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Proserv manufactured the wellhead control panel (WHCP) that controlled the six original wells for Umm Al Dalkh. The panel had been running reliably and without incident for several years. This fact, coupled with our recent success remanufacturing OEM control panels for the operator in a nearby field, convinced ADNOC of our controls expertise. What’s more, we were able to offer an alternative solution that significantly reduced CAPEX and installation downtime over the alternative. As a result, ADNOC recommended that the contractor engage Proserv for this project.
Rather than scrap and replace the existing Proserv WHCP, which was still performing well, Proserv proposed to supply an additional six slot WHCP with a built-in 12 slot hydraulic power unit (HPU) that could integrate with the existing WHCP to support the operation of the entire 12 wells. By integrating the two Proserv WHCPs with the HPU, the entire WHCP worked as a single panel, simplifying operations and enabling the customer to reduce the components under frequent maintenance.
Pamas s40
To meet the customer's requirements a trial run was conducted at our TCM and Flushing Facility in Nigeria, to establish if two identical pumping units could be coupled in parallel to meet the flow rates required by the client, as none of our current rigs could individually deliver the required level of output flow rate.
Two Harben flushing rigs, each capable of delivering 38L/min (10.03 gal US/min) flow rates, were coupled in parallel through a check valve and flow manifold. A series of gauges and pressure sensors then run, to establish working flow consistency and performance. The results confirmed that the desired flow rate exceeded the client requirement of 60 L/min (15.85 gal US/min) and all within the system’s working pressure limits.
Following this successful trial, Proserv was awarded the contract and the Chevron site team witnessed the flushing. 3 micron filters were used to record fluid cleanliness using the NAS 4.5 spec. This was above the NAS 6 levels required.
Due to the large bore size of the pipe being flushed, flow rates of 90 L/min (170 bar / 23.77 gal US/min @ 2465.64 psi) were achieved on site, all within the specifications requested by the client.
The high flow rates achieved, along with the more efficient 3 micron filters allowed us to record fluid cleanliness levels of NAS 4.5 well above the NAS 6 levels required.
The electronic control panels (WHCP) and RTUs provided the ability to control and monitor the instrumentation and wellhead valves for each well.
Proserv had already supplied our own wellhead control panels to the same field, which were still fully functioning with no reliability issues. As a result, they awarded the contract to Proserv to identify the cause of the failures and repair the OEM panels.
Upon inspection of the tube and fittings used in the high-pressure (HP) header, Proserv discovered that the OEM had used off-the-shelf components. As a result, the fittings were operating too close to the maximum working pressure of the line, causing frequent failure and fatigue. In addition, the fittings were not suitable for the application, undermining the pressure issue, hence why they kept failing.
Proserv replaced the incorrect tube and fittings in the HP (20k psi) rated components. Proserv also installed a pressure intensifier to ensure that the HP and pump discharge header matched the existing components’ pressure rating.
Furthermore, Proserv identified that the installed tubing for the pump discharge header was too small. This was causing the pump start/stop controls to sense a false line pressure and send a stop command to the pump, even before it reached the desired header pressure. Proserv installed the proper tube sizing in the pump discharge header, ensuring that the equipment sensed the correct pressure.
Panel 2 – 38 weeks
Based on this expertise, and our longstanding relationships with Baker Hughes and Aker Solutions, Proserv was awarded a contract for the supply of two remotely operated Intelligent Well Control Panels for new platforms. Ekofisk Z/4 2/4L and Eldfisk 2/7, both operated by ConocoPhillips and situated in Scandinavian waters, North Sea.
Once the sub-assembly of the panels were completed in Dubai, they were shipped to Stavanger for factory acceptance testing (FAT). This process was carried out at Proserv’s facility, with Baker Hughes in attendance, to ensure equipment compatibility and compliance with all contractual specifications.
Baker Intelligent Production Systems
At the Holford gas storage site, each of the eight storage caverns has a dedicated wellhead with associated control equipment, one control panel per cavern. This setup aligns with the facility being designed around eight wells drilled to access the salt caverns. The panels regulate injection and withdrawal of gas, managing valve actuation and flow rates.
The work included mounting, cable routing, functional testing, integration with site SCADA systems, and verification under site-specific operating conditions.
Each year, the team conducts a scheduled planned maintenance routine on the panels to ensure their continued safe and reliable operation.
Each panel undergoes a detailed inspection and servicing routine, which includes:
These outcomes collectively contribute to the Holford facility’s role as one of UK’s most flexible underground gas storage assets, capable of rapid response to daily fluctuations in gas demand.
Flowline pilot calibration
Hydraulic supply fluid sampling
Housekeeping
This structured approach ensures the continued safe and efficient operation of the wellhead control panels, aligning with industry best practices and regulatory standards.
