Wellhead Operations & Maintenance Course
Mahmoud Farag Radwan
Subsurface & Integrity Operations Dept. Head
28th Nov : 02nd Dec, 2021 – New Cairo, Egypt
Presenter Name:
Mahmoud Farag Radwan
Short
Biography
Mahmoud Radwan is a Subsurface & Integrity Operations Dept. Head at AMAL Petroleum
Company (AMAPETCO) with more than 13 years of experience in oil & gas industry.
Mahmoud worked in Well Engineering, Intervention, Integrity & Work-over at several
companies, including Badr El-Din Pet. Co. (BAPETCO), Qarun Pet. Co. (QPC) and Wadi
El-Sahel Petroleum Co. (WASPETCO).
Also, a freelance instructor at upstream Oil & Gas in Egypt & UAE since 2008.
Mahmoud received a BSc degree in Petroleum Engineering from Al-Azhar University in
2007.
Publications
 Evaluating Sustainable Annulus Pressure (SAP) in Sour Wells and the Possible
Causes to Avoid Recurrence to the Well Integrity Annual Middle East Conference in
Abu Dhabi; UAE in Apr 2015
 Implementing NDT methods for maintenance and inspection to the Asset Integrity
Management North Africa Conference in Cairo; Egypt in Nov 2015
 Feasibility Evaluation of Using Downhole Gas-water Separation Technology in gas
Reservoirs with Bottom Water; paper number: SPE-183739-MS to the 20th Middle East
Oil & Gas Show and Conference in Mar 2017 http://dx.doi.org/10.2118/183739-MS
 Managing the Operational Challenges in Corroded Wells through Well Integrity
Management System to the Improving Brownfield Performance Technical Convention,
in Cairo; Egypt in Dec 2019
 Safe and Economic Attractive Rigless Operations Using a Digital Slickline in
Unmanned Platform with Low Structure Loads and Spacing; paper number: SPE202857-MS to the Abu Dhabi International Petroleum Exhibition & Conference
(ADIPEC) in Nov 2020 http://dx.doi.org/10.2118/183739-MS
Outlines
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Well Construction Principles
Completion Components
Valves Types & SOP
Component Requirements Applicable to all Wellheads
Components of a Wellhead & Xmas Tree
Advanced wellhead Types
Sweet Flowing Wells
Critical Sour, Sour and Corrosive Wells
Artificial Lift Wells
Other Well Types
How a Well is Drilled on Land
Subsea Production Systems
Back Pressure Valves, Testing Plugs, Bull Plugs & Fittings
Introduction to API 6A (ISO 10423):Specification for Wellhead and Christmas
Tree Equipment
 SSSV, Wellhead & Xmas Tree Integrity & Maintenance Detailed Procedures
 Advanced Technology (Ice Plug, Valve Drilling, Hot Tapping, UT Inspection &
Seal Protection)
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Casing Design : Basic Construction
1
2
3
4
5
7
9
10
11
12
6
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
30” conductor
Conductor setting depth
20” surface casing
20” shoe
Cement
Formation open to C annulus
13 3/8” casing
Formation open to B annulus
9 5/8” production casing
Liner hanger
7” Liner
TD – Total Depth
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Completion Components – What’s installed
1
2
3
4
5
6
9 5/8”
Production
Casing
8
7
9
10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Tubing hanger (Upper annulus barrier)
SC-SSSV (Sub-surface barrier)
Control line
Tubing (Vertical barrier)
A annulus (tubing-casing)
Gas lift valves (in SPMs)
Expansion joint: Tubing Seal Receptacle
Anchor seal assembly
Production packer
Packer sealing element (Lower barrier)
Tailpipe
WEG
11
12
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Completion Components – Why?
1
2
3
4
5
6
9 5/8”
Production
Casing
8
7
9
10
11
12
Function :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Upper annulus barrier & supports tubing
Protects the surface installation
Hydraulically operates the SC-SSSV
Conveys hydrocarbons to surface
Protects production casing from attack
Permit entry of lift gas annulus to tubing
Accommodates expansion / contraction
Ties & seals tubing string to packer
Anchors tubing string to production CSG
Forms lower barrier of the A annulus
Allows installation of instrumentation
Easy entry of production logging tools
back into tailpipe
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VALVES
HIGH pressure
(5000 psi and above)
MEDIUM pressure
(~1500 psi)
LOW pressure
(~180 psi)
Flowhead
Choke manifold, Sand-trap
Heater & Steam-exchanger
Separators
Oil/Gas manifolds
Pumps, Burners
Tanks
1)GATE valves
2)NEEDLE valves
(~sampling~)
1)BALL valves
2)PLUG valves
1)BUTTERFLY
2)GLOBE valves
1)WOM
new, (McEvoy,
Malbranque, Sereg
old)
2)Kerotest, Autoclave
1)Mapegaz, Gachot
2)Texseal, Balon
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GATE valves
•Used for shut off, (on/off function)
•High pressure (5, 10, 15, 20Kpsi)
•ex: FH, CM, Steam-exchanger, Sandtrap
•Sealing method:
-metal/metal for WOM valve
-grease sealing compound for
McEvoy valve
•Standard sizes= 3 1/16” to 4 1/16”
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GATE
valves
GATE
WOM
metal/metal seal
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NEEDLE valves
•Used for shut off, (on/off) + Flow
control (bleed off part of flow)
•High pressure (5, 10, 15, 20Kpsi)
•ex: instrumentation on FH, CM,
Steam-exchanger, Sand-trap
•Kerotest (up to 10Kpsi)
•Autoclave Engineers (10, 15, 20K)
•Sealing method: metal/metal
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(~sizes= ¼”, ½”, ¾”)
BALL / PLUG valves
•Used for shut off, (on/off)
•¼ turn
•Medium pressure (~1500 psi)
•ex: separator, burners, pumps,
etc.
•Sealing method:
-PTFE (Teflon) seal ring or
seat
Standard sizes= 1” to 4”
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GLOBE valves
•Used for control of flow and shut off
•Low pressure
•Rig Water / air lines
•Sealing= metal/metal
•Standard sizes= 1”, 2” 3”
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SAFETY
GATE / BALL / PLUG valves:
• must not be used for throttling
(i.e.: must be fully open or fully
closed) because a restricted flow
through it will erode the seal or
gate or seat, and the valve will
not seal correctly / reliably.
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SAFETY
GATE valves:
• it is common practice to
count the number of turns
taken to open / close a valve
because the operator can tell
if the valve has become
plugged or is not seating
correctly.
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SAFETY
GATE / GLOBE valves:
• it is best to close the gate and
globe valves by ¼ turn after they
are fully opened and vice-versa
because over tightening the
valve upon closing may damage
the disk and seat. Leading to
seizure or leakage.
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SAFETY
NEEDLE valves:
• when used with an instrument, the
valve should only be opened enough: to permit flow and allow the instrument to
register correctly.
- to allow a quick
closure of the valve and to isolate the dial
gauge in case of a sudden increase of
pressure, above the range of the gauge.
One or two turns is usually sufficient.
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Casing Head
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Casing Spool
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Casing Hanger
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Pack-off Flange
PACK-OFF FLANGE FUNCTION
• It may be used during well re-entry where anticipated
pressure rise.
• In temporary operations such as
– Pressure testing primary seals
– As a safety device when drilling out the cement that
remains in the shoe joint.
Tubing Head
Tubing Hanger Types
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Tubing Hanger Types
Extended Neck Tubing Hanger
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Tubing Hanger Back-Pressure Valve
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Tubing Head Adapter Types
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Wear Bushing
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Christmas tree for a flowing well
XMAS TREE
XMAS TREE
Surface valves manifold to control flow of well fluids & access for well
intervention activities.
Features:
1 LMV
Manual, NOT working valve optimum conditions.
2 UMV
Emergency valve (Hydraulic / Pneumatic) & cut
wire.
3 FWV
Permits passage of well fluids to CV.
4 CHOKE VALVE (CV)
Restrict, control or regulate flow of well fluids.
5 KWV
Permits entry of kill fluids into tubing or equalize.
6 SV/CV
Permits entry of well interventions.
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Xmas Tree Types
Xmas Tree type:
 Solid Block (Mono Block) Xmas Tree
- Contains fewer components (for
high pressure wells)
 Composite Block Xmas Tree
- Valves are located on separate
block & joined by API flange.
 Horizontal Xmas Tree
- New concept used for sub-sea
completion.
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Dual Solid Block Xmas Tree
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CONNECTIONS
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SEALS
• Seal composition:
–Elastomer and Graphite / Carbon
Seals.
–Metal Seals.
• Seal types:
–Primary Seals
–Secondary Seals
• If both are installed the wellhead can
be pressure
tested.
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WELDED
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ARTIFICIAL LIFT WELLS
•
Gas Lift
•
•
ESP
PCP
•
Plunger Lift
•
Sucker Rod Pump
•
Hydraulic Pump
Special Wellhead Design
 The conventional wellhead should be modified to meet
the artificial lift method.
 Each method along with the modification applied will
be discussed.
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BEAM PUMPING
•the wellhead must be modified to seal
around the reciprocating rod.
•Emergency precaution in
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.case of broken rod
WELLHEAD EQUIPMENT
• Flowing T
• BOP
• Stuffing Box
• Lubricator
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PCP LIFTING
• the wellhead must be modified to seal
around the rotating rod.
• Emergency precaution in case of broken rod.
• The rod string is supported on the wellhead
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GAS LIFTING
•The X-tree is used not only to
control the production but also
the injection of the gas
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ESP
LIFTING
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HYDRAULIC LIFTING
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PLUNGER LIFTING
•the wellhead must accommodate a
lubricator / “plunger catcher” installed on
top of the flow cross.
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INJECTION WELLHEAD
–Similar in configuration to
flowing wells.
–The major concerns in the
•
wellhead
are
• The operation pressure.
• The injected fluid
Temperature (especially in STEAM
INJECTION)
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The injected fluid
•A wise selection of the wellhead material is a must to be
suitable for the injected fluid and TEMPERATURE variation.
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Offshore Wellhead
•Mudline Suspension
•Subsea Wellhead
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THE MUDLINE HANGER SYSTEM CONSISTS
OF THE FOLLOWING COMPONENTS
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A STANDARD SUBSEA WELLHEAD
SYSTEM WILL TYPICALLY CONSIST OF
THE FOLLOWING:
• Drilling guide base.
• Low-pressure housing.
• High-pressure wellhead housing
(typically 18¾ in.).
• Casing hangers
• Metal-to-metal annulus sealing
assembly.
• Bore protectors and wear bushings.
Mahmoud Farag Radwan
BIG BORE SUBSEA WELLHEAD SYSTEMS
• As a result of the challenges associated with
deepwater drilling.
• Ocean-floor conditions in deep and
ultradeep water can be extremely
mushy and unconsolidated, which
creates well-foundation problems that
require development of new well designs
to overcome the conditions.
• Second, underground aquifers in deep
water have been observed in far
greater frequency than in shallower
waters, and it quickly became clear that
these zones would have to be isolated
with a casing string. wellhead equipment
designs would also have to change to
accommodate the additional
requirements.
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UNITIZED WELLHEAD (COMPACT)
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SH2 SPLIT SPEEDHEAD SYSTEM
•
No need to un-screw the BOP.
• Reduces waste time in testing
BOP .
• Maximum pressure 15,000 psi.
Pack-off
Wellhead API Trim Guide
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How to Order
General Wellhead Equipment Data Sheet
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Leak Rate Criteria
Leak rates based on API 14 B at 15 SCF / min for gas or 400 cc / min for liquid
The following table shall be used to determine allowable leak rates for valve and downhole equipment leaks
Test results below the rates described above are not classed as a leak so test result
and should be assigned a 'Pass'
Mahmoud Farag Radwan
Advanced Technology
(Ice Plug, Valve Drilling,
Hot Tapping, UT
Inspection & Seal
Protection)
Mahmoud Farag Radwan
Thank You