Innovative Wellhead Control Panel for Improving Safety and Reliability in Remote Locations

Abstract This research paper aims to introduce and evaluate a dual mode wellhead control panel designed specifically for remote locations, particularly those with challenging right-of-way (RoW) due to weather and security conditions. The objective is to significantly enhance operational reliability and process safety by ensuring uninterrupted well operation and providing advanced remote-control capabilities. The innovative dual mode wellhead control panel has two operational modes: firstly pneumatic + electronic + hydraulic mode for normal conditions and secondly pneumatic + hydraulic mode for power outages scenarios to avoid intrinsic common cause failures. The panel is equipped with dual safety mechanisms to ensure diversity, i.e. mechanical and electronic, to ensure increased process safety. The design incorporates a seamless transition between these modes to avoid any production losses during power outages to cater to random hardware failures. Additionally, the remote operation capabilities are facilitated by a dedicated HMI button that initiates an automated safety check sequence, verifying conditions like status of mechanical ESD button, fire detectors, fusible plugs, safety input sensors, high/low pilot through FMEDA to incorporate diagnostic coverage and even maintenance bypass status as well. This sequence ensures that all safety devices are normal before allowing remote well opening, making the system ideal for remote and security-sensitive locations. During start up the flowlines are not pressurized so the low-pressure safety is enabled. So manual bypassing of this safety is required. But with the current design the remote start up sequence is triggered by a single button on the HMI. The remote start up sequence starts by charging the pneumatic loop automatically, then starts the pump, then pilot valves and safety operated valves. Once all these are done the system will open the surface controlled subsurface safety valve (SCSSV). After getting feedback that the valve is open the system will open the upper master valve (SSV). Once all safety valves are open the system will automatically control the choke based on the operator input. As the well is flowing and flowline is pressurizing, the low-pressure safety will be normalized. After verification of this condition the system will automatically switch from auto start up mode to normal mode.