OTIS PANEL & WELLHEAD

CONTROLS
(PTP-18)

Training Package PTP 18

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Table of Contents Page No.

1. Introduction 3

2. Glossary of Terms 3

3. General Description 7

4. Operating Sequence – Opening 9

6. Operating Sequence Charts 11

7. Routine Maintenance 13

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OTIS PANEL & Well Head Controls

1. INTRODUCTION

The Otis control panel is connected to monitor a number of conditions at the well site and shut the
safety system if the appropriate monitors detect an abnormal condition.

The design function of the well control system is to provide an immediate shut-in of the surface
and subsurface safety valves in the event of maintenance or an emergency at the well site. A
panel mounted pneumatic relay valve works in conjunction with other manual / automatic
hydraulic control valves to put the safety system in operation (open the well).

Abnormally high or low pressure in the well flow line, a loss of hydraulic pressure or input
pneumatic supply, or the operation of a fusible plug in the ESD pilot line, the flow line pilot will
cause the system to block and bleed safety valve control line pressure and the normally closed
safety valves to shut in the well flow.

The well safety system incorporates a special feature that (when properly adjusted for the well
conditions) equalizes the well pressure on both sides of the subsurface safety valve before
allowing it to open completely. This prevents the damages to the ball and seat of the safety valve.

It must be remembered that the control panel is the central controller for the entire well safety
system installed at the well site. Incorrect operation or adjustments could render the entire system
inoperable and create a dangerous situation for personnel and the possible blowout of the well in
an emergency.

2. GLOSSARY OF TERMS

The following list of definitions is to assist in the understanding of this manual:

Actuator Hydraulic (or pneumatic) cylinder which is mounted on the Christmas tree
valve to provide remote opening and closing. Can be installed on any
reverse acting, gate valve and is operated from the control panel SSV
system.

Air Latch A piston attached to pneumatic valves (e.g. PR-1 on panel) which use air
pressure to hold the valve open. Any reduction of air pressure (such as
tripping ESD) causes valve to close.

Ball Valve Downhole safety valve installed in the safety valve nipple by wire line. Also
known as SCSSV, All wire line retrievable valves presently used by PDO
have ball type closures. However, newer completions may have tubing
retrievable valves installed in the completion which usually have flapper
type closures and may or may not have an equalizing feature depending
upon the valve design. These tubing retrievable valves may still some times
be referred to as "ball valves".

Check Valve To permit flow in one direction only. Available for pneumatic and hydraulic
circuits.

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Differential Pressure The difference in pressure across the ball valve (or any barrier).

Downhole Valve See ball valve and SCSSV.

Downstream Refers to a position furthers away from the formation. Same term as for
"further down a river", as opposed to upstream, e.g. Flow line sensing point
is downstream of the wellhead.

ESD Emergency Shut Down. A means of rapidly bleeding off the 30 psi pilot
pressure to cause the panel to bleed the hydraulic pressure and shut in the
well.

Equalization The slow flow of pressure through a small orifice from a high to low
pressure area. Usually used to describe the balancing of pressure
(equalization) across a downhole safety valve.

Flow line The main outlet pipeline from the wellhead to the gathering facility.

Fusible plug Attached to the ESD pilot line, this device is designed to melt in a fire
hazard situation and vent the 30 psi pilot line pressure so that the control
panel closes in the safety valves. Fusible plugs can a lead filled elbow or a
piece of plastic tubing.

Interlock No. 2 pump "Interlock" 2NC-1: a device between supply pressure and the
pump which blocks or shuts off the supply pressure from the pump until all
the circuit pressures are correct.

Manifold or "header" is a series of connections onto one piece of tubing, e.g. to vent
H2S exhaust gas from the panel; all valve exhaust outlets are connected to a
manifold, which vents outside the panel cabinet.

Monitor Used to constantly check on a particular condition on or near the wellhead,

Pilot Used to continually measure the well pressure at a particular point (e.g.
flowline) until pressure exceeds preset limits (high or low). Pilot then vents
the 30-psi pilot pressure and causes panel to close the safety valve.

Pilot pressure Set at 30 psi (regulator R-2) to energize the pilot system.

Pneumatic Air or gas (as opposed to hydraulic which refers to liquid).

Relay A device for converting a signal from one system to a signal in a system
containing a different pressure or fluid.

Relief Valve Pneumatic or hydraulic over pressure protection. Set to vent pressure above
normal working pressure but below test pressure of circuit.

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Reverse acting A common design of gate valve used on wellheads and flowlines. Inward
movement of the stem and gate opens the valve and outward movement of
the stem and gate close the valve. This is in contrast to a normal acting gate
which closes when the gate moves inward in the valve body and opens
when the gate is moved outward in the valve body.

SCSSV Surface Controlled Subsurface Safety Valve. Two types are in use in PDO,
the wireline retrievable (WR) and the tubing retrievable (TRSCSSV). This
valve is installed downhole in the well and may either be equalizing or non-
eqlializing and may have either a ball type closure or a flapper type closure.
Presently, all WRSCSSV's used by PDO are ball type closure valves that
have the equalizing feature. Both types of valves may be referred to as
"ball valves".

SSV Surface Safety Valve. Refers to the wellhead valve, which has the actuator
to enable remote opening and closing. Actuator may be either hydraulic
operated or pneumatic operated. The hydraulic type is commonly used in
PDO.

SCFM Standard cubic feet per minute. It is a unit to define volume of as flow.

System pressure is 80 psi in the control panel and is set by regulator R-3. The 80-psi
pressure is used to control the Sigma 3-way hydraulic block and bleed
valve.

Trips point The adjustable pressure point at which the pilot will vent the pilot pressure.

Upstream Refers to the point closer to the formation, i.e. against the flow of the well.

WHSIP Wellhead shut in pressure. Also known as THP (tubing head pressure),
CITP (Closed in tubing pressure) or SITP (Shut in tubing pressure).

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Well-Head:

W ell Control
Swab Valve

W ing Valve

SSV

M aster Valve
Control Line for SSV
Control Line for
SCSSV

Control Line

Casing
Tubing

SCSSV

Wellhead Control Sketch:

Control Pannel

Wellhead

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3. GENERAL DESCRIPTION

OTIS CONTROL PANEL FEATURES:

1. Built-in flowline pilot with direct high-low monitoring facility.

2. Equalizing circuit which (when properly adjusted to the well conditions) allows the
SCSSV to equalize any differential pressure before the pressure is increased to the hold
open pressure.

3. To protect the subsurface safety valve from damage when closing, a time delay circuit
prevents SCSSV from closing until after the SSV is closed.

4. The ESD circuit is separate from the pilot line circuit. It allows the SSV to close due to
fluctuations in the flowing pressure in the pipeline without closing the SCSSV.

5. The internal components of the panel are H2S rated so that the panel may be operated with
an H2S supply gas.

6. All components in the panel exhaust into a manifold, which discharges any H 2S gas at
ground level outside the cabinet of the panel.

OTIS CONTROL PANNEL

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Pilot on Flow Line

Pilot Valve

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4.0. OPERATING SEQUENCE:

Detailed Control Schematic

To flow the well, the following sequence is to be followed:

1. Check that all ESD valves and / or pilots are closed.

2. Check the input gas supply to the panel (100 - 140 psi).

3. Check the 30-psi pilot system (regulator-2) and the 80-psi system pressure (regulator 3).

4. Ensure that the flow line pressure on the DS dial pilot (P-1) is between the high and low
tripping points as indicated by the red needles on the pilot gauge face.

Note: If the flow line pressure is below the low setting of the pilot, read just the needle to
below the indicated flow line pressure.

5. Check that the ball valves to the SSV and the SCSSV are open on the panel outlet and the
needle valve for the SCSSV is open at the wellhead.

6. Pull the handle of the ESD relay valve (PR-1) located in the top right corner of the control
panel. The locking button should be depressed while pulling out the handle until the valve
is locked in the "in-service" position. The locking pin will automatically unlock and
release when the air-latch on PR-1 is energized. This will not occur until the ESD line is
fully pressurized through the fixed orifice in the line downstream of PR-1.

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7. Pump No. 2 will now pressurize the control line to the SCSSV. Provided the Pilot-2
(located in the rear lower left hand side of the panel) has been adjusted correctly and the
equalizing delay circuit in the panel is adjusted correctly, pump No. 2 will be stopped with
the SCSSV (ball valve) in the equalizing in position.

8. Once the equalizing delay circuit has been pressurized through the orifice, the air supply is
restored to pump No. 2 and the proper hold open pressure will be applied to fully open the
SCSSV.

9. The SSV can now be opened by pressing PB- I (located on the front of the panel to the
right of flow line pilot P-1). This will activate pump No. 1 which opens the SSV.

Note: If PB-1 is pressed prior to SCSSV opening fully, pump No. 1 will not operate.
However, the circuit will remain activated and will automatically open the SSV
once the SCSSV has opened.

5.0. PANEL SHUTDOWN SEQUENCE

Panel will shutdown as per the following conditions:

1. SSV will close when:

a. PB-2 is pressed manually.

b. The flow line pressure exceeds the high or low limits as set on P-1.

2. The SSV and then (after a delay time) the SCSSV will close when:

a. The pressure in the ESD line is bleed off either by a remote sensing pilot or by
opening a remote valve.

b. PR-1 on panel is manually pressed.

c. The input gas supply is lost.

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6.0. Operating sequence Charts

The final operating sequence should be as shown on the following charts.

OPENING SEQUENCE:

Shutdown Sequence Charts:

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7.0 Routine Maintenance

1. Check the hydraulic fluid level regularly.

Caution:
The hydraulic reservoir cannot be filled full while the safety valves are open. If the
reservoir should be filled while the valves are open, when the valves are closed at a later
time, the reservoir will not be able to contain the returned fluid and the reservoir tank will
over-flow onto the location. It is for this reason that reservoir tanks must be fitted with
pressure relief caps so that the returned fluid or any well pressure can be relieved to
prevent the tank from rupturing.

2. Check for hydraulic and pneumatic leaks in panel. Vibration can cause fittings to loosen
and can cause leaks to occur. Re-tightening all fittings in the panel periodically is
recommended. However, care should be exercised not to over-tighten these fittings as this
may also cause leaks, especially in the hydraulic lines, which must contain much higher
pressures.

3. Hydraulic filter strainers - clean and replace every six months.

4. H2S filter cartridges - replace every 4 months. This time will vary according to service
conditions and it is suggested that the service interval be adjusted to suit local conditions
when necessary.

Note:
If supply gas is taken from scrubber on location and the scrubber is not efficient,
condensate will saturate these filters and reduce the flow of gas to the panel. Fluid will
also accumulate in the various components of the panel.

5. Remove the spool piece from the top of each Haskel pump and coat the o-rings with
Haskel grease. Failure to keep these components greased will lead to pump cycling slowly
and possibly stopping.

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