WHCP (Wellhead Control Panel)

WHCP are also known as Shutdown Panels (SDP), Emergency Shutdown Systems (ESD) or Hydraulic Safety Shutdown System (HSSS).
WHCP are failsafe shutdown systems having pneumatic/hydraulic/electric components and can be integrated with PLC/ RTU/ SCADA.
WHCP are standalone control systems as well as an interface between the plant control and the wellhead safety system.
WHCP are used for monitoring, controlling (Remote/Local) & shutdown of Subsurface Controlled Safety Valves (SCSSV), Surface Safety
Valves (SSV) & other WHCP safety valves (Choke,ESD,HIPPS) in oil & gas fields to ensure safe operation of unattended wells/platforms.

WHCP may have multiple applications, which include, but are not limited to
 Safe and Sequential Operation of Wellhead Valves (SCSSV/SSV/Wing etc.)
 Emergency and Fire Shutdown
 Safe Operation of Riser Valves
 Flow line Pressure control
 Well Test Operation
 HIPPS / ESD / Choke Valve Control
 Partial Stroking

Overview of Wellhead Control Panel

Gas & Oil wells has a high potential hazard, either because the material ejected flammable or potential hazard of gas pressure is high.
Wellhead control panel is key equipment in oil & gas industry to protect oilfield facilities and environment from occurring wellhead
fire and emergency incidents, which is one of main control systems to ensure oilfield oil production and transportation to be safely
operation according to international standards and national regulation.
Its function is to shut down the well in case conditions that harm or for other interventions as well as the work test, etc.
Wellhead control panel is composed of hydraulic power unit (HPU), tubing/fitting and instrument valve and electrical control devices.
HPU supply hydraulic resource to open and close SSVs including MSSV, WSSV and SCSSV.
The level of complexity of each well head control panel vary, each company has its own standard. 

So the definition of well head control panel in General will certainly vary, the definition of well head control panel if we review of its
functionality is part of the surface facilities of the gas well or an oil well that is used to control well, like: be it to shutdown system, the
casing pressure reading parameters, tubing pressure reading parameters, temperature well parameters. So to open or close a Wing
Valve (WV), Master Valve (MV), as well as Down Hole Safety Valve (DHSV) can be through the Wellhead control panel.
Wellhead control panel consists of control pneumatic or hydraulic. Control pneumatic or hydraulic composed of tubing & 3-way valve.
A typical arrangement includes - reservoir, pumps, accumulators, solenoids, valves, pressure regulators, switches, motor control,
transmitters and junction boxes. Each well is typically equipped with:
• Surface Controlled Subsurface Safety Valves (SCSSV) or Down Hole Valves (DHV)
• Surface Safety Valves (SSV)
• Master Valves (MV)
• Wing Valves (WV) (controls production rate)
If it can be inferred is actually a function of well head control panel is to operate well, be it for shut in and POP (put on production).
With the wellhead control panel we able to open or closed the DHSV via the push button in panel.
Also we can open or close a master valve or wing valve with push button in the panel as well.
It is all done manually, by pressing or pulling a push button. But to close DHSV, Master valve, Wing Valve can be done automatically,
namely through the integration with shutdown system from the well.

By looking at the picture, it will give an overview of what functionality or usability of the wellhead control panels.
The components are visible in the picture can be grouped into:
All of these components will give feedback or as a input signal to the Wellhead control panel (WHCP).
While in the well itself (flowline) there is a sensor that is used to monitor the condition of the well, either to shutdown the system, or
just for readability only.

Instrumentation for shutdown system:

 PALL (pressure switch low low)
 PAHH (pressure switch high high)
 Fusible plug (for detection of
fires), usually mounted above
fangles, or parts that there is a
possibility of leaks (source of fire)
Instrumentation used for reading:
 FR (flow recorder) or Flow Indicator
 PR (pressure recorder) or Pressure indicator
 TR (temperature recorder) or Temperature Indicator

Final Element of System Shutdown:

 DHSV, Down hole Safety valve (drived by hydraulic power)
 MV, master valve (drived by hydraulic power)
 SSV, surface safety valve (drived by pneumatic power)
 Choke valve, manually  operated
 SDV (shutdown valve) installed  in flow line of well, outside the part of the wellhead (X-mastree)

Valves are a part of which will receive command of the signal to be opened or closed  from Wellhead control panel.
WHCP is a controller (a control system), SSV, MV, DHSV, SDV are the part that receives the output from the controller, while the PALL,
PAHH, fusible plug is the input of the controller. WHCP generally uses control pneumatic or hydraulic.
WHCP generally use pneumatic control, because most of wells are far location (remote) & hard to find sources of energy (electricity).
And generally WHCP from gas wells using gas from the well itself as a source of pneumatic power. Later will be discussed where the
pneumatic power source to run the WHCP. With pneumatic power from gas, we can also have hydraulic power, i.e. by install the
hydraulic pump on run by pneumatic power. Hydraulic power is used to run valve actuator  which relatively large power needs.
Pneumatic-powered convert  hydraulic power can become larger by using the pump.

The Problems That Often Arise in Wellhead Control Panel (WHCP)

From the various experiences, The problems that often arise in WHCP are leaking, popping, and stuck. Commonly Leaking occurred in
the connection of nuts on tubing. It could be leaking at a three way valve components. To this we can issue leaked retighten the bolts
or given a Teflon sealant. If for three way valve usually replace the internal parts like its o ring, whereas in order to overcome stuck at
three way valve do greasing of internal plunger. Stuck in a 3 way valve because it is dirty or arid.
For ordinary problems popping occur at PSV. PSV is safety equipment to handle excess pressure. Each panel of a pneumatic/hydraulic
there must have been PSV. Just like in the WHCP. When there is an excess pressure, PSV will popping, to release the excess pressure.
When it was popping PSV unbiased back to its normal position, problem is often the case. Clean the inside and then check the setting.
One of disadvantages of pneumatic systems using hydrocarbon gas as source of power instrument is, if liquid into pneumatic system.
This will cause three-way valve not working well. If the wrong selection of the material, example O ring not resistant with hydrocarbon
substances, will certainly damage the o ring itself.

Main Function of WHCP

 Local On/Off SSV
 Remote control SSV through RTU
 High-Low pressure sense shut-down automatically.
 Fusible Plug, Anti-fire Shut-down automatically.
 SSV can not be opened unless local reset after shutoff
 Function of showing system pressure
 Relief Valve shall be installed on each hydraulic circuit to prevent high pressure
 Function of showing hydraulic level and level switch for alarm
 Function of defending pressure impact of system
 Function of defending exorbitant pressure
 Function of system pressure monitoring(by pressure transmitter of control panel)
 Function of remote emergency shut-down (by magnetic valve of control panel)
 Function of On/Off SSV monitoring (by pressure switch of control loop of control panel)
 Function of shield High-low pressure sense

Types of WHCP

Single wellhead Control Panel

Wellhead control panel is used for controlling one well Surface controlled sub-surface safety valve (SCSSV), Master SSV and Wing SSV.
SSVs can be shutdown automatically and manually by WHCP to response all kind of emergency situation.
Single well control panel is categorized the following system according to driven resource:
 Manual control system
 Electrical control system
 Pneumatic control system
 Solar powered control system

Manual Control System

Feature and Function: Manual hydraulic pump supply hydraulic control and output pressure for SSV.
Main function includes Remote ESD, Fusible plugs, low pressure / high pressure sensing, Manual shutdown at panel.

Electrical Control System

Feature and Function: Electrical motor driven hydraulic pump with manual pump as standby will supply hydraulic to control SSV.
Main function includes Remote ESD, Fusible plugs, low pressure / high pressure sensing, Manual shutdown at panel.

Pneumatic Control System

Feature and function: Pneumatic driven hydraulic pump with manual pump as standby will supply hydraulic to control SSV.
Main function includes Remote ESD, Fusible plugs, low pressure / high pressure sensing, Manual shutdown at panel.

Solar Powered Control System

Solar powered control system is designed to be used for wellhead control located remote area and desert area.
Feature and Function :Energy conservation, Reduce operation expense, Duel power supply, Standard control feature
Main function includes RTU shutdown；Fusible plugs；Low pressure/high pressure；Local Manual control

Multi-wellhead Control Panel

Each control module is drawable and can be inter-replaceable without any interruption of other well operation.
Common module include oil reservoir, Pneumatic hydraulic pump and standby manual pump.
Main function shows as following: Remote RTU shutdown;  Fire fusible plugs protection, Low pressure / high pressure sensing, Manual
control at panel.

WHCP Working Principle

It is very common in the oil & gas plant to control its oil or gas well through a wellhead control panel (usually called WHCP).
Each well is always equipped with a SCSSV (Surface Controlled Sub-surface Safety Valves) or usually it is called down hole valve (DHV)
and a SSV (Surface Safety Valves) which is consist of a Master Valves (MV) and Wing Valves (WV). SCSSV in most application is an on-
off valve with hydraulic actuators. While SSV can be driven by hydraulic actuator or pneumatic actuator depends on the pressure
rating. It is also a need to open or close SCSSV and SSV in sequence and accommodate an Emergency Shutdown signal from the
systems. WHCP system usually consist of hydraulic reservoir, strainer, hydraulic pumps, accumulator, wellhead control module &
hydraulic line which are supply & return to wellhead control module. Any other parts except wellhead control module classified into
basic cabinet. Each control module is built up dedicated for one well only. Therefore if there are 5 well in a wellhead platform, then
there will be 1 basic cabinet and 5 wellhead control module needed. First part of WHCP is a hydraulic reservoir. This reservoir contains
hydraulic fluid in sufficient quantity to operate each wellhead. The size of reservoir is determine through an estimation of hydraulic
fluid needed to operate each actuator, possible leakage, distance from the well, and an additional safety factor. Usually the hydraulic
reservoir is an atmospheric tank with a flame arrestor venting. To build up a hydraulic header (high or medium pressure) the WHCP
utilize a hydraulic pump. In general the SCSSV will operate at high pressure rating and SSV will operate at medium pressure rating.
Thus there will be two hydraulic headers at WHCP with its own hydraulic pump. The hydraulic pump can be pneumatic driven or
electric driven depends on criticality and operation area. All hydraulic pump suction will have a strainer to filter hydraulic fluid from
any particulate so that fluid goes to SCSSV or SSV is clean. To make the hydraulic demand from SCSSV or SSV achievable, the
downstream of the hydraulic pump (hydraulic header) is equipped with an accumulator. It helps the hydraulic pump to supply quickly
the hydraulic demand. This arrangement (reservoir, hydraulic pumps, and accumulator) usually is called as a hydraulic power pack or a
hydraulic power unit. After hydraulic fluid accumulated at hydraulic header (high/medium pressure) then it’s ready to supply each
wellhead control module. Usually the line from hydraulic header to wellhead control module is called a hydraulic supply lines.
At this wellhead control module, sequence & logic to operate SCSSV & SSV is built up.  The ESD signal mainly also goes to this module.
When it needs to open the SCSSV and SSV, it supplies the high pressure or medium pressure hydraulic fluid to the SCSSV and SSV.
In case there is a need to close it down, the hydraulic fluid supply will close and the hydraulic fluid will goes to a hydraulic return line
through a three way valves selector. This hydraulic return line will goes to the hydraulic reservoir again. Hence it can be concluded
that the wellhead control panel (WHCP) is a hydraulic system that utilizes a hydraulic power pack and a wellhead control module to
perform its task. The output of WHCP is high pressure hydraulic supply and medium hydraulic supply to operate SCSSV and SSV.
Wellhead control panel is also the interface between the plant control and safety system with the SCSSV and SSV systems.

Working
WHCP systems usually consist of hydraulic reservoir, strainer, hydraulic pumps, accumulator, wellhead control module, and hydraulic
line which are supply and return to wellhead control module. Any other parts except wellhead control module are classified into basic
cabinet. Each control module is built up dedicated for one well only. Therefore if there are 6 well in a wellhead platform, then there
will be 1 basic cabinet and 6 wellhead control module needed.
Part #1 : Hydraulic Reservoir
The reservoir contains hydraulic fluid in sufficient quantity to operate each wellhead. The size of reservoir is determine through an
estimation of hydraulic fluid needed to operate each actuator, possible leakage, distance from the well, and an additional safety
factor. Usually the hydraulic reservoir is an atmospheric tank with a flame arrestor venting. Level gauge / level transmitter / level
switch can be installed on reservoir based on client requirement.
Part #2 : Hydraulic Pump
To build up a hydraulic header (high or medium pressure) the WHCP utilize a hydraulic pump. In general the SCSSV will operate at high
pressure rating and SSV will operate at medium pressure rating. Thus there will be two hydraulic headers at WHCP with its own
hydraulic pump. The hydraulic pump can be pneumatic driven or electric driven depends on criticality and operation area. All
hydraulic pump suction will have a strainer to filter the hydraulic fluid from any particulate so that the hydraulic fluid goes to SCSSV or
SSV is clean. Not only pump suction but also pump discharge need strainer or hydraulic filter to be installed as recommended design.
Part #3 : Accumulator
To make the hydraulic demand from SCSSV or SSV achievable, the downstream of the hydraulic pump (hydraulic header) is equipped
with an accumulator. It helps the hydraulic pump to supply quickly the hydraulic demand. This arrangement (reservoir, hydraulic
pumps, and accumulator) usually is called as a hydraulic power pack or a hydraulic power unit.
After the hydraulic fluid accumulated at the hydraulic header (both high pressure and medium pressure) then it’s ready to supply each
wellhead control module. Usually the line from hydraulic header to wellhead control module is called a hydraulic supply lines.
Part #4 : Wellhead Control Module
At this wellhead control module, the sequence and logic to operate the SCSSV and SSV is built up.  The ESD signal mainly also goes to
this module. When it needs to open the SCSSV and SSV, it supplies the high pressure or medium pressure hydraulic fluid to the SCSSV
and SSV. In case there is a need to close it down, the hydraulic fluid supply will close and the hydraulic fluid will goes to a hydraulic
return line through 3/2 way valves. This hydraulic return line will goes to the hydraulic reservoir again.
From this general explanation we can conclude that the wellhead control panel (WHCP) is a hydraulic system that utilizes a hydraulic
power pack and a wellhead control module to perform its task. The output of WHCP is high pressure hydraulic supply and medium
hydraulic supply to operate SCSSV and SSV. Wellhead Control Panel is also the interface between the plant control and safety system
with the SCSSV and SSV systems.
Surface Safety Valve (SSV):

The SSV is usually mounted as a wing valve on a Christmas tree with high or low pressure wellhead.
This name is derived from the tree-like nature of the branching valves and fittings.
To allow maintenance, a manual valve must be mounted between the SSV and the well.
Normally a reverse gate valve is the type of valve used in a shutdown valve flow line.
Because of its self-closure, this valve is well suited for this application.

The valve consists of a gate assembly operating through the valve at 90 degrees to the pathway.
The stem and gate of the valve rise to be closed.
This stem action is opposite to a typical gate valve’s stem action.
An actuator type with a diaphragm or piston is used with a reverse gate valve.
Through applying pressure above the diaphragm, which drives down the stem, the valve is opened.
To shut the valve, the diaphragm stress is removed.
The flowline pressure drives the gate stem upward, closing the valve.
A spring, located under diaphragm of the actuator, will also close the valve when there is equal pressure on both sides of the valve.

Surface-Controlled Subsurface Safety Valves (SCSSV)

SCSSV are specially designed wellhead shutdown valves which are kept open by continuous hydraulic pressure maintenance.
Typically these valves are hundreds of feet below the seabed or land surface.
Occasionally it takes more than one valve per well.
The number of wells that a hydraulic system controls depends on local preference.
Sometimes it is preferred to have individual hydraulic systems.

The wells are usually grouped into logical “blocks” that allow good access and control of the operator in case of a problem.
Normally, a limit of no more than 10 to 20 wells per hydraulic system will allow resetting of all SCSSVs in less than 5 minutes.
A pneumatically driven pump with a second pump as a backup is supplied with hydraulic pressure.
The backup pump can be another pneumatically driven pump with the option of a manual operator or a pump operated by hand.
To monitor the hydraulic pressure and alert the operator, a low-pressure sensor may be installed.
On the pump discharge, a relief valve is given to release excess backpressure back into the supply tank.