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CONTROL PANEL
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proenix international
The information in this technical resource manual is meant to supplement not replacement to the
proper specific manufacture manual, information or and training. The authors and publisher advise
readers to take full responsibility for their safety and follow all regulations, information and restriction
in their regions. Before practicing the skills described in this book, be sure that your equipment is well
maintained and do not take risks beyond your level of experience, aptitude, training and comfort
level. In no respect shall this recourses incur any liability for any damages including but limited to
direct, indirect, special or consequential damages arising out of resulting from or any way connected
to the use of the resources, contract, tort or otherwise; whether or not injury was sustained by
persons or property or otherwise; and whether or not loss was sustained from or arose out of the
results of the item or any services that may be provided by Proenix International.
All rights reserved. No part of this publication may be reproduced, distributed or transmitted in any
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requests, write to the publisher, addressed “Attention: Permissions Coordinator”
at info@proenix.com.
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WELLHEAD CONTROL PANEL
CONTENTS
Section
1.0 Basic Well Head Control Panel 4
1.1 Definition of a Self-Contained Emergency Shutdown System 5
2.0 Function WHCP 7
3.0 Surface Safety Valves 7
3.1 Components 7
3.2 Valves 8
3.3 Pilot and Block-and-Bleed Valve 8
4.0 Procedure for Operating Surface Safety Valves 9
5.0 Downhole safety valve 10
5.1 Operation 10
6.0 Dual Pump Hydraulic System (Model ‘DPC’) Wellhead Control System 11
6.1 Hook Up 12
6.2 Pre Commissioning 13
7.0 Start-up Sequence 15
8.0 Normal Operation 17
9.0 After Start-up 17
10.0 Surveillance 18
Objectives
At the completion of this module, you will be able to:
Understand the operation of the Well Head Control Panel
• Explain the purpose of the wellhead control panel (WHCP)
• Describe tree, wellhead, valves and production tubing architecture
• Describe main WHCP components
• Explain typical WHCP control logic and operating sequence
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1.0 Basic Well Head Control Panel
What is WHCP?
WHCP is known Well Head Control Panel. Installation of WHCP is near the well, usually inside of
WHCP contains pneumatic components, hydraulic components and other instrumentations.
Pneumatic components: 3-way pilot valve, 3-way push button, pneumatic pressure switch, pressure
regulator etc.
Hydraulic components: interface valve (pneumatic to hydraulic), hydraulic pump, hydraulic reservoir
tank, PSV etc
Instrumentations: Pressure gauge, chart recorder (pressure, temperature ,and flown rate), pressure
switch (PSLL,PSHH), temperature gauge etc.
All that components installed together in WHCP to do as control function to operate the well. Control
line in WHCP usually using stainless tubing, the size 1/4",3/8" and 1/2". Generally WHCP using
control pneumatic combined with control hydraulic. By WHCP we can operate the well to shut in or
running the well. Here an example of main part well head:
X06 X03
X05
Emergency
Shut-Down Station C2000
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Self Contained SSV Control Syste
Standard Arangement
MATERIAL LIST
ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION
A 1 SUCTION STRAINER H 1 RELIEF VALVE
B 1 HAND PUMP J 1 ESD VALVE
C 1 REGULATOR K 1 2-WAY N.O. DUMP VALVE WITH MANUAL OVERRIDE
D 1 PRESSURE GAUGE, 0-200 PSI L 1 HYDRAULIC FUSIBLE PLUG
E 1 PRESSURE GAUGE, 0-6000 PSI M 1 5,000 PSI ACCUMULATOR L-1
F 1 HIGH PRESSURE SENSOR N 1 FILLER/ BREATHER FUSIBLE
PLUG
G 1 LOW PRESSURE SENSOR P 1 RELIEF VALVE 6T
ESD H-1
PULL TO SET @
SHUT IN 150 PSI G-1 F-1
Place (K-1) the hydraulic dump valve in bypass, by turning the handle in the bypass position. Hand pump (B-1) to the required actuator operating
pressure. This pressure can be seen on pressure gauge (E-1). When the flow line pressure is between the low (F-1) and the high (G-1) pressure sensor
set points, the 100 psi regulated pressure from (C-1), which can be seen on pressure gauge (D-1) will flow through the low sensor (G-1) and high
sensor (F-1) allowing the 100 psi to hold (K-1) hydraulic dump valve closed. Now take (K-1) out of bypass by turning the handle to the in-service
position. The system is now in service. If an ESD, Fire, or PSHL occurs, the pilot pressure from (K-1) dump valve will be removed, allowing (K-1) to
dump the fluid from the actuator back into the reservoir, closing the(SSY) Surface Safety Valve.
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2.0 Function WHCP
As mention in other article, the main function of WHCP is to control the well, basically to open or
close the main shut off valve which installed on well head.
Usually each well has three main shut off valve: Wing valve, Master valve (surface master valve) and
DHSV. Those valves can be closed by using local push button on WHCP or activated from ESD
system. Same as PLC or other controller which has input and output, in WHCP also has it.
Input WHCP: Usually from signal ESD like PSLL, PSHH, Fusible plug and
emergency push button.
Output WHCP: Usually signal command to final control element (Wing valve, Master
valve, DHSV and SDV if flow line installed it), signal indicator (local pneumatic
indicator).
WHCP equipped with local chart recorder, means it can be used to record the
pressure, temperature and flow rate of well.
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3.2 Valve
LOCK-OUT NUT
SUPPLY
The valve in a surface safety valve normally has a reverse GAS
INLET SUPPLY GAS
acting gate and a spring loaded, supply-gas operated PISTON
actuator which causes the valve to fail closed. When SPRING
sufficient supply gas pressure is maintained, the spring is ACTUATOR
opposed and the valve is kept open. The supply gas may
be produced gas, or it may be a dry gas such as nitrogen. FLOW
If pressure is relieved, the valve closes. The structure of GATE
the valve is shown below. Note that this is a fail-closed
VALVE
Surface safety valves can be installed with high or low pilots, or both. High pilots sense increases in
downstream pressure; such an increase can be caused, for example, by a cut-out choke. Low pilots
sense decreases in downstream pressure—decreases caused, for example, by a line break.
PLUNGER PISTON
ADJUSTING SCREW
Pilot
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4.0 Procedure for Operating
Surface Safety Valves
If a well has been automatically shut in by the surface safety valve, the well must be brought back
on-line by resetting the pilot manually.
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5.0 Downhole safety valve
A downhole safety valve refers to a component on an oil and gas well, which acts as a failsafe to
prevent the uncontrolled release of reservoir fluids in the event of a worst case scenario surface
disaster. It is almost always installed as a vital component on the completion.
5.1 Operation
These valves are commonly unit-directional flapper valves which open downwards, such that the
flow of wellbore fluids try to push it shut, while pressure from surface pushes it open. This means that
when closed, it will isolate the reservoir fluids from surface.
Most downhole safety valves are controlled hydraulically from surface, meaning they are opened
using a hydraulic connection linked directly to a well control panel. When hydraulic pressure is
applied down a control line, the hydraulic pressure forces a sleeve within the valve to slide
downwards. This movement compresses a large spring and pushes the flapper downwards to open
the valve. When hydraulic pressure is removed, the spring pushes the sleeve back up and causes
the flapper to shut. In this way, it is failsafe and will isolate the wellbore in the event of a loss of the
wellhead. The full designation for a typical valve is 'tubing retrievable, surface controlled, subsurface
safety valve', abbreviated to TR-SCSSV.
Typical
SCSSV
Diagram
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6.0 Dual Pump Hydraulic System
(Model ‘DPC’) Wellhead Control System.
The Dual Pump Hydraulic System (Model 'DPC') was manufactured by Cameron to hydraulically
control a Surface Safety Valve (SSV) and a Surface Controlled Subsurface Safety Valve (SCSSV).
The following actions will cause the SSV to close immediately and the SCSSV to close after a short
time delay, set by needle valve S2:
• Fusible plug exterior to the panel is tripped
• Pressure Sensor A1 senses a pressure outside of its range
• Pressure Sensor B1 senses a pressure outside of its range
• Local ESD Valve is tripped
• Remote ESD Station is tripped
All components used are in compliance with the applicable EU Directives. Installation and servicing
should be performed by trained and qualified personnel only. Necessary precaution must be taken to
protect personnel and equipment when installing and working on and maintaining this system.
Self Contained SSV and SCSSV
MATERIAL LIST 5,000 psi Control System
ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION Standard Arangement
A 1 SUCTION STRAINER K 2 2-WAY N.O. DUMP VALVE WITH MANUAL OVERRIDE
B 1 HAND PUMP L 1 HYDRAULIC FUSIBLE PLUG
C 1 REGULATOR M 2 5,000 PSI ACCUMULATOR G-1 F-1
H-1
D 1 PRESSURE GAUGE, 0-200 PSI N 1 FILLER/ BREATHER SET @
ESD
E 2 PRESSURE GAUGE, 0-6000 PSI P 2 RELIEF VALVE PULL TO
150 PSI
D-1
F 1 HIGH PRESSURE SENSOR Q 1 FLOW CONTROL SHUT IN
G 1 LOW PRESSURE SENSOR R 1 3-WAY VALVE
H 1 RELIEF VALVE S 1 LOW PRESSURE ACCUMULATOR N-1 J-1
PSL PSH
J 1 ESD VALVE
FLOWLINE
6T SENSE
SET @
100 PSI C-1
L-1
FUSIBLE
P-1 PLUG
SET @ 6T
K-1 900 PSI
5,000 PSI N2 M-1 E-1
PRE-CHARGE
A-1 SSV
R-1
P-2 6T
S-1
B-1
SET @ 900 PSI
K-2 N2 M-2 E-2
5,000 PSI Q-1 PRE-CHARGE
SCSSV
4T
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6.1 HOOK-UP
6.1.1 The system is a Self-Contained Unit with mounting clamps for installation onto the hydraulic
actuator. The dual pump hydraulic control unit coupled with the hydraulic actuator becomes a
Self-Contained System.
6.1.2 A hoist or lifting apparatus is recommended when installing the Self-Contained System onto
the valve bonnet, which can be mounted vertically. The DPC weighs approximately 100
pounds.
6.1.3 After the actuator/system is installed, it may be necessary to rotate/align the dual pump
assembly to orient the panel in the desired position. This is because the bonnet bolt canters
“Connector" may not align, this cause the assembly to be in an awkward position.
.
6.1.4 Loosen the assembly mounting clamp by loosening the bolts on the brackets. Rotate the
entire assembly until desired position is achieved.
6.1.5 Securely connect the tubing to the actuator and tighten the bolts to secure the assembly to the
actuator. Use 3/8" x 0.049" wall thickness, stainless steel tubing (4800 psi Maximum pressure
rating).
6.1.6 The DPC System has pressure sensors that require connection to the well's flowline. At the
lower-rear of the system, a tube connection is provided for flowline pressure sensor
connection. It is suggested to route 1/4" O.D. x .035” wall thickness stainless steel tubing
(5100 psi maximum pressure rating) from this connection to the root valve on the flowline.
.
6.1.7 Various operators may require a quick disconnect and block and bleed for pressure
Testing and calibration of the high-low pressure sensors. Additional features shall be the
responsibility of the operators. Optional features can be added upon special request.
6.1.8 Connection must be made to the SCSSV. A 1/4" tube connection is located on the right rear
side of the unit and is labelled "TO SCSSV".
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6.1 HOOK-UP
6.1.9 Route 1/4" O.D. x .065” wall thickness stainless steel tubing (10,200 psi maximum
pressure rating) from the connection to the SCSSV test valve manifold at the base of the tree.
Refer to API 14 G (RP 14 B) for details.
6.1.10 As a safety precaution, all newly installed hydraulic tubing shall be pressure tested using a
hydraulic test pump and reference gauge.
6.1.11 Start at the root valve connection point on the flowline to the high-low sensors and
from the SCSSV connection to the rear of the unit.
6.2 PRE-COMMISSIONING
6.2.1 Check the hydraulic control system tank for proper fluid level via the sight glass on the
reservoir. The level should be approximately 3/4 full. If not, add hydraulic fluid.
6.2.3 Confirm set points of high and low pressure sensors by using a separate hydraulic test hand
pump.
NOTE: Take necessary precautions to prevent opening any shutdown valve prior to
Commissioning /pressuring the hydraulic control system. Disconnect the output lines and plug
prior to testing.
6.2.3.1 Connect hydraulic test pump and test gauge to the PRESSURE SENSE bulkhead located on
the DPC unit.
6.2.3.2 CLOSE TO BYPASS PSL valve (Item C2) and ESD Relay Valve ( Item Y1).
6.2.2.3 Apply pressure via the SCSSV hand pump (Item R1) until panel mounted SCSSV PUMP
DISCHARGE PRESSURE gauge shows approximately 1000psi.
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6.2.3.4 Apply pressure to the PRESSURE SENSE bulkhead via hydraulic test pump until test
gauge reads pressure between PSH and PSL set points.
6.2.3.6 Slowly relieve pressure on the PRESSURE SENSE bulkhead via hydraulic test pump. When
test pump pressure drops below the PSL set point, the PSL will open and pressure will be
relieved from the panel mounted SCSSV PUMP DISCHARGE PRESSURE gauge. Confirm
that this occurs at the proper PSL set point. If it does not, adjust the PSL, and repeat
steps.(6.2.3.2 through 6.2.3.6). This process may need to be repeated several times to
achieve the proper PSL setting. Once proper PSL setting is achieved, repeat test Three (3)
times to confirm set point accuracy.
6.2.3.7 Close CLOSE TO BYPASS PSL valve (Item C2) and ESD Relay Valve (Item Y1).
6.2.3.8 Apply pressure via the SCSSV hand pump (Item R1) until panel mounted SCSSV PUMP
DISCHARGE PRESSURE gauge shows approximately 1000psi.
6.2.3.9 Apply pressure to the PRESSURE SENSE bulkhead via hydraulic test pump until test
gauge reads pressure between PSH and PSL set points.
6.2.3.11 Slowly, applies additional pressure on the PRESSURE SENSE bulkhead via hydraulic test
pump. When test pump pressure rises above the PSH set point, the PSH will open and pres
sure will be relieved from the panel mounted SCSSV PUMP DISCHARGE PRESSURE
gauge. Confirm that this occurs at the proper PSH set point. If it does not, adjust the PSH,
and repeat steps. (6.2.3.7 through 6.2.3.11). This process may need to be repeated several
times to achieve the proper PSH setting. Once proper PSH setting is achieved, repeat test
Three (3) times to confirm set point accuracy.
6.2.4 Now that the pressure sensors have been checked, depressurize and remove the test
pressure connection. Confirm the hydraulic control system pressure is at zero (0) PSIG and
actuator is closed.
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6.2. 5 At completion of pre-commissioning and removal of hydraulic test hand pump the flowline
sense tubing must be installed and secured to the root valve from the PRESSURE SENSE
bulkhead connection at the rear of the DPC.
WARNING: Always purge air from system on initial start-up by operating a minimum of six
(6) times prior to placing system in-service.
7.2 STEP 2
7.2.1 Close CLOSE TO BYPASS PSL valve (Item C2) and ESD Relay Valve (Item Y1).
7.2.2 Apply pressure via the SCSSV hand pump (Item R1) to until the SCSSV is fully open.
Usually, while pumping, the hydraulic pressure will rise, stall momentarily and then
continue to rise. This means the SCSSV begins to crack open, travels open and
becomes fully open. Confirm the hydraulic control pressure remains stable after the
SCSSV opens.
7.2.3 Pump the SSV hand pump (Item F1) until the actuator is fully open, Observe the
position of the actuator stem to confirm the actuator is open.
7.2.4 Once the well flowline becomes pressurized, read the flowline pressure indicator on the
flowline. If the pressure is stable and acceptable, open the CLOSE TO BYPASS PSL
valve (Item C2) to return Pressure sensors to service.
.
7.2.5 Test shutdown sequence.
7.2.5.1 Check that flow control valve (Item S1) is fully open. (If this valve is not fully open SSV
closure will be delayed by a short time.)
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7.2.5.2 Open LOCAL ESD Relay Valve (Item Y1). Upon activating the Local ESD the SSV
valve should close quickly followed at a short delay by the SCSSV. This time delay is
controlled by adjusting the flow control valve (Item S2). If this time delay interval is set
to an undesirable length, adjust valve accordingly and repeat steps 5.2.1 to 5.2.5 until
a desirable delay interval is achieved.
7.2.6 After setting time delay, repeat steps 5.2.1 to 5.2.4 to begin producing the well.
NOTE: Ensure that the CLOSE TO BYPASS PSL valve is open (In-service). Failure to do
so will prevent the panel from shutting in the well due to the PSL going out of
range.
7.3 STEP 3
7.3.1.1 Observe the well flowing pressure on the pressure indicator at the flowline. It
should be stable.
7.3.1.2 Observe the hydraulic control system control pressure. It should be stable.
7.3.1.4 Confirm that the CLOSE TO BYPASS PSL valve (Item C2) is fully open.
NORMAL OPERATION
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8.0 NORMAL OPERATION
To manually shut off the well, simply open the ESD Relay Valve (Item Y1). The actuator should
close, (stem is out) and all panel mounted pressure gauges will read zero (0).
NOTE: Re-confirm that ESD Relay Valve (Item Y1) is in the closed position.
9.2.2 If leaks persist or system pressure will not stabilize (no noticeable leaks), suspect a
faulty relief valve, check valve or pressure sensor.
9.2.4 Check the hydraulic tank fluid level. Always keep the breather cap on the tank.
9.2.5 When filling tank, always use new/clean hydraulic fluid. It is recommended not to
exceed 3/4 full according to the sight glass.
9.2.6 Always check fluid level when system is de-energized and re-fill if necessary.
9.2.7 When performing maintenance, grease the SSV actuator stem and apply grease to the
pump rod. Position the handle so the pump rod is not exposed to the elements.
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10.0 Surveillance
10.1 Cycle the entire system once a month, not to exceed three (3) a month. Cycle the
system by testing the low pressure sensor.
10.2 Observe the system for hydraulic leaks. This is best observed visually where "clumps
of dust" form at a leak point. For best performance, clean and correct all leakage, how
ever slight.
10.3 Inspect hydraulic filter/strainer once every six (6) months. The strainer is easily
removed and can be cleaned in approved solvent, dried and returned to service. Use
only 100 mesh strainer when replacing a severely clogged strainer. Again, use good
cleaning proce dures.
10.5 Clean filler cap in approved solvent and blow dry. A clogged breather could cause tank
collapse while hand pumping the system. Always install the breather/fill cap
immediately.
10.6 Should the hand pump fail, it is recommended that it is replaced and repairs made
within a clean repair and test facility. (Must be done by trained and qualified mainte
nance technician)
10.7 Conduct relief valve pop test once every two (2) years. This can be tested while the
relief valve is on the system, using the system hand pump to increase the pressure to
the relief valve set point. (Must be done by trained and qualified maintenance
technician and operator)
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8 7 6 5 4 3 2 1
REVISIONS
REV DESCRIPTION BY DATE CHK APPR.
A A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
REV DESCRIPTION BY DATE CHK APPR.
A A
8 7 6 5 4 3 2 1
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