The well head control panel is a control panel with the main function of controlling the opening and closing the valves or openings on the wellhead. The hazardous conditions due to the flammable materials coming out of the well and the high pressure inside the well on the ejection of the materials make it a dangerous combination or individual aspect that has to be monitored and controlled. The interventions required either planned for periodical maintenance or repair works, or unplanned due to some unexpected occurrences is managed with the help of the well head control panel. The main function of the control panel is to operate in general the three main shut off valves – wing valve master valve and down hole safety valve (DHSV). It can be operated through pushing of a button to shut the valve or open the valve for ‘put on production’ and through the Emergency Shutdown System (ESD) for emergencies where unplanned critical shutdowns are required. A well head control panel also does the work of monitoring the pressure, flow, and other sensitive details to relay the same to the personnel concerned and also to the integrated main systems.
A well which is under pressure has to be monitored for its pressure as it poses the threat of a hazard above all other aspects for which the monitoring becomes a requirement. Pressure gauges have to be suitably selected for the system in relation to the pressure of the well, so as to be able to read the different pressures at different levels of the system and to be monitored from low to high pressures. Thus, for example, there must be pressure valves to read the choke pressure, standpipe pressure, and incase of floating rigs, kill line static pressure. The pressure gauges with low pressure must also be easy to install, remove or replace. An equipment has to have the required personnel to operate and maintain it and it goes without saying the same is applicable to the well head control panels. Though the system does operate on its own on the emergencies there should be contingency plans and personnel allocated to the well head control panel for these contingency plans. These allocations will help in the controlled execution of the plans and actions in general & emergencies, that complements the functions of the well head control panel functions.
Pressure Vessel Components and Materials
Well head control panel functions as described above through the inputs and outputs of the WHCP. The inputs of the WHCP are normally from emergency shutdown systems (ESD), emergency push button, fusible plug, Pressure switch low-low, and Pressure switch high-high. These components pass on the input signals to the control panel which activates the required output in relation to the inputs. A fusible plug will pass on the signal of a potential fire for example, which will initiate an output signal for the emergency shutdown and save from a potentially disastrous situation. The outputs of the well head control panels are usually signaling the command for the shutdown of the valves at the well head. A well head control panel initiates the shutdown of the system by receiving inputs from the above-mentioned components with recordings taken from the flow recorder, pressure recorder, and temperature recorder which relays the information to shutdown to the down hole safety valve, master valve, surface safety valve, shutdown valve etc.
The Well head control panels are comprised of pneumatic components, hydraulic components, and instrumentations. The pneumatic components are the likes of three-way pilot valves, three-way push buttons, pneumatic pressure switches, pressure regulators, etc. The hydraulic components includes interface valves for pneumatic to hydraulic, hydraulic pumps, hydraulic reservoir tanks, pressure safety valve, etc. And finally, the instrumentation of the well head control panel has the pressure gauges, chart recorders, pressure switches, temperature gauges, etc. The combined installation of the components inside a panel to do the control function of the operation or shutdown of the well is the well head control panel.
Well Head Control Panel Principles
The Well head control panels can be categorized into different systems according to its source for operation from the manual control systems, electrical control systems, solar control systems, to finally the pneumatic control systems. Each suite to the different requirements and challenges of different well types. The well head control panel comes in two different configurations where one is used for single well head control and the other is used in multi-well head control. These well head control panels in different configurations and categorization in general is here to serve the purpose in the emergencies and aiding in avoiding costly errors and to have planned stoppages for the repair or maintenance purposes. The WHCP is an imperative instrument for the effective monitoring and controlling of the well head that which provides required outputs and commands to the other components in effectively shutting down the process to enable the safety and avoid hazards.
The different valves on the Christmas tree serve its functions on the production of the oil & gas and the manpower working and monitoring on and around cannot be as accurate and reliable as a well head control panel in executing its purpose. The involvement of hazardous material in and around humans always poses threats and more greatly with oil & gas as the losses incurred on the loss of time, materials and money are far greater, faster, and longer than of any preparation against such occurences. Well head control panels bring that safety element in such precarious situations and provide a measured safety and security.
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