BOP系统试验大纲(中英文)

第 1 页 共 13 页 伊拉克鲁迈拉项目伊拉克鲁迈拉项目 750 修井机修井机 BOP 系统联动试验大纲系统联动试验大纲 甲方 甲方 大庆油田公司井下作业分公司大庆油田公司井下作业分公司 乙方 河北华北石油荣盛机械制造有限公司乙方 河北华北石油荣盛机械制造有限公司 第 2 页 共 13 页 防喷器组试验防喷器组试验 一 一 试验目的试验目的 对大庆油田井下分公司所订购的防喷器组及配套设备进行功能试验 另外 按照需 方的要求进行其它项目的试验 二 二 联动试验设备联动试验设备 防喷器组 钻井四通 防喷器控制装置 高压耐火软管 节流 压井管汇 试验项目和要求试验项目和要求 1 闸板防喷器液压开关动作操作 应无卡阻 到位准确 2 闸板防喷器的四处密封试验 闸板前部与管子的密封 闸板顶部与壳体的密封 侧门与壳体的密封 侧门腔与活塞杆间的密封 3 FH28 35 环形防喷器密封用 3 1 2 钻杆 进行 35Mpa 液压密封试验 4 2FZ 28 35 双闸板防喷器上腔装 3 1 2 闸板总成 进行 35Mpa 液压密封试验 5 2FZ28 35 双闸板防喷器下腔装全封闸板 进行 35Mpa 液压密封试验 三 试验前准备工作试验前准备工作 1 联接 F 28 35 防喷器组 安装顺序从上向下依次为 FH35 35 环形防喷器 2FZ 35 35 双闸板防喷器 FS 35 35 钻井四通和试压底座 2 把防喷器组用地矛固定 3 地面控置装置通过高压耐火软管与 F28 35 防喷器组相连接 4 FS28 35 钻井四通与手动阀门 液动阀门 内控管线 节流 压井管汇连接 5 节流管汇低压区的法兰口用手动闸板阀安装好 6 把地面控置装置油箱的液压油加到额定容量 同时把液压泵电机的电源 气动泵的 气源连接好 8 试压泵加满清水并把高压管线与试压底法兰进液口进行连接 9 防喷器及节流 压井管汇内加满清水 10 把地面控置装置的储能器压力升至 21Mpa 四 试验程序试验程序 一 FH28 35 环形防喷器试验 1 下入 3 1 2 钻杆 2 用液控压力 10 5Mpa 关闭 FH28 35 环形防喷器 记录该压力值 3 井压从 0 升至 35Mpa 稳压 15min 记录各段压力值 稳压时间 4 密封情况 目测油路 油缸无渗漏 密封部位无渗漏为合格 第 3 页 共 13 页 5 泄井压为零 6 打开 FH28 35 环形防喷器 二 2FZ28 35 双闸板防喷器上腔半封闸板试验 1 下入 3 1 2 钻杆 2 用液控压力 10 5Mpa 关闭 2FZ28 35 双闸板防喷器上腔的 3 1 2 闸板 记录该 压力值 3 打井压至 1 4 2 1Mpa 稳压 10min 压力降允许试验压力值的 5 升井压至 35Mpa 稳压 10min 压力降允许试验压力值的 5 记录各段压力值 稳压时间 4 密封情况 目测各密封处无渗漏为合格 5 泄井压为零 6 打开 2FZ28 35 双闸板防喷器上腔 3 1 2 闸板 7 取出 3 1 2 钻杆 三 2FZ28 35 双闸板防喷器下腔全封闸板试验 1 用液控压力 10 5Mpa 关闭 2FZ28 35 双闸板防喷器下腔全封闸板 记录该压力 值 2 打井压至 1 4 2 1 稳压 10min 压力降允许试验压力值的 5 升井压至 35Mpa 稳压 10min 压力降允许试验压力值的 5 记录各段压力值 稳压时间 3 密封情况 目测各密封处无渗漏为合格 4 泄井压为零 5 打开 2FZ28 35 双闸板防喷器下腔全封闸板 五 试验完毕后试验完毕后 1 泄掉各部压力 排空防喷器内清水及控制回路的液压油 放空储能器的压力 2 将环形防喷器 双闸板防喷器 钻井四通上面的水用空气吹扫干净 注意保护密 封槽 第 4 页 共 13 页 FKQ640 6G 防喷器地面控制装置调试防喷器地面控制装置调试 一 一 试验目的试验目的 对大庆油田井下作业分公司所订购的防喷器地面控制装置及配套设备进行功能试验 另外 按照需方的要求进行其它项目的试验 二 二 联动试验设备联动试验设备 防喷器控制装置 防喷器组 钻井四通 高压耐火软管 三 三 试验项目和要求试验项目和要求 1 远程台三位四通液转阀开 中 关动作操作 应无卡阻 到位准确 2 储能器组充压时间试验 3 电动泵 气动泵自动启停试验 4 溢流阀超压保护试验 5 司钻台与远程台开关动作一致性试验 6 关闭时间试验 四 试验前准备工作四 试验前准备工作 1 远程控制台储能器充气压力 7 0 7MPa 气源压力 0 65 0 8 MPa 电源电压 380 19V 2 2 将远程控制台 司钻台 防喷器组 液压管线安装好 五 调试程序五 调试程序 1 储能器组充压时间试验 远程控制台泄压到 7 MPa 各三位四通液转阀处于 中位 的情况下 启动泵组给储能器组充压 记录从充压开始至压力升高到 21 MPa 的时间 充 压时间应小于 15 min 2 电动泵 气动泵自动启停试验 主令开关在 自动 位置 在油压降至接近19MPa 5 0 0 时自动接通电路 油压升至21MPa时自动切断电路 关闭气泵旁通阀 接气源 0 53 0 5 0 MPa 0 8 MPa 使气泵在17 9MPa 时自动启动 油压升至21MPa时自动停止 自动 5 0 0 0 1 启停三次 启停可靠 运转正常 第 5 页 共 13 页 3 溢流阀超压保护试验 在主令开关放在手动位置 切断液气开关的情况下 启动泵 组逐渐升压 观察益流阀开始产生溢流的压力 并且观察随着系统压力降低 导致溢流 阀关闭的压力 其调定压力不大于 23 1MPa 其关闭压力不得低于 18 9MPa 4 司钻台与远程台开关动作一致性试验 操作司钻控制台上各操作阀 观察远程控制 台上相应的三位四通转阀的开关动作是否一致 5 关闭时间试验 在调压阀出口压力为 10 5 MPa 条件下 操作司钻控制台上的各操 作阀 记录关闭闸板防喷器 环形防喷器 液动阀的时间 地面防喷器控制装置应能在 30s 内关闭任一个闸板防喷器 标称通径小于 476mm 的环形防喷器 关闭时间不应超过 30s 标称通径等于或大于 476mm 的环形防喷器 关闭时间不应超过 45s 关闭或打开液动阀的时间 应小于防喷器组任一闸板防喷器的实际关闭时间 第 6 页 共 13 页 节流管汇和压井管汇连调试验节流管汇和压井管汇连调试验 一 试验目的一 试验目的 对 YG35 JGY35 压井 节流管汇进行联组 并进行功能试验 二 试验项目和要求试验项目和要求 YG35 JGY35 压井 节流管汇试验液动节流阀动作操作 应无卡阻 到位准确 1 节流管汇控制箱试验 2 压井管汇和节流管汇的密封试验 三 试验前的准备工作试验前的准备工作 1 按 YG35 JGY35 压井 节流管汇示意图 分别将压井 节流管汇安装到防喷器钻井 四通两侧 将节流管汇外出口端用平行闸板阀关闭 没有阀的可用盲板法兰封死 2 节流 压井管汇内加满水 四 试验程序四 试验程序 1 节流管汇出口端 3 只阀门关闭 其余阀门全部开启 压井管汇阀门关闭 井压至 1 4 2 1Mpa 稳压 10min 升压至 35Mpa 稳压 10min 记录各段压力值 稳压时间及密封 情况 2 节流管汇出口四通后 1 只阀门和节流阀前 2 只阀门关闭 其余阀门全部开启 压井管 汇阀门关闭 井压至 1 4 2 1Mpa 稳压 10min 升压至 35Mpa 稳压 10min 记录各 段压力值 稳压时间及密封情况 3 节流管汇节流阀后 2 只阀门和五通出口前 1 只阀门关闭 其余阀门全部开启 压井管 汇阀门关闭 井压至 1 4 2 1Mpa 稳压 10min 升压至 35Mpa 稳压 10min 记录各 段压力值 稳压时间及密封情况 4 节流管汇五通出口前三只阀门关闭 其余阀门全部开启 压井管汇单流阀前阀门开启 其余阀门全部关闭 井压至 1 4 2 1Mpa 稳压 10min 升压至 35Mpa 稳压 10min 第 7 页 共 13 页 记录各段压力值 稳压时间及密封情况 5 钻井四通旁的液动平板阀与防喷器控制系统联动试验 在液缸操作压力不超过 10 5Mpa 的情况下 保证阀门的正常开启与关闭 全部试验结束 全部试验结束 Iraq 鲁迈拉项目鲁迈拉项目 BOP System Joint Test Program of 750 workover rig Part A Downhole Operation Branch of Daqing Oilfield Part B Rongsheng Machinery Manufacture Ltd Of Huabei Oilfield Hebei 第 8 页 共 13 页 BOP Stack Test 一 一 Test purpose Do capacity test for BOP stack and matching equipment ordered by Downhole Operation Branch of Daqing Oilfiel And do other items test according to Part A s requirements 二 二 Equipments for test BOP stack drilling spool BOP control unit high pressure fire hoses choke and kill manifold Test item and its requirements 1 The hydraulic open and close operation of ram BOP should be smooth and accurate 2 Four position seal test of ram BOP seal between the front of ram assembly and pipe seal between the top of ram assembly and the body seal between the bonnet and the body seal between the bonnet cavity and piston rod 3 Hydraulic seal test of 11 5000psi Annular BOP uses 3 1 2 drill pipe with pressure of 5000psi 4 3 1 2 ram assembly is installed into the top cavity of 11 5000psi Double Ram BOP Do hydraulic seal test with pressure of 5000psi 5 Blind ram assembly is installed into the bottom cavity of 11 5000psi Double Ram BOP Do hydraulic seal test with pressure of 5000psi 三 Preparation before test 1 Install 11 5000psi BOP stack The order from top to bottom is 11 5000psi annular BOP 11 5000psi double ram BOP 11 5000 spool and test base 2 Fix the BOP stack with spear 3 Connect the BOP control unit with 11 5000psi BOP stack by high pressure fire hoses 4 Connect 11 5000psi spool with manual valve hydraulic valve inner control pipe choke and kill manifold 5 Flange of kill manifold should be installed by manual gate valve 6 Add hydraulic oil in the oil box of BOP control unit to the rated volume Connect the power of the hydraulic pump motor gas source of the air pneumatic pump 8 Fulfill water into the testing pump Connect the high pressure pipe with inlet of testing bottom flange 9 Fulfill water into BOP choke and kill manifold 10 Increase pressure of BOP control unit pressure accumulator to 3000psi 第 9 页 共 13 页 四 Test procedure Test of 11 5000psi Annular BOP 1 Install 3 1 2 drill pipe 2 Close 11 5000psi annular BOP with 10 5MPa hydraulic pressure And record the pressure data 3 Increase the well pressure from 0 to 5000psi and maintain for 15min Record the pressure and time of each period 4 Seal condition Observe no leakage from oil pipe and oil cylinder There is no leakage on sealing parts 5 Drain the well pressure to 0 6 Open 11 5000psi annular BOP Half seal pipe ram assembly test in top cavity of 11 5000psi double ram BOP 1 Install 3 1 2 drill pipe 2 Close 3 1 2 ram assembly in top cavity of 11 5000psi double ram BOP with 10 5MPa hydraulic pressure And record the pressure data 3 Increase the well pressure to 200 300psi and maintain for 10min Pressure drop is allows 5 of test pressure data Increase the well pressure to 5000psi and maintain for 10min Pressure drop is allows 5 of test pressure data Record the pressure and time of each period 4 Seal condition Observe no leakage on seal positions 5 Drain the well pressure to 0 6 Open 3 1 2 ram assembly in the top cavity of 11 5000psi double ram BOP 7 Take off 3 1 2 drill pipe 三 Blind ram assembly test in top cavity of 11 5000psi double ram BOP 1 Close blind ram assembly in bottom cavity of 11 5000psi double ram BOP with 10 5MPa hydraulic pressure And record the pressure data 2 Increase the well pressure to 200 300psi and maintain for 10min Pressure drop is allows 5 of test pressure data Increase the well pressure to 5000psi and maintain for 10min Pressure drop is allows 5 of test pressure data Record the pressure and time of each period 3 Seal condition Observe no leakage on seal positions 4 Drain the well pressure to 0 5 Open blind ram assembly in the bottom cavity of 11 5000psi double ram BOP 五 After test 1 Drain each part pressure Drain off water in the BOP and hydraulic oil in control circuit Relieve all pressure of the accumulator 第 10 页 共 13 页 2 Clean the water on the annular BOP double ram BOP and spool by air Pay attention to protect the sealing groove FKQ640 6G BOP control system test 四 四 Test purpose Function test for BOP control system and matching equipment which make for 大庆油田井下 作业分公司 Also contain other test according the request of buyer 五 五 Test equipment BOP Control system BOP stacks Drilling spool High pressure refractory hose 六 六 Test item and Requirement a The switch of 3 position 4 way valve should be flexible and reliable b Test of Time for oil pressure rising to 21MPa for Accumulator group c Start and Stop Test of Oil Pump and Air Pump d Overpressure protect test of Relief valve e Test of control system s on off action same with Drilling s panel s operation f Close time test 七 七 Prepare job for test a Accumulator charge pressure is 7 0 7MPa Air pressure is 0 65 0 8 MPa voltage is 380 19V b Fix BOP control system Drill s panel BOP stacks and hydraulic line 八 八 Program of test a Test of Time for oil pressure rising to 21MPa for Accumulator group Pressure relief of the system make sure that nitrogen pressure is 7MPa 0 7MPa close the relief valve 3 position 4 way valve is at middle position and make oil pressure rising from 7MPa to 21MPa Start electric pump and air pump time for pressure rising of the accumulators is less than 15 minutes b Start and Stop Test of Oil Pump and Air Pump When the command switch is at the automatic position adjust system pressure control starts automatically when oil pressure is 190 0 5MPa and stops automatically when oil pressure is rising to 210 0 5MPa Turn off the bypass valve of air pump connect air source 0 53 0 8 MPa The air pump shall start automatically prior to the pressure decreasing below 17 90 0 5MPa and shall stop automatically when oil pressure is rising to 210 1MPa Stops and starts automatically thrice 第 11 页 共 13 页 c Overpressure protect test of Relief valve When the command switch is at the manual position and shut off the air for Hydro pneumatic pressure switch start pump unit when pressure raise observe the pressure of Relief valve overflow and when pressure decrease observe the pressure of Relief valve shut The overflow pressure no more than 23 1MPa and the shut pressure no less than 18 9MPa d Test of control system s on off action same with Drilling s panel s operation Operate all valve of Drilling s panel observe the corresponding 3 position 4 way valve of BOP control system whether or not same with the operation e Close time test when the Air manual operate regulating valve s out port pressure at 10 5MPa operate all valve of Drilling s panel note the time of shut ram preventer annular blowout preventer hydraulic valve separately The BOP control system should close every preventer in 30s When the Annular blowout preventer drift diameter less than 476mm the time of closing should no more than 30s When the Annular blowout preventer drift diameter less than 476mm the time of closing should no more than 45s The time of close or open hydraulic valve should less than the actual time of closing each ram preventer 第 12 页 共 13 页 Connection test of Choke Manifold 2 1 Test of control panel of the Choke manifold 2 2 Sealing test of Choke manifold close the valves of the kill manifold increase the pressure to 1 4 2 1Mpa hold the pressure for 10min increase the pressure to 35Mpa hold the pressure for 10min and record each pressure value holding time and sealing condition 4 2 Close 1 piece of valve behind the exit cross of the choke manifold and the 2 pieces of valve in front of the choke valve open the rest valves c