-.

SPE
-Of PeWdeurnEngineer%

SPE 13743

Surface and Downhole Production Safety Systems for Sour Oil

and Gas Wells
by K.M. Morsi, Abu Dhabi Co. for Onshore Oil Operations
SPE Member

Copyright 1985, Seciety of Petroleum Engineers

This paper was presented st the SPE1985

Mkldle
East
CM Technicel Conference and Exhibition held in Bahrain, March 11-14, 1985, The material ia
subject to correction by the author. Permission to copy is restricted to an abstract of not more than 300 words. Write SPE, Box 833836, Richardson,
Texas 75083-3S36 Telex: 730989 SPE DAL.

ABSTRACT Being aware of these dangers, several types

of surface and sub-surface systems have been used
The work on sour gas and oil wells by its in ADCO fields. The downhole safety systems
nature is dangerous. Highly flamable and toxic include a surface controlled - subsurface safety
sour gas and fluids under high pressure need to be valve, a direct controlled - subsurface safety
handled by special equipment in a hostile valve (Storm choke), a dump/kill valve and
environment. corrosion protection via a COntiWaWaS Chemicai
injection system. The selection of sub-surface
Within ADCO, safety systems have been safety systems for high pressure, sour and
developed to protect the large investment, the corrosive gas completions suitable for our fields
----- L .. ——
envircme~t S?.6SSfety cf upe~~clng personnel. is a complex undertakingin which many aspects must
be considered.
As a result of the high pressure and sour
production involved, it is necessary to incorporate The surface safety systems include X-Mas tree
high - strength tubular materials and safety pneumatic and hydraulic valves, a kill annulus
features such as surface controlled sub-surface valve, a casing relief valve, fusible plugs for
safety valves, kill/dump valves, downhole packers fire protection, high/low pressure pilots and an
and chemical injection systems into the completion emergencyshut down system.
design.
VariCUS pOWEi Siipp;ysystems can be used to
Several types of surface and sub-surface actuate the wellhead hydraulic control unit to
systems have been reviewed and tested for use in operate the SC-SSSV. These power supplies include
our onshore sour gas and oil wells in Abu Dhabi. a photovoltaic solar system, an associated
(scrubbed)gas system , a bottled Nitrogen system
INTRODUCTION and a self contained integrated hydraulic control
system.
This paper highlights the equipment and
procedures used to provide safe and secure
operations during the production phase of oil and A. EquipmentDesign and Installationin Sour Gas
gas wells. Wells

In nearly every case, a blow out of a The Thamama Zone “C” sour gas reservoir was
producing well is caused by a combination of completelydevelopedin 19S4.
factors, including:
This sour gas field produces from a limestone
An act of God (earthquake,etc.). formation in the lower Cretaceous horizon,
The failure of a surface control equipment. with an average gas production rate of 30
A fire or explosion which causes the failure MMSCF/D per well and an average H2S and
of surface control equipment. C02 contents in the range of (0.7-S.0 Mole
Sabotage. %) and (3.9-8.0 Mole %) respectively. These
Human error: wells are located in a roughly U-shaped
Lack of proper safety equipment. pattern.

Referencesand illustrationsat end of paper.

“n,
. SURFACEAND DOWNHOLE
PRODUCTIONSAFETY
The original reservoir pressure is 4300 psig
at 8500 ft. SS and the bottomhole temperature
(BHT) is 260”F.
The gas wells are connected to four trunk
lines (legs) which tie into tbe production
facilitiesthrough four gathering lines.
Equipment design and completion suitable for
these wells is a complex undertakingin which
many aspects must be considered. The
following highlights the equipment and
procedures used to provide safe and secure
operations:-
I. Downhole Completion
In general, the Thamama C gas wells are cased
with a 9.5/8” casing from the surface to a
depth of about 8500 ft. SS followed by a
short 7“ liner to the total depth
approximately9000 ft. SS.
(Fig. 1 shows a typical completiondesign)
The tubing consists of a 7“ OD, 29 lb/ft. to
about 300 ft. below surface followed by a
4.1/2” O.D. 12:6 lb/ft. string to the packer
setting depth at about 8100 ft. SS.
The tubing string is provided with a landing
nipple to accommodate a 7’ ball type surface
controlled - sub-surface safety valve
(SC-SSSV)which is installedat 300 ft. below
surface. A 10 ft. length of alloy flow
coupling is run above the SC-SSSV in order to
provide anti- turbulenceprotection.
A continuous downhole open chemical injection
system is provided; it utilizes the
casing/tubing annulus as the injection
conduit. The annulus between the tubing and
casing is filled with corrosion inhibitor
mixed with diesel oil. The injection
chemical enters the Side Pocket Mandrel (SPM)
directly from the casing annulus, then flows
through the chemical injection valve latched
into the mandre1 pocket. The chemical
volumes and the injection pressure are
regulated at the surface by a chemical pump
and associatedcontrol equipment.
A 1“ O:D;, spring loaded differential type
wireline retrievablechemical injection valve
is set in the SPM. This valve is actuated by
differential pressures across the valve
seat. The injection chemical pressure acts
upon the underside of the ball Gf the SkST,
tip. When the combined pressure of the fluid
head in the casing annuius (hydrostatichead)
and the surface chemical injection pump
pressure exceeds the force of the preset
tension of the valve spring, plus the force
exerted by the tubing pressure acting upon
the area of the valve port, the ball of the
stem tip is forced upward, off the valve
seat, opening the valve.
-smS FOR WJROIL ANDGAS WELLS SPE 1374;
(Fig. 2 shows a typical chemical injection
valve in the side mfi~~-+
r------ w,a-a.fil~
‘J”.=A, .
All items below the side pocket mandrel,
which is set as deep as possible, are made of
25% Cr duplex stainless steel since they do
not receive any corrosioninhibition.
The tubing string is furnished with another
SPM for D/K valve installation. The D/K
valve is a 1.1/2” O.D. wireline retrievable
which is used to provide a means of
circulation between the casing and tubing.
This valve is normally closed. The
differential D/K valve acts initially as a
dummy valve to prevent communicationbetween
the annulus and the tubing. The design of
the valve in use includes a moveable piston
which, when in the closed position, blocks
off the circulatingports and prevents fluid
movement through the valve. This piston is
held in place by shear screws, the number and
combination of which establish the shear
pressure for the valve. Many different shear
pressures are obtainable by varing the shear
screw combination. The D/K valve opens when
the required differential pressure between
the annulus and tubing is obtained.
(Fig. 3 shows a D/K valve in the side pocket
mandrel).
A 7“ permanent production packer is normally
set using electric wireline at about 150 ft.
above the top of perforation. This type is
selected due to the sour gas environment and
the high differential pressure generated
during stimulationoperations.
The landing nipples in the tail pipe section
are used to pressure test the tubing, packer
seals and to set Amerada pressure gauges. The
bottom of the tail pipe is kept some 60 feet
above the top of the pay.
Three of the Thamama Zone C wells have
different downhole completion,being provided
with duplex stainless steel tubing and no
downhole chemical inhibition.
II. Surface Equipment
a. Wellhead
5000 psig maximum working pressure
rating stainless steel wellhead
components are used. The secondary
~l~St~iis cl? km hydraulic type whiie
one of the side wing valves and annulus
valve are pneumaticallyoperated.
A 400 ft. kill line is connected to the
annulus pneumatic outlet valve to allow
killing the well in case ~f eMeICJenCY.
A surface relief valve is installed on
the annulus of the three wells completed
with the duplex stainless steel to avoid
subjecting-itto a high pressure.
I
K 13743 yin$alir
Ml wellhead, piping, flanges, valves,
choke and fitting specificationsare in
accordance with the U.S. National
Association of Corrosion Engineers
(NACE) standardsMR-01-75.
b. Wellhead Control Manifold
A single wellhead control manifold is
installed to open and close the surface
and downhole safety valves in sequence.
When the control system is activated the
SC-SSSV is opened first followed by the
master valve and then the wing valve.
When the control panel is activated to
close, the safety valves will shut
beginning with the wing valve, master
valve and last the Sc-sssv. The
sequencing is accomplishedby using time
delays.
The control panel is designed so that
the operation of the pneumatic annulus
valve is totally independent from the
rest of the system. This valve can be
opened through SCADA (Telemetry) or
locally during an emergency.
The following 9 (nine) status signal
indications show the operability of the
whole system and are monitored through
the SCADA system in the main plant
control room:-
1. Wing valve closed.
2. Wing valve opened.
3; Surface master valve closed.
4. Surface master valve opened.
5. SC-SSSV closed.
6. SC-SSSV opened.
7. Well fire and H2s actuation.
8. Inhibitiondosing system healthy.
9. Inhibitiondosing system faulty.
Also, the control system provides five
(5) command as follows:
1. Well close.
2. Well open.
3. Wing valve close.
4. Wing valve open.
5. Annulus valve open.
The control panel uses two gas driven
pumps to supply hydraulic pressure to
the master valve and SC-SSSV. One pump
is totally automated and the other has a
manual operation feature. Either pump
can be used as the primary pump with the
other acting as a back-up. The
advantage of the two pump system is the
easy maintenance, as one pump can
operate the system and SC-SSSV whilst
maintenance is performed on the other
pump.
Sweet gas supplied by a separate
pipeline from the central gas processing
plant is utilised to operate the
wellhead hydrauliccontrol manifold.
To summarise,the surface safety control
system for Thamama “c” provides the
following:
Continuous well monitoring and
automaticemergencyaction.
Highly reliable emergency shutdown
of wells in conditions such as fire,
abnormalpressure and flowline leaks.
Interlocked control to assure
~Q~~~~~ n.ar.’ualva1.Ve operating
sequence in start up and fully
automatic valve closing sequence on
shut down.
c. Chemical InjectionSystem
The chemical injection system comprised
of one injection pump, a 60 barrels
capacity Inhibitor tank and the
necessary accessories to meter and
inject inhibitor into the well annulus
and flowline (if necessary).
(Fig. 4 shows the hook-up of wellhead
control and chemical injectionsystems).
d. CorrosionMonitoringFacilities
The constant threat of corrosion and the
potentialdamaging results of a sour gas
leak dictate that facilities be
installed to monitor the rate of
potential corrosion at any location in
the gathering system where corrosion is
consideredmost likely.
To monitor corrosion rates, Magna
resistance probes and weight loss disc
coupons are installed near wellheads and
at the station manifold.
Non Destructive Testing Techniques of
Ultrasonic and Radiographyare also used
on a routine basis to monitor metal
thinning, of the flowlines and gathering
lines.
Special pipeline pigs such as “LINALOG’
will be carried out to note and record
any changes in the thickness of the pipe
wall, pitting or cracking.
Furthermore, cathodic protection of the
external pipeline walls is being
implemented.
e. Hiqh and Low Pressure Pilots
E1/Lpressure pilots are installed on the
flowline and connected to the safety
control panel.
 SURFACEANDEKMIHOLEPRODLKHONSAFETY $
These pressure activated pilots are
designed to activate the closing of the
safety system in the event of an
abnormal change in line pressure.
f. EmerqencyShut Down (ESD)
The safety system is designed to be
remotely operated. In an emergency the
well can be closed either remotely from
the control room or by operating a
manual valve 100 ft. away from the
wellhead. Also, the wellhead can be
closed from the ESD valve inside the
wellhead panel:
9. Annulus surface safetv relief valve
TO avoid pressure build up in the
annulus of the three wells of duplex
stainless steel tubing, annulus surface
safety relief valves are installed.
This is EQ avc!idtubing collapse due to
differential pressure between annulus
and tubing. When the sensed pressure
rises above the pre-set limit of the
spring the valve opens, also it can
sense a decrease in pressure.
h. Fusible Pluqs
Low and high pressure fusible plugs are
used in surface safety installation at
various points. The fusible material
will melt in the event of fire or
dangerously high temperatures. This
action will cause the control line
pressure to be exhausted, thereby
per!nikting
bhe valves tc close.
i. Piqqinq Facilities for Corrosion
Prevention
The ability to remove water pockets,
sludge, deposits or other negative
elements by running pigs through the
pipeline is a necessary design feature
for the Thamama “C” gas gatheringsystem.
It is generally accepted within the gas
industry that metal bodied pigs should
not be used for running through sour gas
pipelines. Firstly, this is to avoid
embrittlement and cracking of metal
parts by the sour gas leading to
eventual failure which would affect the
proper performance of the pig.
Secondly, in the event a pig
disintegratingdue to high velocitiesor
mechanical problems in the system a
metal bodied pig will result in unwanted
debris left in the pipeline which may
cause a subsequent pig to become stuck
and thereby adversely affect the
performanceof the pipeline.
TO avoid these problems a solid
polyurethane pig is used for pigging
Zone C gathering lines. The advantage
of using this type of pig is that in the
4
,TRv!SFOR SOUROIL AND GAS -S WE 137Li
event of a problem the pig
disintegrating it will not affect the
integrity or proper performance of the
pipeline. Pigging to remove condensate
is carried out every six months. This
will be changed if found necessary to
extend or reduce the period to meet
operationalrequirements.
B. Equipment Design and Installation in
Sour Oil Wells
Thamama Zone B sour oil reservoir was
put on stream in October 1983. The
original reservoir pressure and
temperature were 4178 psig and 255°F
respectively at 8300 ft. Ss . The
average H2S content is in the range of
(0.5 - 10 Mole %).
Downhole completion and wellhead
installation of the sour oil wells is
simple compared to sour gas wells. D/K
and continuous chemical injection
systems are not incorporated into sour
oil wells completion. A manually
operatedX-Mas tree valve is also used.
Our safety policy is to install a
sub-surfacesafety device in wells which
are located in potentially hazardous
areas i.e. near production station
facilities, flares, main roads, living
quarters etc.
Direct controlled sub-surface safety
valves (DC-SSSV’S)of VariOUS types were
tested in some of the oil producers,
aiSO the different power supply systems
are being utilized to operate. the
Sc-sssv’s, the details of which are
discussedbelow.
I. Direct Controlled - Subsurface Safety
Valves (Storm Chokes)
The downhole safety valve is an
important feature of a well system, and
acts as a safety backup for the surface
flow control equipmentand wellhead.
The SC-SSSV is the most reliable type of
valve and is widely recommended for all
producers. This type of valve requires
a separate external hydraulic control
which can only be installed by workover
or during the well completion. However,
many of our oil producer have already
been completed or worked over, the storm
choke was thought to be the most likely
reliable interim measure as a
sub-surface safety device. This would
avoid using a workover rig to install
surface controlled - sub-surface safety
devices. Therefore, subsurface
controlled- direct safety valves (storm
chokes) were selected for testing in our
existingwells.
 Eight (8) storm chokes were installed in
different wells to evaluate their
performance. These valves were supplied
by four differentmanufacturers.
These valves were tested forty (40)
separate times by tripping and then
re-opening, on seventeen (17) occasions
an unsuccessfultest was recorded:
This gave an average estimated failure
rate of 43%, which was considered too
high.
Several problems were encountered while
testing these storm chokes e.g. frequent
valve malfunction, equalizing problems,
loss of wireline tools in hole, etc.
These problems were due to many
different reasons.
Two modified DC-SSSV’S were purchased
from each of the most promising two
suppliers for long term testing. These
are being tested for possible use in
suitable wells since their application
will yield a substantialcost saving.
So far the results on these DC-SSSV9S
indicate that they are more reliable
than those used in previous test.
II. Power Source to Operate the Wellhead
HydraulicUnits
The types of power source to operate the
surface hydraulic control units to
actuate Sc-sssv’s are a photovoltaic
solar, associated (scrubbed) gas,
bottled Nitrogen and self- contained
integratedhydraulicpower systems.
a. PhotovoltaicSolar System
The testing and evaluation of a
solar system as a power supply to
operate the hydraulic control unit
for SC-SSSV has been successfully
completed. Two solar powered air
supply units were tested for more
than one year in ADCO fields:
The solar supply system consisted
essentiallyof a solar panel, charge
controller, storage batteries,
electric motor controller, electric
motor/air compressor and air storage
(tank).
The photovoltaic system energizes a
D.C. battery cel1 which supplies
power to an electrical air
compressor. This charges a low
pressure air tank that supplies the
end user (safety system) with
compressed air regulated to the
appropriate pressure. The
compressor is capable to charging
the tank to about 120 psig which can
provide the required amount of
useable air to the safety system.
4
The development of a solar energy
system has provided a conversable
form of energy which in certain
areas of the world, including most
desert areas, is available at
practicallyall times of the year.
(See the attached figure No. 5)
The ultimate objective is to employ
solar units on all oil producing
wells remote from existing power
sources:
For remote and low associated gas
production oil wells solar powered
units may provide an attractive and
eConQrniCally j,dg~if~ca~~~
alternativeto other methods.
b. Associated (Scrubbed)Gas
For high GLR wells the associated
(scrubbed) gas is used as a power
source to operate the hydraulic
control unit for SC-SSSVO
The gas scrubber is used as a
separator to remove the condensate
and water and produce the dry gas
required to operate the control
system.
The gas scrubber vessel, valves,
controllers and piping should be
designed for sour service.
This power supply system requires
more frequent field operator
attention.
(see the attached figure No. 6)
c. Bottled Nitrogen
The amount of energy required at
each wellsite to operate the SC-SSSV
is small. So Nitrogen bottles can
also operate the hydraulic control
system. However, this requires
frequent operator attention and the
risk of inadvertent well ‘shut-ins”
due to pressure drops caused by
system leakage.
Handling a large number of Nitrogen
bottles is very difficult and it is
preferable te Me the= 2s afi extra
back up for other primary systems.
d. Self-contained (Integrated)
HydraulicPower System
At present the testing and
evaluation of a self-contained
(integrated) hydraulic power system
as a power supply for the hydraulic
control unit is being carried out.
Two units from different
manufacturers are under test. If
L SURFACEANDDOWNHOLE
PRODUCTIONSAFETY S
they prove successful, this system
may be consideredwhen an associated
gas supply is not available due to
low GOR of the producingoil wells.
ITEMSFOR SOUROIL AND GAS WELLS SPE 13742
Pigging to remove condensate from the
gathering system is being carried out using solid
polyurethane pigs. The metal bodied pigs should
not be used for running through sour gas pipelines.

The system is comprised of two NOMENCLATURE

parts, the single well hydraulic
control panel and a portable BHT . Bottom Hole Temperature
hydraulicpower unit: H2S = Hydrogen Sulphide
C02 . Carbondioxide
The single well hydraulic panel is a MMSCF/D . Million standard cubic feet per day
self-contained Systen ~es~gge~ tc SPk! = SitiePocket Handrel
provide safety control for the wells Ss . Sub-sea
by automatically operating a Sc-sssv . Surface controlled - subsurface
hydraulicSC-SSSV’S. safety valve
DC-SSSV . Direct controlled - subsurface
A Nitrogen pre-charged hydraulic safety valve (storm choke)
accumulator is provided to maintain SCADA . Supervisory control and data
operating pressure. The system is acquisitionsystem
designed so that the accumulatorcan GLR . Gas liquid ratio
be hydraulically charged GOR . Gas oil ratio
(pressurized) from a transportable ADco . Abu Dhabi Company for Onshore Oil
engine driven pump. Operations
O.D. . Outside diameter
The volume of the accumulator is I.D: . Inside diameter
sized so that six (6) repetitive lb/ft. . pound per feet
open and close operations of the CIV ?s Chemical in]ectionvalve
SC-SSSV can be performed without D/K valve . Dump/kill valve
rechargingthe accumulator: NACE . National Association of cQ~rQsiQn
Engineers
The portable hydraulic power unit is ESD . Emergencyshut down
a skid mounted, self-contained H/L Press. . High and low pressure
hydraulic pump used as a
transportable source of hydraulic ACKNOWLEDGEMENTS
pressure. This is used to charge
the accumulator contained in the The author wish to express high appreciation
well control panels. to Department of Petroleum of Abu Dhabi
Government. Abu Dhabi Company for Onshore Oil
The power unit is comprised of a Operations (ADCO) and its Shareholders for
diesel engine powered electrical permission to submit this paper at the SPE Middle
generator which operates an motor East Oil Technical Conference and Exhibition,
electricdriven hydraulicpump: Bahrain, March 11-14, 1985.

The engine has a battery starter REFERENCES

with manual start as a back-up. An
adjustable pressure switch provides 1. K.M. MORSI & N.!4.CONSTANTINE ‘operating an
for automatic pump stop when the onshore sour gas field in Abu Dhabi= a paper
desired discharge pressure is presented at the 3rd Middle East oil show in
cbtair,ed. Bahrain - 14-17 March 1983.

(See the attached figure No. 7) 2. Will G. Boyle, P.E.

The design and protection of completion
equipment in sour gas wells in ADCO has been
carried out successfully, by incorporating high
strength tubular materials and safety features such
as surface controlled sub-surface safety valves,
D/K valves, downhole packers and continuous
chemical injectionsystems in the completiondesign.
The surface controlled - subsurface safety
valve is the most reliable type of valve and is
widely recommendedfor oil and gas producers.
For remote and low associated gas production
oil wells solar powered air supply systems provide
an attractive and economically justifiable
alternativeto other methods.
‘Designingproductionsafety system’
The Pertoleum Publishing Company, Tulsa
Oklahoms.
3. K.M. Morsi ‘Testing and evaluation of
sub-surface controlled sub-surface safety
valves (storm chokes) in ADCO oil wells”
April 1983.
4: M.R. Milligan “Sour gas well completion
practices in Foothills,Western Canada”
An SPE paper published in JPT, September 1982:
5. William H. Stone “a completion for high
pressure,corrosive,offshore gas wells”
A paper presented at the 13th annual OTC in
Houston - May 4-7, 1981.

.? ;
 T
Tubi!
Control Lina

—L- NiPPk For

SC. Sssv
Spring
7 “ Tubing

43 3/e”A P
—— 4 $/2”’ Tubing

S. P. M. For
D/)( Valw
Seat
—S. P.M. FOr C. I.V.

Side pocket
Mandrel
—- 9 5A3” Permtmont Packer
Check Valve

— Lher Hang.r
9 5/6 “
A
- Landing Nipple
Par fOrcfted Tube __
1
‘NO 90 Lending NiPP18
Nm -rfOmtd TUtW ——
%odl
FIOI
T(biw Shoe— —

POrfOratkms __

7’ b

Fig. 1—Typical wellcompletion,

Fig. 2—Typical (:IV in SPM.
 hbing T-
1
. ‘— Piston Latch

I
j COMMAND

E---------
(5)

J
‘—-— Shear Screws WELL WEN

‘—— Circulot ing Ports F----------

. . . . .,=,
Side Pocket
Mandrel ‘—— Piston k~~; ~;~ -
D
CLOSE
! F---------
&:: LaLvll

kiiii---

VALVE
OPEN
FTWMTIC WING
/s~ETY VALjIE”-
—

h!i!iiz
1 —— I

I
CHDKE

1
~g(a SAFETY
.
,... - CWTFOL FANEL MDRAWIC MASTER
CHEMICALlNJECTm AFETY VALVE
I // ‘i”~”
gQ@ SYSTEM
‘reduction 1~ r
Flow

Annululs

b
SURFACECDNTRC)LLIII w
. f S118SURFACESAFETY VALVE
w
*
FIQ. 3-TYplcal D/K valve in SPM
w
Fig. 4—Wellhead controland chemicalinjectionsystems,
 FLLSISLE RM LOOP ( IOI,Vpre~ur.g)

ESD STATION
kl

Fig. 5-Photovoltaic solar systemas a powersupply.

Fig. 6-Scrubbed gas as a powersupply.

 *.

SPE 13743

I I FUSISLE PLUQ ~ P(low Pre seure)

ESD STATfON

H
I I 1) -

I 1

Ehct.
Motor +
Hyd Pu~

I J
DIESEL GENERATOR

Fig. 7—Self-contained hydraulic control system.