Proceedings of the ASME 2014 Power Conference
POWER2014
GO WITH THE FLOW:
THE EVOLVEMENT OF GEOTHERMAL WELLHEAD MAINTENANCE AT THE
HELLISHEIDI POWER PLANT
Reynir S. Atlason
University of Iceland
Reykjavik, Iceland
Ari Elisson
University of Iceland
Reykjavik, Iceland
ABSTRACT
Iceland relies greatly on geothermal energy, for
electricity, district heating and industrial activities. It is
therefore of great importance that the maintenance on site is
carried out quite successfully to minimize down time.
Reykjavik Energy is the largest energy company in Iceland
utilizing geothermal energy. The company operates two
cogenerating geothermal power plants, Hellisheidi (303 MWe
and 133 MWt) and Nesjavellir (120 MWe and 300 MWt). In this
study we investigate the development of the wellhead
maintenance at the Hellisheidi geothermal power plant. We
look at the maintenance recommendations provided to on-site
employees and how maintenance procedures have developed
since the power plant began its operations. We investigate real
data retrospectively and use it to calculate expected waiting
times between repairs. The result is a maintenance model based
on the observed and statistically analyzed data provided by the
power company on the maintenance procedures. Such model
should prove of great significance to other geothermal power
plants in the early stages of planning the wellhead maintenance.
INTRODUCTION
Geothermal wellheads play an important role in the overall
efficiency at geothermal power plants. Their role is to control
the flow of steam and fluid from the ground to the separators
and turbines [1]. The importance of wellheads, and their
smooth operation is therefore of great importance. Wellheads
can at first seem like a simple piece of equipment; they are
however often referred to as Christmas trees because of their
complexity. Wellheads used in the Icelandic geothermal sector
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July 28-31, 2014, Baltimore, Maryland, USA
POWER2014-32305
Oli P. Geirsson
University of Iceland
Reykjavik, Iceland
Runar Unnthorsson
University of Iceland
Reykjavik, Iceland
are in many cases designed for the oil industry, therefore
sharing many characteristics of that particular industry. This
however leads to wellhead problems not frequently observed in
the oil industry. In this study, wellhead maintenance at the
Hellisheidi geothermal power plant is investigated. A detailed
location of Hellisheidi power plant can be seen in Figure 1.
Throughout time, the maintenance methods at that particular
power plant have developed from the original recommendations
provided both by engineering firms and the wellhead producers.
These methods have evolved to address and minimize negative
effects from the harsh geophysical conditions observed at
Hellisheidi. Even though methods have evolved, they remain
greatly undocumented within the maintenance staff. In this
study, this knowledge is documented, diagnosed and
statistically analyzed. We then provide a statistical model
describing wellhead maintenance based on the findings of this
research. Geothermal projects are currently under way in
various parts of the world. When those geothermal power
plants will begin operating, it should prove valuable to possess
the wellhead maintenance plan from another successfully
established power plant, as it has been shown that possibilities
are great when it comes to efficiency improvements [2]. It
should also be of value to see how wellhead maintenance has
developed from the original recommendations throughout the
years. This can be seen in this article, as original
recommendations are shown as well as statistical analysis to
visualize how wellhead maintenance procedures have
developed throughout the years. In theory, such model should
be usable by geothermal power plants operating under similar
conditions as described in this article. The scientific literature
seems to lack such analysis as is shown in this article.
1 Copyright © 2014 by ASME

Figure 1. Location of Nesjavellir geothermal power plant.
However, very general recommendations are given by
Thorhallsson [3] as general problems associated with wellheads
are mentioned. However, the objective of this paper is not to
present a list of common difficulties related to geothermal
wellheads, but rather to deliver a model to maintain them and
minimize problems.
HELLISHEIDI
The Hellisheidi geothermal power plant is owned by
Reykjavik Energy and began its electricity production in 2006
[5]. The plant is located on the southern part of the Hengill
geothermal field. It produces approximately 303 MW of
electric power and 133 MW of hot water through a double flash
process. Approximately 50 wells are used to harness hot water
[6]. One of the reasons for the variance in maintenance
activities and difficulties with the mechanical equipment at
geothermal power plants are the different geological conditions.
Data showing the chemical structure of the brine was provided
by Reykjavik Energy. Table 1 shows the chemical composition
from the power plant under study. One can see that the fluid
consists mostly of SiO2 (822 mg/kg), Na (213 mg/kg), Cl (170
mg/kg), K (38.4 mg/kg), and SO4 (19 mg/kg) [3].
1) Survival valve, used for temperature and pressure
measurements. It is also used to prevent too much pressure
in the wellhead by allowing it to blow.
2) Located on top of the master valve is the working valve
which has the role of opening and closing flow from the
well.
3) Choke valve, has the role of allowing the well to be choked
or shut off by infusing cold water into it [7].
4) Master valve, located on top of the expansion spool has the
role of being the closing valve for the well.
5) Expansion spool, permitting thermal expansion of the
wellhead assembly and casings,
6) Casing head and
7) Silencer valve. The silencer valve allows the flow to enter
the silencers. This is purely done when the well is allowed
to blow full steam but not entering the gathering system.
This is primarily done when holes have been inactive and
attempts are made to re-activate them.
8) Control valve, controlling the flow from the well as needed
by the power plant.
9) Gathering system valve. Typically, gathering system valves
are placed at each wellhead, one on each side of the control
valve. This is done so the steam system can be isolated from
the well or if the control valve requires repairs. By closing
both gathering system valves the control valve can be
isolated for maintenance [7].
COMMON WELLHEAD PROBLEMS

Table 1. Brine chemical composition at Nesjavellir [4].

Chemical mg/kg
pH/C° 9.2/100
SiO2 822
Na 213
Cl 170
K 38.4
SO4 19
Al 1.7
F 1.1
B 1.039
Ca 0.456 Figure 2. A typical wellhead assembly used at Hellisheidi
As 0.09 geothermal power plant [6]. The pipe assembly shown in view
H2 S 20 A-A is vertical in the top view.
WELLHEADS AT HELLISHEIDI
Only one valve is regularly or continuously moved on the
A typical geothermal wellhead at Hellisheidi comprises wellhead assembly. This is the control valve, which controls the
primarily of the following 9 parts shown in Figure 2. These are: flow from the well [8]. The valve is frequently located outside

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 the well house. Scaling is a very common problem within GENERAL GUIDELINES
geothermal power plants and the wellheads are very prone to
Preventive maintenance is the maintenance method
scaling. To avoid scaling to occur in the control valve, different
typically carried out at Hellisheidi when it comes to wellheads.
designs of control valves have been used with mixed results [8].
This means that certain procedures are conducted at routine
Operating the wellhead in the pressure zone of 10-25 bar also intervals to avoid failures. General recommendations on
assists with avoiding scaling. Wherever any leakage occurs, weekly, yearly or four-yearly maintenance procedures are listed
scaling is prone to build very rapidly [8]. The importance of
in Table 2.
adequately packing the glands and joints such as those at the
expansion spool is therefore of great significance.
COLLECTION OF DATA Table 2. Overall guidelines for wellhead maintenance at
Hellisheidi.
Operation diaries were provided by Reykjavik Energy. The
diaries include activities taking place on a daily basis with in Part Activity
terms of wellhead maintenance. The diaries were studied three Four year intervals
years retrospectively, looking at the year 2010, 2011 and 2012. Silencer valve Pressure test
Operation manuals for the wellheads, which describes the Yearly maintenance
guidelines provided to the employees. The activities were put in Head valve Check movement
a time sequence for further investigation, shown in Figure 3. Shaft seal Check tightness
Hot spots were then identified to locate maintenance activities Spindle Lubricate on valves
taking place at the wellheads to avoid failures. These hotspots Weekly maintenance
can be seen in Figure 4. Regular visits to the Hellisheidi plant Seals General cleaning
took place between January and April, 2013 where interviews Measure Power
were conducted with maintenance staff. The operations All valves Visual inspection
Leak hole Visual inspection
conducted on site at the power plant are thoroughly
All seals Search for leaks
documented and should provide a clear picture of the wellhead
maintenance.
It is evident that the guidelines are very general. However,
STATISTICAL MODEL more detailed operating instructions are also given to staff.
The waiting times between wellhead maintenance at
Hellisheidi geothermal power plant are assumed to be 1. Full shut seals are kept on pipes not in use. This is done to
independent and identically distributed. Maintenance activities prevent pipe tearing.
are inferred separately. Furthermore, the waiting times are 2. To prevent tearing on the exterior, silencers (mufflers) and
assumed to follow a Weibull distribution [9, 10]. That is, let 𝑦!" pipes are frequently sandblasted and painted.
3. When yearly maintenance is conducted at the wellheads,
denote the 𝑗-th waiting time for the 𝑖-th activity, then the
the blow (exhaust) equipment is checked.
corresponding probability density function is given by
4. Only experienced personnel is allowed to open the wells. If
𝑘! 𝑦!" !! !! extensive period has passed since the well was shut, the
!!
𝑓! 𝑦!" = 𝑒 !(!!"/!!) , 𝑦!" ≥ 0 occupational, safety and health authority must be
𝜆! 𝜆! consulted.
5. In case of any change in the pressure system of the plant,
A survival Weibull model [11] is implemented for the materials selected shall be according to international
waiting times for each activity, where some of the observations standards, and professionals shall conduct all welding.
are right censored as the corresponding wellhead maintenance Independent inspector shall be consulted to inspect the
occur after the end of the study. Maximum likelihood estimates quality of all weld work.
are obtained for the scale and shape parameters [12], along with
standard deviations and 95% confidence intervals, which in The operation of the wellheads is divided in three phases.
turn yields estimates for expected waiting times. Standard 1) Well in usage. The pipes shall be tested for pressure
deviations of expected waiting times are obtained with the delta reliability as often as is needed dependent on the exterior
method [13]. The results were then tested for Kaplan-Meir condition. No more than 4 years should however pass between
goodness of fit [14], which are shown in the Appendix. these tests. 2) Well is ready to use. In this stage, the well is
RESULTS connected to the collection pipes. It is monitored so it can be
put into production without much notice. 3) Well in waiting
This segment outlines the findings from our analysis. First,
stage. In this stage the well is closed or has no pressure. The
it shows the general guidelines with regards to the wellheads
wellhead equipment is protected against corrosion, on the
provided by the Reykjavik Energy. It consequently shows the
inside and outside.
frequency of maintenance on the wellheads. Finally, a model
based on the findings of this study is provided.

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 VALVE MAINTENANCE GUIDELINES
The preventive maintenance procedures conducted at
Hellisheidi vary between different valves.
• Master valve 10" and 12" - 900 Class
Sealing filler shall be injected to the shaft seal if any
leakage is detected. Leak holes shall be visually examined and
checked if they are working appropriately. The spindle shall be
lubricated consistently. The valve should be moved at least
yearly. Under no circumstances shall this valve be half open, as
turbulence forms, causing deterioration. Reykjavik Energy
replaces 900 class valves if breakdowns occur instead of
repairing them, no instructions have therefore been provided for
the repairs of such valves.
• Working valve 10" and 12" - 900 Class
Tightening the seal should stop any leakage in the shaft
seal. New insulation rings may perhaps be needed. Any
chemical buildup on the seals shall be cleaned. The spindle and
shaft should be lubricated on a frequent basis.
• Choke valve 2" - 1500 Class
If leakage is detected in a power seal valve, it shall be
instantly filled with seal filler. In the case of normal sliding
valve, the shaft seal shall be tightened or new gaskets shall be
inserted. As is the case with the 900 Class valves, the 1500
Class valves are also not repaired, but instead replaced. No
guidelines are therefore provided for the repairs of these valves.
• Survival valve and other 3", 8", 10" and 16" valves -
600 Class
These valves include the survival valve, silencer valve and
gathering system valve. If any leakage is detected the seal shaft
shall be tightened or new gaskets shall be put into place if
needed. The 600 class is the only valve class that is repaired by
Reykjavik Energy.
• Bolts and threads
Bolts and threads shall be lubricated regularly and kept
clean. Leakage shall be repaired instantly.
600 CLASS VALVE REPAIR PROCEDURES
Like mentioned previously, only the 600 Class valves are
repaired. In this segment we outline the maintenance
procedures of the 600 class valves.
• General
It is estimated that the valves are constructed out of A 216
WCB steel in accordance with ANSI or GS-C 25 in accordance
with DIN. If the valve consists of other chemical composition,
a consultant is to be advised. This should be done to avoid any
crack formations or other faults, which may occur because of
the material composition.
• Grinding
Special consideration shall be taken when grinding, where
the grinding must occur outside the area that is to be repaired.
Production faults can differ between valves and an expert
should be advised with each case.
• Pre-heating
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For A 216 WCB steel or comparable steel, the area which
is to be welded shall be pre-heated to 100 degrees Celsius.
• Welding
Electric welding shall be used when welding. The wire
used shall be composed of C - 0.07%, Si - 0.7% and Mn - 1.0%.
However, when valves need repair, the wire SAFER GTi has
been used, as it is approved by DIN 1913 as E 43 45 R(C) 3
and has the following composition; C - 0.07%, Si - 0.3%, Mn -
0.5%, S - 0.018% and P - S 0.022%. The producer of the valve
should however be consulted before repair of the valve.
• Sound wave testing
As repair of the valve has finished, the repaired area shall
be sound wave tested. If any faults are located on the weld
work, the repair shall be re-done
• Post heating
As the repair has finished, the repaired area is heated to
620 degrees Celsius and wool insulation put on the area to slow
down the cooling. Heating shall be conducted well outside the
repaired area so deformation of the repaired part can be
avoided.
• After repair on the valve house (Class 600)
Test for leakage should be conducted with air under 2 bar
pressure at 20 degrees Celsius. The valve is kept shut, where
the other end of the valve opening is completely closed off. Air
is then blown into the valve and soap mixed water put on the
repair area and the area, which is keeping the valve tight. When
this procedure has been conducted at one end of the valve it is
conducted at the other. Pressure testing with water is conducted
under 150 bars at 20 degrees Celsius for one minute. Both
openings of the valve are completely shut off. The valve is
opened half way and filled with water. The valve should
contain no air. Pressure should be kept constant while the
pressure test is conducted.
• After repair on tongue, seats or spindle.
Leak testing of back seal with air under 2 bar pressure with
20 degree Celsius. Both openings of the valve are completely
closed off and the valve itself kept completely open. Gaskets
are loosened and pressure allowed to build inside the valve.
Pressure shall be kept steady as long as the examination
requires. Pressure and leakage testing with water under 100 bar
at 20 degrees Celsius. The valve is kept completely shut, and
one of the openings shut off completely. Pressure is then let
build up in the closed area. While the testing is conducted, any
leakage is thoroughly searched for.
FREQUENCY AND REAL MEASURES
In the operational guidelines it is often stated that
certain parts should be lubricated or checked frequently. It is
however not described in detail how frequent these repairs
should be. It also does not take into account if maintenance
needs to be less frequent as time goes by since the geothermal
field becomes more stable and less amount of minerals exit the
wells. Therefore real data was acquired. Also, it was
investigated which maintenance measures are most frequently
undertaken at the wellheads, regardless if they are a part of
major overhauls. Figure 3 shows clusters of maintenance
4 Copyright © 2014 by ASME
 activities with regards to wellhead maintenance. In Figure 3,
Figure 3. Maintenance activities shown in a time sequence. Bars
reaching a value of 3 represent a major overhaul, values of 2
represent two or more maintenance procedures. Bars given the
value 1 represent a minor operation.
bars reaching the value 3 represent that a major overhaul was
conducted at some wellhead at that point in time. When a bar
reaches value of 2, two or more procedures were conducted at
that wellhead at that point in time. When a bar reaches a value
of 1, one minor procedure was conducted. As can be observed,
one bar reaches a value of 4, this was done to indicate an
accident that occurred at the wellhead and required a major
repair. When Figure 3 is observed with regards to major
overhauls, certain hotspots can be noticed. The hot spots at
Hellisheidi seem to be three. First is from early May 2010,
through June the same year. Another is from early July 2011,
through September same year. 2012 seems to be more
dispersed than the two previous years. However, Mars, May
and July are particularly active in this regard.
When all activities conducted are analyzed in more detail, it is
easy to see which activities are undertaken at each visit at the
wellheads. In Figure 4 the 7 most regularly conducted
procedures are listed and their frequency. The most frequent
procedures are diagnosed in this study and used to create a
maintenance model. These activities include 1) lubrication of
top valve, 2) Lubrication of working valve, 3) Lubrication of
choke valve, 4) Lubrication of silencer valve, 5) Lubrication of
collection system valve, 6) Movement of head valve, 7)
Movement of silencer valve. The results from the statistical
analysis are shown in Table 3. The table includes the scale and
shape parameters of the estimated Weibull distribution for each
of the seven activities. The table also includes the expected
waiting times between maintenance activities (Ev).
Furthermore, the standard deviation (Sd) and the 95%
confidence intervals are provided. It is shown that most
activities have the expected waiting time of approximately 2
years (Ev). The movement of the silencer valve does however
have the expected waiting time of 1201 days, which is in
accordance with the recommendations, stating that the silencer
valve is to be pressure tested every four years. As these
activities can all be regarded as preventive maintenance, it is
possible to put the activities with similar waiting time in a
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maintenance package, where those activities are conducted
simultaneously. That means that lubrication of top valve,
working valve, choke valve, silencer valve and collection
Figure 4. Most frequently conducted maintenance activities on
wellheads at Hellisheidi geothermal power plant over three years,
divided in quarters. MOV is moving, LUB is lubrication.
system valve would have the expected waiting time of
approximately two years (ev). The movement of head valve
would then be done approximately after 830 days, and the
movement of the silencer valve every four years, along with its
pressure testing.
DISCUSSIONS
The model presented should be of value to geothermal power
plants. This can be used to get a feeling for the required
maintenance intervals in the beginning stages of developing
their maintenance management procedures for their wellheads.
This is of course dependent on the geological condition of the
field. When the data has been gathered, the model can be used
to improve the wellhead maintenance management. Due to the
vibrant nature of a power plant, the model has to be updated
regularly. In the case study presented, the power plant had been
operating for several years. This means that the frequency of
maintenance activities had dropped to some extent. This is
obvious in the expected waiting times, which is for most
actions roughly two years which is almost double the originally
recommended time. The extended waiting times can be
explained by the fact that the wells at Hellisheidi where not
given time to clean themselves by blowing for some period, but
were rather instantly put into production. This leads to wearing
of the wellheads since minerals in great quantities flow through
the wellheads. At present, the amount of the mineral flow has
gone down significantly, leading to the extended waiting time
between maintenance activities. It should also be noted that
over 50 different maintenance activities were recorded over the
timeframe studied. The seven activities that are used in this
study cover however the vast majority of maintenance
conducted at the Hellisheidi geothermal power plant with
5 Copyright © 2014 by ASME
 Table 3. Results from the statistical analysis of different CONCLUSION
maintenance activities. Ev is expected waiting time in days
between preventive maintenance activities. We have provided a statistical model for visualizing
and establishing the time intervals between maintenance
Lubrication of top valve
activities. Such model is necessary because the provided
guidelines do not state an actual cycle frequency. Further
Estimate Sd 2.5% 97.5%
development of the model should include an updating
Scale 813.01 112.99 619.16 1067.56 mechanism of the model, since old data is becomes relevant
Shape 1.41 0.21 1.05 1.90 than new data. A statistical model such as the one presented
Ev 739.9 119.21 523.89 955.91 here is a practical tool for geothermal power plant managers
Lubrication of working valve developing maintenance model and procedures for the
geothermal wellheads.
Estimate Sd 2.5% 97.5%
Scale 791.48 86.45 638.94 980.43
Shape 2.17 0.37 1.55 3.03 REFERENCES
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 ANNEX A

RESULTS FROM THE KAPLAN-MEIR GOODNESS OF FIT TEST

Figure 3. Results from the Kaplan-Meir goodness of fit test. 1) Lubrication of top valve,
2) Lubrication of working valve, 3) Lubrication of choke valve, 4) Lubrication of silencer
valve, 5) Lubrication of collection system valve, 6) Movement of head valve, 7)
Movement of silencer valve

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