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Wellhead Operations and Maintenance Course

This document provides an outline for a wellhead operations and maintenance course presented by Mahmoud Farag Radwan. The course covers topics such as well construction principles, completion components, valve types and operations, wellhead and Christmas tree components, different well types, and API standards for well integrity and maintenance. Mahmoud has over 15 years of experience in oil and gas and will provide detailed procedures for wellhead integrity and maintenance. The course aims to educate attendees on well construction, completion design, valve functionality and safety, and wellhead equipment.

Uploaded by

Abdelkhak Khalla
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
3K views65 pages

Wellhead Operations and Maintenance Course

This document provides an outline for a wellhead operations and maintenance course presented by Mahmoud Farag Radwan. The course covers topics such as well construction principles, completion components, valve types and operations, wellhead and Christmas tree components, different well types, and API standards for well integrity and maintenance. Mahmoud has over 15 years of experience in oil and gas and will provide detailed procedures for wellhead integrity and maintenance. The course aims to educate attendees on well construction, completion design, valve functionality and safety, and wellhead equipment.

Uploaded by

Abdelkhak Khalla
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
  • Well Construction Principles
  • Completion Components
  • Valves
  • Safety Precautions
  • Wellhead Functions
  • Wellhead Classification
  • Basic Components of a Wellhead
  • XMAS Tree
  • Artificial Lift Wells
  • Offshore Wellhead Systems
  • Wellhead Maintenance Procedures
  • Advanced Technology

Wellhead Operations and Maintenance Course

Mahmoud Farag Radwan


Subsurface & Integrity Operations Dept. Head
https:\\www.linkedin.com/in/mahmoud-farag-radwan-a9266626
Presenter Name:
Mahmoud Farag Radwan

Mahmoud Radwan is a Subsurface & Integrity Operations Dept. Head at AMAL


Petroleum Company (AMAPETCO) with 15 years of experience in oil & gas
industry. Mahmoud worked in Well Engineering, Intervention, Integrity & Work-
Short over at several companies, including KDT Global Solutions, Badr El-Din Pet.
Co. (BAPETCO), Qarun Pet. Co. (QPC) and Wadi El-Sahel Petroleum Co.
Biography (WASPETCO).
Also, a freelance instructor at upstream Oil & Gas in Egypt & GCC since 2008.
Mahmoud received a BSc degree in Petroleum Engineering from Al-Azhar
University in 2007.

o 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
o Implementing NDT methods for maintenance and inspection to the Asset
Integrity Management North Africa Conference in Cairo; Egypt in Nov 2015
o 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
Publications http://dx.doi.org/10.2118/183739-MS
o 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
o Safe and Economic Attractive Rigless Operations Using a Digital Slickline in
Unmanned Platform with Low Structure Loads and Spacing; paper number:
SPE-202857-MS to the Abu Dhabi International Petroleum Exhibition &
Conference (ADIPEC) in Nov 2020 https://doi.org/10.2118/202857-MS
❑
Outlines
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)
Mahmoud Farag Radwan
Casing Design : Basic Construction

1 1. 30” conductor
2 2. Conductor setting depth
3 3. 20” surface casing
4 4. 20” shoe
5. Cement
5
6. Formation open to C annulus
6 7. 13 3/8” casing
7 8. Formation open to B annulus
8 9. 9 5/8” production casing
9 10. Liner hanger
10
11. 7” Liner
12. TD – Total Depth
11

12 Mahmoud Farag Radwan


Completion Components – What’s installed

1 1. Tubing hanger (Upper annulus barrier)


2. SC-SSSV (Sub-surface barrier)
3 2 3. Control line
4 4. Tubing (Vertical barrier)
5 5. A annulus (tubing-casing)
6. Gas lift valves (in SPMs)
9 5/8”
Production
6 7. Expansion joint: Tubing Seal Receptacle
Casing 8. Anchor seal assembly
9. Production packer
8 7 10. Packer sealing element (Lower barrier)
11. Tailpipe
9 10 12. WEG

11
12
Mahmoud Farag Radwan
Completion Components – Why?

1 Function :

3 2 1. Upper annulus barrier & supports tubing


2. Protects the surface installation
4 3. Hydraulically operates the SC-SSSV
5 4. Conveys hydrocarbons to surface
9 5/8” 5. Protects production casing from attack
Production 6 6. Permit entry of lift gas annulus to tubing
Casing
7. Accommodates expansion / contraction
8. Ties & seals tubing string to packer
8 7 9. Anchors tubing string to production CSG
9 10
10. Forms lower barrier of the A annulus
11. Allows installation of instrumentation
11 12. Easy entry of production logging tools
back into tailpipe
12
Mahmoud Farag Radwan
VALVES

HIGH pressure (5000 MEDIUM pressure LOW pressure (~180


psi and above) (~1500 psi) psi)

Flowhead Separators Tanks


Choke manifold, Sand-trap Oil/Gas manifolds
Heater & Steam-exchanger Pumps, Burners

1)GATE valves 1)BALL valves 1)BUTTERFLY


2)NEEDLE valves (~sampling~) 2)PLUG valves 2)GLOBE valves

1)WOM new, (McEvoy, 1)Mapegaz, Gachot


Malbranque, Sereg old) 2)Texseal, Balon
2)Kerotest, Autoclave

Mahmoud Farag Radwan


GATE valves
•Used for shut off, (on/off function)
•High pressure (5, 10, 15, 20Kpsi)
•ex: FH, CM, Steam-exchanger, Sand-trap
•Sealing method:
-metal/metal for WOM valve
-grease sealing compound for McEvoy
valve
•Standard sizes= 3 1/16” to 4 1/16”

Mahmoud Farag Radwan


GATE
valves

GATE
WOM

metal/metal seal

Mahmoud Farag Radwan


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 (~sizes= ¼”, ½”, ¾”)

Mahmoud Farag Radwan


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”

Mahmoud Farag Radwan


GLOBE valves
•Used for control of flow and shut off
•Low pressure
•Rig Water / air lines
•Sealing= metal/metal
•Standard sizes= 1”, 2” 3”

Mahmoud Farag Radwan


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.

Mahmoud Farag Radwan


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.

Mahmoud Farag Radwan


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.

Mahmoud Farag Radwan


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.


Mahmoud Farag Radwan
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Casing Head

Mahmoud Farag Radwan


Casing Spool

Mahmoud Farag Radwan


Casing Hanger

Mahmoud Farag Radwan


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

Mahmoud Farag Radwan


Tubing Hanger Types
Extended Neck Tubing Hanger

Mahmoud Farag Radwan


Tubing Hanger Back-Pressure Valve

Mahmoud Farag Radwan


Tubing Head Adapter Types

Mahmoud Farag Radwan


Wear Bushing

Mahmoud Farag Radwan


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.
Mahmoud Farag Radwan
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.

Mahmoud Farag Radwan


Dual Solid Block Xmas Tree

Mahmoud Farag Radwan


CONNECTIONS

Mahmoud Farag Radwan


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.
Mahmoud Farag Radwan
WELDED

Mahmoud Farag Radwan


ARTIFICIAL LIFT WELLS
• Gas Lift
• ESP
• PCP
• Plunger Lift
Special Wellhead Design
• Sucker Rod Pump
• Hydraulic Pump

❑ The conventional wellhead should be modified to meet


the artificial lift method.
❑ Each method along with the modification applied will
be discussed.
Mahmoud Farag Radwan
BEAM PUMPING
• the wellhead must be modified to seal
around the reciprocating rod.
• Emergency precaution in case of broken rod.

Mahmoud Farag Radwan


WELLHEAD EQUIPMENT

• Flowing T
• BOP
• Stuffing Box
• Lubricator

Mahmoud Farag Radwan


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

Mahmoud Farag Radwan


GAS LIFTING

• The X-tree is used not only to


control the production but also
the injection of the gas

Mahmoud Farag Radwan


ESP
LIFTING

Mahmoud Farag Radwan


HYDRAULICLIFTING

Mahmoud Farag Radwan


PLUNGER LIFTING
• the wellhead must accommodate a
lubricator / “plunger catcher” installed on
top of the flow cross.

Mahmoud Farag Radwan


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)

Mahmoud Farag Radwan


The injected fluid
• A wise selection of the wellhead material is a must to be
suitable for the injected fluid and TEMPERATURE variation.

Mahmoud Farag Radwan


Offshore Wellhead

• Mudline Suspension
• Subsea Wellhead

Mahmoud Farag Radwan


THE MUDLINE HANGER SYSTEM CONSISTS
OF THE FOLLOWING COMPONENTS

Mahmoud Farag Radwan


Mahmoud Farag Radwan
Mahmoud Farag Radwan
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.
Mahmoud Farag Radwan
UNITIZED WELLHEAD (COMPACT)

Mahmoud Farag Radwan


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

Mahmoud Farag Radwan


How to Order
General Wellhead Equipment Data Sheet

Mahmoud Farag Radwan


Mahmoud Farag Radwan
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 down-
hole 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

Common questions

Powered by AI

It is important to avoid using gate and globe valves for throttling because restricting flow through them can erode the seals, gates, or seats, leading to improper sealing and potential reliability issues. These valves should operate in a fully open or fully closed position to maintain their integrity and extend operational lifespan .

The pack-off flange is crucial in well re-entry operations due to its ability to manage anticipated pressure rises and support temporary operations, such as pressure testing primary seals. It also acts as a safety device when drilling out leftover cement in the shoe joint, ensuring operational integrity and safety under increased pressure conditions .

The primary considerations for selecting wellhead materials for injection wells include the operation pressure, the specific properties of the injected fluid, and temperature variations, especially in steam injection scenarios. The wellhead material must be compatible with these factors to prevent material degradation and ensure efficient operation .

The Christmas tree controls the flow of well fluids and provides access for well intervention activities. Different configurations include the Solid Block, Composite Block, and Horizontal Xmas Trees, which serve various operational needs. The Horizontal Xmas Tree, for example, is a relatively new concept used in subsea completions .

A subsea wellhead system addresses deepwater drilling challenges by incorporating a high-pressure wellhead housing and metal-to-metal annulus sealing assemblies to withstand the mushy, unconsolidated ocean-floor conditions. Additionally, big bore systems are used to isolate underground aquifers frequently encountered in deep water, necessitating new well designs to effectively manage foundation problems .

A unitized wellhead system facilitates operations by combining multiple components into a single, compact unit, which simplifies installation, reduces the need for extensive assembly, and minimizes potential leak paths. This design efficiency leads to reduced maintenance needs and enhances the speed and reliability of drilling operations .

Gate valves are designed for shut-off functions and are used across high-pressure applications ranging from 5,000 to 20,000 psi. They are typically sealed using metal-to-metal seals, with WOM gate valves employing this method to ensure reliability. Different sealing compounds, like grease for McEvoy valves, cater to specific operational needs .

Wellheads must be modified to accommodate the specific requirements of various artificial lift methods such as gas lift, ESP, and plunger lift. For instance, a lubricator or "plunger catcher" is required for plunger lift applications. Each modification ensures that the wellhead can effectively support the mechanical and operational demands posed by the lifting technology .

Non-destructive testing (NDT) methods play a critical role in maintaining well integrity by allowing for the inspection and maintenance of well equipment without causing damage. Techniques like ultrasonic testing (UT) and seal protection help identify potential weaknesses or failures in the system, allowing for timely intervention that prolongs equipment life and ensures operational safety .

Corroded wells present operational challenges such as leaks, structural weakness, and safety hazards. A well integrity management system can mitigate these issues by implementing regular inspection, applying corrosion-resistant materials, and ensuring rigorous maintenance procedures to detect early signs of corrosion and prevent further deterioration .

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