Precision Automation at the Wellhead - Hydroplex

Managing flow and pressure at the wellhead is crucial for maximizing production and maintaining safety. Hydroplex’s automated wellhead solution offers advanced control using precision components and seamless system integration.

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How Automation Works

This method ultimately yields better production control because of the staged drop. The secondary valve regulates flow or pressure to required production levels. Cost of acquisition and maintenance is also substantially reduced.

Benefits of Installing a Hydroplex Valve

Hydroplex valves are engineered for long-term performance and accuracy:

• Precise Control: “Direct Mount” actuation eliminates brackets, linkages, or adapters.
• Superior Resolution: 270° rotation and Twin Disc trim provide superior accuracy.
• Longer Lifespan: Twin disc design separates control and sealing surfaces.
• Chemical Injection Port: Built into the valve body for streamlined operations.
• Durable Materials: Solid tungsten carbide trim reduces wear on seals and surfaces.
• Pressure Drop Control: Optional internal multistage pressure drop.
• Minimal Maintenance: Stainless steel internals extend service intervals.
• Repeatable Performance: High repeatability ensures consistent control.
• Robust Design: Stem and seal assembly handles hundreds of thousands of cycles.

Why It Matters

Real-time control and monitoring of wellhead flow ensures optimal production while minimizing downtime. Hydroplex valves integrate with your system to deliver safe, efficient, and precise control at every stage of your well’s life.

Sizing & Application Assistance

Hydroplex’s continuous research and development results in improved products to better serve the industry. Comprehensive assistance for sizing and application are provided through Hydroplex engineering. 

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Wellhead control systems are the devices and components that regulate the flow and pressure of fluids and gases from the wellbore to the surface. They include valves, chokes, gauges, sensors, actuators, and control panels. Wellhead control systems can be classified into two main types: conventional and intelligent. Conventional wellhead control systems rely on manual or hydraulic operations, while intelligent wellhead control systems use electronic or pneumatic controls and communication systems.

In my experience Surface X-trees will mostly have valves that are mainly manually operated – production master valve, wing valves, choke, swab valve, some lower master valve also referred to as surface safety valve would be hydraulic. In intelligent wells with downhole chokes that allow you to control flow in separate producing zones, the chokes will be mainly hydraulically controlled. Subsea wellheads may have a combination of remote-control system; hydraulic control is very common; they will also include the option of the ROV to mechanically operate the wellhead valves.

There are alot of things to consider when selecting well control systems for well workovers. First of all, well workovers encompass a broad range of wellsite activities from wireline operations to larger scale completions activities involving service rigs. First determine if the well will need to be killed (zero surface pressure) for the selected operations or if there will be surface pressure. There should always be conventional wellhead control systems in place for these activities unless there is a need to remove or replace these valves. Then determine what activities will need to be conducted which may need additional well control. In my opinion, intelligent systems make less sense for workovers and more sense for producing wells.

When overseeing workover operations, it's crucial to consider safety mechanisms including wellhead control systems. These systems are designed to regulate and monitor the flow of oil or gas during extraction or workover operations. Key considerations include the Hydraulic Control System (HCS), Blowout Preventer (BOP), and safety valves. The HCS monitors pressure and flow rates, offering precise control for optimal extraction. The BOP is a critical safety device, designed to seal, control and monitor wells to prevent blowouts. The safety valves prevent the uncontrollable release of pressure if there's a failure. Choosing the right systems enhances operation safety, efficiency, and productivity.

Conventional wellhead control systems are the most common and widely used in workover operations. They consist of a wellhead assembly, a christmas tree, and a blowout preventer (BOP). The wellhead assembly is the part that connects the casing and tubing to the surface equipment. The christmas tree is the arrangement of valves and fittings that control the flow and pressure of the well fluids. The BOP is the device that seals off the wellbore in case of a high-pressure event or an emergency. Conventional wellhead control systems are usually operated by manual or hydraulic levers or switches.

Whereas the Conventional Wellhead Control Systems are cheaper, intelligent wellhead control comes in extremely useful when seeking to isolate a section especially when the well completion cuts through multiple stacks/zones. Data can be read intelligently and in real time. In the end, smart decisions are made when every other factor (including cost) is put to consideration, and when cost is considered, the best evaluation should be a comparison of what it costs to do it and what it costs not to.

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Using the conventional Wellhead control system like the BOP, it must have been pressure tested to be sure it can control the well during any emergency that might arise. Check all rams are functioning properly from annulus ram to blind shear ram.

Used to control pressure during the operation by diverting the flow of well fluids, allowing for pressure adjustments and safe handling of unexpected high-pressure situations. Inspect and test the wellhead and associated equipment to ensure they are in good condition and capable of withstanding the expected pressures during workover operations.

Intelligent wellhead control systems are the more advanced and sophisticated option for workover operations. They incorporate sensors, actuators, and communication devices that enable remote monitoring and control of the well parameters and conditions. Intelligent wellhead control systems can also provide real-time data and feedback, as well as self-diagnosis and self-correction capabilities. Intelligent wellhead control systems can be integrated with the wellhead assembly, the christmas tree, or the BOP, or they can be installed as standalone units.

Intelligent wellhead control systems offer several benefits for workover operations, such as improved efficiency, safety, reliability, and performance. They can also reduce operational costs, downtime, and environmental impacts. However, intelligent wellhead control systems also pose some challenges, such as higher initial investment, maintenance, and training requirements, as well as compatibility and interoperability issues with existing equipment and systems.

Smart well systems make oil or gas production better and let you control things from far away. But they can be expensive, need special skills, have cybersecurity worries, and might cause issues if something goes wrong.

When you are overseeing workover operations, you need to consider several factors when choosing the wellhead control systems that suit your needs and objectives. These include the type and condition of the well and reservoir, the scope and duration of the operation, the flow and pressure characteristics of the well fluids and gases, the availability and accessibility of power and communication sources, regulatory and environmental standards, as well as operational and financial risks and benefits. By evaluating these factors, you can select the wellhead control systems that will ensure optimal and safe execution of your workover operations.

In addition to the type of fluids, its pressure and temperature, sand production, corrosive or not...etc we need to put into consideration that some of the wellhead components are belong the elements of Well Barrier to compose an Envelope these elements require specific specification in some country it is given by the regulator while some operator do refer to international standards such as API, NORSOK, ISO...etc

While choosing the wellhead and Christmas we must consider some points that may be useful for safety and smooth operations. For example in offshore their are two wellhead and XMT One is HXT and other is VXT you must design or chose your as per your future requirements. Because in HXT tubing Is hanged to XMT but in VXT tubing Is hanged to Wellhead