- Preparation & Inspection
-Ensure all BOP components are inspected and pressure-tested as per API standards.
-Verify correct BOP stack configuration for the well (e.g., Annular + Double Ram or Triple Ram).
-Check compatibility with wellhead and casing spool dimensions.
-Confirm all tools, gaskets, and lifting equipment are available. - Assemble BOP Stack on the Ground (if possible)
-Start from the bottom:
-Install the wellhead adapter/spool.
-Stack the lower rams (e.g., pipe ram or shear ram).
-Stack the upper rams (e.g., blind or pipe ram).
-Mount the annular preventer on top.
-Torque all bolts to specification.
-Test individual components during assembly if required. - Install BOP Stack on Wellhead
-Use crane or rig hoist to lift the assembled BOP stack.
-Align the BOP with the wellhead flange.
-Bolt or clamp the BOP stack to the wellhead securely.
-Install proper sealing gaskets between flanges. - Connect Choke & Kill Lines
-Attach choke and kill manifolds to their respective ports.
-Ensure valves and lines are rated for the same or higher pressure as the BOP.
-Secure all connections and check for potential leaks. - Connect Hydraulic Control Lines
-Connect hydraulic hoses from the Accumulator Unit (Koomey Unit) to:
-Annular preventer
-Each ram preventer
-Choke and kill valves (if remotely operated)
-Function test each component to verify hydraulic response. - Pressure Testing
-Conduct Low Pressure Test (e.g., 250 psi for leaks).
-Then do High Pressure Test (per well design – e.g., 5,000 or 10,000 psi).
-Record test results for documentation and verification.
-All tests must comply with API RP 53 or local regulatory standards. - Final Checks Before Drilling
-Verify full functionality of all BOP components.
-Perform BOP drills with crew to ensure readiness.
-Check that the accumulator unit is charged and backup systems are in place.
Safety Notes:
-Never perform BOP setup under pressure.
-Always wear full PPE.
-Only trained personnel should operate or assemble BOP equipment.