipment is emergency equipment and must be maintained in its proper working
condition at all times. The Drilling Foreman can best ensure that Saudi Aramco is provided with
equipment that performs to our specifications by being an active participant in the maintenance
requirements of the BOP equipment.
Several maintenance items, which the Drilling Foreman should verify on a daily basis, by reviewing the
Drillers pre-tour checklist or by personal observation, are listed below:
1) Examine the fluid level in the accumulator. Make sure it is at the proper level and proper
pressures are indicated on the accumulator, manifold, and annular pressure gauges.
2) Verify the control lines are run to prevent damage by trucks or dropped tools.
3) Confirm the preventer controls are either in their proper opened or closed position (not
neutral) and that leaks are not evident.
4) Assure the preventer stack is well guyed so that vibrations are minimized while drilling.
5) All preventers must be operated at least each time a trip is made. Alternate trip closures
between the remote stations and the accumulator. The annular preventer does not have to be
operated to complete shut-off. Do not close the pipe rams on open hole.
6) The emergency kill line and choke/kill lines shall be washed out as required to prevent mud
solids settling. Clear water should be used to flush and fill the lines (except in extremely cold
weather, where diesel or glycol should be used).
7) DO NOT circulate green cement through the preventer stack or choke manifold. Always
thoroughly flush with water any piece of blowout prevention equipment, which has come in
contact with green cement and verify the equipment is clear upon the next nipple-up.
NOTE: This requirement includes the wellhead annulus valves. If green cement is pumped
through these they must be flushed well with fresh water to ensure that they will be
operable.
8) Ensure the rig is centred over the well to reduce drill string and BOP equipment contact and
abrasion.

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9) Do not use the kill line as a fill-up line during trips.

10) If possible, install the ram preventers so that the ram doors are positioned above and shield
the valves installed on the casing head below.
11) All rigs shall maintain a logbook of BOP schematics detailing the components installed in
each ram cavity. The logbooks shall contain the part number, description and installation date
of ram blocks, top seals, ram or annular packers and bonnet/door seals. To be witnessed and
co-signed by the Contract Toolpusher and Saudi Aramco Drilling Foreman (or Liaisonman).
12) Only OEM parts are acceptable when repairing or redressing the BOPE. Furthermore, only
OEM approved high-temperature lubricant is acceptable for valve maintenance.
13) At least one spare set of ram seals (top seals and packer rams) for all rams including packer
rams for each size of tubing or drill pipe, as well as bonnet seals, must be on the rig site.
14) Ram blocks should not be dressed until ready to use.
15) All BOP rubber goods shall be kept in a cool place and remain in the original packaging with
expiration dates.
16) Preventer assemblies shall be dismantled between wells to inspect for internal corrosion and
erosion and to check flange bolts.
17) Manufacturers installation, operation, and maintenance (IOM) manuals should be available
on the rig for all BOP equipment installed on the rig.
18) New ring gaskets shall be installed on each nipple-up at each connection, which has been
parted. Ring gaskets shall never be reused.
19) Studs and nuts should be checked for proper size and grade. Using the appropriate lubricant,
torque should be applied in a criss-cross manner to the flange studs. All bolts should then be
re-checked for the proper torque as prescribed in API Specification 6A. Bolt sizes 2-3/4 and
larger require more make-up torque than can be provided with Hammer Wrenches. These
larger sizes must be torqued using hydraulic torque units.
20) Field welding shall not be performed on any BOP or associated well control equipment. All
repairs to BOP equipment must be performed at an OEM facility, or their Licensee. OEM
repairs and recertification may be completed outside of Saudi Arabia if necessary.
21) A Maintenance Log for each piece of BOP equipment shall be maintained. This log shall
include, at a minimum, records of all service and inspections performed on the BOP, serial
numbers for each BOP and expiration date of all elastomers exposed to wellbore fluid. The
log will travel with the Contractor-owned equipment and shall be kept in the BOP shop for
Saudi Aramco-owned equipment.
22) All BOP equipment shall be API monogrammed.

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23) A full OEM Certification of the BOP, choke manifold (including chokes), and all related
equipment (i.e. kill line valves, choke line valves, Coflex hoses, etc.) shall be required at
contract start-up and contract renewal with a maximum period of 3 years between OEM recertification.
24) Accumulator bottles must have hydrostatic pressure testing completed every 5 years in
accordance with Department of Transportation (DOT) Cylinder Maintenance, Retest and
Certification Requirements #173.34.
25) The BOP should be opened, cleaned, and visually inspected after every nipple down,
including servicing the manual tie-down screws.
26) Elastomers having long-term exposure to wellbore fluids shall be changed at a maximum of
every 12 months, unless visual inspection requires changing earlier. However, it is
acceptable to use seal elements for 30 annulars up to 36 months (provided inspections are
satisfactory, properly documented, and the expiration date of the elastomer is not exceeded).
Seal elements for all other annulars (21-3/4 and smaller) shall be replaced no later than
every 12 months, as per policy.
27) All BOP equipment must have documentation of last inspection and certification. Documents
and Certification for Saudi Aramco owned BOP Equipment will be maintained and located at
the Saudi Aramco BOP Facility.
3.0
TESTING OF BLOWOUT PREVENTION EQUIPMENT

The objective of BOP equipment testing is to eliminate all leaks and to determine that the
equipment will perform under unplanned pressure conditions. This is accomplished by verifying:
3.1
Specific functions are operationally ready

Pressure integrity of installed BOP equipment
Compatibility between control system and BOP equipment
General Pressure Testing Requirements
All BOP equipment pressure tests shall be conducted in accordance with the following
guidelines.
Test Frequency
1) BOP equipment (including blind rams and shear blind rams) shall be pressure
tested as follows:
When installed
Before drilling out each string of casing
Following the disconnection or repair of any wellbore pressure seal in the
wellhead/BOP stack (limited to the affected components only)
NOTE: When rams are changed, the casing and/or tubing Rams (and annular
PREVENTOR) shall be pressure tested with a test plug and casing/tubing

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joint to 80% of the pipe collapse or the rated working pressure of the BOP
(whichever is less).
Working Pressure: 5,000 psi and lower; Test a maximum of every 21 days (no
extensions)
Working Pressure: 10,000 psi and higher; Test every 14 days. A maximum 2 day
extension is allowed with Superintendent written approval. Rig crews must be
alerted when pressure test operations are underway. Only necessary personnel
shall remain in the test area.
2) All tests shall be performed using clear water.

3) When a gas well is being flow tested, the test equipment (manifolds, lines, etc.) must
be tested with nitrogen.
4) The low-pressure test of each piece of BOP equipment shall be conducted at a
pressure of 300 psi.
5) The high-pressure test is specified in the following sections, by BOP class.
6) The low-pressure test shall be performed first. Do not test to the high- pressure and
then bleed down to the low pressure. The higher pressure could initiate a seal after the
pressure is lowered and thereby misrepresent the low-pressure test.
7) All valves located downstream of the valve being tested shall be placed in the OPEN
position.
8) OPEN casing valves to the atmosphere when using a test plug to test the BOP stack to
prevent possible leaks from rupturing the casing.
9) OPEN annular valves when testing to prevent pack-off leaks from pressuring up outer
casing strings.
10) Vent the cup tester through the drillpipe when testing the upper 60 feet of casing to
prevent possible leaks from rupturing the casing or applying pressure to the open hole.
11) Test all valves on the wellhead individually to their rated working pressure on
installation (using a VR plug) and to 80% of casing burst on subsequent pressure tests,
with a cup tester at located + 90.
12) Casing rams shall be tested to the maximum anticipated surface pressure (refer to
Section C, 6.0 for specific test pressures), with a joint of casing connected to a test plug
with appropriate cross-over.
13) Variable Bore Rams (VBR) shall be tested with all sizes of pipe in use, excluding drill
collars and bottom-hole tools.

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14) All pressure tests must be held for a minimum duration of ten (10) minutes with no
observable pressure decline.
15) Only authorized personnel shall go in the test area to inspect for leaks when the
equipment is under pressure.
16) Tightening or repair work shall be done only after pressure has been released and all
parties have agreed that there is no possibility of trapped pressure.
17) The BOPE flange bolt torque must be checked after every other BOP test. This will
help prevent leaks from the flanged connections in the BOP stack.
18) A pressure test is required after the installation of casing rams or tubing rams. This test
is limited to the components affected by the disconnection of the pressure containment
seal. The bonnet seals and rams shall be tested using a test joint connected to a test
plug, or cup tester, with appropriate crossover.
19) The initial pressure test performed on hydraulic chambers of annular preventers should
be at least 1,500 psi. Initial pressure tests on hydraulic chambers of rams and
hydraulically operated valves should be to the maximum operating pressure
recommended by the manufacturer. Test should be run on both the opening and
closing chambers. Subsequent pressure tests on hydraulic chambers should be upon
re-installation.
20) All pressure tests shall be conducted with a test pump. Avoid the use of rig pumps for
pressure testing. Cement units are acceptable.
21) All test results must be documented on a pressure chart, with the following information,
Date of Test
Well Name
Driller
Toolpusher
Saudi Aramco Representative
21) Test stumps are an acceptable method for pressure testing the BOP stack at the rig
site. The bottom connection (and any other connection not tested) must be tested with
a test plug upon installation of the BOP stack.
3.2
Specific Pressure Testing Requirements for Class A 15M BOP Stack

1) The initial high-pressure test of the following equipment shall be conducted upon
installation at the rated working pressure of the weakest component:
Wellhead
Ram-Type Preventers
Kill Line and Valves

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Emergency Kill Line and Valves

Choke Line and Valves
Choke Manifold
2) Subsequent high-pressure test(s) of the above equipment shall be conducted to a

pressure greater than the *maximum anticipated surface shut-in pressure.
Note: For Khuff development wells (Jilh Dolomite casing point)

Initial high-pressure test is 15,000 psi (full working pressure)
Subsequent high-pressure test(s) are 12,000 psi
For Pre-Khuff wells (Jilh Dolomite casing point and below)
For K1/MK1 wells only (where NU occurs above Jilh Dolomite casing point)
Subsequent high-pressure test(s) are 7,500 psi minimum.
(Prior to drilling into the Jilh Dolomite a high-pressure test(s) must be completed
at 15,000 psi)
3) The high-pressure test (initial and subsequent) of the annular preventer shall be
conducted at 70% of the rated working pressure.
4) All pressure tests, excluding casing tests, must be done with a test plug, due to the
minimum yield strength (burst rating) of the 13-3/8 72# and 9-5/8 53.5# casing. Test
plugs must be checked to insure the test plug is of the same manufacture and model as
the wellhead where it is to be installed. (i.e. Cameron to Cameron, Gray to Gray, FMC
to FMC and Wood Group to Wood Group.) The test plug Tong Neck must be checked
to insure that the O.D is smaller than the minimum I.D. of the wellhead.
5) The initial high-pressure test of the upper/lower kelly cocks, inside BOP, and safety
valves shall be conducted to their rated working pressure. Subsequent high-pressure
test(s) shall be conducted at the maximum anticipated surface shut-in pressure.
6) Rotary hoses, standpipe, vibrator hoses, and piping to pumps shall all be tested to
7500 psi.
7) The initial pressure test on the closing unit valves, manifold, gauges, and BOP
hydraulic lines shall be at the rated working pressure of the closing unit (3,000 psi).
Subsequent pressure shall be performed on each well installation at the same pressure
or after repairs to the hydraulic circuit.
8) At nipple up, the casing shall be tested to 80% of burst rating.

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9) The casing string in use shall be tested with a cup tester to 80% burst rating every 14
days (along with the scheduled BOP test). This will provide a pressure test of the
casing valves in addition to verifying casing integrity.
3.3

Wellhead
Ram-Type Preventers
Choke Manifold

pressure greater than the *maximum anticipated surface shut-in pressure.
Note: For Khuff development wells (Jilh Dolomite casing point)

For Pre-Khuff wells (Jilh Dolomite casing point and below)
For K1/MK1 wells only (where NU occurs above Jilh Dolomite casing point)
Subsequent high-pressure test(s) are 5,000 psi minimum
11) All pressure tests, excluding casing tests, must be done with a test plug, due to the
minimum yield strength (burst rating) of the 13-3/8 72# and 9-5/8 53.5# casing. Test
plugs must be checked to insure the test plug is of the same manufacture and model as
the wellhead where it is to be installed. (i.e. Cameron to Cameron, Gray to Gray, FMC
to FMC and Wood Group to Wood Group.) The test plug Tong Neck must be checked
to insure that the O.D is smaller than the minimum I.D. of the wellhead.
12) The initial high-pressure test of the upper/lower kelly cocks, inside BOP, and safety
valves shall be conducted to their rated working pressure. Subsequent high-pressure
test(s) shall be conducted at the maximum anticipated surface shut-in pressure.

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13) Rotary hoses, standpipe, vibrator hoses, and piping to pumps shall all be tested to
5,000 psi.
14) The initial pressure test on the closing unit valves, manifold, gauges, and BOP
hydraulic lines shall be at the rated working pressure of the closing unit (3,000 psi).
Subsequent pressure shall be performed on each well installation at the same pressure
or after repairs to the hydraulic circuit.
3.4

Wellhead
Ram-Type Preventers (including fixed PR, VBR, and SBR)
Choke Manifold

pressure greater than the maximum anticipated surface shut-in pressure. This test
pressure will be determined by the particular application (i.e. formations exposed,
fracture gradient or estimated fracture gradient, casing burst rating).
Note A cup tester may be used if the high-pressure test does not exceed 80% of the
casing burst rating.
4) The casing cup tester must be the appropriate size/weight for the application. When
using this tester, care must be taken that the total load applied to the drill string (cup
area times test pressure, plus the weight of the suspended drill string) does not exceed
the strings tensile limit.
5) The upper/lower kelly cocks, inside BOP, safety valves, rotary hose, standpipe, vibrator
hose, and piping to pumps shall be tested to same high-pressure tests (initial and
subsequent), as the BOP equipment, but not to exceed their rated working pressure.
6) The initial pressure test on the manifold and BOP hydraulic lines shall be at the rated
working pressure of the closing unit (3,000 psi). Subsequent pressure shall be

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performed on each well installation at the same pressure or after repairs to the
hydraulic circuit.
NOTE: BOP equipment may have a higher working pressure than required, due to rig
equipment availability. The high-pressure test requirement in these situations
shall be site-specific (limited by the WP rating of wellhead).
3.5

Wellhead
Ram-Type Preventers (including fixed PR, VBR, and SBR)
Choke Manifold
2) Any subsequent high-pressure test(s) of the above equipment shall be conducted at

2,500 psi or maximum anticipated surface shut-in pressure (whichever is greater), as
determined by the particular application (i.e. formations exposed, fracture gradient or
estimated fracture gradient, casing burst rating).
conducted at 2100 psi (70% of the rated working pressure).
5) Test plugs must be checked to insure the plug fits the casing head.

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hydraulic circuit.
3.6
Specific Pressure Testing Requirements for Class B 3M BOP Stack

Wellhead
Ram-Type Preventers
Choke Manifold

2500 psi or maximum anticipated surface shut-in pressure (whichever is greater), as
conducted at 2100 psi (70% of the rated working pressure).
5) Test plugs must be checked to insure the plug fits the casing head.
hydraulic circuit.

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3.7
Specific Pressure Testing Requirements for Class C or II 3M BOP Stack

installation and at the rated working pressure of the weakest member:
Wellhead
Double Ram Preventer
Choke Manifold

2,500 psi or maximum anticipated surface shut-in pressure (whichever is greater), as
conducted at 2,100 psi (70% of the rated working pressure).
hydraulic circuit.
Note: When testing a Class II 3M Workover stack on a Power Water Injection well
equipped with a ball master valve, the following must be observed:
a) Check the ball valve for leaks with wellhead pressure, from below, prior
to nippling-up the BOP stack.

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3.8
b) Report any observed leak for decision to spot a cement isolation plug.
c) Test the blind ram on the ground against a blind flange prior to nippling-up
the BOP stack. This will provide a pressure test on the blind ram without
relying on the ball valve, which may leak at higher pressure. The pipe ram
and annular can be tested with a cup tester after nippling up.
Specific Pressure Testing Requirements for Class D Diverter Stack
1) Activate the close/open sequence with drillpipe or test mandrel in the diverter to verify
control functions. DO NOT attempt to close the diverter on open hole except in an
emergency.
2) Pump water through the diverter system at low pressure and high rates. Examine entire
system for leaks, excessive vibration, and proper tie down.
3) The low-pressure test on the diverter shall be conducted upon installation and at 300
psi.
4) The high-pressure test shall be based on 80% rated working pressure of the weakest
component in the diverter system.
5) Function test the diverter daily.
4.0
PRESSURE TESTING PROCEDURE

The recommended pressure testing procedure for a Class A 10,000 psi BOP hook-up is given
below. This test procedure can be easily amended and made applicable for the other classes of
preventer stacks. Although the actual testing sequence may vary somewhat, the ultimate
objective must be achieved: To test each individual preventer, valve, and all associated lines in
the BOP system from the wellbore direction at a 300 psi low-pressure and then a specified highpressure.
The pressure source is shown down the drillpipe and through a perforated sub or ported test plug
(excluding blind ram or casing test); although, a BOP side outlet may be used. The annular and
pipe rams are tested individually in this manner. The blind rams are tested after removing the
drillpipe and applying pressure through the kill line, between closed rams and test plug.
Note: In the case of the Class A 10,000 psi (non-tapered string, where a lower set of blind rams
are positioned below the kill line), the test pressure must be applied through the side outlet
of the BOP.
In order to test each individual valve on the kill line, choke line, and manifold; proceed after
pressure testing the far outside valves, (all other valves open) by opening these valves and closing
each inside adjacent valve, pressure testing, and working inward to the stack.
Note: The steps in the following procedure should be performed in numerical sequence. The
instructions assume that at the beginning of each step, the equipment is arranged as in the
end of the previous step. Therefore, if this particular procedure is not followed in sequence,
erroneous test results may be obtained.

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4.1
Function Testing and Flow Testing
Before applying test pressure to the preventers, perform the following:
4.2
1)
Close and open all preventers. Do not close pipe rams or annular preventer on open
hole.
2)
Pump through the kill line, flow line, mud-gas separator, and choke lines and all flare
lines with water to make sure none are plugged.
Fill the Stack with Water
Drain the mud from the BOP stack and fill with clear water.
4.3
Casing Test
A casing test is generally conducted at nipple-up and when testing DV or float equipment. In
addition, this test is required every 14 days (along with the scheduled BOP test), with the use of a
cup tester, to provide a pressure test on casing head valves and verify casing integrity.
To conduct a casing test, perform the following:
1) Connect the pressure source to the kill line and open kill line valves #4 and #5.
Figure C.1 Casing
Shear Blind Rams
#3
Note:
Very Important - Monitor valves #1, #2, #3 and #3a for leaks/well flow.
2) Open all valves and chokes on choke manifold. Close valve #7 on choke line.
3) Close outer casing head valves #1 and #3a.
4) Close the blind/shear blind rams (or upper pipe rams, if pipe in the hole).

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5) Pump into the well through the kill line monitoring/recording the test pressure at the test
pump. For all casing strings other than drive pipe or structural casing, conduct the test
to 80% of the minimum internal yield (burst) of the casing.
6) To test inner casing head valves, close valves #2 and #3 and open outer valves #1 and
#3a. See Figure C.1.
Note: No manufacturer recommends opening rams, which are holding pressure.
Damage to the ram rubbers, ram blocks and ram cavities may occur.
4.4
Shear Blind Ram Test (or Blind Rams for other BOP Stack Configurations)
To pressure test the Shear Blind Ram (or Blind Ram), the following is required:
1) Land test plug in the casing head and remove running tool from the wellbore.
2) Connect the pressure source to the kill line and open kill line valves #4 and #5 (see
Figure C.2).
Figure C.2
Shear Blind Ram Test
Shear Blind Rams
#3a
Note:
Monitor valves #1, #2, #3 and #3a for well flow.
3) Open all valves and chokes on the choke manifold.

4) Open all casing head valves and close the choke line valve #7.
5) Close the shear blind rams.

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6) Pump into the well through the kill line. Monitor and record the test pressure at the test
pump. Conduct the low-pressure test first at a pressure of 300 psi. Conduct the highpressure test next at the pressure specified in previous requirements (Section K 2.2 for
Class A 10M).
Note: This test will also evaluate the choke line HCR valve and thereby eliminate the
need for Step 3.11.
4.5
Annular Preventer
Test the annular preventer as follows:
1) Land the test plug and test joint in the casing head.
2) Connect the pressure source to the test joint at the rig floor.
3) Close the kill line HCR (valve #4) and open all other kill line valves (the kill line check
valve should be crippled).
3) First, open all choke line and choke manifold valves. Then close the outermost choke
manifold valves #15, #16, #17, and #18 (before buffer tank). See Figure C.3.
Figure C.3
Annular Test
Shear Blind Rams
#19
#3a

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5) Verify that the casing head valves #2 and #3 are open.

6) Close the annular preventer and pump into the well through the test joint. Conduct the
low-pressure test first at a pressure of 300 psi. Conduct the high-pressure test next at a
pressure equal to 70% of the rated working pressure of the annular preventer. Verify
the accuracy of the gauge installed downstream of choke manifold valve #19 by
observing the test pressure.
4.6
Upper Pipe Rams

Without changing the choke manifold or testing arrangement, immediately test the upper
pipe rams as follows.
1) Close choke manifold valve #19 (see Figure C.4).
2) Close the upper pipe rams and pump into the well through the test joint. Conduct the
low-pressure test first at a pressure of 300 psi. Conduct the high-pressure test next at
the pressure specified in previous requirements. Confirm that choke manifold valve #19
is not leaking by observing a zero pressure indication on the downstream gauge.
Figure C.4
Upper Pipe Rams
Shear Blind
#3a
Note: Monitor valves #1, #2, #3 and #3a for well flow.

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4.7
Remote Hydraulic Choke Integrity Verification:

Verify as described below; before proceeding to Step 3.8.
1) Open outermost choke manifold valves #15, #16, and #18.
2) Close Hydraulic Chokes (see Figure C.5).
low-pressure test first at a pressure of 300 psi. Record bleed-off time, if any. Increase
pressure to 2500+ psi (do not exceed 10,000 psi). The purpose of the test is to verify
the choke is not washed-out and is capable of operating and holding adequate backpressure during well kill operations.
Note: API Specification 16C for Choke and Kill Systems states in section 9.9: Drilling
chokes are not intended to be used as shut off valves.
Note: The chokes are being shell tested to both low and high pressure under section
3.6 of this manual as well as the pressure integrity test in this section.
Figure C.5
Positive-Sealing Choke Test
Shear Blind Rams
#3a
Note:

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4.8
Choke Manifold Valves (continued)

Continue testing the choke manifold valves by performing the following:
1) Open outermost choke manifold valves #15, #16, #17, and #18.
2) Open chokes.
3) Close choke manifold valves #11, #12, and #14 (see Figure C.6).
the pressure specified in previous requirements.
Note:

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4.9
Choke Manifold Valves (continued)

Continue testing the choke manifold valves by performing the following:
1) Open choke manifold valves #11, #12, and #14.
2) Close choke manifold valves #9, #10, and #13 (see Figure C.7).
Figure C.7
Choke Manifold Valves
Shear Blind Rams
#3a
Note:
Monitor valves #1, #2, #3 and 3a for well flow.

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4.10 Choke Manifold Valves (continued)

1) Open choke manifold valves, #9, #10, and #13.
2) Close choke manifold valve #8 (see Figure C.8).
Figure C.8
Choke Manifold Valves
Shear Blind Rams
#3a

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4.11 Choke Line HCR Valve

Test the choke line HCR valve by performing the following:
1)
Open choke manifold valve #8.
2)
Close outer choke line HCR (valve #7). See Figure C.9.
Figure C.9
Choke Line HCR Valve
Shear Blind Rams
#3a
Note:

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4.12 Choke and Kill Line Manual Valves

Test the inner choke and kill line valves by performing the following:
1) Open choke line HCR (valve #7).
2) Close choke line manual valve #6.
3) Open kill line HCR (valve #4).
4) Close kill line manual valve #5 (see Figure C.10).
Figure C.10
Choke and Kill Line Manual Valves
Shear Blind Rams
#3a
Note: No manufacturer recommends opening rams, which are holding pressure. Damage to
the ram rubbers, ram blocks and ram cavities may occur.

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4.13 Master Pipe Rams

Test the master pipe rams by performing the following:
1) Open the upper pipe rams (see Figure C.11).
2) Close the master pipe rams and pump into the well through the test joint. Conduct the
Figure C.11
Master Pipe Rams
Shear Blind Rams
#1
#2
#3
#3
Note: Monitor valves #1, #2, #3 and 3a for well flow.


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4.14 Small Pipe Rams

Test the small pipe rams by performing the following:
1) Open the master pipe rams (see Figure C.12).
6) Pull the large test joint and test plug. Run a small test joint and plug.
3) Close the small pipe rams and pump into the well through the test joint. Conduct the
Figure C.12
Small Pipe Rams
Shear Blind Rams
#1
#2
#3
#3a
Note: Monitor valves #1, #2, #3 and 3a for well flow.


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4.15 Kelly, Surface Circulating Equipment, and Safety Valves

1) Pick up kelly and install full-opening safety valve on bottom of lower kelly valve.
2) Using an adaptor, connect to an independent test pump or cement pump.
3) Open appropriate standpipe valves and all kelly valves.
4) Fill the system with water and close standpipe valve to test the standpipe, rotary hose,
swivel, and kelly.
5) Conduct the low-pressure test first at a pressure of 300 psi.
6) Conduct the high-pressure test next at the pressure specified in previous
requirements.
7) By alternating closing upstream and opening downstream valves, all the kelly valves
could be tested without pressuring up again, although it may not possible to operate the
upper kelly valve under pressure.
8) The inside BOP (float type) can be tested similarly by installing below the full- opening
safety valve and opening all valves through the standpipe.
4.16 Wellhead Valves
Test all valves on the wellhead individually to their rated working pressure on installation
(using a VR plug) and to 80% of casing burst on subsequent pressure tests, with a cup
tester located at + 90.
5.0
ACCUMULATOR TESTS
These tests are for the purpose of determining the operating condition of the accumulator and
BOP system. They shall be performed every 14 days, at the same time the BOP equipment is
pressure tested, and at any other time deemed necessary by the Saudi Aramco Foreman. The
results shall be noted on the Saudi Aramco BOP Pressure Test Report (see Figure C.13, or Form
# 2.0 in Section S of this manual). To analyse the performance of the accumulator, the results of
each test should be compared with results of several previous tests. Any increase in closure or
recharge time indicates an immediate need for a thorough examination of the accumulator
system. The accumulator test shall include the following,
Record the accumulator capacity and useable volume

Record the accumulator pressure
Record the pre-charge pressure and last date checked
Record the closing and opening times for each component
Note: Alternate accumulator bi-weekly tests between the main nitrogen unit (with charging
system isolated) and air/electric back-up system (with bottle banks isolated).

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Preventer functions should also be operated remotely to insure proper operation of all
functions from the remote stations.
The accumulator test shall also comply Saudi Aramcos general requirements as follows:
Closing time for ram preventers should not exceed 30 seconds.
Closing time for annular preventers (less than 18-3/4) should not exceed 30 seconds.
Closing time for annular preventers (18-3/4 and larger) should not exceed 45 seconds.
The accumulator must have enough stored fluid under pressure to close all preventers,
open the choke hydraulic control gate valve (HCR), and retain 50% of the calculated
closing volume with a minimum of 200 psi above pre-charge pressure, without assistance
of the accumulator pumps.
The accumulator-backup system shall be automatic, supplied by a power source

independent from the power source to the primary accumulator-charging system, and
possess sufficient capability to close all blowout components and hold them closed.

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Figure C.13
Saudi Aramco BOP Pressure Test Form

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6.0
HANG-OFF LIMITATIONS WHILE TESTING

Many times, a portion of the bottom-hole assembly will be hung-off below the test plug while
conducting a BOP test. This is done for a variety of reasons including:
Leaves pipe in the hole to circulate through in case the well kicks.
Shortens the trip time by not having to pull completely out of the hole.
IT MUST BE REMEMBERED however, that hanging-off weight below the test plug reduces the
maximum allowable BOP test pressure. The table below lists the maximum allowable hang-load
for a given BOP test pressure for the wellhead manufacturers used by Saudi Aramco. This chart
should be reviewed before hanging-off and testing BOP equipment.
Bowl
Size
0
psi
1,000
psi
2,000
psi
3,000
psi
4,000
psi
5,000
psi
6,000
psi
7,000
psi
8,000
psi
9,000
psi
10,000
psi
11
580,000
580,000
580,000
580,000
580,000
580,000
543,000
466,000
389,000
312,000
235,000
13
580,000
580,000
580,000
580,000
580,000
515,000
388,000
261,000
134,000
7,000
20
580,000
580,000
580,000
580,000
580,000
580,000
26
580,000
580,000
580,000
580,000
580,000
580,000
7.0
TEST PRESSURE REQUIREMENTS FOR CASING/TUBING RAMS
Casing rams (and annular preventer) shall be pressure tested with a test plug and casing/tubing joint.
The test pressure shall be 80% of collapse of the pipe of the pipe or the working pressure of the flanges,
whichever is less.
8.0
RE-CERTIFICATION REQUIREMENTS
8.1 A full OEM certification or recertification of the BOP, choke manifold (including chokes)
and all related equipment must be performed at the start of the contract and least once
every three years thereafter. The documentation package shall be kept with the equipment
and must be available for inspection at the rig site by Saudi Aramco personnel. This
includes, but is not limited to [See Chapter A of Saudi Aramco Well Control Manual (WCM)]:
Ram preventers.
Annular preventers.
Gate, HCR and Check Valves on the kill, emergency kill, choke line and choke manifold.
Drilling chokes.
Kill, emergency kill and choke lines (and line components) including both hard line and
flexible hoses.
Drilling spools.
NOTE: Recertification can only be performed by the OEM or their licensee and the facility
must be Certified and Registered to API Q1 and/or Q2 in addition to API
Specifications 6A, 16A, and 16C. If recertified by a licensee, the document package
shall include a copy of the license issued by the OEM and Registration Certificates

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for the applicable API Specifications. The Repair Level (RL) for API Specification 6A
equipment (Valves, Drilling Spools, Flanged Hard Lines, etc.) must correspond to the
relevant Product Specification Level (PSL) as specified when manufactured.
NOTE: Choke and Kill flanged hard-lines mounted in semi-permanent locations may have insitu recertification using NDT methods to accurately determine Wall Thickness
(erosion or corrosion), Material Defects and Material Hardness.
NOTE: Re-Certified Gate, HCR and Check Valves must correspond and comply to Repair
Level RL-2 for 3000 and 5000 PSI and 10,000 and 15,000 must correspond and
comply to Repair Level RL-3 with Gas Test (Ref. API 6A, Annex J and Section A of
Saudi Aramco WCM, Line Item 2.4)
NOTE: New/Repaired equipment shall be accompanied by the manufacturer's/Repair Facility
certificate of compliance and a full documentation package including inspection and
test reports.
8.2 There is no re-certification requirement for Accumulator Control Systems. However, the
Accumulator Control Unit must undergo maintenance and testing every five years with
individual hydrostatic testing of the accumulator bottles. All documentation including
individual Accumulator Bottle test charts must be resident at the rig.

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CHAPTER D - WELL CONTROL POLICIES
CHAPTER D: WELL CONTROL POLICIES

TABLE OF CONTENTS
1.0
WELL CONTROL POLICIES
D-4
2.0
WELL CONTROL CERTIFICATION
D-4
3.0
USE OF DIVERTERS
3.1
Onshore Wells
D-4
3.2
Offshore Wells
D-4
4.0
LEAK IN FLANGE OR RING GASKET BETWEEN BOP AND CASING HEAD
D-4
5.0
DRILL PIPE FLOAT
D-5
6.0
TAPERED STRING
D-5
7.0
SPACE OUT
7.1
Space Out Data
D-5
7.2
Space Out For BOPs With SBRs
D-5
8.0
SLOW PUMP RATE DATA
9.0
TRIPPING PIPE
10.0
D-5
9.1
Pulling Out of Hole
D-6
9.2
Running In Hole
D-6
PERFORMING FLOW CHECKS

10.1 While Drilling
D-6
10.2 While Tripping
D-6
11.0
DISPLACING TO BRINE ON HORIZONTAL WELLS
D-7
12.0
SHUTTING IN WELL
12.1 Shutting In Well without Flow Checking
D-7
12.2 While Drilling
D-7
12.3 While Tripping
D-7
12.4 With BHA across BOP Stack
D-8
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
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12.5 Shutting In On Pre-Perforated Liner with DP and 10,000 psi Class A BOP Stack
D-8
13.0
FAILURE OF UPPER PIPE RAMS DURING A WELL KILL OPERATION
D-8
14.0
BOP CONFIGURATION WHEN RUNNING CASING OR LINERS
15.0
14.1 Running Casing or Liner W/ Class B 3M Stack
D-9
14.2 Running Casing or Liner W/ Class A 3M or 5M Stack
D-9
14.3 Running Casing or Liner W/ Class A 10M Stack (W/ SBR)
D-9
14.4 Running 7 Liner W/ Class A 10M Stack (W/ SBR)
D-10
14.5 Running 4-1/2 Liner W/ Class A 10M Stack
D-10
14.6 Running 4-1/2 Pre-Perforated Liner W/ Class A 10M Stack
D-10
CHANGING RAMS OR INSTALLING CASING RAMS

15.1 Isolation Policy
D-10
15.2 Pressure Testing Casing Rams
D-10
16.0
INSTALLING CASING SLIPS WITH MULTI STAGE CEMENTING
D-10
17.0
BOP CONFIGURATION WHEN RUNNING PRODUCTION TUBING
18.0
17.1 Running 5-1/2 or 5-1/2 x 4-1/2 With Class A 10M and Higher Stack
D-11
17.2 Running 4-1/2 Tubing With Class A 10M and Higher Stack
D-11
17.3 Running Dual Strings Simultaneously With Class A 5M Stack
D-11
BOP CONFIGURATION WHEN RUNNING PRODUCTION TUBING WITH

PACKER
18.1 Running Tubing/Packer Simultaneously w/ Class A 3 or 5M Stack
19.0
20.0
REMOVING BOP STACK OR PRODUCTION TREE

19.1 Isolation Policy for Low GOR Oil Wells
D-12
19.2 Isolation Policy for High GOR Oil Wells
D-12
19.3 Isolation Policy for Gas Wells
D-12
19.4 Isolation Policy for WIW Wells
D-12
RIGGING DOWN ON HIGH GOR WELLS W/ SSSV

20.1 RD Procedure (w/ Little Clearance between Rig and Tree)
21.0
D-12
D-13
RUNNING OR PULLING TUBING AND ESP CABLE

21.1 BOP Configuration
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
D-13
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22.0
23.0
21.2 Pressure Testing Annulars
D-13
21.3 Shut-In Procedure
D-13
BOP CONFIGURATION WHEN RUNNING TEST STRING

22.1 Running 3-1/2 Test String w/ Class A 10M Stack (W/ SBR)
D-14
22.2 Running 3-1/2 Test String w/ Class A 5M Stack
D-14
RIGGING UP SURFACE WELL TEST EQUIPMENT

23.1 Installing Surface Lines Upstream of Test Manifold
24.0
25.0
26.0
D-14
PRESSURE TESTING WITH NITROGEN

24.1 Surface Well Test Equipment (Gas Wells)
D-14
24.2 Lubricator (Gas Wells)
D-15
PROBLEMS WHILE LOGGING

25.1 Shutting in While Logging With Side Entry Sub (Wireline across BOP)
D-15
25.2 Fishing Procedure for Stuck Logging Tool in Open Hole
D-15
RUNNING PDHMS AND/OR SMART-WELL LINES ON TUBING OR CASING

26.1 Oil Wells
D-16
26.2 Gas Wells
D-16
27.0
SETTING BRIDGE PLUGS
D-17
28.0
PLATFORM WELL SECURITY REQUIREMENTS PRIOR TO WORKOVER

OPERATIONS
28.1
Required Number of Mechanical Barriers of Isolation
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
D-3
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VOLUME I
1.0
WELL CONTROL POLICIES
This Chapter of the Well Control Manual sets forth the well control policies and specifications that are
routinely referenced. These policies (as well as the equipment standards and procedures throughout this
well control manual) are considered mandatory. Variations or deviations from these requirements require
endorsement of the Well Control Committee, and approval by the Vice President of Drilling and Workover.
The enforcement of these requirements shall be the responsibility of the Saudi Aramco Drilling Foreman (or
Liaisonman) as directed by the Drilling Superintendent.
2.0
WELL CONTROL CERTIFICATION

POLICY
All Saudi Aramco Drilling and Workover Superintendents, Rig Foremen,

Liaisonmen, Engineers, Engineering Supervisors, Engineering General
Supervisors, Liaisonmen Consultants, Contract Toolpushers, Drillers, and
Assistant Drillers shall have current Supervisor Level Well Control Certification
(Well Cap) from an IADC accredited school.
NOTE: IWCF Certification is not acceptable for Saudi Aramco D&WO
Operations.
3.0
USE OF DIVERTERS
3.1
NIPPLING UP DIVERTERS ONSHORE

POLICY
A Class D diverter stack shall be installed on the conductor and/or next casing
string for all exploration wells and development wells in the shallow gas area or
areas where offset data indicates shallow gas wells.
All other onshore areas do not need a diverter.
3.2
NIPPLING UP DIVERTERS OFFSHORE

POLICY
A class D diverter stack shall be installed on the conductor of all offshore

exploration wells and wells where offset data indicates possible shallow gas.
The diverter lines must have the capability of discharging to Port and / or
Starboard.
4.0
LEAK IN FLANGE OR RING GASKET BETWEEN BOP STACK AND

CASING HEAD (WHILE TESTING BOP STACK)
If a leak is observed in a flange during a BOP test, the bolts on the flange should first be tightened to
recommended torque. If tightening the bolts does not cure the leak the following should be followed
for any leak which would require the removal of the BOP from the Wellhead:
Set a Cement Plug or RTTS Packer in accordance with GI: 1853.001
Current Revision:
Previous Revision:
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MAY, 2010
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VOLUME I
5.0
DRILL PIPE FLOAT

POLICY
A drill pipe float shall be run at all times (except when planned operations preclude running a
float; as testing, treating, or squeezing).
A ported float is not recommended as these ports can be easily plugged and sometimes
washout.
6.0
TAPERED STRING
POLICY
When working with a tapered drill string always be in a position to have at least one stand of
either size pipe available to pick up.
7.0
SPACE OUT
7.1
SPACE OUT DATA

POLICY
7.2
Space out data shall be clearly visible in the dog house and recorded in the IADC tour book
each time the rig performs a bop drill.
SPACE OUT FOR BOPs WITH SBRs

POLICY
When spacing out in BOP Stacks with SBRs a tool joint shall be positioned 23 feet
above the lower (Master) pipe rams. In the event that pipe is to be sheared, the following
steps will be taken:
1)
2)
3)
4)
Close lower master rams

Lower the tool joint lowered to land out in rams
Slack off so that the pipe is relaxed (not in tension)
Activate the SBRs using proper procedures
NOTE: This procedure will negate the recoil effects of shearing free, suspended pipe
allowing pipe to drop and prevent stored energy in drill string releasing suddenly
causing a recoil and possible damage to top drive main shafts and lodging pipe
across BOP stack.
8.0
SLOW PUMP RATE DATA

POLICY
Slow pump rate shall be recorded in the IADC tour book

1)
2)
3)
4)
5)
6)
Tourly
After a mud weight change
After a bit nozzle or BHA change
After each 500 of depth
After a drilling or completion fluid type change
Whenever mud properties significantly change
NOTE: All flow checks shall be at least 15 minutes.
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
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VOLUME I
9.0
TRIPPING PIPE
9.1
Pulling Out Of Hole

POLICY
The following procedure is required when POH

1)
2)
3)
Ensure a full opening safety valve, inside BOP, closing wrench, and crossover subs are
on rig floor
Record data on trip sheet every 5 stands for DP, 2 stands for HWDP, and every stand
for DC
Compare data to expected displacement values
NOTE:
9.2
Avoid pulling a wet string whenever possible.
RUNNING IN HOLE
POLICY
The following procedure is required when RIH

1)
2)
3)
4)
5)
Ensure full opening safety valve, inside bop, closing wrench, and crossover subs are
on rig floor
Run in hole approximately one minute per stand
Record data on trip sheet every 5 stands for DP, 2 stands for HWDP, and every stand
for DC
Compare data to expected displacement values
Fill drill pipe every 10 to 20 stands
NOTE: Use the trip tank when running casing.
10.0 PERFORMING FLOW CHECKS

10.1
PERFORMING FLOW CHECKS WHILE DRILLING

POLICY
A FLOW CHECK SHALL BE PERFORMED WHENEVER

1)
2)
3)
4)
5)
6)
Decrease in pump pressure

Increase in pump strokes
Decrease in mud weight
Increase in chlorides
Gradual increase in drill rate
Drilling break

10.2
PERFORMING FLOW CHECKS WHILE TRIPPING

POLICY
A FLOW CHECK SHALL BE PERFORMED WHENEVER

1)
2)
Current Revision:
Previous Revision:
When the hole is not taking the correct amount of fluid

Before pumping a slug
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VOLUME I
3)*
4)*
5)
6)*
7)
Before pulling out of the hole

After pulling 5 to 10 stands
When bit enters casing shoe
Prior to pulling last 5 stands
Prior to pulling the BHA
Indicates additional flow checks required when a hydrocarbon zone is open.
11.0 DISPLACING TO BRINE ON HORIZONTAL WELLS

POLICY
The following SHALL BE required

1)
2)
3)
4)
A brine density that will provide the same overbalance (at bottom hole temperature) as
mud weight utilized
Measurement of brine density in/out to verify that both are the same at same
temperature
A minimum of one hour to wait/observe well after displacing to brine
Pumping out of the hole for minimized swabbing, continued fill-up, and improved gas
displacement in the horizontal open hole
12.0 SHUTTING IN WELL

12.1
Shutting In Well Without A Flow Check

POLICY
Immediate action should be taken to shut in well whenever there is:

1)
2)
12.2
Shutting In Well While Drilling

POLICY
Shut-in procedure (HARD SHUTIN)

1)
2)
3)
4)
5)
12.3
An increase in pit gain

An increase in flow rate
Space OUT (SPOT TOOL JOINT)

Stop mud pumps
Close annular or upper ram preventer
Confirm well is shut in and flow has stopped
Open HCR
Shutting In Well While Tripping

POLICY
Shut-in procedure (HARD SHUTIN)

1)
2)
3)
4)
5)
Current Revision:
Previous Revision:
Stab full open safety valve

Close safety valve
Space out (spot tool joint)
Close annular or upper ram preventer
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6) Open HCR
NOTE: DO NOT attempt to run in hole with the well flowing.
12.4
Shutting In Well With BHA Across Bop Stack

POLICY
SHUT-IN PROCEDURE (hard shutin)

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Set slips
Install crossover to full open safety valve
Stab full open safety valve
Close safety valve
Close annular
Open HCR
Install inside BOP
Open safety valve
Reduce closing pressure on annular and strip-in a stand of drill pipe
NOTE: In the event of a failure in the annular (with BHA across bop stack) and
uncontrolled flow, the BHA should be dropped and well shut in with the blind rams.
12.5
Shutting In On Pre-Perforated Liner with Drill Pipe

POLICY
SHUT-IN PROCEDURE:
1) Set casing slips
2) Install XO's to DP
3) Make up a stand of DP and RIH
4) Stab full open safety valve and close valve
5) Install inside bop and open safety valve
6) Shut upper pipe rams
7) Open HCR
NOTE:
If this procedure cannot be accomplished due to the amount of flow (or inner
string), the liner shall be dropped (by closing pipe rams, hanging off, and opening
pipe ram) and shutting the blind rams.
13.0 FAILURE OF UPPER PIPE RAMS DURING A WELL KILL

OPERATION (10,000 + psi Class A)
POLICY
Current Revision:
Previous Revision:
RECOMMENDED ACTION TO INCLUDE

1) Close master pipe rams
2) Replace upper pipe rams with newly dressed rams. NOTE: Circulation and kill
operations should continue using the secondary choke line on a Class A 10M or 15M
BOP stack and repair later.
3) Close upper pipe rams
4) Equalize pressure between upper and lower pipe rams
5) Open master pipe rams
6) Continue with well kill
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14.0 BOP CONFIGURATION WHEN RUNNING CASING OR LINERS

14.1
RUNNING CASING OR LINER WITH CLASS B 3000 PSI BOP STACK

POLICY
BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING

ANNULAR:
USED AS CASING RAMS
TOP RAM:
BLIND RAMS
MASTER PIPE: DRILL PIPE RAMS
HAVE XO (CASING X DP) ON DRILL FLOOR.
14.2
RUNNING CASING WITH CLASS A 3,000 OR 5,000 PSI BOP STACK (WITH OR WITHOUT
SBR)
POLICY
FOR SHORT LINERS (< 2000)

ANNULAR:
USED AS CASING RAMS
TOP RAM:
PIPE RAMS
MIDDLE RAM: BLIND RAMS (OR SHEAR BLIND RAMS)
MASTER PIPE: PIPE RAMS
POLICY
FOR LONG LINERS (>2000) LONG STRINGS

ANNULAR:
TOP RAM:
CHANGE PIPE RAMS TO CASING RAMS
MASTER PIPE: PIPE RAMS
14.3
RUNNING CASING WITH CLASS A 10,000 PSI (and Higher) BOP STACK (with SBR)
POLICY

ANNULAR:
TOP RAM:
CHANGE PIPE RAMS TO CASING RAMS
MIDDLE RAM: SHEAR BLIND RAMS
TOP MASTER: BLIND RAMS
BTM MASTER: PIPE RAMS
HAVE XO (CASING X DP) ON DRILL FLOOR
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
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Drilling & Workover
VOLUME I
14.4
RUNNING LINER WITH CLASS A 10,000 PSI (and Higher) BOP STACK (with SBR)
POLICY
14.5

ANNULAR:
USED AS CASING RAMS
TOP RAM:
PIPE RAMS
TOP MASTER: BLIND RAMS
BTM MASTER: PIPE RAMS
RUNNING PRE-PERFORATED LINER WITH 10,000 PSI (and Higher) CLASS A BOP STACK
POLICY

ANNULAR:
TOP RAM:
LARGE DP PIPE RAMS
TOP MASTER: SMALL DP PIPE RAMS
BTM MASTER: LARGE DP PIPE RAMS
HAVE XOS (LINER x DP) ON DRILL FLOOR.
15.0 CHANGING RAMS OR INSTALLING CASING or TUBING RAMS

15.1
ISOLATION POLICY WHEN CHANGING RAMS OR INSTALLING CASING OR TUBING RAMS

POLICY
REQUIRES 2 BARRIERS FOR ISOLATION

1) Closed pipe or blind ram (mechanical shut-off)
2) Kill fluid (non-mechanical shut-off)
Monitor annulus using wellhead valves.
If the bottom master ram is to be changed and the well is open to the formation, a packer
and storm valve with kill string is required for a mechanical barrier.
15.2
NOTE:
Refer to GI 1853.001
NOTE:
A test plug or tubing hanger with installed BPV should not be used as a
mechanical barrier in this application.
PRESSURE TESTING CASING AND TUBING RAMS

POLICY
Casing and Tubing Rams (and annular PREVENTOR) shall be pressure tested with a test
plug and casing joint to 80% of the pipe collapse or the rated working pressure of the BOP
(whichever is less).
16.0 INSTALLING CASING SLIPS WITH MULTI STAGE CEMENTING

POLICY
Current Revision:
Previous Revision:
SET CASING SLIPS AS FOLLOWS

1) Displace 1st stage cement w/ mud ( 2nd, if 3 stage job)
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2)
3)
4)
5)
Open upper most DV

Circulate hole clean w/ mud
WOC 4 hrs. with well static (observing well for flow)
Break circulation every Hour to prevent cement from setting up across ports (if packer
failure and Expansion)
6) Circulate bottoms up
7) Pickup BOP stack (DO NOT DROP CASING SLIPS)
8) Set casing slips prior to cementing final stage
NOTE:
Consider pumping second stage cement before setting slips, if the packer fails and
loss circulation is experienced (especially with a hydrocarbon or H2S zone open).
this situation should be referred to operations management on a case by case
basis.
17.0 BOP CONFIGURATION WHEN RUNNING PRODUCTION TUBING

17.1
RUNNING 5-1/2 PRODUCTION TUBING (OR 5-1/2 x 4-1/2 TUBING) AND CLASS A 10,000
AND HIGHER PSI BOP STACK
POLICY
BOP CONFIGURATION SHALL CONSIST OF THE FOLLOWING:

ANNULAR:
TOP RAM:
5-1/2 PIPE RAMS
TOP MASTER: 5-1/2 PIPE RAMS
BTM MASTER: 5-1/2 PIPE RAMS
HAVE XO (5-1/2 x 4-1/2 TBG) ON DRILL FLOOR.
17.2
RUNNING 4-1/2 PRODUCTION TUBING CLASS A 10,000 AND HIGHER PSI BOP STACK
POLICY

ANNULAR:
TOP RAM:
4-1/2 PIPE RAMS
BTM MASTER: RAMS TO MATCH THE LARGEST DP IN USE
HAVE XO (5-1/2 DP x 4-1/2 TBG) ON DRILL FLOOR.
17.3
RUNNING DUAL STRINGS SIMULTANEOUSLY WITH CLASS A 5,000 PSI BOP STACK
POLICY

ANNULAR:
TOP RAM:
DUAL RAMS
MASTER PIPE: DUAL RAMS
18.0 BOP CONFIGURATION WHEN RUNNING PRODUCTION TUBING

AND PACKER
Current Revision:
Previous Revision:
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MAY, 2010
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Drilling & Workover
VOLUME I
18.1
RUNNING PRODUCTION TUBING AND PACKER SIMULTANEOUSLY WITH CLASS A 3,000

OR 5,000 PSI BOP STACK
POLICY

ANNULAR:
TOP RAM:
**TUBING RAMS
MASTER PIPE: *DRILL PIPE RAMS
*
Do NOT change the master pipe rams to tubing rams (they should remain drill pipe
rams) this will eliminate the need for running a RBP and/or RTTS and storm valve.
**
If a tapered string is to be run, the upper pipe rams shall be changed to the size of the
major section of tubing in the string.
Have XOs (tbg x DP) and (large tbg x small tbg, for tapered strings) on the drill floor.
NOTE:
In case of loss circulation, the hole shall be continuously filled (both tubing and
backside) while running the completion string.
19.0 REMOVING BOP STACK OR PRODUCTION TREE

19.1
ISOLATION POLICY FOR LOW GOR OIL WELLS

POLICY
19.2
ISOLATION POLICY FOR HIGH GOR OIL WELLS

POLICY
19.3
REQUIRED BARRIERS FOR OIL WELLS (GOR > 850 SCF/BBL)

3 SHUT-OFFS (TWO MECHANICAL)
FOR DETAILS REFER TO G.I. 1853.001
ISOLATION POLICY FOR GAS WELLS

POLICY
19.4
REQUIRED BARRIERS FOR OIL WELLS (GOR < 850 SCF/BBL)

2 SHUT-OFFS (ONE MECHANICAL)
REQUIRED BARRIERS FOR GAS WELLS

3 SHUT-OFFS (TWO MECHANICAL)
ISOLATION POLICY FOR WATER INJECTION WELLS

POLICY
REQUIRED BARRIERS FOR WIW WELLS (IF POSITIVE WHP)

2 SHUT-OFFS (ONE MECHANICAL)
POLICY
REQUIRED BARRIERS FOR WIW WELLS (IF NOT POSITIVE WHP)

1 SHUT-OFF
Current Revision:
Previous Revision:
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VOLUME I
20.0 RIGGING DOWN ON HIGH GOR WELLS WITH OR WITHOUT SSSV

20.1
RIG DOWN PROCEDURE (WITH LITTLE CLEARANCE BETWEEN RIG AND TREE)
POLICY
PROCEDURE
1) NU and PT tree
2) Retrieve wireline plug from tail pipe
3) Close crown valve (do not RD wireline unit)
4) Open well for clean-up
5) Close lower master valve (observe negative test)
6) RIH with wireline and set plug
7) Bleed off pressure (observe plug is holding) - barrier 1
8) Close SSSV
9) Install barrier 2: Mechanical Retrievable Barrier
10) Split tree above closed lower master valve - barrier 3
11) Move the rig out
12) Re-install tree above the lower master valve
13) Later, RU wireline unit and retrieve the plug
NOTE:
A BPV may be installed instead of setting a wireline plug.
21.0 RUNNING OR PULLING TUBING AND ESP CABLE

21.1
BOP CONFIGURATION WHEN RUNNING OR PULLING TUBING AND ESP CABLE

POLICY

ANNULAR:
ANNULAR:
BOP STACK:
BASED ON BOP CLASS
NOTE: One annular may be used if there is 0 psi SIWHP whenever the ESP is not running
or if Shear Blind Rams are installed on the BOPs.
21.2
PRESSURE TESTING ANNULARS

POLICY
PRESSURE TEST ANNULARS TO 1,000 PSI (WITH ESP CABLE).

NOTE: Testing performed in the shop has shown that an annular can hold 1,000 psi with
3-1/2 tubing and 1 cable. However, it is normal to have small leaks when
annulars are closed on cables. The annular in these instances is to slow the kick
only while performing the procedure in section 21.3.
21.3
SHUT-IN PROCEDURE WHEN RUNNING OR PULLING TUBING AND ESP CABLE

POLICY
Current Revision:
Previous Revision:
SHUT-IN PROCEDURE
1) Shut-in well with annular (upper) using Saudi Aramco shut-in procedure for tripping.
2) Cut ESP cable with mechanical cutter at the rig floor (a wire line mechanical cutter must
be on the floor)
3) Open annular and lower tubing
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4) Close annular (upper) around tubing
22.0 BOP CONFIGURATION WHEN RUNNING TEST STRING

22.1
RUNNING 3-1/2 TEST STRING WITH TEST HEAD AND CLASS A 10,000 PSI BOP STACK
(WITH SBR)
POLICY

ANNULAR:
TOP RAM:
5 PIPE RAMS (FOR STIFF JOINT)
BTM MASTER: RAMS TO MATCH THE LARGEST DP IN USE
CHANGE TOP 5 PIPE RAM TO 3-1/2 PRIOR TO POH WITH TEST STRING
HAVE XO (3-1/2 PH6 x 3-1/2 DP) ON DRILL FLOOR.
22.2
RUNNING 3-1/2 TEST STRING WITH TEST HEAD AND CLASS A 5,000 PSI BOP STACK
POLICY

ANNULAR:
TOP RAM:
5 PIPE RAMS (FOR STIFF JOINT)
MIDDLE RAM: BLIND RAMS
MASTER RAM: 3-1/2 PIPE RAMS
HAVE XO (3-1/2 DP x 5 DP) ON DRILL FLOOR.
23.0 RIGGING UP SURFACE WELL TEST EQUIPMENT

23.1
INSTALLING SURFACE LINES UPSTREAM OF TEST MANIFOLD

POLICY
Only connections with metal-to-metal seals are acceptable (API flanged, hubbed, or
Grayloc).
NOTE: Weco connections are not allowed (leaks in the lip seal can occur with gas,
CO2, and HT/HP situations).
24.0 PRESSURE TESTING WITH NITROGEN

24.1
SURFACE WELL TEST EQUIPMENT - GAS WELLS

POLICY
Current Revision:
Previous Revision:
Test procedure on gas wells (with 10M WP surface equipment)

1) Pressure test string to 8,500 psi
2) Negative test surface safety valve (if run) and lower master valve
3) Pressure test downstream of choke manifold to 1,200 psi with water
4) Pressure test upstream of choke manifold to 10,000 psi with water
5) Pressure test downstream of choke manifold to 1,200 psi with nitrogen
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6)
24.2
Pressure test upstream of choke manifold to 8,000 psi (80% of water pressure test)
with nitrogen
LUBRICATORS - GAS WELLS

POLICY
If a lubricator is required on a gas well (for well testing, completion, or workover operations),
the lubricator shall also be tested with nitrogen to 80% of water pressure test.
25.0 PROBLEMS WHILE LOGGING

25.1
SHUTTING IN WHILE LOGGING WITH SIDE-ENTRY SUB (WIRELINE ACROSS BOP STACK)
POLICY
25.2
SHUT-IN PROCEDURE
1) Close annular around drill pipe and wireline to restrict flow
2) Install wireline clamp to drill pipe
3) Cut wireline (above clamp) at rotary table with manual cutter
4) Open annular and lower DP until wireline is below bop stack
5) Close annular or uppermost ram as per approved shut-in procedure
FISHING PROCEDURE FOR STUCK LOGGING TOOL IN OPEN HOLE

POLICY
STUCK NON-RADIOACTIVE TOOL

1) Pull off electric line at rope socket
2) POH with electric line
3) RIH and engage tool w/ overshot on drill string
STUCK RADIOACTIVE TOOL
1) Cut and strip over electric line w/ drill string
2) Engage tool with overshot
3) Pull off electric line at rope socket
4) POH with electric line
NOTE:
May consider stripping over the electric line on a non-radioactive tool if:
A)
B)
C)
Hole conditions are poor

Large hole size compared to tool OD
Open hole section is not known to contain hydrocarbons
Logging companies have a circulating sub that can be made up on the drill string
(in the event of a well control situation) to hang off the electric line and enable
circulation; however, this may be difficult to install with a strong flow up the drill
pipe.
26.0 RUNNING PDHMS AND/OR SMART-WELL LINES ON TUBING OR

CASING
Pipe rams will not close and seal around lines and flat packs. The only way wells with these lines
installed on the OD of the tubing can be controlled is to close the annular (does not provide a full seal),
Current Revision:
Previous Revision:
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cut the line and then strip the pipe into the well until the pipe rams can be closed above the line or to
shear the tubing and the line. 26.1 and 26.2 (below) outlines the requirements
26.1
OIL WELLS
POLICY

1) The use of Shear Blind Rams on ALL smart well and PDHMS completions is required
when deep set control lines or flat packs are utilized.
NOTE: The Shear Blind Rams must be capable of shearing the tubing string being run
with the lines on the OD.
2)
Run multiple flat-packs with at least 2 inches of space between them.

NOTE: This may require a redesign of the cable clamps.
3)
26.2
Use a closing pressure of at least 2,000 psi on the annular BOP.
GAS WELLS
POLICY

1) A downhole barrier
2) Kill weight mud
3) The use of Shear Blind Rams on ALL smart well and PDHMS completions are required
when deep set control lines or flat packs are utilized.
NOTE: The Shear Blind Rams must be capable of shearing the tubing string being run
with the lines on the OD.
4)
Run multiple flat-packs with at least 2 inches of space between them.
5) Use a closing pressure of at least 2,000 psi on the annular BOP.
Current Revision:
Previous Revision:
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27.0 SETTING BRIDGE PLUGS

Bridge plugs are often set to serve as downhole barriers. Bridge plugs, after being tested (positive and
negative tests), may be considered a mechanical barrier. They are normally run and set in kill weight
mud positively tested then the hole above them is circulated to lighter fluid for the negative test. If the
well is not circulated back to kill weight fluid and the plug fails while tripping out, a pipe light condition
could occur which, if encountered, may not be controllable.
POLICY:
1. Bridge plugs will be run in kill weight fluid
2. Perform positive test
3. Perform negative test
4. Well circulated back to kill weight fluid before tripping out of hole.
5. Bridge Plug must incorporate Elastomer seals and 2 slip sets rated for the well
conditions. The Slips must prevent plug movement and achieve positive anchoring.
28.0 PLATFORM WELL SECURITY REQUIREMENTS PRIOR TO

WORKOVER OPERATIONS
28.1
REQUIRED NUMBER OF MECHANICAL BARRIERS OF ISOLATION

POLICY
All wells on the same platform shall be shut-in prior to workover operations using two (2)
mechanical methods of isolation,
BARRIER 1
CLOSED AND TESTED SURFACE CONTROLLED SUB-SURFACE SAFETY VALVE.
AT SURFACE
CLOSED MASTER VALVE
Current Revision:
Previous Revision:
Prior to moving in a rig, insure that the above referenced barriers are in place and effective.
JUNE, 2014
MAY, 2010
D - 17

Drilling & Workover
VOLUME I
CHAPTER- E WELL CONTROL DRILLS
CHAPTER E: WELL CONTROL DRILLS

TABLE OF CONTENTS
1.0
2.0
3.0
PIT DRILLS
1.1
Equipment
E-2
1.2
Frequency
E -2
1.3
Procedure
E -3
TRIP DRILLS
2.1
Frequency
E -4
2.2
Procedure
E -4
ACCUMULATOR DRILL
3.1
Procedure
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
E -5
E-1

Drilling & Workover
VOLUME I
INTRODUCTION
Shutting-in the well quickly to minimize the size of the influx is a major element of successful well
control. Drilling crews can only get proficient in this action through training and practice. The Drilling
Foreman should ensure that the Contract Toolpusher administers training in the areas of kick
detection and shut-in procedures until proficiency is demonstrated. The training must be repetitive
and frequent enough so that shutting-in the well becomes automatic whenever a kick is detected.
The Drilling Foreman can judge the level of crew shut-in proficiency through the use of pit drills and
trip drills. These drills should always be coordinated with the contract toolpusher. Proper drills and
training can prevent panic and provide for orderly operation if a kick should occur. The following
discussions describe how to conduct the drills and provide a basis for crew evaluation.
1.0
PIT DRILLS
The pit drill is designed to simulate an actual kick while drilling ahead and is designed as
both a teaching and a testing tool. While drilling ahead, it teaches the drilling crews to be
alert for positive indicators of a kick and provides practice in the proper Saudi Aramco shutin procedures. It also defines and reinforces the assigned duties of every member of the
drilling crew in well control situations. Pit drills are conducted unannounced so that realism
is created and so the crews can be observed under actual operating conditions.
Pit drills train the Driller to be constantly aware of the fluid level in the mud pits and the
return mud flow, much as the driver of an automobile subconsciously checks his
speedometer. This training is expected to prepare the driller to detect a kick at the first
surface indication and with a minimum of reservoir fluid influx. He will then be able to take
correct preventive action, lessening chances of disaster. Pit drills should be supervised by
the Contract Toolpusher and coordinated through the Drilling Foreman.
1.1
Equipment
All equipment required for pit drills is to be installed prior to drilling and kept in good
operating condition. A multi-float pit level indicator and flow show device must be available.
A pre-arranged horn or siren signal is an essential part of the pit drill. At the signal, each
crewmember must go immediately to his assigned post and execute his assigned duties.
The Drilling Foreman should note the times required (in minutes) for various aspects of the
pit drills and record them on the tour report. The number and times for these drills should
be relayed to the office.
1.2
Frequency
One or more pit drills should be conducted each day until the crews become proficient;
then at least twice weekly per crew, or more often if deemed advisable by the Drilling
Foreman. Pit drills should be held at least one each day on offshore wells, wildcats, and
wells where above-normal bottom hole pressure could exist. New drillers should be given
special drills and thorough explanation of this practice. It is one of the most important
safety measures that can be initiated and followed.
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
E-2

Drilling & Workover
VOLUME I
Drills are to be conducted during both routine and special operations. Typical times would
be while drilling, shut down for equipment repairs, logging, waiting on orders, circulating,
the Driller has gone to eat and is replaced by one of his men, the Driller is talking to
someone, or any other time there is open hole and blowout preventers installed.
1.3
Procedure
1)
The Toolpusher simulates the kick by raising a float in the mud pits or by raising the
arm on the flow show indicator and making a note of the time. The Drilling Foreman
should assist in observing the crew and recording completion times.
2)
The Driller must detect the kick and sound the alarm. The time of the alarm should be
noted. Upon hearing the alarm, all members of the drilling crew should immediately
execute their assigned duties.
3)
The Driller should prepare to shut in the well using the approved Saudi Aramco Shutin Procedure While Drilling. The Drilling Foreman should be on the rig floor to
announce to the driller that the exercise is only a drill and to stop him before he
actually closes the blowout preventers. The time should be noted when the driller is
prepared to shut in the well.
4)
Members of the drilling crew should report back to the rig floor having completed their
assigned duties. These duties may include:
Driller
Shut in the well (simulated)
Record drillpipe pressure and casing pressure
Record time
Measure pit gain
Check choke manifold for valve positioning and leaks
Derrickman
Weigh sample of mud from suction pit
Check volumes of barite, gel, and water on location
Floor Hand #1
Check accumulator pressures and pumps
Check BOP stack for leaks and proper valve positions
Turn on water jets to diesel exhausts
Floor Hand #2
Assist Driller on rig floor
Floor Hand #3
Assist Derrickman on mud pits
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
E-3

Drilling & Workover
VOLUME I
2.0
TRIP DRILLS
The trip drill is designed to train the drilling crews to recognize and respond to kick
indications, which occur while tripping pipe. Like the pit drill, the trip drill is useful for both
teaching and testing purposes. The pit drill also proves that essential detection equipment
is installed and in good operating condition.
The trip drill is supervised by the Contract Toolpusher with the knowledge of the Saudi
Aramco Drilling Foreman. All parts of the well control system must be kept hooked up and
in good condition, ready for drills.
2.1
Frequency
When a new rig is picked-up, trip drills should be conducted during each trip (both while
pulling out and going into the hole) while the bit is up in the casing. When the crew
becomes proficient, trip drills should be conducted at least twice weekly per crew,
conditions allowing.
2.2
Procedure
1)
The Toolpusher simulates the kick by raising a float in the mud pits and making a note
of the time. The Drilling Foreman should assist in observing the crew and recording
completion times.
2)
The Driller must detect the kick and sound the alarm. The time of the alarm should be
noted. Upon hearing the alarm, all members of the drilling crew should immediately
execute their assigned duties.
3)
The Driller should prepare to shut in the well using the approved Saudi Aramco Shutin Procedure While Tripping. This will include spacing out and stabbing/closing the full
open safety valve. After the safety valve is installed and the Driller is ready to close
the preventers, the Drilling Foreman should announce to the Driller that the exercise
is only a drill and that it is not necessary to close the preventers. The time should be
noted when the driller is prepared to shut-in the well.
4)
Members of the drilling crew should proceed with their assigned duties and report
back to the rig floor upon completion. These duties may include:
Driller
Shut in the well (simulated)
Record drillpipe and casing pressure
Record time
Measure pit gain
Check choke manifold for valve positioning and leaks
Derrickman
Weigh sample of mud from suction pit
Check volumes of barite, gel, and water
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
E-4

Drilling & Workover
VOLUME I
Floor Hand #1
Check accumulator pressures and pumps
Check BOP stack for leaks
Turn on water jets to diesel exhausts
Floor Hand #2
Stab safety valve. Close safety valve
Stab inside BOP. Open safety valve
Assist Driller on rig floor
Floor Hand #3
Assist Derrickman on mud pits
3.0
ACCUMULATOR DRILL
Accumulator drills are designed to verify that the accumulator/closing system is in good
working order and that it is properly sized for the particular blowout preventer stack.
Accumulator performance must be proven with an accumulator drill when the blowout
preventers are first installed (which verifies proper sizing), and every 14 days thereafter in
conjunction with the weekly BOP pressure tests (which checks for hydraulic leaks).
Results of the accumulator drill, including closing times of the rams and annular preventer,
and initial final accumulator pressures are to be reported on the Blowout Preventer Test
and Equipment Checklist. A notation should also be made on the tour report that an
accumulator drill was conducted.
Accumulator drills must be conducted when the drill pipe is not in open hole, but up in the
casing. At least one joint of drillpipe must be in the hole for the pipe rams to close on. The
Saudi Aramco Drilling Foreman and Contract Toolpusher should witness all accumulator
drills, but the Toolpusher is responsible for the actual supervision of the drill. Use the
remote station to close the preventers every other drill.
3.1
Procedure
1)
Turn off all accumulator-pressurizing pumps.
2)
Record the initial accumulator, manifold, and annular pressures.
3)
Close all of the preventers (except the blind rams). Substitute a re-opening of a pipe
ram to simulate the blind ram closure when applicable. Open the HCR valve.
4)
Measure and record the closing times for each preventer with a stopwatch.
5)
Record the final accumulator, manifold, and annular pressures.
6)
To pass the accumulator test, all BOPs must have closed in less than 30 seconds
with at least:
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
E-5

Drilling & Workover
VOLUME I
1500 psi accumulator pressure remaining (for a 3000 psi accumulator)

Note: Equipment that does not meet these requirements either has insufficient
capacity, insufficient pre-charge or needs repair. Closing time for annular
preventers 20" and larger should not exceed 45 seconds.
7)
Observe the remaining pressure for at least 5 minutes to detect any possible am
piston seal leaks.
8)
Turn the accumulator pump(s) back on. Record the time required to charge system
back up (re-charge time).
9)
Open BOPs..
Current Revision:
Previous Revision:
JUNE, 2014
MAY, 2010
E-6
PRESSURE TESTING BLOWOUT PREVENTERS & RELATED EQUIPMENT

RIG:
PREVIOUS TEST:
WELL NUMBER:
WELL INFORMATION
BLOWOUT PREVENTERS
HOLE
LAST CASING STRING SET

BURST SHOE
WT GRADE RATING DEPTH
SIZE DEPTH SIZE
TESTER
DRILL PIPE DATA
CUP PLUG NONE SIZE
WT GRADE CONN
MUD WEIGHT:
THIS TEST:
UNIT
TYPE
SIZE
PRESSURE RATING
ANNULAR
PSI
PIPE RAMS
BLIND RAMS
PIPE RAMS
PIPE RAMS
PSI
PSI
PSI
PSI
PCF
ACCUMULATOR UNIT DATA
NOTE:
USEABLE
OPERATING
PRESSURE
VOLUME
GAL
PSI
GAL
PRECHARGE PRESSURE
DATE LAST CHECKED
PSI
HYDRIL TO BE TESTED @ 70% RATED

WORKING PRESSURE WITH PIPE IN HOLE
SYSTEMS
CAPACITY
MANIFOLD PRESSURE
ANNULAR
ACCUMULATOR
CUT-IN
PRESSURE
AIR PUMPS
ELECTRIC PUMPS
MANIFOLD
PSI
TEST DETAILS
CUT-OFF
PRESSURE
PSI
PSI
PSI
PSI
PSI
TEST OF AUXILIARY SYSTEMS AS PER SAUDI ARAMCO WELL CONTROL MANUAL

KILL LINE
PSI
CHOKE LINE
MANUAL
HCR
CHECK
KILL
MANUAL
HCR
CHOKE
VALVE
VALVE
VALVE
LINE
VALVE
VALVE
LINE
KELLY
SWACO
LEFT
RIGHT
EMERGENCY KILL LINE
UPPER
LOWER
MANUAL
HCR
KILL
COCK
COCK
VALVE
VALVE
LINE
LOW
HIGH
TIME
LOW
HIGH
REMARKS:
DRILLER SIGNATURE
Revision Date: 02/01/2014

Form # 2.0
TOOLPUSHER SIGNATURE
COMPANY REPRESENTATIVE SIGNATURE
Page 1 of 2
PRESSURE TESTING BLOWOUT PREVENTERS & RELATED EQUIPMENT

RIG:
WELL NUMBER:
PREVIOUS TEST:
THIS TEST:
ALTERNATE BI-WEEKLY TESTS WITH
BOP TEST IN PSI AND TIME
CHARGING SYSTEM ISOLATED
TEST PRESSURE
LOW
HIGH
UNIT
ANNULAR
PIPE RAMS
BLIND RAMS
PIPE RAMS
PIPE RAMS
PSI
PSI
PSI
PSI
PSI
DURATION OF TEST
LOW
HIGH
PSI
PSI
PSI
PSI
PSI
CLOSE
MIN
MIN
MIN
MIN
MIN
MIN
MIN
MIN
MIN
MIN
OPEN
SEC
SEC
SEC
SEC
SEC
BOTTLE BANKS ISOLATED
CLOSE
SEC
SEC
SEC
SEC
SEC
OPEN
SEC
SEC
SEC
SEC
SEC
SEC
SEC
SEC
SEC
SEC
ARE THE BELOW ITEMS ON THE RIG AND IN GOOD WORKING ORDER:
YES
YES
NO
ROTATING HEAD AND STRIPPER (PACK-OFF)
ACCUMULATOR BOTTLE AND TEST GAUGE
STRIPPING VALVE (TIW)
FILL ADAPTER FOR NITROGEN BOTTLE
DRILL PIPE BACK PRESSURE VALVE (INSIDE BOP)
SPARE NITROGEN BOTTLES
X-OVER: DC x DP
DRILL PIPE PRESSURE GAUGE
KELLY COCK WRENCH (S)
ANNULAR PRESSURE GAUGE
ADJUSTABLE CHOKES STEM AND BONNETS
DRILL PIPE FLOAT VALVE
MUD GAS SEPARATOR
DE-GASSER
P.V.T. SET TO ALARM AT 10 BBLS
ALL BOLTS, STUDS & NUTS INSTALLED

AND TIGHTEN PROPERLY
CHOKE MANIFOLD LINED UP FOR A HARD SHUT-IN
ALL RING GASKETS ARE NEW
NO
REMARKS:
DRILLER SIGNATURE
Revision Date:
Form # 2.0
02/01/2014
Page 2 of 2
DESCRIPTION OF BLOWOUT PREVENTERS AND INTERNAL COMPONENTS

RIG:
WELL NUMBER:
BLOWOUT PREVENTERS
ANNULAR PREVENTER
SIZE
WORKING PRESSURE
RAM PREVENTERS
SIZE
WORKING PRESSURE
MODEL
MAKE
SERIAL #
ELEMENT PART #
TYPE
PIPE
BLIND
PIPE
PIPE
MAKE
SERIAL #
SINGLE/DOUBLE
INTERNAL COMPONENTS
UNIT
RAM
SIZE
RAM
BLOCK #
RAM
PACKER #
TOP
SEAL #
BONNET/DOOR
SEAL #
CONN. ROD
SEAL #
DATE
INSTALLED
ANNULAR
PIPE RAMS
BLIND RAMS
PIPE RAMS
PIPE RAMS
REMARKS:
DRILLER SIGNATURE
Form # 1.0
Date: 02/01/2014
CAMERON INFORMATION SHEET
01-001
SUBJECT: Cameron High Temperature Shearing Blind Ram (SBR)

Blade and Side Packers for 11 and 13-5/8 Cameron U Type Blowout
Preventers
PURPOSE: To provide information on qualification test results and new
part numbers assigned to qualified blade and side packers
Qualification Requirement: API 16A 2nd Edition, Appendix C plus
additional pressure hold time at elevated temperatures
Test Conditions:
BOP used Cameron 13-5/8-10,000 psi U mounted on a special test stump with internal
heating system
Test Fluid Synthetic hydrocarbon motor oil (to simulate a mineral oil based drilling mud)
Test Temperatures - 250F, 300F, and 350F
Test Pressure 10,000 psi
Test Durations API 16A 2nd Edition, Appendix C One hour pressure hold all test temperatures
- Cameron Requirement An additional 8 hour pressure hold - 250F
- An additional 3 hour pressure hold - 300F and 350F
Results Standard Cameron Blade and Side Packers qualify to API 16A, 2nd Edition,
Appendix C high temperature verification test requirements and successfully
complete Cameron required additional 8 hour pressure hold test at 250F .
- High Temperature Cameron Blade and Side Packers qualify to API 16A,
2nd Edition, Appendix C high temperature verification test requirements and
successfully completed Cameron required additional 3 hour pressure hold test at
300F and 350F .
U BOP Shearing Blind Ram
CIS 01-001 / 5-24-01 REV / HT SBRs 11 & 13
U BOP H2S Shearing Blind Ram
01-001
SUBJECT: Cameron High Temperature Shearing Blind Ram (SBR)

Blade and Side Packers for 11 and 13-5/8 Cameron U Type Blowout
Preventers
Applicable Part Numbers
BOP Size - Pressure Rating
Up to 250F & 5% H2S
Description
Up to 350F & 35% H2S
11-10,000 psi
Blade Packer
Side Packer
Side Packer
Top Seal
046910-04-00-01
046751-04-00-01
046752-04-00-01
644217-01-00-01
644834-04-00-01
2164284-04
2164285-04
644703-01-00-01
13-5/8-10,000 psi
Blade Packer
Side Packer
Side Packer
Top Seal
644435-01-00-01
046751-01-00-02
046752-01-00-02
644223-01-00-01
644834-01-00-01
645427-01
645428-01
644707-01-00-01
For additional information contact Cameron Elastomer Technology (CET), Katy Texas
or your local Cameron representative.
29501 Katy Freeway, Katy, Texas 77494
CIS 01-001 / 5-24-01 REV / HT SBRs 11 & 13
Tel: 281-391-4615 Fax: 281-391-4640
Spare Parts List for 13-5/8 10M

Type U Large Bore Shear Bonnet and Shear Rams
High Temperature and H2S Service
Item
Part Number
Description
BONNET ASSEMBLY: LARGE BORE SHEAR, RIGHT HAND, for
13-5/8" 10M WP TYPE 'U' BOP WITH TANDEM BOOSTER,
MANUAL LOCKING SCREW AND BONNET BOLTS, PER API 16A,
T-20, OPERATION TEMP RATING 'BF' (0-350 DEG SERVICE),
NACE, EST. NET WT. = 3,850 LBS.
BONNET ASSEMBLY: LARGE BORE SHEAR, LEFT HAND, for 135/8" 10M WP TYPE 'U' BOP WITH TANDEM BOOSTER, MANUAL
LOCKING SCREW AND BONNET BOLTS, PER API 16A, T-20,
OPERATION TEMP RATING 'BF' (0-350 DEG SERVICE), NACE,
EST. NET WT. = 3,850 LBS.
BONNET BOLT: for LARGE BORE SHEAR Bonnets, 13-5/8"
10M WP TYPE 'U' BOP, MODEL II
BONNET REBUILD KIT: for LARGE BORE SHEAR RAM,
13-5/8" 3M/5M/10M WP TYPE 'U' BOP (parts for ONE
BONNET), 350 DEG SERVICE
Qty
1 EA
1.
2011803-01
2.
2011803-02
3.
041366-12
4.
2164210-09
5.
644573-03-00-01
BONNET SEAL: for 13-5/8" 3M/5M/10M 'U' BOP, PER API

16A, TEMP CLASS "BF" (0-350 DEG SERVICE)
2 EA
6.
645077-36-00-01
SEAL, LIP: CONNECTING ROD; for 13-5/8" 3M-15M,

20-3/4" 3M, 21-1/4" 2M and 26-3/4 3M TYPE 'U' BOP,
5.505" OD X 4.008" ID X 0.938" LG, PER API 16A, TEMP
CLASS "BF" (0-350 DEG SERVICE)
2 EA
7.
644781-03
RAM ASSEMBLY: H2S SHEARING BLIND; UPPER, for 13-5/8"

3M/5M/10M WP TYPE 'U' BOP, CAMRAM 350 (TM)
1 EA
8.
644781-04
RAM ASSEMBLY: H2S SHEARING BLIND; LOWER, for 13-5/8"

3M/5M/10M WP TYPE 'U' BOP, CAMRAM 350 (TM)
1 EA
9.
644581-01-00-01
INSERT BLADE: UPPER, H2S SBR, for 13-5/8" 10M WP TYPE

'U' AND 'T' BOP, PER QP-10005-01
1 EA
10.
644581-02-00-01
INSERT BLADE: LOWER, H2S SBR, for 13-5/8" 10M WP TYPE

'U' AND 'T' BOP, PER QP-10005-01
1 EA
11.
644834-01-00-01
BLADE PACKER: SBR, for 13-5/8" 3M-15M WP TYPE 'U'

BOP, PER API 16A, TEMP CLASS "BF" (0-350 DEG SERVICE)
1 EA
12.
645427-01
SIDE PACKER: SBR, for 13-5/8" 3M-10M WP TYPE 'U' BOP,

CAMRAM 350 (TM)
2 EA
13.
645428-01
SIDE PACKER: SBR, for 13-5/8" 3M-10M WP TYPE 'U' BOP,

CAMRAM 350 (TM)
2 EA
14.
644707-01-00-01
TOP SEAL: for 13-5/8" SBR, 3M/5M/10M WP TYPE 'U' BOP,

CAMRAM 350 (TM) HIGH TEMP, API 16A, TEMP CLASS "BF"
2 EA
15.
644582-01
MODIFIED SET SCREW: for 13-5/8" 10M TYPE U UPPER

SHEARING BLIND RAM, .750-10 UN-2
2 EA
16.
200231
PIN: SPIROL - .250 X 1.000 SST 18-8
2 EA
17.
2164148-02
REPAIR KIT: TANDEM SHEAR BOOSTER, COMPOSITE STYLE OR

ORIGINAL STYLE, 11" 15M AND 13-5/8" 3M-10M TYPE 'U'
BOP (QUANITY for 1 UNIT)
1 EA
1 EA
8 EA
2 EA
09/15/02
Spare Parts List for 11 10M

Type U Large Bore Shear Bonnet and Shear Rams
Item
Part Number
Description
Qty
2164067-02
BONNET ASSEMBLY: LARGE BORE SHEAR, RIGHT HAND, for

11" 10M WP TYPE 'U' BOP WITH TANDEM BOOSTER, MANUAL
LOCKING SCREW AND BONNET BOLTS, API 16A, T-20,
OPERATION TEMP RATING 'BF' (0-350 DEGREE SERVICE),
NACE, EST. NET WT. 2,620 LBS.
1 EA
2.
2164067-01
BONNET ASSEMBLY: LARGE BORE SHEAR, LEFT HAND, for

11" 10M WP TYPE 'U' BOP, WITH TANDEM BOOSTER, MANUAL
LOCKING SCREW AND BONNET BOLTS, API 16A, T-20,
OPERATION TEMP RATING 'BF' (0-350 DEGREE SERVICE),
NACE, EST. NET WT. 2,620 LBS.
1 EA
3.
041366-05
BONNET BOLT: for LARGE BORE SHEAR RAM, 11" 10M WP

TYPE 'U' BOP, MODEL II
8 EA
4.
2164210-12
BONNET REBUILD KIT: for LARGE BORE SHEAR RAM, 11"

3M/5M/10M WP TYPE 'U' BOP (PARTS for ONE BONNET),
350 DEGREE SERVICE
2 EA
5.
644573-02-00-01
BONNET SEAL: 11" 3M/5M/10M WP TYPE 'U' BOP, API 16A,

TEMP CLASS "BF" (0-350 DEGREE SERVICE)
2 EA
6.
645077-38-00-01
SEAL, LIP: CONNECTING ROD; fOR 11" 5M/10M WP TYPE

'U' BOP, - 4.867" OD x 3.383" ID x 0.688" LG, API
16A, TEMP CLASS "BF" (0-350 DEGREE SERVICE)
2 EA
7.
645011-01-00-01
RAM ASSEMBLY: H2S SHEARING BLIND; UPPER, for 11"

5M/10M WP, TYPE 'U' BOP, API 16A, TEMP CLASS 'BF'
(0-350 DEGREE SERVICE)
1 EA
8.
645011-02-00-01
RAM ASSEMBLY: H2S SHEARING BLIND; LOWER, for 11"

5M/10M WP, TYPE 'U' BOP, API 16A, TEMP CLASS 'BF'
(0-350 DEGREE SERVICE)
1 EA
9.
645010-01-00-01
INSERT BLADE: UPPER, H2S SBR, for 11" 5M/10M WP

TYPE 'U' BOP, API 16A
1 EA
10.
645010-02-00-01
INSERT BLADE: LOWER, H2S SBR, for 11" 5M/10M WP

TYPE 'U' BOP, API 16A
1 EA
11.
644834-04-00-01
BLADE PACKER: SBR, for 11" 3M-15M WP TYPE 'U' BOP,

API 16A, TEMP CLASS "BF" (0-350 DEGREE SERVICE)
1 EA
12.
2164284-04
SIDE PACKER: FOLDOVER SHEAR RAM, for 11" 3M-10M WP

TYPE 'U' BOP, API 16A, TEMP CLASS "BF" (0-350 DEGREE
SERVICE)
2 EA
13.
2164285-04
SIDE PACKER: FOLDOVER SHEAR RAM, for 11" 3M-10M WP

TYPE 'U' BOP, API 16A, TEMP CLASS "BF" (0-350 DEGREE
SERVICE)
2 EA
14.
644703-01-00-01
TOP SEAL: for 11" SBR, 3M/5M/10M WP TYPE 'U' BOP,

CAMRAM 350 (TM) HIGH TEMP, API 16A, TEMP CLASS "BF"
2 EA
15.
644582-01
MODIFIED SET SCREW: for 11" 10M TYPE U UPPER

SHEARING BLIND RAM, .750-10 UN-2
2 EA
16.
200231
PIN: SPIROL - .250 X 1.000 SST 18-8
2 EA
17.
2164148-03
REPAIR KIT: TANDEM SHEAR BOOSTER, COMPOSITE STYLE OR

ORIGINAL STYLE WITH ST/STL END CAP, for 11" 3/5/10M
TYPE 'U' BOP (QUANTITY FOR ONE UNIT)
1 EA
1.
09/15/02
Shaffer
A Varco Company
Spare Parts List for 13-5/8 10M

Model SL Large Bore V Shear Rams
Item
Part Number
Description
Qty
1.
124992
BOOSTER KIT: 10 BOOSTER ASSEMBLY CONVERSION KIT FOR

13-5/8 10M WP TYPE SL RAM BOP, NACE (COMPLETE WITH
22 COMPONENTS).
2 EA
2.
114651
RAM SHAFT: POSLOCK FOR 13-5/8" 10M WP TYPE 'SL' BOP,

NACE.
2 EA
3.
132492
RAM SHAFT SUB-ASSEMBLY (RSSA): FOR 13-5/8" 10M WP

TYPE 'SL' BOP, NACE.
2 EA
4.
030102
CYLINDER O-RING:
2 EA
5.
030791
CYLINDER O-RING:
2 EA
6.
030105
CYLINDER BACK-UP RING:
2 EA
7.
030061
MANIFOLD O-RING:
8 EA
8.
030065
HINGE BRACKET O-RING:
4 EA
9.
134481
POSLOCK PISTON ASSEMBLY: FOR 13-5/8" 10M WP TYPE 'SL'

BOP, NACE.
2 EA
10.
RAM V-SHEAR: COMPLETE WITH 13-5/8 10M WP ULTRATEMP

ELASTOMERS (350 DEGREES F AND 20% H2S)
1 EA
11.
RAM RUBBER ASSEMBLY: UPPER, V-SHEAR, ULTRATEMP

(350 DEGREES F AND 20% H2S)
1 EA
12.
RAM RUBBER ASSEMBLY: LOWER, V-SHEAR, ULTRATEMP

(350 DEGREES F AND 20% H2S)
1EA
10/01/02
02-001
SUBJECT: Cameron Extended Range High Temperature VBR-II Packers

for Cameron 13-5/8 U Type Blowout Preventers
PURPOSE: To provide information on qualification test results and new
part numbers assigned to 250F - 5000 psi Extended Range HT VBR-II
packers for the 13-5/8" Cameron U BOP.
Qualification Requirement: API 16A 2nd Edition, Appendix C plus
additional pressure hold time at elevated temperature.
Test Conditions:
BOP used Cameron 13-5/8-10,000 psi U BOP mounted on a special test stump with internal
heating system.
Test Fluid Synthetic hydrocarbon oil (to simulate a mineral oil based drilling mud).
Test Temperatures - 250F
Test Pressure 5,000 psi
Test Durations API 16A 2nd Edition, Appendix C One hour pressure hold at 250F
- Cameron-Saudi Aramco Requirement An additional 7-hour pressure hold at 250F
Results Extended Range HT VBR-II Packers P/N 2164765-01 successfully completed:
1-API 16A, 2nd Edition, Appendix C high temperature verification test requirements
for one hour on both 5-7/8" and 3-1/2" pipe mandrels at 250F and 5000 psi.
2-Cameron-Saudi Aramco requirement - an additional 7 hour pressure hold test on
both 5-7/8" and 3-1/2" pipe mandrels at 250F and 5000 psi.
Total time at 250F and 5000 psi, 16 hours.
3-API 16A fatigue test (546 closures and 78 pressure tests) at ambient temperature.
Ram Subassembly P/N 2164806-01

Top Seal P/N 2164807-01
Ram P/N 2164404-01
Extended Range HT VBR-II Packer P/N 2164765-01
250F - 5000 psi Extended Range HT VBR-II Packer & Top Seal
CIS 02-001 / 6-11-02 / Ext Range HT VBR-II
02-001
SUBJECT: Cameron Extended Range High Temperature VBR-II Packers

for Cameron 13-5/8 U Type Blowout Preventers
Applicable Part Numbers
BOP Size Pressure Rating
13-5/8
5,000 psi
Description
Part Number
Ram subassembly
Ram
Ext. Range HT VBR-II Packer
HT/SS VBR Top Seal
2164806-01
2164404-01
2164765-01
2164807-01
Note: The Extended Range HT VBR-II packers and HT/SS top seals are molded using CAMLAST(tm)
elastomer, which provides H2S resistance up to 35%.
For additional information contact Cameron Elastomer Technology (CET), Katy Texas
or your local Cameron representative.
29501 Katy Freeway, Katy, Texas 77494
CIS 02-001 / 6-11-02 / Ext Range HT VBR-II
Tel: 281-391-4615 Fax: 281-391-4640
Engineering Standard
SAES-B-062
23 July 2009
Onshore Wellsite Safety

Loss Prevention Standards Committee Members
Ashoor, Esam Ahmed, Chairman
Fadley, Gary Lowell, Vice Chairman
Ageel, Adel Abdulaziz
Churches, David Kenneth
Cole, Anthony Richard
Ghobari, Ali Mahdi
Hassar, Fahad Abdullah
Janaby, Mohammad Taqy
Juraifani, Hatim Hamad
Sayed, Salah Moh'D Al-Housseiny
Seba, Zaki Ahmed
Solomon Jr, Clarence Ray
Sultan, Sultan Abdul Hadi
Utaibi, Abdul Aziz Saud
Zahrani, Mansour Jamman
Saudi Aramco DeskTop Standards

Table of Contents
1
2
3
4
5
6
7
8
9
Scope............................................................. 2
Conflicts and Deviations................................. 2
References..................................................... 2
Definitions....................................................... 3
Determination of Rupture Exposure
Radius (RER).......................................... 8
Wellsite Location............................................ 9
Well Safety Valves and Wellsite Hardware.. 13
Abandoned Wells......................................... 15
Drilling Rig Access Routes........................... 16
Appendix 1 Procedure for Determining RER

of Oil and Gas Wells.................................... 17
Previous Issue: 31 March 2009 Next Planned Update: 31 March 2014

Primary contact: Ashoor, Esam Ahmed on 966-3-8728431
CopyrightSaudi Aramco 2009. All rights reserved.
Page 1 of 32
Document Responsibility: Loss Prevention Standards Committee

Issue Date: 23 July 2009
Next Planned Update: 31 March 2014
SAES-B-062
Scope
1.1
This Standard covers the minimum mandatory requirements for site layout,
wellhead protection, access, and flow isolation for all wells that are drilled into
or through a geological zone that contains hydrocarbons such as oil and gas
production wells, water injection wells, observation wells, abandoned wells,
suspended wells, and waste disposal wells.
1.2
This standard shall apply in the following circumstances:

1.2.1
All new wellsites.
1.2.2
All new wells drilled at existing wellsites.
1.2.3
Re-activation of previously abandoned or suspended wells or re-drilling

of existing wells such as drilling of new laterals or deepening.
1.2.4
Existing wells located in areas that have become populated per this
Standard shall be upgraded with automated shut-in systems, vehicle
crash protection, fencing, wind socks, and other items only when a
workover is required for other remedial work.
Conflicts and Deviations

2.1
Any conflicts between this Standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Saudi Aramco Materials System Specifications
(SAMSSs), Saudi Aramco Standard Drawings (SASDs), or industry standards,
codes, and forms shall be resolved in writing by the Company or Buyer
Representative through the Manager, Loss Prevention Department of Saudi
Aramco, Dhahran.
2.2
Direct all requests to deviate from the Standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Loss Prevention Department of Saudi
Aramco, Dhahran.
References
All referenced specifications, standards, codes, forms, drawings, and similar material
shall be of the latest issue (including all revisions, addenda, and supplements) unless
stated otherwise.
3.1
Saudi Aramco References

Safety Management Guides [http://lp.aramco.com.sa/]
Page 2 of 32

SAES-B-062
Emergency Management Guide

Safety Management Guide for Emergency Preparedness
Saudi Aramco Engineering Procedure
SAEP-302
Instructions for Obtaining a Waiver of a

Mandatory Saudi Aramco Engineering
Requirement
Saudi Aramco Engineering Standards

SAES-B-064
Onshore and Nearshore Pipeline Safety
SAES-F-007
System Design Criteria of Flares
SAES-J-505
Combustible Gas and Hydrogen Sulfide in Air

Detection Systems
SAES-L-410
Design of Pipelines
SAES-M-006
Fencing
Saudi Aramco Materials System Specification

34-SAMSS-624
Wellhead Control, Monitoring and Shutdown

Systems
45-SAMSS-005
Wellhead Equipment
Saudi Aramco Standard Drawings
3.2
AA-036454
Remote Controls for Onshore Wells
AB-036685
Wellhead Guard Barrier
Industry Codes and Standards

American Petroleum Institute
API RP 14B
Design, Installation, Repair and Operation of

Subsurface Safety Valve Systems
Definitions
Absolute Open Flow (AOF): In general terms, the rate of flow that would be produced
by a well if the only back-pressure at the surface is atmospheric pressure.
Choke: An adjustable pressure control valve that is used to control backpressure on the
well. Controlling the backpressure adjusts the production rate of the well.
Page 3 of 32

SAES-B-062
Drilling Island: A wellsite for drilling one or more wells, normally used in populated
areas to minimize land usage. A drilling island is an exclusive land use area.
Drilling Pad: A compacted area of marl located at the wellsite. The drilling pad is
required to be level for use by drilling and workover rigs.
Gas-Oil Ratio (GOR): The ratio of volume of gas produced from a well in a barrel of
crude oil at standard conditions (14.7 psia, 15C).
GOSP: A gas-oil separation plant (GOSP) is a plant area where water and gas are
separated from the produced crude oil so that the oil is of suitable quality for shipping
through a pipeline to an oil terminal or to a refinery. The gas is sent to gas plants for
further processing.
High-Population Building: Any building, such as a office building, mosque, cafeteria,
or training building, that can be expected to contain 25 or more people at any time.
H2S: Hydrogen Sulfide, a colorless toxic gas that is sometimes produced with natural
water, crude oil, and natural gas.
High Pressure Well: Wells where the shut-in wellhead pressure is expected to exceed
20,700 kPa (3000 psig).
Kick: A unplanned flow of reservoir gas, oil or water from the formation into the
wellbore during drilling operations.
Low Pressure Well: Wells where the shut-in wellhead pressure is not expected to
exceed 20,700 kPa (3000 psig).
LFL: Lower flammable limit of a fuel vapor in air mixture. If a vapor/air mixture is
above the LFL, a fire is likely in the presence of an ignition source.
Major Facility: The outer-most security fence, property line, or other demarcation of
land-use claim of refineries, gas treatment, NGL plants, gas-oil separating or processing
facilities, and the property line of any third party manufacturing facilities (Refer to
Table 1 below for examples).
Page 4 of 32

SAES-B-062
Table 1 Examples of Major Facilities

Refineries
Gas Treating
NGL
Jeddah
Berri
Juaymah
Rabigh
Uthmaniyah
Yanbu
Oil Process
Abqaiq Plants
Complex
Safaniya
Onshore GOSP
Tanajib
Onshore
GOSP;
Khursaniya
Ras
Tanura
Shedgum
Riyadh
Hawiyah
Shaybah CPF
Haradh
Khurais
Terminals
Non-Aramco
Juaymah
SCEC Power
Generation
(formerly SCECO)
Jeddah
SWCC Treatment
Ras
Tanura
(North &
South)
Commercial
International
Airports
Yanbu
Jubail or Yanbu
Industrial
Complexes
Non-Associated Gas Fields: Areas that are developed for the primary purpose of
producing natural gas. The produced gas is not a by-product of crude oil production.
Population: Any concentration or grouping of people. Population is normally indicated
by the existence of buildings, but may also be a camp site, a site where construction or
maintenance crews are working. Separation spacing from a well shall be measured from
the nearest fence or other landmark that indicates the boundary. For the purposes of this
standard, a road or highway is not considered population.
Populated Area: For the purposes of this standard, a well is in a populated area if
the population exceeds 20 persons residing, working, or otherwise located inside the
30 ppm rupture exposure radius (RER). For the purpose of this Standard, the number of
persons considered does not include personnel residing at the rig camp, on-site workers
in support of the drilling or workover rig, or the occupants of vehicles traveling on
roads or highways.
Rupture Exposure Radius (RER):
1)
For toxic effects, the rupture exposure radius refers to the horizontal distance from
a leak source to a specified level of hydrogen sulfide (H2S) concentration in parts
per million (ppm).
2)
For a flammable gas hazard, the rupture exposure radius refers to the horizontal
distance from a leak source to the Lower Flammable Limit (LFL).
Surface Safety Valve (SSV): An automated spring-assisted fail-safe valve installed on

a wellhead to automatically shut in flow during an abnormal condition such as high or
low pressure of the flowline. This can be the upper master valve, a wing valve
(upstream of choke), or a production valve (downstream of the choke).
Page 5 of 32

SAES-B-062
Suspension Procedure: Wireline or workover rig procedures for securing a standing

well from production on a long-term basis.
Subsurface Safety Valve (SSSV): An automated valve installed below ground level in
the tubing string of an oil or gas well. The SSSV is used to shut in flow during an
abnormal condition. SSSVs, when required, shall be installed 60 m or more below
ground level per API RP 14B.
Wellhead: The valve manifold directly at the top of the well bore. The wellhead
consists of several specialized valves including the following:
a)
Crown Valve: Topmost valve of the wellhead. This valve is used for wireline
and coil tubing access to the well.
b)
Lower Master Valve: The first valve on a wellhead. This is not a surface safety
valve (SSV).
c)
Upper Master Valve: A second isolation gate valve just above the Lower Master
Valve on a wellhead. If this is automated, it is considered a surface safety valve
(SSV).
d)
Wing Valve: The valve on the side branch of the wellhead, normally located
immediately upstream of the choke.
Page 6 of 32

SAES-B-062
7-1/16" 3M PSI Onshore Production Tree
7" 3M QUICK UNION TREE CAP

14-7/8"
24-1/8"
7" 3M GATE VALVE
7" 3M FLANGE
16"
7" 3M TEE
24-1/8"
7" 3M HYDRAULIC ACTUATED SSV
24-1/8"
7" 3M GATE VALVE
32-1/4"
Saudi Aramco
3M PSI WP WOG
6M PSI TP
Figure 1 Example of Wellhead (from 45-SAMSS-005, Figure 6)

Wellsite: A wellsite consists of wellhead(s), associated drilling pad, a well flare/burn
pit area or areas, and flare/burn pit buffer zone(s). The entire wellsite constitutes an
exclusive land use area. No other uses are permitted in this area, except as allowed by
this Standard. Size of the wellsite and distances between wellheads shall be specified
by Drilling and Workover Engineering, Drilling Operations, Production and Facilities
Development (P&FDD), and the Proponent Operating Department, on a case-by-case
basis.
Well Status: Wells that are not flowing oil or gas may be described by the following
terms:
a)
Abandoned Well: A well that is permanently plugged with cement. This well
Page 7 of 32

SAES-B-062
cannot be produced again.
b)
Observation Well: A well drilled to monitor reservoir conditions such as bottomhole pressure in the reservoir.
c)
Suspended Well: A well that has been shut-in on a long term basis with all
productive zones isolated and production shut-off on a long-term basis.
d)
Standing Well: A well that is shut-in awaiting action, such as flowline tie-in or
well perforation, before it can be returned to production.
Determination of Rupture Exposure Radius (RER)

5.1
Three concentric circles representing the three rupture exposure radii - 30 ppm,
100 ppm hydrogen sulfide (H2S) and lower flammable limit (LFL) shall be
plotted from the well's proposed surface location as shown in Figure 2 below.
Refer to Appendix 1 for procedures to determine the RERs.
5.2
For fields, reservoirs, or service not listed in Appendix 1, the rupture exposure
radius shall be obtained from the Saudi Aramco Loss Prevention Department's
Technical Services Unit. In order to calculate the RER, the following
information should be provided with the request: Well composition of produced
fluid (mole %), temperature (Flowing Wellhead Temperature, FWHT), and AOF
for gas wells or maximum flow rate and GOR for oil wells.
Figure 2 RERs
A well is considered to be in a populated area if the population is above 20 persons living,
working, or otherwise located inside the 30 ppm H2S RER (see 6.3). In populated areas,
requirements in sections 6.5, 7.3, and 7.7, and 8 apply.
Page 8 of 32

SAES-B-062
Wellsite Location
6.1
Wells that are drilled through a hydrocarbon bearing formation shall be located
so that no person(s) unrelated to the drilling activity, no portion of an occupied
building or manned facility is within the well's 100 ppm H2S or LFL RER.
The RER for a well is normally provided by Production and Facilities
Development Department (P&FDD). Minimum spacing shall not be less than
that stated in Table 2. The RER to be used for well spacing shall be based on the
worst case of all hydrocarbon zones that are penetrated during drilling. Where
evacuation is strategically not feasible e.g. electrical power plants, military
defense installations, hospitals, schools, or major facilities, wells shall be located
so that such no portion of these types of establishments or facilities are within
the wells 30 ppm H2S RER.
Exception:
Mobile rig camps at the rig location and unoccupied lands, such as those used
primarily for agriculture, are not required to meet this spacing requirement.
Emergency response coordination with any on-site workers is required to meet
Section 6.9 below.
6.2
Manifolds, significant aboveground appurtenances for cross-country

transportation pipelines such as junctions containing a several scraper
launcher/receiver facilities, Khuff and Jouf gas distribution facilities, and their
associated utilities, roads, highways, and expressways, are allowed to be within
the 100 ppm H2S circle but not within the LFL RER nor closer than the
minimum spacing stated in Table 2.
Table 2 Spacing from Oil and Gas Wells (4, 5)
Minimum Spacing
from the Wellhead
Facility
(1, 2)
Pipelines
Overhead powerlines for site-related CP, etc.
(<69 kV); site related rectifiers
Main overhead powerlines
100 m
200 m
Saudi Aramco or Government roadways

Divided Limited-Access Expressways
60 m
(3)
(3)
(3)
100 m
150 m
Railroads
Major electrical distribution centers
(use only if 100 ppm H2S RER is <450 m)
Occupied buildings, major facilities
(use only if 100 ppm H2S RER is < 450 m)
150 m
Non-well flares and burn pits

Hospitals and schools
(use only if 100 ppm H2S RER is < 1000 m)
450 m
1000 m
450 m
450 m
Page 9 of 32

SAES-B-062
1)
The existing elevated marl pad around wellhead(s) on a wellsite shall not be crossed by a
pipeline. Rig access shall not be obstructed by installation of a pipeline. In addition, the
minimum spacing does not apply to flowlines that are associated with a multi-well wellsite.
2)
New wells may require additional spacing from existing flowlines for wellsite construction and
drilling operations. Spacing shall be increased as needed at the request of the Drilling
Services or Drilling Operations Departments.
3)
Spacing from the well to the closest edge of right-of-way, such as a fence.
4)
Minimum spacing applies to wells drilled after March 30, 2001.
5)
Wells are to be spaced a minimum of 60 m from the closest edge of a burn pit for an oil well
or LP gas well and 150 m from a flare for a HP gas well. See Table 3 for more details on
flare burn pits.
6.3
Water gravity injector, power injector and supply wells that penetrate
hydrocarbon formations shall be spaced the same as hydrocarbon producing
wells. Injector and supply wells that do not penetrate hydrocarbon bearing
formations shall have a basic 60 m minimum spacing requirement from plant
equipment, buildings, etc. Gas injection wells shall use the same location criteria
as producing gas wells.
6.4
A well is in a populated area if the population exceeds 20 persons (unrelated

to drilling activities) residing, working, or otherwise located within the 30 ppm
H2S rupture exposure radius of that well (see Figure 2).
Commentary Notes:
For purposes of this Standard, roads do not generate populated areas.
Where wells are located near areas of potential concern, such as roads, parking
areas, or camp sites, the Proponent Operating/Engineering Department shall
determine whether additional precautionary measures, such as subsurface safety
valves, fencing, etc., are required.
6.5
Wells to be drilled or wells subject to workover in a populated area shall

implement the following additional precautionary measures in addition to the
normal drilling safety program during drilling of hydrocarbon zones. Other
drilling precautionary measures may be added at the request of the Manager,
Loss Prevention or the General Manager of Drilling and Workover.
Precautionary measures during drilling and workover in a populated area:
1.
Rig-site H2S monitoring systems with 24-hour coverage by a competent

and qualified safety professional.
2.
Placement of remote H2S monitors in the vicinity of populations and

nearby facilities to monitor H2S levels at those locations in an emergency.
Page 10 of 32

SAES-B-062
3.
An additional one-hole volume of kill-weight mud available at the drillsite

for immediate use.
4.
Capability of cutting the drill pipe with shear rams.
5.
On-site coverage 24 hours a day by on-site foremen (minimum 2-man

coverage on 12-hour shifts) with authority for immediate ignition of the
well without prior approval in the event of loss of well control.
6.
Capability of burning gas in a controlled release using a properly designed

separation system and an elevated flare with pilot (Only for wells to
protect population within the 30 ppm H2S RER; the use of this equipment
is not required for drilling near GOSPs, process plants or facilities). The
design, location, and elevation of flare shall take into account the potential
dispersion of flammable or toxic materials from the flare during a flameout condition, the toxic products of combustion, such as sulfur dioxide,
during flare operation, and other design considerations as specified in
SAES-F-007. Alternative designs for gas handling shall follow a
management of change (MOC) engineering process. The design shall be
approved by the Manager, Drilling Operations and Manager, Drilling
Technical Department.
Commentary Note:
The intent of the MOC process is to assure compliance with standards,
material specifications, and Codes that apply for gas handling facilities. The
engineering review provides a check on the engineering soundness,
concepts, and calculations used in the design. The dispersion analysis is
required in order to identify alternative design or procedures needed to
protect life safety should the flare extinguish during operation.
7.
A wellsite emergency response plan that meets the Saudi Aramco Safety
Management Guide for Emergency Preparedness.
8.
Other applicable safeguards as needed.
6.6
Under no circumstances shall population be exposed to over 30 ppm H2S gas

concentration for more than 1 hour.
6.7
Well burn pits shall be subject to the same spacing from population and major
facilities as well spacing. The exceptions to 6.1 shall also apply to burn pits.
Minimum spacing shall meet Table 3.
6.7.1
Oil wells and low-pressure gas wells shall have at least one flare while
being drilled.
6.7.2
High-pressure gas well shall have two flares while being drilled.
Page 11 of 32

SAES-B-062
6.7.3
Burn pits shall be at predominantly downwind and crosswind locations,

at least 60 meters from the well (300 m for high-pressure gas wells)
ranging from 60 to 270 arc degrees from true North. Burn pits shall be
placed to point away from populations and facilities as much as possible.
6.7.4
If there are two flares, they should be a minimum of 90 degrees and a

maximum of 180 degrees from each other and pointing away from
populations and facilities as much as possible.
Table 3 Spacing from Well Burn Pits (3)
Minimum Spacing
from Oil & Gas Well Burn
Pits
60 m (Oil & LP Gas)
300 m (HP Gas Well)
60 m (Oil & LP Gas)
150 m (HP Gas Well)
Facility
Well and Well Burn Pits
(1)
Existing Wellheads
Pipelines (Above Ground)
Pipelines (Buried)
60 m
(2)
30 m
Main Overhead Powerlines

Overhead Powerlines for Site-Related CP, etc.,
(<69 kV); Site Related Rectifiers
Powerlines (Buried)
(2)
Railroads
(3)
100 m
30 m
Saudi Aramco or Government Roadways

Divided Limited-Access Expressways
200 m
(3)
(3)
100 m (Oil Wells and LP Gas)

200 m (HP Gas Wells)
450 m (Oil and Gas Wells)

200 m
Population (use only if RER <450 m)
450 m
Non-well Flares and Burn Pits

Hospitals and Schools
(use only if RER < 1000 m)
450 m
1000 m
1)
Spacing of any well related burn pit from a well being drilled shall be a minimum
distance of 60 m for an oil well and 300 m minimum for a high-pressure gas well.
Wells are to be spaced a minimum of 60 m from the closest edge of a burn pit for an
oil well or LP gas well and 150 m from a flare for a HP gas well. A minimum of 60 m
buffer zone shall be maintained around the outside of each burn pit (not on the
wellsite side). The edges of the burn pits shall have a 2 m high berm (minimum
elevation above flare outlet center).
2)
Buried CP powerlines, flowlines, and trunklines related to a wellsite shall have no

other spacing restrictions provided the powerlines do not interfere with rig access or
future production flare operations.
3)
Spacing from the closest edge of the burn pit to the edge of the right-of-way.
Page 12 of 32

SAES-B-062
6.8
For existing wells in populated areas, the special precautions in 6.5 shall be used
for workovers. Precautions appropriate for stimulation and wireline work on
existing wells shall be as requested by the Proponent Operating Department,
Drilling and Workover Services, and Loss Prevention as needed.
6.9
Pre-incident Emergency Response Planning

6.9.1
In areas where drilling will take place, an emergency response plan that
meets the Saudi Aramco Safety Management Guide for Emergency
Preparedness shall be created and used by drilling operations, facility
proponents, responding personnel, Saudi Aramco communities, and
other entities to manage emergency response to a drilling, workover, or
producing related incident.
Commentary Note:
Refer to the Emergency Management Guide (http://lp.aramco.com.sa) for
information on how to develop, implement, and maintain a viable
emergency management program.
6.9.2
The plan shall indicate locations where people may be located within the
30 ppm RER or 5 km of the wellsite, whichever is greater. Such
locations include, but are not limited to, occupied buildings, employee
housing compounds, shopping complexes, office buildings, manned
facilities, factories, camp grounds, schools, hospitals, project
construction sites, and other similar situations. The plan shall include an
effective notification protocol for all locations where people may be
impacted by a drilling, workover, or producing related incident.
6.9.3
Participants in the plan shall receive training to help communicate the

plans expectations, especially those entities that do not normally work
together.
6.9.4
A system for using the plan shall be in place so that the plan itself or a
summary of key elements can be accessed by the responders while in
transit to and at the site of the incident.
6.9.5
Facilities that are potentially impacted shall modify their own emergency
response plans to help provide guidance on how to respond to a nearby
wellsite related incident.
Well Safety Valves and Wellsite Hardware

7.1
Hydrocarbon Producing and/or Hydrocarbon Injection Wells - General

Requirements
Page 13 of 32

7.1.1
SAES-B-062
All well installations shall be in accordance with the specifications

prepared by Saudi Aramco Drilling and Workover Engineering. Refer to
34-SAMSS-624 and 45-SAMSS-005 for the minimum requirements for
Saudi Aramco oil and gas production trees, wellheads, valves and
miscellaneous equipment relating to the wellhead. Naturally flowing
hydrocarbon wells shall be completed in a manner that permits flow only
through a tubing string equipped with a downhole packer or polished
bore receptacle.
7.1.2 Requirements for wellhead piping, flowlines, trunklines, and testlines are
covered in SAES-L-410.
7.2
7.1.3
All wells shall have a manual lower master valve.
7.1.4
At the discretion of the Proponent Operating Department, oil wells may

be equipped with manual remote operators attached to the master valve
and/or wing valve. If manual remote operators are installed on oil wells,
they shall be in accordance with Standard Drawing AA-036454.
7.1.5
Any lockout device used to temporarily hold a surface safety valve

(SSV) in the open position by restricting movement of the valve stem
shall be constructed of fusible materials with a melting point 30C above
the higher of the flowing wellhead or maximum design ambient
temperature.
Safety Valves for HP Gas Producing Wells

7.2.1
All high-pressure gas production wells shall have at least two springassisted failsafe surface safety valves (SSVs).
7.2.2
The two SSVs shall be triggered when an abnormally high or low

pressure is sensed in the piping to the well. Fusible devices, with a set
point 30C above either the flowing wellhead or the maximum design
ambient temperature, whichever is highest, shall be installed on the
wellhead to close the safety valves.
7.2.3 At the discretion of the Proponent Operating Department, addition of

other automated valves, such as subsurface safety valves, shall be
installed as requested.
7.3
Safety Valves on Oil Wells and Low Pressure Gas Wells

7.3.1
Where an oil well or low pressure gas well is in a populated area or

where the associated flowline has Location Class 3 or 4 populations (as
specified in Tables 1 and 2 of SAES-B-064), the well shall be provided
with an SSV and SSSV.
Page 14 of 32

SAES-B-062
7.3.2
For all existing oil wells and low pressure gas wells in populated areas or
where areas become populated due to growth of communities, those
wells shall remain active, but shall require installation of a SSV and
SSSV. The upgrade shall be done only when other needs justify the use
of a rig on the well.
7.3.3
The upper wellhead master valve shall be a spring-assisted fail-safe

surface safety valve (SSV), triggered when an abnormally high or low
pressure is sensed.
7.3.4
A subsurface safety valve (SSSV), per API RP 14B specification, shall

be installed more than 60 m below ground level in oil wells. The SSSV
shall be triggered when an abnormally high or low pressure is sensed.
7.3.5
A fusible device with a melting point 30C above the higher of the
flowing wellhead temperature or maximum design ambient temperature
shall be installed on the wellhead to trigger the SSV and SSSV systems.
Commentary Note:
Values for pipeline associated RERs are found in SAES-B-064, Tables 1
and 2. Location Class 3 is where the pipeline RER includes areas with a
population greater than 30. Location Class 4 is where the pipeline RER
includes 4-story or greater buildings, schools, hospitals, hotels, prisons,
shopping malls or similar retail complexes.
Table 4 Well Safety Valves

Additional
Drilling
Precautions
Oil/LP Gas Well
(a)
Unpopulated Area
Oil/LP Gas Well
Populated Area
HP Gas Well
PWI Well
Unpopulated Area
PWI Well
Populated Area
No
Automated
SSV
No
(a)
Automated
SSSV
No
(a)
Yes
Yes
Yes
No
Yes, 2 SSVs
(b)
No
No
No
Yes
No
No
Note a
Even if the well is in an unpopulated area, if the flowline passes through a

populated area per 8.3, an SSV and SSSV shall be required.
Note b
HP gas production wells shall have at least two spring-assisted failsafe SSVs.
Addition of other automated valves, such as subsurface safety valves, shall be
installed where required by the Proponent Operating Department per Section 8.2.
Page 15 of 32

7.4
SAES-B-062
Hydrocarbon Injection Wells

Hydrocarbon injection well flowlines shall each be provided with a check valve
in the wellhead piping.
7.5
Observation Wells
Wells shall be equipped with the relevant safety devices equivalent in function
to those that would be required for a producing well unless suspended with a
subsurface plug or other acceptable method.
7.6
Suspended Wells
Wells shall be suspended in accordance with Producing Engineering
requirements. Suspension procedures for wells shall be documented by
Producing Operations and shall be available for review.
7.7
7.8
Vehicular Crash Protection and Fencing

7.7.1
All wellheads shall be protected with a guard barrier per Saudi Aramco
Standard Drawing AB-036685.
7.7.2
Wellsites and associated burn pits in populated areas shall be enclosed

by a fence meeting the specifications of SAES-M-006 (Type III). The
fence shall have four lockable vehicle gates, one in each quadrant locked
at all times. Keys shall be kept with the Proponent Operating
Department. Two gates shall be a minimum of 18 m wide rig-access
gates. The locations of these rig-access gates shall permit access to all
wells on the wellsite from either gate.
A wind sock pole and a wind sock (e.g., SAP Material Number 1000132744) are
to be permanently installed at each hydrocarbon production or injection wellsite
in populated areas.
Abandoned Wells
The following requirements apply to a wellsite only if all its wells have been
permanently plugged and if it is located in a populated area:
8.1
The perimeter of the drilling pad shall be provided with a fence (SAES-M-006,
Type III) if there is no fence at the perimeter of the buffer zone.
8.2
The fence shall have one lockable vehicle gate 10 m wide.
8.3
One access route 10 m wide shall be maintained to the wellsite gate.
Page 16 of 32

SAES-B-062
Drilling Rig Access Routes

Two land based access routes shall be available to each wellsite. These shall meet the
following requirements:
9.1
Each access route shall be 18 m wide, terminating at a rig access gate.
9.2
Vertical clearance over the access routes shall be 14 m minimum.
9.3
An access route shall not include grades or transverse slopes of more than 5%.
9.4
No obstruction is allowed on an access route.
9.5
The minimum radius of curvature of access routes shall be 70 m. The center

point of all access route curves shall be outside the wellsite served.
9.6
One of the access routes required by paragraph 10.1 above shall have within it a
prepared roadway consisting of a compacted marl surface 0.3 m thick and 9.0 m
wide with 2.5 m wide shoulders, giving a total clear road width of 14 m.
9.7
The two access roads shall have a separation of from 90 to 270 arc degrees from
each other through the 100 ppm RER.
9.8
In situations where a second land-based route per 9.7 is not feasible (e.g. the
wellsite is near a body of water, in wetlands, located on a peninsula, or on a
causeway-connected drilling island), an alternative second method of emergency
egress shall be planned for all personnel that are at the site, including all drilling
personnel, non-drilling personnel, and visitors. Pre-incident planning shall also
include alternative means for accessing the rig site for search and rescue,
firefighting, well control, and other anticipated emergency response needs. The
alternatives shall be approved by the Manager, Drilling Operations.
31 March 2009
23 July 2009
Revision Summary
Major Revision.
Editorial revision in Section 9.8 to removed approval by Manager, DTD.
Page 17 of 32

SAES-B-062
Appendix 1 Procedure for Determining RER of Oil and Gas Wells

Introduction
To allow for more cost-effective well spacing, while at the same time maintaining a safe
distance between wells and exposed populations, SAES-B-062 provides variable
rupture exposure radii (RER) that are based on field and well conditions (i.e., the well
fluid composition and maximum potential release rate).
This appendix is based on a comprehensive analysis of RERs for Saudi Aramco oil and
gas wells. Production and Facilities Development Department (PRED/1-099-99)
provided the data used for the RER calculations. Tables A7 and A8, at the end of this
Appendix, summarize the data provide. The RER calculations were made in
accordance with LPD Guidelines for Determining the Consequences of Well Blowouts.
Note that the information in Tables A7 and A8 are based on the latest LPD gas
dispersion model PHAST (Version 6.0). The RERs may change in future updates of
SAES-B-062 as a result of changes in well data or refinements in the models. If the
information for the well or production zone needed is not in Appendix 1, contact the
Supervisor, Technical Services Unit, Loss Prevention Department.
The following sections illustrate the use of the correlations for predicting RERs for oil
and gas wells. The correlations are of the form RER = aQb, where a and b are fieldspecific constants and Q is based on the release rate of gas from the well. Correlations
are provided for the following oil and gas fields:
Non-Associated Gas Fields
North Ghawar Areas-Ain Dar and Shedgum
Central Ghawar Areas-Uthmaniyah
South Ghawar Area-Hawiyah
South Ghawar Area-Haradh

Qatif
Berri
Oil Fields
Abqaiq (Abqaiq Cap Gas)
Abu Hadriyah
Abu Jiffan
Ain Dar
Berri Onshore
Dammam
Fadhili
Fazran
Haradh
Harmaliyah
Hawiyah
Khurais
Khursaniyah
Mazalij
Qatif
Shedgum
Uthmaniyah
The following sections explain and demonstrate the process of RER calculations.
Worksheets for calculating RERs are provided at the end of this Appendix.
Page 18 of 32

SAES-B-062
Procedure for Determining RER of Gas Wells

Sour gas wells are considered in this Standard to have three Rupture Exposure Radii
(RER): a 100 ppm H2S RER (RER100 ppm), a 30 ppm H2S RER (RER30 ppm) and a
LFL RER (RER LFL). Sweet gas wells would only have a RER LFL. These radii
are used in SAES-B-062 to determine spacing requirements. Follow these steps when
determining the RER for a gas well.
1.
Identify the gas field and reservoir for the well of interest (Contact the General
Supervisor, Northern Area or Southern Area Facilities Div., Production and
Facilities Development Department (P&FDD) and obtain the Absolute Open Flow
(AOF) and mole fraction of hydrogen sulfide (H2S) in the gas stream. Note that
the correlations included in this appendix are based upon the expected upper and
lower range of AOFs and H2S content in the gas stream.
2.
Determine release rate of H2S (QH2S) from the following:

QH2S = (QAOF)(xH2S)
Where xH2S = mole fraction of H2S in gas stream
QAOF = Absolute Open Flowrate of gas from the well, MMscfd
QH2S = maximum release rate of H2S, MMscfd
3.
Use the constants in Table A6 to calculate RER100 ppm, RER30 ppm and RER LFL from
the following
RER100 ppm = e(QH2Sf);
RER30ppm = g(QH2Sh);
RER LFL = l(QAOF)m
The AOF or H2S concentration of a gas mixture must fall within the limits
presented in Table A6. If an AOF or the H2S concentration is outside the limits,
then LPD/TSU will calculate RER values specifically for the well of interest
(users need to supply LPD/TSU with well name, AOF, gas composition (mole%),
and flowing wellhead temperature).
Example of RER for Gas Well

As an example, consider a high-pressure gas well in the South Ghawar Area, Hawiyah.
Information available indicates that the anticipated Absolute Open Flow of the well is
100 MMscfd and the H2S concentration is expected to be 3 mole%.
Page 19 of 32

SAES-B-062
The following steps are necessary to determine the RER:

1.
Data Requirements
The AOF and the H2S concentration are within the ranges specified in Table A6.
Table A6 indicates that the appropriate constants for this field are as follows:
Table A1 RER Constants for South Ghawar Area,
Hawiyah Field (from Table A6)
RER100 ppm
2.
RER30 ppm
RER LFL
245
0.79
700
0.77
11.7
0.54
Calculate maximum H2S release rate

The maximum H2S release rate is given by the following:
QH2S = (QAOF)(xH2S)
= (100 MMscfd)( 3 / 100 )
=3 MMscfd of H2S
3.
Calculate RERs
RER100 ppm = 245[(3).79] = 583 m
RER30 ppm = 700[(3).77] = 1,631 m
RERLFL = 11.7[(100).54] = 141 m
The RER for this example well are in Table A2.
Table A2 RER for Example Well
Rupture Exposure Radii
Distance, m
RER100 ppm
583
RER30 ppm
1,631
RERLFL
141
Procedure for Determining RER of Oil Wells

Gas is flashed during a large release of crude and is then dispersed downwind. As with
gas wells, oil wells have three Rupture Exposure Radii (RER): a 100 ppm H2S RER
Page 20 of 32

SAES-B-062
(RER100 ppm), a 30 ppm H2S RER (RER30 ppm) and a LFL RER (RERLFL).
Sweet oil wells only have a RER LFL. These radii are used in SAES-B-062 to
determine spacing requirements and to assist in determining emergency response
planning and notification. Follow these steps when determining the RER for an oil well:
1.
Identify the oil field and reservoir for the well of interest (Contact the General
Supervisor, Northern Area or Southern Area Facilities Div. /P&FDD, and obtain
the maximum oil flow rate, Gas-Oil Ratio (GOR) and mole fraction of hydrogen
sulfide (H2S) in the oil. The correlations included in this appendix are based upon
the expected upper and lower range of maximum flow rates, gas-oil ratios, and
H2S content in the oil.
2.
Use the following equation to calculate the rate of gas flashed from the crude
released at the maximum flow rate:
Qgas = (Qoil)(GOR) /1,000
Where:
Qgas = Release rate of flashed gas, MMscfd
Qoil = Maximum oil release rate, Mbpd
GOR = Gas-Oil Ratio, scf/stb
3.
Calculate the concentration of H2S in the flashed gas from the following
equations:
[xH2S]gas = [xH2S]oil
where:
= a(GOR)b (Note: a, b are obtained from Table A7)
Determine release rate of H2S (QH2S)
QH2S = (Qgas) ([xH2S]gas) [MMscfd of H2S]
4.
Calculate RER100 ppm

RER100 ppm = e(QH2S)f (Note: e, f are obtained from Table A7)
5.
Calculate RER30 ppm

RER30 ppm = g(QH2S)h (Note: g, h obtained from Table A7).
Page 21 of 32

6.
SAES-B-062
Calculate RER LFL

RER LFL = l(Qgas)m (Note: l, m obtained from Table A7)
If the AOF or H2S concentration do not fall within limits of Table A7, then LPD/TSU
will calculate RER values specifically for the well of interest (users need to supply
LPD/TSU with well name, maximum oil flow rate, oil composition (mole%), gas-oil
ratio, and flowing wellhead temperature).
Example of Oil Well RER Determination
As an example, consider an oil well that is producing Arab-D in the Khurais field.
Available information indicates the well will have a maximum flow rate of 30,000 bpd,
the oil will have an H2S concentration of 2.9 mole %, and the GOR is 277. What are
the RER values for this well?
1.
Available information
The available information is summarized below. The maximum flow rate and the
H2S concentration are within the limits specified in Table A7.
Maximum Flow Rate, Mbpd
30
GOR, scf/stb
277
Mole percent of H2S in Oil
2.9%
Constants for evaluating this well are summarized in Table A3.

Table A3 RER Constants for Khurais Field (From Table A7)
H2S in Flashed
Gas
2.
RER100 ppm
RER30 ppm
LFL
2.2
1,285
0.69
2,656
0.64
47.3
0.63
Calculate flashed gas release rate

The flow rate of released gas may be estimated by the following:
Qgas = (30 Mbpd) x (277 scf/stb) = 8.31 MMscfd
3.
Calculate the H2S concentration in flashed gas

= a(GOR)b = (2.2) x (277)0 = 2.2
[xH2S]gas = [xH2S]oil = (2.2) x (2.9 %) = 6.4%
Page 22 of 32

4.
SAES-B-062
Calculate H2S release rate

QH2S = (8.31 MMscfd) x (.064) = 0.53 MMscfd H2S
5.
Calculate RERs
RER100 ppm = e(QH2S)f
RER100 ppm = (1285)(0.53)0.69 = 829 m
RER30 ppm = g(QH2S)h
RER30 ppm = (2656)(0.53)0.64 = 1,769 m
RERLFL = l(Qgas)m
RERLFL = (47.3)(8.3)0.63 = 180 m
Table A4 RER for Example Oil Well
Rupture Exposure Radii
Distance, m
RER100 ppm
829
RER30 ppm
1,769
RERLFL
180
Method of Using RER Results

Saudi Aramco uses the maximum of the 30 ppm RER (100 ppm RER with additional
drilling precautions) or the LFL RER to establish the minimum distance between
wells and population or major facilities (note that spacing can never be less than the
minimums stated in Table 2 of the Standard see Section 6 for more details). The
purpose for this RER method of spacing is to minimize the possibility of exposing
people to either potentially lethal or flammable vapor clouds. Table A5 summarizes the
effects of hydrogen sulfide exposure to people.
Once the RER100 ppm, RER30 ppm, and RERLFL are known, draw the RERs as circles with
the well at the center (see
Figure A1). For sour gas wells, the LFL RER will not dominate, but it should still be
drawn on the map showing RERs.
Page 23 of 32

SAES-B-062
Figure A1 RER Circles Superimposed Over Wellsite Map

Table A5 Effects of Hydrogen Sulfide on People
H2S Concentration
(ppm)
0.10
Effect on People
ERPG-1*: The maximum airborne concentration below which it is believed
that nearly all adult males could be exposed for up to 1 hour without
experiencing other than mild transient adverse health effects or perceiving a
clearly defined objectionable odor.
Moderate odor, easily detected.
10
Time Weighted Average (TWA) exposure limitation, beginning of eye irritation.

Setting for Warning low level H2S alarm for control rooms and other indoor
areas protected by air intake sensors. Saudi Aramco work permit procedures
require use of SCBA for work in areas with 10 ppm or greater H 2S.
15
Short Term Exposure Limit (STEL) for 15 minutes.
20
Warning High H2S Level alarm setting at Saudi Aramco plants per SAES-J-505.
30
50
70 150

experiencing or developing irreversible or other serious health effects or
symptoms that could impair their abilities to take protective action.
Inhalation limit for 60 minutes, threshold limit of possible eye injury.
Setting for Warning High-high Level H2S alarm at Saudi Aramco plants per
SAES-J-505.
Headaches, dizziness, sore throat and increasing stress.
100

experiencing or developing life-threatening health effects.
150
Loss of sense of smell.
Page 24 of 32

H2S Concentration
(ppm)
150 300
SAES-B-062
Effect on People
Severe irritation of eyes and lungs.
Immediately Dangerous to Life and Health Concentration: The maximum
airborne concentration to which a healthy male worker can be exposed for as
long as 30 min and still be able to escape without loss of life or irreversible
organ system damage.
Loss of sense of reasoning and balance, loss of consciousness and possible
death in 30 60 minutes.
300
500
1,000
Immediate loss of consciousness and death within a few minutes.
* Emergency Response Planning Guideline (ERPG), American Industrial Hygiene Association.
Table A6 Gas Field Constants for RER Calculations

Properties
H2S
(mole%)
Field
Constants
AOF or Qgas
(MMSCFD)
100 ppm
30 ppm
LFL
min
max
min
max
Abqaiq Cap Gas
1.0
5.0
50
150
268
0.73
729
0.73
14.8
0.49
Berri
20
20
50
120
789
0.63
1894
0.64
11.7
0.49
North Ghawar
(Ain Dar and Shedgum)
0.72
6.0
50
150
273
0.75
689
0.81
14.0
0.48
South Ghawar (Haradh)
0.50
2.0
50
125
242
0.71
654
0.67
14.6
0.49
South Ghawar (Hawiyah)
0.5
4.5
50
150
245
0.79
700
0.77
11.7
0.54
Qatif
7.23
11.2
50
120
376
0.74
1032
0.72
11.1
0.50
Uthmaniyah
2.28
9.27
50
175
295
0.80
855
0.76
16.1
0.46
Equations for Oil and Gas Wells:

RER100 ppm = e(QH2S)f
RER30 ppm = g(QH2S)h
RERLFL = l(QAOF)m
Equations for Oil Wells Only:
[xH2S]gas
H2S]oil
b
Note:
All RER distances are in meters. QH2S = release rate of H2S, MMSCFD. Qgas = release rate of
gas, MMSCFD
Page 25 of 32

SAES-B-062
Table A7 Oil Fields Constants for RER Calculations

Properties
Constants
H2S (mole%)
in Oil
Qoil (MBD)
min
max
min
max
Abqaiq
0.93
3.19
2.9
85
11.7
-0.29
815
0.58
1,895
0.58
49.4
0.59
Abu Hadriyah
0.21
2.23
1.9
88
2.2
1,024
0.57
2,249
0.55
63.8
0.57
Abu Jiffan
2.58
3.61
10
50
2.5
1,182
0.56
2,470
0.55
51.2
0.58
Ain Dar
0.25
2.7
6.9
37
1.7
897
0.76
2,251
0.84
45.5
0.42
Berri
1.06
8.92
15
143
33.5
-0.48
1,152
0.53
2,474
0.52
59.1
0.59
Dammam
1.04
2.18
52
2.8
432
0.48
725
0.49
24.1
0.47
Fadhili
4.13
11.1
31
1.5
878
0.77
1,949
0.71
51.7
0.54
Fazran
0.66
2.15
4.5
27
1.8
273
0.25
911
0.37
38.4
0.29
Haradh
0.02
0.79
32
2,741
0.77
3,825
0.37
50.4
0.52
Harmaliyah
1.69
5.3
32
1.6
856
0.61
1,980
0.59
45.3
0.44
Hawiyah
0.21
1.05
30
1,173
0.73
2,617
0.71
48.8
0.56
Khurais
0.58
2.94
36
2.2
1,285
0.69
2,656
0.64
47.3
0.63
Khursaniyah
1.96
4.77
43
1,079
0.59
2,346
0.58
47.9
0.53
Mazalij
1.9
5.47
6.3
37.8
2.2
1,232
0.71
2,565
0.67
50.6
0.65
Qatif
3.72
11.95
90
1.9
1,708
0.34
3,488
0.32
64.6
0.55
Shedgum
0.75
1.57
46
1.8
630
0.51
1,511
0.49
50.0
0.38
Uthmaniyah
0.23
1.55
29
1.8
1,438
0.83
3,279
0.83
36.5
0.70
Field
Flash
100 ppm
30 ppm
LFL
Page 26 of 32

SAES-B-062
Table A8 Oil Field Data from Exploration and Producing

Components (mole %)
Well Name
Abqaiq
Abqaiq
Abqaiq
Abu Hadriyah
Abu Hadriyah
Abu Hadriyah
Abu Jiffan
Abu Jiffan
Abu Jiffan
Ain Dar
Ain Dar
Ain Dar
Berri
Berri
Berri
Dammam
Dammam
Dammam
Fadhili
Fadhili
Fadhili
Fazran
Fazran
Fazran
Haradh
Haradh
Haradh
Harmaliyah
Harmaliyah
Harmaliyah
Hawiyah
Hawiyah
Hawiyah
Khurais
Khurais
Khurais
Reservoir Range
Arab-D
Min.
Arab-D Wt. Avg.
Arab-C
Max.
Arab-A&B Min.
Wt. Avg.
Arab-C
Max.
Arab-D
Min.
Arab-D Wt. Avg.
Arab-D
Max.
L. Fadhili
Min.
Arab-D Wt. Avg.
Arab-D
Max.
Arab-B
Min.
Wt. Avg.
Hanifa
Max.
Arab-D
Min.
Wt. Avg.
Arab-D
Max.
Arab-D
Min.
Wt. Avg.
Arab-D
Max.
L. Fadhili
Min.
Wt. Avg.
L. Fadhili
Max.
Arab-D
Min.
Arab-D Wt. Avg.
Arab-D
Max.
Arab-D
Min.
Arab-D Wt. Avg.
Arab-D
Max.
Arab-D
Min.
Arab-D Wt. Avg.
Arab-D
Max.
Arab-D
Min.
Arab-D Wt. Avg.
Arab-D
Max.
N2
0.3
0.1
0.6
0.2
0.4
0.3
0.2
0.2
0.3
0.1
0.1
0.2
0.1
0.1
0.1
0.2
1.4
1.5
0.0
0.1
0.1
0.3
0.2
0.1
0.3
0.2
0.2
0.1
0.1
0.1
2.1
1.0
0.4
0.3
0.5
0.8
CO2
4.9
4.6
5.1
1.0
1.2
1.3
1.7
1.9
2.1
3.9
5.9
6.3
1.2
1.5
6.6
2.8
4.8
5.5
2.9
2.3
9.8
3.8
4.5
2.1
1.4
3.8
4.8
4.8
5.1
5.3
4.8
4.8
4.1
1.4
1.9
4.5
H2S
0.9
1.8
3.2
0.2
1.4
2.2
2.6
3.1
3.6
0.3
1.7
2.7
1.1
2.1
8.9
1.0
1.7
2.2
4.1
5.5
11.1
0.6
1.5
2.2
0.0
0.4
0.8
1.7
4.1
5.3
0.2
0.8
1.1
0.0
0.6
2.9
C1
27.4
29.6
6.1
3.5
14.5
17.2
9.6
9.2
8.9
34.3
25.1
24.0
4.3
4.6
24.9
21.9
22.6
22.4
33.4
31.8
25.8
21.0
21.5
34.0
19.5
22.2
27.4
25.5
27.7
24.9
29.4
22.8
15.9
13.8
13.7
12.8
C2
C3
10.7 4.4
10.3 6.6
4.7
7.4
2.9
6.7
8.1
8.1
8.4
7.8
9.6
9.3
8.9
8.8
8.3
8.3
13.8 8.5
10.4 7.7
10.2 7.0
6.7
9.7
6.4
9.2
10.2 7.2
2.0
1.5
2.1
1.6
1.6
1.1
11.1 6.8
12.8 8.3
9.3
7.1
11.3 9.3
11.3 8.5
11.7 6.8
10.5 10.0
9.5
8.5
10.7 8.2
11.8 8.3
11.4 7.8
10.6 7.6
6.9
5.8
9.1
7.9
8.3
7.6
9.2
8.9
9.3
9.2
6.1
8.9
i-C4
1.6
0.6
1.2
1.4
1.1
1.1
1.2
1.2
1.2
1.0
1.0
0.9
1.7
1.5
0.9
0.3
0.4
0.2
0.5
0.9
0.9
1.2
1.0
0.8
1.2
1.1
1.0
0.9
0.9
0.9
0.8
1.0
1.0
1.3
1.2
1.4
n-C4
3.7
4.3
5.1
5.4
4.9
4.6
4.9
4.7
4.6
4.0
3.8
3.5
6.1
5.7
3.5
1.3
1.4
0.8
3.9
3.8
3.5
5.2
4.1
3.7
5.1
4.5
3.9
3.8
3.7
3.8
3.5
4.1
4.3
4.8
4.9
4.9
i-C5
2.6
1.0
2.1
2.2
1.8
1.6
1.7
1.7
1.8
1.1
1.2
1.2
2.3
2.2
1.2
0.4
0.8
0.4
0.8
1.0
1.2
1.8
1.3
1.3
1.6
1.6
1.3
1.2
1.3
1.2
1.2
1.4
1.7
1.7
1.7
1.9
n-C5
1.8
3.0
3.5
3.9
3.2
3.1
3.0
3.1
3.1
2.1
2.2
2.1
3.6
3.6
2.1
0.9
1.3
0.9
2.5
2.0
2.0
3.4
2.5
2.2
2.8
2.8
2.3
2.3
2.4
2.3
2.2
2.6
3.4
3.1
3.0
3.0
C6
4.2
3.1
4.6
4.3
3.4
2.8
3.9
4.4
5.0
1.6
3.0
3.2
3.5
3.7
2.8
4.7
3.6
3.4
3.2
1.4
1.8
3.7
4.0
2.1
2.8
3.9
2.0
3.1
3.0
3.2
3.0
3.5
6.0
4.0
3.8
3.9
C7+ GOR
37.4 860
35.1 860
56.6 135
68.3
57
52.0 260
49.6
57
52.4 253
52.7 253
53.0 253
29.3 730
37.8 550
38.7 550
59.8 139
59.3 145
31.6 659
63.1 353
58.4 360
60.0 353
30.7 955
30.3 962
27.4 955
38.5 1100
39.5 565
33.0 1100
44.7 470
41.4 470
37.6 470
36.6 772
32.7 772
34.8 772
40.2 485
40.9 485
46.1 485
51.4 277
50.1 277
48.7 277
Page 27 of 32

SAES-B-062
Table A8 Oil Field Data from Exploration and Producing (Cont'd)

Components (mole %)
Well Name Reservoir Range
Khursaniyah
Arab-D
Min.
Khursaniyah
Wt. Avg.
Khursaniyah
Arab-B
Max.
Mazalij
Arab-D
Min.
Mazalij
Arab-D Wt. Avg.
Mazalij
Arab-D
Max.
Qatif
Fadhili
Min.
Qatif
Wt. Avg.
Qatif
Arab-D
Max.
Shedgum
Arab-D
Min.
Shedgum
Wt. Avg.
Shedgum
Arab-D
Max.
Uthmaniyah
Arab-D
Min.
Uthmaniyah
Arab-D Wt. Avg.
Uthmaniyah
Arab-D
Max.
N2
0.1
0.2
0.1
0.1
0.3
0.3
0.2
0.9
0.3
0.3
0.2
0.2
0.1
0.2
0.1
CO2
2.5
3.1
4.7
3.4
2.6
1.6
3.5
6.6
6.7
5.4
5.3
5.4
3.8
4.5
5.2
H2S
2.0
2.4
4.8
1.9
3.2
5.5
3.7
7.9
11.9
0.8
1.1
1.6
0.2
0.8
1.6
C1
C2
19.4 9.8
21.5 9.8
15.8 7.2
28.7 5.8
19.2 8.0
5.3
8.7
38.2 12.3
14.4 7.0
20.8 9.0
25.0 10.0
24.4 9.9
24.3 9.8
26.1 9.7
24.6 10.0
23.9 9.2
C3
8.6
8.5
6.9
6.4
7.5
8.3
7.4
7.2
7.1
7.7
7.8
7.6
7.7
8.1
7.7
i-C4
1.1
1.1
1.0
1.0
1.1
1.2
0.9
1.0
1.0
1.0
1.0
1.0
0.9
1.0
1.1
n-C4
4.5
4.2
3.8
3.7
4.3
5.0
3.6
4.1
3.6
3.9
4.0
3.9
4.2
4.1
4.4
i-C5
1.7
1.5
1.5
1.4
1.7
2.1
1.2
1.6
1.4
1.3
1.4
1.3
1.6
1.4
1.5
n-C5
3.1
2.6
2.7
2.2
2.7
3.4
2.2
2.7
2.2
2.4
2.4
2.4
3.0
2.5
2.7
C6
3.2
2.8
2.9
3.2
4.0
5.6
3.0
3.8
3.6
3.3
3.2
3.3
3.4
3.3
4.1
C7+ GOR
44.0 350
42.3 380
48.7 350
42.1 398
45.4 398
53.0 398
23.8 1266
43.0 330
32.5 870
38.9 540
36.2 540
39.3 540
39.4 515
39.3 515
38.7 515
Page 28 of 32

SAES-B-062
Table A9 Gas Field Data from Exploration and Producing

Mol Wt.
Range
Well Name Reservoir
Component (mole %)
N2
CO2
H2S
C1
C2
C3
i-C4
nC4
iC5
nC5
C6
C7
C8
C9
C10+
North Ghawar (Ain Dar and Shedgum)

ANDR-277
Khuff-B
23.1
Min.
14.7
3.8
0.7
70.4
4.9
1.8
0.4
0.6
0.2
0.2
0.2
0.3
0.4
0.3
1.1
SDGM-226
Khuff-C
23.7
Med. 11.8
3.7
3.6
69.4
5.1
2.0
0.5
0.8
0.3
0.3
0.4
0.4
0.4
0.3
1.1
SDGM-212
Khuff-C
24.6
Max. 11.5
3.9
6.0
66.6
5.0
2.1
0.5
0.8
0.4
0.3
0.5
0.6
0.6
0.4
1.0
Central Ghawar Area (Uthmaniyah)

UTMN-622
Khuff-B
25.5
Min.
10.5
1.7
2.3
68.4
6.7
3.0
0.6
1.2
0.5
0.5
0.7
0.8
0.8
0.6
1.8
UTMN-616
Khuff-C
24.9
Med. 11.5
3.3
5.2
66.0
5.8
2.5
0.5
1.0
0.4
0.4
0.6
0.6
0.6
0.5
1.3
UTMN-2000 Khuff-C
26.4
Max. 10.2
3.1
9.3
62.0
6.2
2.7
0.5
1.0
0.3
0.3
0.6
0.9
0.8
0.6
1.5
South Ghawar Area (Hawiyah)

Avg.
9.6
2.2
2.5
68
6.7
2.9
0.5
1.1
0.4
0.4
0.7
1.0
1.0
0.7
2.2
26.6
Min.
9.8
2.3
0.5
69.4
6.8
3.0
0.5
1.1
0.4
0.4
0.7
1.0
1.0
0.7
2.2
27.1
Med.
9.6
2.2
3.0
67.7
6.6
2.9
0.5
1.0
0.4
0.4
0.7
1.0
1.0
0.7
2.2
27.2
Max.
9.4
2.2
4.5
66.6
6.5
2.8
0.5
1.1
0.4
0.4
0.7
1.0
1.0
0.7
2.1
Avg.
9.0
1.5
0.6
71.1
7.4
3.3
0.6
1.4
0.5
0.5
0.6
0.8
0.8
0.6
1.2
Khuff-C
27
Khuff-C
Khuff-C
Khuff-C
South Ghawar Area (Haradh)

Khuff-C
25
Khuff-C
25
Min.
9.0
1.5
0.5
71.2
7.4
3.3
0.6
1.4
0.5
0.5
0.6
0.8
0.8
0.6
1.2
Khuff-C
25
Med.
1.5
1.0
70.9
7.4
3.3
0.6
1.4
0.5
0.5
0.6
0.8
0.8
0.6
1.2
Khuff-C
25
Max.
1.5
2.0
70.1
7.3
3.3
0.6
1.4
0.5
0.5
0.6
0.8
0.8
0.6
1.2
Qatif
QTIF-51
Khuff-A
20.9
Min.
6.5
9.1
7.2
75.8
1.2
0.2
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
QTIF-152
Khuff-B
24.7
Max.
42.2
2.0
11.2
42.2
0.9
0.2
0.0
0.2
0.0
0.0
0.1
0.8
0.0
0.0
0.0
Abqaiq
Abq Cap
Gas
Berri
Abqaiq
0.7
8.6
2.3
64.5 14.1
6.1
2.2
0.9
0.3
0.1
0.1
0.1
0.0
0.0
0.0
Berri Khuff
Berri
10.0
8.2
19.8
61.4
0.2
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
23.2
0.3
The table below shows examples of the maximum RERs for some fields. The RER values shown
are based on the calculation information above and the maximum open flow and highest sour gas
concentration typically expected the fields listed. The values below are for example only.
RER100ppm
(meters)
RER30ppm
(meters)
RERLFL
(meters)
Abqaiq Gas Cap
1170
3170
170
North Ghawar (Ain Dar and Shedgum)
1420
4090
160
South Ghawar (Haradh)
460
1210
160
South Ghawar (Hawiyah)
1110
3050
180
Uthmaniyah
2740
7110
170
Gas Fields
Page 29 of 32

SAES-B-062
RER100ppm
(meters)
RER30ppm
(meters)
RERLFL
(meters)
Abqaiq
1780
4140
620
Abu Jiffan
1270
2660
220
Ain Dar
850
2130
160
Dammam
460
770
100
Fazran
280
960
100
Haradh
910
2250
210
Harmaliyah
1340
3060
190
Hawiyah
490
1130
220
Khurais
950
2010
200
Khursaniyah
1340
2890
200
Mazalij
1880
3820
300
Shedgum
530
1270
170
Uthmaniyah
700
1590
240
Oil Fields
Page 30 of 32

SAES-B-062
Gas Field RER Work Sheet

Information
Value
Well Name
Field
Absolute Open Flow, Qgas MMSCFD
Mole % of H2S in Gas, [xH2S]gas
DATA from Table A6
Minimum AOF, MMSCFD, per Table A6
Maximum AOF, MMSCFD, per Table A6
Is AOF for well greater than minimum
and less than maximum AOF for field?
Minimum mole percent (%) of H2S per Table A6
Maximum mole percent (%) of H2S per Table A6
Is H2S mole % for well greater than minimum
and less than maximum flow rate for field?
( ) Yes (continue)
( ) No (stop: Contact LPD/TSU)
( ) Yes (continue)
Constants from Table A6

e
f
g
h
l
m
Calculate H2S Release Rate
QH2S = (QAOF)(xH2S) [MMscfd of H2S]
Calculate RERs
f
RER100 ppm = e(QH2S) :
h
RER30 ppm = g(QH2S)
m
RER LFL = l(QAOF)
Results
RER100 ppm
RER30 ppm
RER LFL
Page 31 of 32

SAES-B-062
Oil Field RER Work Sheet

Information
Value
Well Name
Field
Maximum Flow Rate, Qoil Mbpd
GOR, scf/stb
Mole % of H2S in Oil, [xH2S]oil
DATA from Table A7
Minimum Flow Rate, Mbpd, per Table A7 or Qoil
Maximum Flow Rate, Mbpd, per Table A7 or Qoil
Is flow rate for well greater than minimum
Minimum mole percent (%) of H2S per Table A7
( ) Yes (continue)
Maximum mole percent (%) of H2S per Table A7

Is H2S mole % for well greater than minimum
( ) Yes (continue)
Constants from Table A7

a
Calculate flashed gas release rate

Qgas = (Qoil)(GOR)/1,000 [MMscfd]
Calculate the H2S concentration in flashed gas
b
[xH2S]gas
H2S]oil
QH2S = (([xH2S]gas)/100)Qgas [MMscfd of H2S]

Calculate RERs
f
RER100 ppm = e(QH2S)

h
RER30 ppm = g(QH2S)
m
RER LFL = l(Qgas)
Results
RER100 ppm
RER30 ppm
RER LFL
Page 32 of 32
Saudi Aramco 7180 (5/89)

G.I. NUMBER
SAUDI ARABIAN OIL COMPANY (Saudi Aramco)

GENERAL INSTRUCTION MANUAL
1852.01
ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT:
RIG SITE FLARE GUN AND COMMUNICATION EQUIPMENT
10/29/2011
APPROVAL
AAR
Approved
REPLACES
01/31/2010
PAGE NUMBER
OF
CONTENT:
This General Instruction contains policy for equipping a rig with a Flare Gun and standard Communication
Equipment.
1. OBJECTIVE
2. BACKGROUND
3. FLARE GUN
4. COMMUNICATION EQUIPMENT
1.0
OBJECTIVE **
The purpose of this policy is to ensure that every rig is fully equipped with a Flare Gun and
Communication Equipment in case of an uncontrolled surface well flow (blowout) or other
emergency.
All rigs must have functional and dedicated flare gun on location, prior to commencing and
during Drilling and Workover Operations.
2.0
3.0
BACKGROUND
2.1
During Drilling and Workover operations, with a rig on the well, an uncontrolled surface flow
(blowout) may occur, requiring immediate ignition of the well effluent to protect human life and
company assets. In such a case, a Flare Gun is fired to ignite the effluent before spreading.
2.2
During the blowout emergency, it becomes imperative to have reliable means of communication
at the rig site and with headquarters, especially when all power is turned off at the well site to
avoid uncontrolled ignition. The use of mobile radios and portable communication devices
(such as Walkie-Talkies) become essential in effective transmittal of instructions and expedient
control of the well.
FLARE GUN *
Drilling & Workover will have a Flare Gun on each rig site, as well as a minimum of 20 cartridges
with long shelf life. The Flare Gun and cartridges will be locked up in a clearly marked wooden box in
the Foreman's office, and the location of the key will be known only to the Foreman and the
Contract rig Supervisor. The Foreman and Contract rig Supervisor should be proficient in operation
of the Flare Gun.
Note: Foremen should ensure that the cartridge is compatible with the length of the gun barrel.
* CHANGE
** ADDITION
NEW INSTRUCTION
COMPLETE REVISION
Saudi Aramco 7180 (5/89)

G.I. NUMBER

ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT:
RIG SITE FLARE GUN AND COMMUNICATION EQUIPMENT
4.0
1852.001
10/29/2011
APPROVAL
AAR
Approved
REPLACES
01/31/2010
PAGE NUMBER
OF
COMMUNICATION EQUIPMENT
Drilling & Workover, Area Information and Communications Operations Departments will
work together to forecast, acquire and install the following communication equipment:
4.1 One (1) Trunk mobile radio (for on-shore rigs only) in rig Foremans vehicle to provide the
capability to communicate with management, etc. in case of an emergency. The radio will only be
used when at a safe distance from the well site in case of an un-ignited hydrocarbon accumulation
since the vehicle and radios are both source of ignition.
4.2 One (1) Trunk desktop radio (all rigs) in every rig Foremans office to enable communication with
management, etc. if incase V-Sat communication is non functional or an emergency situation
exists at the rig.
4.3 One (1) Trunk portable radio (hand held) for all rigs.
4.4 Six (6) VHF portable radios. The radios are needed on every rig site during an emergency or critical
operation. The portable radios will be locked up in a clearly marked wooden box in the Foremans
office, and the location of the key will be known only to the Foreman and the Contractor Rig
Supervisor. The foreman is responsible for the proper operation and charging of the radios. The
radios must be rated for use in Class I, Div. I electrically classified areas (i. e. Explosion proof).
4.5 One (1) Base Station VHF System (Aviation Radio) for Offshore Rigs only to communicate with
helicopter.
4.6 One (1) V-Sat unit at every rig to enable use of telephone / data (internet) communication at rig
during normal non-emergency operations.
4.7 One (1) satellite phone at every rig as back-up communication to provide the capability to
communicate with management, etc. if incase V-Sat communication goes down.
Prepared by :
__________________
Iqbal Ahmed
Sr. Consultant D&W/O
Approved by:
__________________ _______
ABDULHAMEED A. AL-RUSHAID
General Manager (A), Drilling.
* CHANGE
** ADDITION
____
SULAIMAN H. ARJAH
Manager, Area Info. Tech. Dept.
NEW INSTRUCTION
___________________________
ABDULRAHMAN E.ALMUAGLE
Manager, Comm. Oprs. Dept.
COMPLETE REVISION
G. I. Number
APPROVED
1853.001
ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT
ISOLATION BARRIERS FOR WELLS DURING DRILLING &

WORKOVER OPERATIONS (WITH AND WITHOUT RIG)
02/05/2014
APPROVAL
DMD
REPLACES
05/30/2012
PAGE NO.
1 OF 7
CONTENT:
This document contains Instructions for providing adequate isolation barriers (or shut-offs) when
removing surface control equipment while drilling or working over wells. These instructions are also
applicable for well repair work, performed by the Drilling & Workover organization with and without
a rig on location.
1. OBJECTIVE
2. BACKGROUND
3. MINIMUM REQUIREMENT
4. TYPES OF ISOLATION BARRIERS
5. RELIABILITY OF ISOLATION BARRIER
6. WAIVER
1.0
OBJECTIVE:
The purpose of this GI is to ensure safe operations during drilling and well repair work by strict
compliance to the guidelines. Deviation from these guidelines will not be permitted unless a waiver
is obtained from the Vice President, Drilling and Workover or designated representatives.
2.0
BACKGROUND:
When drilling or working over wells, with or without a rig, situations arise where surface
equipment such as Blow Out Preventers (BOPs), wellheads, master valves and trees have to be
removed for various reasons. In these situations, surface well control is temporarily removed and
is substituted with down-hole isolation barriers so that the reservoir pressure is isolated and work
can continue around the wellhead safely. More than one isolation barrier or shut-off is normally
required in certain wells in case of unexpected failure of the primary barrier. Adequate back-up
barriers reduce the chances of uncontrolled surface flow (blowout) and costly repair work.
3.0 MINIMUM REQUIREMENT:

The following guidelines will apply at all times unless a waiver has been obtained from
Management (as described in paragraph 6.2). The mandatory number of barriers or shut-offs in
each case is the minimum; any additional barriers are optional, dictated by the well condition
and down-hole completion equipment.
CHANGE
ADDITION *
NEW INSTRUCTION
COMPLETE REVISION
G. I. Number
APPROVED
1853.001
ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT

02/05/2014
APPROVAL
DMD
REPLACES
05/30/2012
PAGE NO.
2 OF 7
3.1) Oil Wells (GOR less than 850scf/bbl)

2 shut-offs, at least one of which is mechanical. (See notes below)
3.2) Oil Wells (GOR more than 850 scf/bbl)

3 shut-offs, at least two of which are mechanical. (See notes below)
3.3) Oil Wells (Dead Wells 0 psi when the ESP is not running)
1(one) shut-off for tubing - While continuously pumping kill fluid down the
Tubing/Casing Annulus.
Notes:
a)
For completing wells with tubing and down-hole packer, the shut-off guideline is
applicable to tubing only. A minimum of 2 shut-offs is required for the Tubing/Casing
Annulus (tubing hanger and packer seals).
b)
For de-completing well with down-hole packer, the shut-off guideline is applicable to
the Tubing. The shut-offs for the tubing/casing annulus (TCA) are:
Packer.
Tubing Hanger.
Positive pressure test of Casing.
If any one of the shut-offs is deemed to be ineffective or questionable, then additionally a

Cement Plug or a Thru-Tubing Drillable Bridge-Plug (TTBP) must be placed above the
producing / injecting zone, capped with cement. The Top of Cement (TOC) must be
tagged.
CHANGE
c)
For de-completing wells with up-hole packer completions it is mandatory that full
circulation is established with kill fluid. If full circulation is not achieved a Cement Plug or a
TTBP capped with cement is required. The TOC must be tagged.
d)
For Wells equipped with ESP (without Y- assembly) and positive Wellhead
Pressures, the shut-off guideline is applicable to the Tubing. The shut-offs for the
tubing/casing annulus (TCA) are:
Tubing Hanger
TCA standing full with kill-weights fluids or continuously pumping kill-weight

fluids down the TCA.
ADDITION *
NEW INSTRUCTION
COMPLETE REVISION
G. I. Number
ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT

e)
3.3
APPROVED
1853.001
02/05/2014
APPROVAL
DMD
REPLACES
05/30/2012
PAGE NO.
3 OF 7
When changing the tree above the master valve on wells that have a pressure tested
master valve, only one barrier in addition to the master valve is required. This
additional barrier should be mechanical.
Water Injection Wells
If positive WH pressure, 2 shut-offs are required, one of which is mechanical.
If no WH pressure, 1 shut-off is required.
Notes:
a) Water Injection Wells encountering Loss Circulation (LC) after pumping kill fluid.
It is acceptable to Nipple-Up (NU) or Nipple-Down (DN) the BOPE on top of the injection
tree by closing the Master Valve and continuously pumping kill fluid down the well-bore.
No additional shut-offs are required as long as the tree was never removed and has been
pressure tested prior to NU/ND the BOPE.
b) Injection Wells with guide string extended into the Open Hole.
It is acceptable to NU/ND the BOPE with tubing full of kill fluid. MV closed & a
mechanical plug (tested) in place, tubing hanger seals (tested) while continuously pumping
kill fluid down the Tubing/Casing Annulus.
3.4
Gas Wells
3 shut-offs, at least two of which are mechanical.
Notes:
CHANGE
a.
For completion, the 3 shut-off guideline is applicable to the tubing only. A minimum of 2
shut-offs is required for the tubing-casing annulus (tubing hanger and packer seals).
b.
For de-completion positive pressure test of Tbg. & TCA with kill fluid in both sides is
mandatory.
c.
When changing the tree above the master valve on wells that have a pressure tested master
valve, barriers in addition to the master valve (barrier) are required.
ADDITION *
NEW INSTRUCTION
COMPLETE REVISION
G. I. Number
ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT

3.5
APPROVED
1853.001
02/05/2014
APPROVAL
DMD
REPLACES
05/30/2012
PAGE NO.
4 OF 7
Water Supply Wells (with or without submersible pump)

- If well flows to surface, 1 mechanical shut-off is required with kill weight fluid in the
well-bore
- If well does not flow to surface, no shut-off is required.
4.0
TYPES OF ISOLATION BARRIERS:

4.1
A number of acceptable isolation barriers or shut-off alternatives are available and can be used
under different operating conditions. These barriers can be separated into two main groups:
Mechanical and Non-Mechanical.
4.2
The following are examples of Mechanical and Non-Mechanical isolation barriers. The type of
barrier to be utilize will depend on the well condition and down-hole completion equipment.
These barriers include, but are not limited to:
Mechanical:
- Drillable or Retrievable Bridge Plug
- Retrievable Tubing Plug
- Back Pressure Valve
- Valve Back-Seat
- Surface Valve
- Un-perforated Casing
Non-Mechanical:
- Kill Fluid
- Cement
GLASS AND CERAMIC DISKS:
Both types can be considered a barrier when completing a well under the following
conditions:
a. The disks must be rated to hold the formation pressure from below. The working
pressure must be a minimum of 20% higher than the anticipated formation pressure.
b. They are only used during BOP nipple down and tree nipple up operations.
c. A negative test must be successfully performed on the disks.
d. After the negative test, the integrity of the disks may not be compromised by any
subsequent operation (e.g.: wire-line, CT work, dropped objects, etc.)
e. They must be used in conjunction with a BPV.
CHANGE
ADDITION *
NEW INSTRUCTION
COMPLETE REVISION
G. I. Number
ISSUE DATE
ISSUING ORG.
DRILLING & WORKOVER
SUBJECT

5.0
APPROVED
1853.001
02/05/2014
APPROVAL
DMD
REPLACES
05/30/2012
PAGE NO.
5 OF 7
RELIABILITY OF ISOLATION BARRIERS:

5.1
Equipment Testing
5.1.1 Vendor Testing: Prior to delivery of a new mechanical pressure isolation device, the
vendor must conduct the required and appropriate hydrostatic pressure tests per Saudi
Aramco Materials System Specification (SAMSS) to insure that the device meets
design specifications.
5.1.2 Field-Testing: Whenever a mechanical isolation barrier is installed in a well, every
effort should be made to field test and insure the barrier is holding. Since plugs are
designed to hold pressure from above, below or from both directions, the field test
should be designed according to the plug functionality.
5.1.3 While drilling or working over a well, if BOPE repairs are required, the mechanical
isolation barriers must be installed and positive tested.
5.2
Kill Fluid
5.2.1 A kill fluid can be used as one of the isolation barriers as mentioned in section
4.2 above. In order for the kill fluid to be effective as an isolation barrier, two
conditions must be met:
a) The hydrostatic pressure of the kill fluid column must exceed the reservoir
pressure.
b) The wellbore kill fluid must remain static at surface for a period of time (as
per item 5.2.2 below) to insure the presence of a competent barrier.
5.2.2
The following are the minimum mandatory observation times for a kill fluid to be
declared static:
Oil Well (GOR less than 850 scf/bbl):
*Well (GOR more than 850 scf/bbl):
*Gas Well
Water Injector
Water Supply Well
1 hour Oil
2 hour
3 hours
1 hour
30 minutes
*The depth and permeability of the producing formation should be taken into
consideration. Deeper or less permeable producing formations may need longer
observation period..
CHANGE
ADDITION *
NEW INSTRUCTION
COMPLETE REVISION
Appendix I
GI 1853.001
Page 7 of 7
WAIVER REQUEST FOR ISOLATION BARRIER

Date Requested
Well Name & Number
Plant#
Waiver Request#
Facility Connected to
Include number, Paragraph, and Issue date of this affected GI

Waiver request
After-the-fact
WAIVER ORIGINATOR
Justification (include discussion of impact assessment)
Y
Impact Assessment
Financial Impact
Safety Impact
Discuss under justification

Alternative to waiving requirements
Originating organization
(Originators name)
(Signature)
Date
(Signature)
Date
Phone:
Originators Supervisor
REMARKS
APPROVAL
Well Control Committee Chairperson
Signature
Date
Signature
Date
Name:
Vice President or Designated Representative
Name:
SAUDI ARAMCO
DRILLING & WORKOVER
ROOM 221A, BLDG 3193
DHAHRAN 31311, SAUDI ARABIA
TEL. 862-8000, FAX. 862-8011
October 18, 1999
D&WO/GM-160
Clarification of GI 1853.001
Managers
Drilling & Workover
The new GI 1853.001 entitled Isolation Barriers for Wells during Drilling & Workover
Operations (with and without Rig) was approved in November 1998 and distributed for
implementation. The interpretation of the GI with respect to changing rams or installing casing
rams has been questioned. The following clarifies the shut-off requirements for these
operations as per the subject GI.
Section 3.0,
Paragraphs 3.2 (Oil Wells with GOR more than 850 scf/bbl) and 3.4 (Gas Wells)
Three mandatory shut-offs are required; two of which should be mechanical.
Clarification:
i)
For BOP stack removal or tree removal, the mandatory shut-off requirements are
applicable.
ii)
For changing rams or installing casing rams, the mandatory shut-offs do not apply.
Two barriers are adequate; one of which should be mechanical. Shutting the blind
rams with kill fluid in the hole will provide proper isolation since the 1) BOP
preventers below the open ram cavity are effective and reliable (recently pressure
tested), 2) time involved in changing rams is much less than removing the entire
BOP stack or tree. When changing the lowermost set of rams, a down-hole
mechanical shut-off (either cased hole or packer) with kill fluid is required.
Signed 10/18/99
__________________________________
F. A. Al-Moosa, General Manager
Drilling & Workover
dgn/
cc: Drilling Superintendents, Deep Drilling and Onshore Workover Dept.
Drilling Superintendents, Dev. Drilling and Offshore Workover Dept.
General Supervisors, Drilling and W/O Engrg. Dept.
Originator
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